Tadano Faun Boom Truck TM-2000-1 Service Manual SN EX0069 - PDF DOWNLOAD

Publication No.

Service Manual

TM-2000-1/S1(U)-1E

01 Boom Truck

PRINTED IN JAPAN 0609

K

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TM-2000-1/S1(U)-1E

ｃ2006 ◯

Model

TM-2000-1 Applicable Serial No.

EX0069～

Safety Safety

[NOTICE] [NOTICE] indicates an important operational or maintenance procedure or condition, which, if not strictly observed, can result in damage to machine components or deteriorated machine performance.

Most accidents that occur during machine operation and maintenance are caused by failure to observe basic safety rules and precautions. Before operating your machine or performing maintenance, read and become familiar with all the safety precautions and recommendations given in this section.

Remember that failure to observe even a single precaution could involve you and the people around the machine in a serious accident.

It is virtually impossible to anticipate every situation that might present a hazard. The safety precautions given in this manual and on the machine labels are not exhaustive.

It is important, therefore, to strictly follow the instructions in this manual and be sensitive to potential dangers in order to prevent bodily injury and damage to the machine.

Foreseeing potential dangers is vital for preventing accidents. All personnel working with the machine, including the supervisor, machine operator and oiler, should be sensitive to potentially dangerous situations and take the necessary measures to prevent accidents.

Remember that your most important duty is to ensure the safety of you, your co-workers and any other people in the area.

Safety precautions and recommendations are outlined in this section and are also included in the operation and maintenance instructions given in subsequent sections. Warning labels are also provided on the machine.

The cautionary instructions in this manual are identified as "DANGER", "WARNING", "CAUTION" or "NOTICE". These terms are defined as follows:

DANGER DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation, which, if not avoided, may result in a minor or moderate injury.

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WA01-0041E

Safety 1. Fundamental cautions

fatal accidents, as there is a possibility that the vehicle loses its balance and falls down on a worker in a dismounting process of certain units.

Servicemen inexperienced in the units of this machine should be cautious about safety operations. They must acquire sufficient knowledge about the equipment before dismounting and disassembling it.

Before dismounting each component, a serviceman should read this service manual thoroughly and find out the weight of the component, then lift it by proper means.

7.When the working is done on a team of more than one person, make arrangements about co-operation and communication between workers beforehand. Give a sign without fault and make sure that the sign has been transmitted to other workers before starting the next operation.

The following are cautions to be observed all the time.

8.When it is inevitable to measure oil pressure, rotational speed, and temperature for machine inspection without stopping the engine, be careful not to be caught or pinched in rotating or moving parts such as a fan, fan belt. Make sure that there is no obstruction or no person around the machine before operating it.

1.Before starting repairs, find out the origin of the problem. When it becomes clear that disassembly and maintenance are necessary, first of all read this manual and parts catalog and thoroughly understand the principle of operation and construction. Then carefully check and examine each portion. Don't disassemble portions unrelated to the problem. Unless taking all possible measures before starting disassembly, new troubles or decline in performance may be induced.

2. Cautions in working 2.1 General

2.Before operating the machine, oiling or repairing, read warning labels and instructions on the machine and understand the contents.

1.When hoisting up components weighing more than 20 kg, use hoist or the like to prevent injury to your lumbar or spine. For specific components, their weights are listed on the chapter for "service data" in this manual.

3.Wear a safety helmet and safety shoes whenever you carry out maintenance operation around the machine. Be sure to wear safety goggles when you hit the machine or its attachments with a hammer. In welding operation, wear safety gears such as leather gloves, helmet, goggles, apron and proper working clothes, but don't wear loose or torn clothes. Take a ring and so on off your finger when you conduct maintenance or repair.

2. When using eyebolts, lift parts vertically so that only tension is applied to them.

3.Protect wire ropes and plastic lifting slings by covering corners with pads so that they are not bent sharply by directly contacting corners.

Keep the sling angle of wire ropes within 60°and as vertical as possible.

4.Park the machine on as level and hard ground as possible. Place chocks under wheels to prevent the vehicle from moving when doing maintenance on or below the machine.

4.Be careful about hot or heated portions when conducting repair or maintenance just after the vehicle has stopped or the machine operation has been finished or interrupted.

5.Before starting maintenance, remove cables to the battery and allow the capacitors to discharge.

Pull out the ignition key and hang a tag saying, "Don't start the engine." in the cab.

5.When hitting parts, be sure to either hit on a pad placed on the parts or use a plastic hammer.

6.Put units, especially similar parts, in order. them with tags or marker if necessary.

6.Don't carry out maintenance while lifting the vehicle with only a jack or a hoist. Sustain the vehicle positively with blocks and so on to prevent

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WA01-0041E

Mark

Safety 7.Put disassembled parts in order so that parts such as bolts are not left behind in the machine. And check that no parts run short at assembly.

In case that the position of the center of gravity is not clear and there is a possibility of swing of load after removing, use two hoists.

8.Watch your step in the following cases:

8.If a part cannot be lifted smoothly, make sure that all the fasteners are removed and other parts don't hinder removing.

When stepping up to or stepping down from the upper surface of a boom for replacing wire ropes and applying grease. Be careful not to stumble on protrusions on the upper surface of a boom.

When greasing at the root of a elevating cylinder When checking engine oil, radiator coolant, or battery fluid.

When replacing a filter of air cleaner When getting on and off the cab

2.3 Remounting and assembling 1.Before assembling, clean all the parts and repair or replace defective parts.

2.As dirt and soil adversely affect sliding portions and they may decrease the life of the machine, pay special attention to avoid intrusion of dirt and soil.

Be careful not to slip in the above operations in winter as snow and ice may attach to the exterior of boom and it becomes very slippery.

3.Use special tools for parts when specified to do so.

2.2 Dismounting and disassembling

4.Remove dirt, soil, water, and resin completely from surfaces where liquid gasket will be applied.

1.Before dismounting and disassembling, make sure of the construction and part sales unit by reading this manual and the separate parts catalog, then understand the procedures of dismounting and remounting and disassembling and reassembling.

5.After remounting, be sure to inspect the machine and verify that there is no error by oversight. If adjustment or air bleeding is required, conduct it according to instructions. Conduct function and performance test to verify its integrity.

2.When dismounting piping or equipment that may contain pressurized oil or air, be extremely cautious and dismount them only after discharging the confined pressure.

3. Cautions in operation 3.1 Brake fluid replenishment

3.Before removing, clean the part to be dismounted and the area surround it. Seal the opening with a plug or tape, etc. to prevent foreign material from entering it.

1.When the brake-warning lamp (for fluid level) is lighted, replenish brake fluid and check and make sure of the thickness of disk brake pads. (Refer to Chapter Y for periodical inspection periods.)

4.Measure and record the data such as shim thickness adjustment and pre-load at disassembly that will be required at reassembly.

2.Check the thickness of disk brake pads whenever brake fluid is replenished.

5.If required, before disassembling clearly put marks to avoid errors at reassembling.

3.2 Handling of battery 1.Erroneous handling of a battery may cause it to catch fire and explode.

Be extremely sure to avoid short circuits, sparks and fire of cigarettes and the like when using a jumper cable. They are very dangerous.

Charge up batteries and use them only in well ventilated places.

6.If a part cannot be removed after removing bolts or nuts fixing it, don't apply too much force to it but check the part for the cause. Only after relieving the cause, proceed disassembling.

7.Use lifting slings appropriate for the weight and characteristics of a part. Lift up it in balanced condition.

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WA01-0041E

Safety 4.1 Gasoline

2.Battery fluid (dilute sulfuric acid) may cause loss of sight or burn injury.

If battery fluid stains an eye, skin, or clothes, immediately wash down them with a great deal of water.

If battery fluid enters into an eye, immediately wash it down with water and see a doctor for medical aid.

1.Spill or leak: Review fire and explosion hazards before proceeding with clean up. Use appropriate personal protective equipment during clean up.

Dike spill. Prevent liquid from entering sewers, waterways, or low areas. Soak up with sawdust, sand, oil dry or other absorbent material. Shovel or sweep up.

3.When removing terminals, remove the minus (－) terminal first. When connecting terminals, connect minus (－) terminal last.

2.Remove source of heat, sparks, flame, impact, friction or electricity including internal combustion engines and power tools. If equipment is used for spill cleanup, it must be explosion proof and suitable for flammable liquid and vapor.

3.3 Handling of radiator 1.Don't open the radiator cap while the coolant is still hot.

Note: Vapors released from the spill may create an explosive atmosphere.

2.Check the coolant at the reservoir tank.

3.4 Cooling fan

3.Waste disposal method: Treatment, storage, transportation and disposal must be in accordance with applicable federal, state, provincial, and local regulations. Do not flush to surface water or sanitary sewer system.

1.Stop the engine completely before checking the tension of the engine fan belt.

4.By itself, the liquid is expected to be a RCRA ignitable hazardous waste.

2.The oil cooler fan may rotate the moment the engine is started. Be sure to pull out the ignition key before accessing the cooling fan.

4.2 Hydraulic oil

3.If high-pressure water is used for radiator cleaning, fins may be damaged.

1.Spill of leak: Contain spill immediately in smallest area possible. Recover as much of the product itself as possible by such methods as vacuuming, followed by soaking up of residual fluids by use of absorbent materials. Remove contaminated items including contaminated soil and place in proper containers for disposal. Avoid washing, draining or directing material to storm or sanitary sewers.

4. About waste disposal 1.Waste oils, used filters, and other such petrochemical-related products, if disposed of thoughtlessly, will cause environmental contamination.

2.Waste disposal method: Recycle as much of the recoverable product as possible. Dispose of nonrecyclable material as a RCRA hazardous waste by such methods as incineration, complying with federal, state, and local regulations.

2.Obtain a proper-sized vessel before releasing waste oils from the machine. Never discharge waste oils on the ground or into rivers, lakes or marshes.

3.Follow all governing environmental rules and regulations when disposing of oils, fuels, cooling water, brake fluid, solvents, filters, batteries or any other damaging substances.

4.3 Motor oil See HYDRAULIC OIL above.

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WA01-0041E

Foreword 1.1 Unit No. of the TM-2000-1 series

Foreword This manual contains information on the systems

Spec.

and components of TM-2000-1 series cranes.

It also contains repair, inspection, and adjustment procedures for those systems and components.

To be sure of performing repair and service operations correctly ,read this manual in conjunction with the separate operation and maintenance manual and the separate parts catalog.

Boom nameplate unit No.

Frame nameplate unit No.

TM-2000-1-104

411-431-10010

TM-2000-1-114

411-431-10020

TM-2000-1-204

411-431-10050

TM-2000-1-214

Whenever a part need to be replaced, check the

411-431-10060 411-431-20040

part sales unit in the parts catalog.

TM-2000-1-304

411-431-10030

1. Applicable unit No.

TM-2000-1-314

411-431-10040

Boom nameplate

TM-2000-1-404

411-431-10070

TM-2000-1-414

411-431-10080

(1) Unit No. (2) Lot No.

(1)

2. Separate service manual

(2) UNI T

NO.

LOT

NO.

IWA04-062001

Separate service manual

Publication No.

General Caution

SA01-01-2E

Frame nameplate (1) Unit No. (2) Serial No. (3) Date of mounting

Please note that, for product improvement, some changes may have been incorporated in the

(1) (2)

SPEC.

NO.

machine that are not covered in this manual.

SERIAL. NO.

MFG. DATE.

KAGAWA,JAPAN

(3)

IWA04-062002

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WA04-2140E

Foreword 3. Outline of specifications Spec. No. Item

TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 -104 -304 -114 -314 -204 -214 -404 -414

No. of boom sections

5-section

Winch

Hydraulic motor driven, planetary gear speed reduction, provided with automatic brake

Outriggers extended width

Min.7.15’

Crane mount position

Min.7.38’

Front outriggers extended width

Operation

Safety devices

Max.18.7'

Cab back mount

Rear stabilizers extended width

Swing

Mid.13.1'

Rear mount

Max.11.48'

–

– Non-continuous 375° rotation Manual

Radio remote controls

Min.7.15’ Continuous rotation Manual

Radio remote controls

Non-continuous 375° rotation Manual

Anti-two-block with alarm Hook safety latch Level gauge Hydraulic safety valves, check valves and holding valves Over load shutoff with load indicator Load / Boom angle indication Audible warning External warning lamps

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Mid.13.1'

WA04-2140E

Radio remote controls

Max.18.7'

Continuous rotation Manual

Radio remote controls

Foreword 4. Conversion table Length millimeter, mm

centimeter, cm

meter, m

inch, in, ”

foot, ft, ’

mile, mi

kilometer, km

1

0.1

0.001

0.03937

0.00328

1

1.6093

10

1

0.01

0.3937

0.03281

0.6214

1

1000

100

1

39.37

3.281

–

–

25.4

2.54

0.0254

1

0.08333

–

–

304.8

30.48

0.3048

12

1

–

–

Area square millimeter, mm

2

square centimeter, cm

2

square meter, m

2

square inch, in

2

2

square foot, ft

1

0.01

0.000001

0.00155

-

100

1

0.0001

0.155

0.001076

1000000

10000

1

1550

10.764

645.2

6.452

0.000645

1

0.006944

92903

929.03

0.0929

144

1

Volume cubic centimeter, 3 cm , cc 1

cubic meter, m

cubic inch, in

cubic foot, ft

gallon, gal

cubic inch, in

liter, lit, L

0.000001

0.0610

0.0000353

1

231

3.785

1000000

1

61024

35.31

0.004329

1

0.01639

16.39

0.0000164

1

0.000579

0.2642

61.02

1

28320

0.02832

1728

1

–

–

–

gram, g

kilogram, kg

ounce, oz

pound, lb

metric ton, ton, t

short ton, s. t

1

0.001

0.03527

0.0022

–

–

1000

1

35.27

2.205

0.001

0.001102

28.349

0.02835

1

0.0625

0.00002835

0.00003125

453.592

0.4536

16

1

0.0004536

0.0005

1000000

1000

35274

2205

1

1.102

907185

907.2

32000

2000

0.9072

1

3

3

3

3

Mass

Pressure Pa

kPa

MPa

1

1×10

1×10

3

1

1×10

6

1×10

-3

1×10

3

1×10

4

kgf/cm

2

2

lb/in , psi

-6

1.01972×10

-3

1

-5

14.5×10

1.01972×10

-2

14.5×10

1.01972×10

14.5×10

-2

-5 -2

9.80665×10

9.80665×10

9.80665×10

1

14.22

6895

6.895

0.006895

0.07031

1

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WA04-2140E

Foreword

Torque N-cm

N-m

1

1×10

kgf-cm

-2

2

1×10

-1

1.01972×10

1

9.80665

9.80665×10 2

0.00737

-1

0.7376

8.851

1×10

0.0723

0.868

foot-pound, ft-lb

1.01972×10

1.01972×10 -2

-3

inch-pound, in-lb 0.0885

kgf-m

1.01972×10 -2

1 2

9.80665×10

9.80665

1×10

1

7.233

86.8

135.58

1.3558

13.83

0.1383

1

12

11.3

0.113

1.1525

0.01153

0.08333

1

Centigrade-Fahrenheit °F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

-90

-67.78

-40

-40

10

-12.22

60

15.56

110

43.33

160

71.11

-80

-62.22

-30

-34.44

20

-6.67

70

21.11

120

48.89

170

76.67

-70

-56.67

-20

-28.89

30

-1.11

80

26.67

130

54.44

180

82.22

-60

-51.11

-10

-23.33

40

4.44

90

32.22

140

60

190

87.78

-50

-45.56

0

-17.78

50

10

100

37.78

150

65.56

200

93.33

Conversion equation: t°C =5(T°F -32)/9, T°F =(9×t°C +160)/5

Force N

kgf

lbf -1

-1

1

1.01972×10

2.24809×10

9.80665

1

2.20461

4.44822

0.45359

1

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WA04-2140E

GROUP INDEX A B

Hydraulic Power Generating System

C

Outrigger System

D

Swing System

E

Boom Elevating System

F

Winch System

G

Boom Telescoping System

H

Safety System

I J K L M N O P Q R S T U V

Radio-control System

W X Y

Data, Adjustment and Checks

Z

System Diagrams 5

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WA04-2140E

Foreword 5. Contents Chapter

TM-2000-1

Spec. No.

Section

-104

-304

-114

-314

-204

-214

-404

-414

General A

Refer to separate manual SA01-01-2E

General Cautions

Hydraulic Pressure Generating System

B

Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high / low shift)

B-1

Manual Control Valve (Outrigger)

B-2

Manual Control Valve (Winch)

B-3

Hydraulic Pump

B-4

Sequence Valve (Pilot pressure)

B-5

Solenoid Valve (Auto stop)

B-6

Solenoid Valve (Winch high speed and swing brake)

B-7

Solenoid Valve (Winch unload)

B-8

Solenoid Valve (Outrigger select)

B-9

Pressure Regulator Valve (Outrigger)

B-10

Hydraulic Valve

B-11

Shuttle Valve

B-12

Rotary Joint

–

B-13

–

B-13

Outrigger System Jack Cylinder (Front and rear stabilizer) C

C-1

Jack Cylinder (Outrigger and front outrigger)

C-2

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–

WA04-2140E

Foreword

Chapter

-104

Pilot Check Valve (Front and rear stabilizer)

C

TM-2000-1

Spec. No.

Section

-304

-114

-314

-204

C-3

-404 –

Pilot Check Valve (Outrigger jack and front outrigger jack)

C-4

Power Slide Cylinder (Outrigger and front outrigger)

C-5

Power Slide Cylinder (Rear stabilizer)

C-6

–

Relief Valve (Front stabilizer)

C-7

–

Pressure Sensor (Front stabilizer)

C-8

–

Swing System Hydraulic Motor (Swing)

D-1

Swing Speed Reducer

D-2

Swing Bearing

D-3

D

Boom Elevating System

E

-214

Boom Elevating Cylinder

E-1

Counterbalance Valve (Elevating)

E-2

Winch System Winch

F-1

Hydraulic Motor (Winch)

F-2

Counterbalance Valve (Winch)

F-3

F

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WA04-2140E

-414

Foreword

Chapter

TM-2000-1

Spec. No.

Section

-104

-304

-114

-314

-204

-214

-404

-414

Boom Telescoping System

G

General description of telescoping system

G-1

Boom (Five-section boom)

G-2

Telescoping Cylinder

G-3

Counterbalance Valve (Telescoping)

G-4

Safety Devices AMA (Load moment indicator)

H-1

Boom Length / Angle Detector

H-2

Outrigger extension detector

H-3

H

Radio-control System

V

Configurations of Radio-control System

–

V-1

–

V-1

–

V-1

–

V-1

Radio-control Valve

–

V-2

–

V-2

–

V-2

–

V-2

Accelerator Cylinder

–

V-3

–

V-3

–

V-3

–

V-3

Measures for Emergency Case

–

V-4

–

V-4

–

V-4

–

V-4

Data, Adjustment and Checks

Y

Service Data

Y-1

Adjustment and Checks

Y-2

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WA04-2140E

Foreword

Chapter

Spec. No.

Section

-104

-304

-114

-314

-204

System Diagrams Hydraulic Circuit (Spec. No.: TM-2000-1-104, 114, 204, 214) Hydraulic Circuit (Spec. No.: TM-2000-1-304, 314, 404, 414) Electric Circuit (Spec. No.: TM-2000-1-104, 204)

Z

Z-1 Z-2 Z-3

Electric Circuit (Spec. No.: TM-2000-1-114, 214)

Z-4

Electric Circuit (Spec. No.: TM-2000-1-304, 404)

Z-5

Electric Circuit (Spec. No.: TM-2000-1-314, 414)

Z-6

Location of Hydraulic Parts

Z-7

Location of Electrical Parts

Z-8

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WA04-2140E

TM-2000-1 -214

-404

-414

B Hydraulic Power Generating System

Contents B-1 Manual Control Valve (Boom elevating, telescoping, swing, outrigger, high/low shift)................. 1

B-7 Solenoid Valve (Winch high speed & swing brake) .......................19 1.

1.

B-8 Solenoid Valve (Winch unload).......................21

B-2 Manual Control Valve (Outrigger)................................ 7

1.

1.

Structure ................................................. 21

Structure ................................................... 7

B-9 Solenoid Valve (Outrigger select)...................22

B-3 Manual Control valve (Winch) ................................... 11

1.

1.

Structure ................................................. 19

Structure ................................................... 1

Structure ................................................. 22

Structure ..................................................11

B-4 Hydraulic Pump.............................. 13

B-10 Pressure Regulator Valve (Outrigger) ..............................24

1. Structure .................................................... 13

1.

B-5 Sequence Valve (Pilot pressure) ...................... 14

B-11 Hydraulic Valve ..............................25 1.

1.

Structure ................................................. 24

Structure ................................................. 25

Structure ................................................. 14

B-12 Shuttle Valve...................................26 B-6 Solenoid Valve (Auto stop) ............................. 17

1.

1.

B-13 Rotary Joint ....................................27

Structure ................................................. 17

1.

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Structure ................................................. 26

Structure ................................................. 27

B

B-1

B-1

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

B-1 Manual Control Valve (Boom elevating, telescoping, swing, outrigger, high/low shift) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

Thread size and tightening torque Sign / Port

Thread size

A1 – A4 B1 – B4 P1

Tightening torque N-m

ft-lbf

G1/2

58.8 – 68.6

43.3 – 50.5

P2

G3/8

39.2 – 49.0

28.9 – 36.1

T

G1

98.1 – 117.7

72.3 – 86.8

G1 – G3

G1/4

24.5 – 29.4

18.0 – 21.6

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W113-0400E

B-1

B-1

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

Cross section

Body assy

1. Body assy

5. Valve (Telescoping)

9. O-ring

13. Relief valve (PR1)

2. Valve (Swing)

6. Valve (Confluence)

10. Relief valve (RV1)

14. Stud bolt

3. Body assy

7. Plate

11. Relief valve (RV2)

15. Nut

4. Valve (Elevation)

8. O-ring

12. Relief valve (RV3)

22. Plug 23. O-ring

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W113-0400E

B-1

B-1

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

Valve (Swing)

Body assy

11. Relief valve (RV2)

36. O-ring

43. Hexagon socket bolt

57. Screw

12. Relief valve (RV3)

37. Oil seal

44. Hexagon socket bolt

58. Valve

22. Plug

38. Retainer

52. Valve

59. Spring

23. O-ring

39. Retainer

53. Spring

60. Retainer

33. Check valve

40. Spring

54. Plug

61. Plug

34. Spring

41. Spool end

55. O-ring

62. O-ring

35. Retainer

42. Cover

56. Screw

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W113-0400E

B-1

B-1

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

Valve (Elevation)

Valve (Telescoping)

Valve (Confluence)

13. Relief valve (PR1)

38. Retainer

44. Hexagon socket bolt

81. Rod end

33. Check valve

39. Retainer

45. Plug

82. Cover

34. Spring

40. Spring

77. O-ring

83. Cover

35. Retainer

41. Spool end

78. Retainer

84. Hexagon socket bolt

36. O-ring

42. Cover

79. Spring

37. Oil seal

43. Hexagon socket bolt

80. Retainer

4 Downloaded from www.Manualslib.com manuals search engine

W113-0400E

B-1

B-1

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

Relief valve (RV1)

Relief valve (RV2)

10. Relief valve (RV1)

106.O-ring

112.O-ring

140.Backup ring

11. Relief valve (RV2)

107.O-ring

113.Nut

141.Backup ring

62. O-ring

108.Body

114.Cap nut

142.Backup ring

103.O-ring

109.Regulator valve

128.Stopper

143.Backup ring

104.Spring

110.Spring

129.Retainer

105.Retainer

111.Screw

137.O-ring

5 Downloaded from www.Manualslib.com manuals search engine

W113-0400E

B-1 .

B-1 .

Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift)

Relief valve (RV3)

Relief valve (PR1)

12. Relief valve (RV3)

111.Screw

151.Body

157.Body

13. Relief valve (PR1)

113.Nut

154.O-ring

158.O-ring

109.Regulator valve

114.Cap nut

155.Backup ring

159.Backup ring

110.Spring

137.O-ring

156.Spring

160.O-ing

0 366-382-50000 △

6 Downloaded from www.Manualslib.com manuals search engine

W113-0400E

B-2

B-2

Manual Control Valve(Outrigger) B-2

Manual Control Valve (Outrigger)

[NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Cover assy

5. Valve (Outrigger / Right)

9. Relief valve (RV5)

13. O-ring

2. Valve (Front stabilizer)

6. Valve

10. O-ring

14. Plug

3. Valve (Ext / Ret)

7. Body assy

11. Bolt

15. O-ring

4. Valve assy

8. Nut

12. Plug

7 Downloaded from www.Manualslib.com manuals search engine

W113-0440E

B-2

B-2

Manual Control Valve(Outrigger) Valve (Front stabilizer)

Valve(Extension/Retraction)

2. Body assy

25. Retainer

29. Spring

33. Hexagon socket bolt

3. Valve (Swing)

26. O-ring

30. Spool end

34. Hexagon socket bolt

23. O-ring

27. Bracket

31. Cover

35. Check valve

24. Oil seal

28. Retainer

32. Retainer

36. Spring

8 Downloaded from www.Manualslib.com manuals search engine

W113-0440E

B-2

B-2

Manual Control Valve(Outrigger) Valve (Outrigger/Right)

Valve(Rear Stabilizer & Outrigger/Left)

5. Valve(Outrigger / Right)

25. Retainer

33. Hexagon socket bolt

59. Spring

6. Valve

26. O-ring

56. Retainer

60. Retainer

23. O-ring

31. Cover

57. Spool end

61. Steel ball

24. Oil seal

32. Retainer

58. Case

63. Hexagon socket bolt

9 Downloaded from www.Manualslib.com manuals search engine

W113-0440E

B-2 .

B-2 .

Manual Control Valve(Outrigger) Relief valve(RV5)

9. Relief valve (RV5)

84. O-ring

86. O-ring

83. Spring

85. O-ring

90. Spring

94. O-ring

Thread size and tightening torque Sign / Port

Thread size

P, V, T

Tightening torque N-m

ft-lbf

G1/2

58.8 – 68.6

43.3 – 50.5

A, B,C3

G3/8

39.2 – 49.0

28.9 – 36.1

Gauge port

G1/4

24.5 – 29.4

18.0 – 21.6

4 366-382-80000 △

10 Downloaded from www.Manualslib.com manuals search engine

W113-0440E

B-3

B-3

Manual Control valve (W inch) B-3

Manual Control valve (W inch)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General view

11 Downloaded from www.Manualslib.com manuals search engine

W113-0431E

B-3 .

B-3 .

Manual Control valve (W inch) 1. Body

10. Cover

18. Fork end

25. Nut

2. Body

11. Washer

19. Poppet

26. Spring washer

4. Plug

12. Hexagon socket bolt

20. Spring

29. Flange

5. O-ring

14. Spring

21. Cap

30. O-ring

7. O-ring

15. Spring seat

22. O-ring

31. Hexagon socket bolt

8. O-ring

16. Packing

23. Relif valve

9. Cover

17. Bolt

24. Stud bolt

Thread size and tightening torque Sign / Port

Thread size

P2

Tightening torque N-m

ft-lbf

G1

372 - 412

274‐303

t1

M10

54 - 66

39 - 48

t2

M12

88 - 108

64 - 79

t3

M16

100 - 120

73 - 88 0 366-383-70000 △

366-382-60000

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W113-0431E

0 △

B-4 .

B-4 .

Hydraulic Pump B-4

Hydraulic Pump

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1. Gear pump (No.1)

3. Gear pump (No.3)

2. Gear pump (No.2)

4. Coupling

5. Coupling

6. Distance piece

Thread size and tightening torque Sign / Port

Thread size

T1 T2

Tightening torque N-m

ft-lbf

-

294

217

-

55 - 69

40.6 - 50.9 0 366-541-30000 △

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W101-0340E

B-5

B-5

Sequence Valve (Pilot pressure) B-5

Sequence Valve (Pilot pressure)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

Thread size and tightening torque Sign / port

Thread size

P, V Dr Pi, G

G1/2 G3/8 G1/4

Tightening torque N-m ft-lbf 98 72 49 36 29.4 22

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W122-0113E

B-5

B-5

Sequence Valve (Pilot pressure) Cross section along the line A-A (back pressure regulating valve, pressure reducing valve)

6

1.Body 2.Filter

5

3.Filter retainer

4.Back pressure regulating valve 5.Pressure reducing valve 6.Hex. socket head bolt 7.Plug 8.O-ring 9.Plug

4

1

A-A

2

3 IW122-0112E01

Thread size and tightening torque Sign / port

Thread size

3 6

G1/2 M6

Tightening torque N-m 9.81 - 11.8 9.81 - 10.8

ft-lbf 7.2 - 8.7 7.2 - 8

Back pressure regulating valve (illustrated as 4 in the cross section along the line A-A)

1

2

6

7

3

4

8

5

1.Spring cover 2.Stopper 3.Piston 4.Valve 5.Socket 6.Spring 7.O-ring 8.O-ring IW122-011004

Thread size and tightening torque Sign / port

Thread size

1

M24×1.5

Tightening torque N-m

ft-lbf

58.8 – 68.6

43.4 – 50.6

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W122-0113E

B-5 .

B-5 .

Sequence Valve (Pilot pressure) Pressure reducing valve (illustrated as 5 in the cross section along the line A-A)

7

11

9

10

8

1

6

3

5

12

2

13

4 IW122-011005

1.Body

5.Spring seat

9.O-ring

2.Spool

6.Spring

10.Nut

3.O-ring

7.Adjust screw

11.Cap nut

4.Plug

8.Body

12.O-ring

13.O-ring

0 366-038-80000 △ 0 366-060-30000 △

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W122-0113E

B-6

B-6

Solenoid Valve (Auto stop) B-6

Solenoid Valve (Auto stop)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure Hydraulic symbol

Solenoid valve assy

1. Body

3. Filter element (100μ)

5. Plug

7. O-ring

2. Distance piece

4. Plug

6. O-ring

8. Solenoid valve assy

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W121-0910E

B-6 .

B-6 .

Solenoid Valve (Auto stop) Thread size and tightening torque Sign / Port

Thread size

A, B, T

Tightening torque N-m

ft-lbf

G1/4

29.4

22

4

G3/8A

30 - 37

22.1 - 27.3

T1

M5

6.9 – 8.9

5 – 6.5

0 367-402-00000 △

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W121-0910E

B-7

B-7

Solenoid Valve (Winch high speed & swing brake) B-7

Solenoid Valve (Winch high speed & swing brake)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure A2

A1

T P IW121-067001

701

171

T A2

A1

P

101.Casing 171.Hex. socket head bolt 701.Solenoid valve (DC12V) T1

101

Thread size and tightening torque Sign / Port

Thread size

P,T,A1,A2

Tightening torque N-m

ft-lbf

G1/4

34 - 38

25 - 28

171

M5

6-8

4.5 - 6

T1

M8

26 - 32

20 - 24

19 Downloaded from www.Manualslib.com manuals search engine

W121-0900E

IW121-067002

B-7 .

B-7 .

Solenoid Valve (Winch high speed & swing brake)

Solenoid valve assy

Connector 31 1

326

324

IW121-0671E01

P 312 361

A 362

T 363

861

801

802 IW121-067003

311.Spool

326.Retaining ring

363.O-ring

861. O-ring

312.Sleeve

361.O-ring

801.Solenoid valve

324.Spring

362.O-ring

802.Seal nut

Thread size and tightening torque Sign / Port

Thread size

802

M6

Tightening torque N-m

ft-lbf

6.9 - 7.9

5.1 - 5.8

1 367-401-90000 △

20 Downloaded from www.Manualslib.com manuals search engine

W121-0900E

B-8 .

B-8 .

Solenoid Valve (Winch unload) B-8

Solenoid Valve (Winch unload)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the parts sales unit described in the parts catalog before starting disassembling operations.

1. Structure Solenoid valve Assy

Hydraulic symbol A B P

T

T P IW121-0460E02

Overall plan

1. Body

3. Spring

5. Plug

7. Solenoid valve assy

2. Plunger

4. Plug

6. O-ring

10. Orifice 11. O-ring

Thread size and tightening torque Sign / Port

Thread size

P, T

G3/4 A

Mounting bolt for solenoid (part no.7)

Tightening torque N-m

ft-lbf

107.8 - 122.5

79.5 – 90.3

6.9 – 8.9

5.1 – 6.5

0 366-402-10000 △

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W121-0870E

B-9

B-9

Solenoid Valve (Outrigger select) B-9

Solenoid Valve (Outrigger select)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the parts sales unit described in the parts catalog before starting disassembling operations.

1. Structure A1 701

T

P IW121-0880E04

171

T A1

P

T1

101

101. Body

171. Hexagon socket bolt

IW121-0880E02

701.Solenoid valve assy (DC12V)

Thread size and tightening torque Sign / Port

Thread size

P, T, A1

Tightening torque N-m

ft-lbf

G1/4

34 - 38

25 - 28

171

M5

6–8

4.5 – 6

T1

M8

26 - 32

20 – 24

22 Downloaded from www.Manualslib.com manuals search engine

W121-0880E

B-9 .

B-9 .

Solenoid Valve (Outrigger select)

Solenoid valve assy 31 1

326

P 312 361

A 362

324

T 363

861

801

802 IW121-0880E03

311. Spool

326. Retaining ring

363. O-ring

861. O-ring

312. Sleeve

361. O-ring

801.Solenoid valve

324. Spring

362. O-ring

802.Seal nut

Thread size and tightening torque Sign / Port

Thread size

802

M6

Downloaded from www.Manualslib.com manuals search engine

Tightening torque N-m

ft-lbf

6.9～7.9

5.1 – 5.8

23

W121-0880E

B-1 0 .

B-1 0 .

Pressure Regulator Valve(Outrigger) B-10 Pressure Regulator Valve (Outrigger) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

2. O-ring

3. Spring

5. Plug

7. O-ring

Thread size and tightening torque Sign / Port

Thread size

A, B

G 3/8

Specification {Cracking pressure

Tightening torque N-m

ft-lbf

44 - 54

32.4 – 39.8

0.22 – 0.36MPa(31.9 – 52.2psi)

A --->B

0.29 – 0.44MPa(42.0 – 63.8psi)

B --->A}

0 366-062-40000 △

24 Downloaded from www.Manualslib.com manuals search engine

W131-0020E

B-1 1 .

B-1 1 .

Hydraulic Valve B-11 Hydraulic Valve [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure B

T Dr AC

P.P IW123-012001

1

T

7

3

B

P.P

AC 4

6

5

Dr 2 IW123-012002

1.Valve body

3.Plug

5.Spring seat

2.Spool

4.Plug

6.Spring

7.O-ring

Thread size and tightening torque Sign / Port

Thread size

AC, B, Dr, T P.P

Tightening torque N-m

ft-lbf

G1/4

29

22

G1/4

29

22

0 366-467-20000 △ 0 366-473-80000 △

25 Downloaded from www.Manualslib.com manuals search engine

W123-0122E

B-1 2 .

B-1 2 .

Shuttle Valve B-12 Shuttle Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

2.Joint

3. O-ring

4. Steel ball

Thread size and tightening torque Sign / Port

Thread size

A, B

G1/4

Tightening torque N-m

ft-lbf

29.4

22

0 366-242-50000 △

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W128-0150E

Ｂ -1 3.

Ｂ -1 3.

Ｂ -1 3.

Rotary Joint B-13 Rotary Joint

1.Body

2.Core

3.Slip ring assy

4.Plain bearing

5. Plain bearing

6.Plate

[NOTICE]

7. Plate

8.Packing

9.Ring seal

10.Bolt

11.Bolt

12.Spring washer

13.Plain washer

14.Bolt

15.Bolt

16. Bolt

17. Bolt

18.Grease nipple

19. Grease nipple

20. Nipple

21. Sleeve

22. Nipple

23.Pipe

24. Nipple

25.Connector

26. Plate

27. Connector

28.Plate

29.Cap

30.Plug

31.Plug

32.Plug

33. Spring washer

34..Plain washer

35.Cap

36. Cover

There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure Tightening torque

Sign / Port

Thread size

A, B

G1

196

145

C,D,E,G

G3/4

167

123

H

G1/2

98

72

K

G3/8

49

36

I,J

G1/4

29

22

N-m

ft-lbf

1 316-317-41000 △ 0 316-317-41000 △

27

W181-0391E

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27

C Outrigger System

Contents C-1 Jack Cylinder (Front and rear stabilizer).................................. 1

C-7 Relief Valve (Front stabilizer) ..........7 1.

1.

Structure ................................................... 1

2.

Check valve Retaining Bolt Tightening Torques ......................................... 1

C-8 Pressure Sensor (Front stabilizer).......................8 1.

C-2 Jack Cylinder.................................... 2 1.

Structure ................................................... 2

C-3 Pilot Check Valve (Front and rear stabilizer).................................. 3 1.

Structure ................................................... 3

C-4 Pilot Check Valve (Outrigger jack)........................ 4 1.

Structure ................................................... 4

C-5 Power Slide Cylinder (Outrigger).... 5 1.

Structure ................................................... 5

C-6 Power Slide Cylinder (Rear stabilizer).................................. 6 1.

Structure ................................................... 6

i Downloaded from www.Manualslib.com manuals search engine

Structure ................................................... 7

Structure ................................................... 8

C

C-1 .

C-1 .

Jack Cylinder (Front & rear stabilizer) C-1

Jack Cylinder (Front and rear stabilizer)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Cylinder

3. Rod cover

5. Packing

7. Dust seal

2. Plain bearing

4. O-ring

6. Backup ring

8. Rod

2. Check valve Retaining Bolt Tightening Torques Check Valve

0 360-356-40000 △ 0 360-355-90000 △ 0 360-355-70000 △

1 Downloaded from www.Manualslib.com manuals search engine

W151-0270E

C-2 .

C-2 .

Jack Cylinder C-2

Jack Cylinder

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Cylinder

5. Packing

9. Backup ring

13. Packing

2. Spring pin

6. Backup ring

10. Rod

14. Backup ring

3. Piston

7. Backup ring

11. Rod cover

15. Dust seal

4. Plain bearing

8. O-ring

12. O-ring

16. Retaining ring 17. Plain bearing

0 360-357-20000 △ 0 360-357-10000 △

2 Downloaded from www.Manualslib.com manuals search engine

W151-0291E

C-3 .

C-3 .

Pilot Check Valve (Front & rear stabilizer) C-3

Pilot Check Valve (Front and rear stabilizer)

[NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Plug

3. Spring

5. Piston

2. O-ring

4. Poppet

6. O-ring

7. Body

Thread size and tightening torque Sign / Port

Thread size

A-B port

Tightening torque N-m

ft-lbf

G 1/4

24.5 - 29.4

18.1 - 21.7

Plug-1

G 3/8

44.1 - 53.9

32.5 - 39.8

Mounting bolt

M 10

43 - 49

31.7 - 36.1 1 366-239-30000 △

3 Downloaded from www.Manualslib.com manuals search engine

W115-0351E

C-4 .

C-4 .

Pilot Check Valve (Outrigger jack) C-4

Pilot Check Valve (Outrigger jack)

[NOTE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Body

3. O-ring

5. Spring

7. O-ring

2. Plug

4. Poppet

6. Piston

8. Backup-ring 9. Seat

Thread size and tightening torque Sign / Port

Thread size

Mounting bolt T1

M 10

Tightening torque N-m

ft-lbf

43 - 49

31.7 - 36.1

0 366-248-00000 △

4 Downloaded from www.Manualslib.com manuals search engine

W115-0560E

C-5 .

C-5 .

Power Slide Cylinder (Outrigger) C-5

Power Slide Cylinder (Outrigger)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Cylinder

4. Backup ring

7. Rod

10. Packing

2. Nut

5. O-ring

8. Rod cover

11. Backup ring

3. Packing

6. Piston

9. O-ring

12. Dust seal

0 360-433-10000 △

5 Downloaded from www.Manualslib.com manuals search engine

W153-0090E

C-6 .

C-6 .

Power Slide Cylinder (Rear stabilizer) C-6

Power Slide Cylinder (Rear stabilizer)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1. Dust seal

4. O-ring

7. Rod

10. Backup ring

2. Backup ring

5. Rod cover

8. Piston

11. O-ring

3. Packing

6. Cylinder

9. Packing

12. Nut

Thread size and tightening torque Thread

Thread size

12

–

Tightening torque N-m

ft-lbf

98

72.3

2 360-429-60000 △ 2 360-429-50000 △

6 Downloaded from www.Manualslib.com manuals search engine

W153-0140E

C-7 .

C-7 .

Relief Valve (Front stabilizer) C-7

Relief Valve (Front stabilizer)

[NOTE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

IW111-012002

3. Spring

6. O-ring

11. Screw

14. O-ring

4. O-ring

7. Body

12. Nut

16. O-ring

5. O-ring

10. Spring

13. Nut

Thread size and tightening torque Sign / Port

Thread size

P, T

Rc 1/2

7 Mounting bolt

M8

Tightening torque N-m

ft-lbf

71 - 97

52.3 – 71.5

78.5 – 88.3

57.9 – 65.1

13 - 15

9.5 – 11.0

1 366-062-90000 △

7 Downloaded from www.Manualslib.com manuals search engine

W111-0280E

C-8 .

C-8 .

Pressure Sensor (Front stabilizer) C-8

Pressure Sensor (Front stabilizer)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

Use example

Specification Setup value----------17.7MPa (180.5 kgf/cm2)

[NOTE] The adjustment of pressure detector is unnecessary.

1 366-828-90000 △

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W337-0040E

D Swing System D

Contents D-1 Hydraulic Motor (Swing) ..................................... 1 1.

Structure ................................................... 1

D-2 Swing Speed Reducer ..................... 3 1.

Structure ................................................... 3

2.

Removing of hydraulic motor .................... 4

3.

Disassembly of reducer ............................ 4

4.

Assembly of reducer ................................. 5

5.

Installation of hydraulic motor ................... 5

D-3 Swing Bearing .................................. 6 1.

Structure ................................................... 6

2.

Notes for installation ................................. 7

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D-1

D-1

Hydraulic Motor (Swing) D-1

Hydraulic Motor (Swing)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure Hydraulic symbol

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W102-0570E

D-1 .

D-1 .

Hydraulic Motor (Swing) 1.Housing

8.Plate

16.Spring

35.Retaining Ring

2.Rotary Assy

9.Retaining Ring

17.Distance Piece

41.Cover

3.Shaft Assy

10.Oil Seal

20.Plug Assy

43.Plate

4.Cover Assy

11.Ring

31.Shaft

44.Pin

5.Piston

12.O-ring

32.Bearing

46.Hexagon Socket Bolt

6.Retaining Ring

13.O-ring

33.Bearing

7.Plate

14.O-ring

34.Retaining Ring

Thread size and tightening torque Sign / Port

Thread size

Pp

Tightening torque N-m

ft-lbf

G1/4

29

21

A, B

G3/4

167

123

R1,R2

G3/8

49

36

Note Pilot port

Drain port

0 366-636-50000 △

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W102-0570E

D-2

D-2

Swing Speed Reducer D-2

Swing Speed Reducer

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure 1. This reducer is two-stage planetary-gear speed reducing mechanism.

2. The rotation power of the hydraulic motor is transmitted in the following order.

Motor output shaft

Sun gear (20)

planetary gear (15)

Planetary gear (26)

carrier B (10)

reducer output shaft (1)

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carrier A (22)

W511-0280E

Sun gear (12)

D-2

D-2

Swing Speed Reducer 1. Output shaft

9. Plug

17. Ring

25. Plate

2. Bolt

10. Carrier (B)

18. Plug (G1/2)

26. Planetary gear (B)

3. Spring washer

11. Snap ring

19. Seal washer

27. Needle bearing

4. Retainer (A)

12. Sun gear (B)

20. Sun gear (A)

28. Plate

5. Casing

13. King pin (A)

21. Plate

29. King pin (B)

6. Ball bearing

14. Plate

22. Carrier (A)

30. Roller bearing

7. Retainer (B)

15. Planetary gear (A)

23. Snap ring

31. Oil seal

8. Snap ring

16. Needle bearing

24.Ring

32. Sleeve

Thread size and tightening torque Sign / Port

Thread size

2 18

Tightening torque N-m

ft-lbf

M8

23.5 – 27.5

17.3 – 20.3

G1/2

175 – 196

129.1 – 144.6

2. Removing of hydraulic motor

3. Disassembly of reducer

[NOTICE]

[NOTICE]

After fixing the swing frame, remove the hydraulic motor and the reducer to prevent the swing frame from self-rotating.

Disassembly and assembly should be always performed in a clean place caring dust and so on.

Careful work is necessary.

Do not beat and lever to prevent burrs and breakages that cause impossible assembly and performance deteriorations.

1. Before disassembly, mark to each mating surface 2. Drain oil from the hydraulic motor and the reducer.

1. Take out parts from sun gear-A (20) to carrier

3. After removing bolts (2) (eight places) securing

B(10).

the hydraulic motor, remove the motor by using pulling-out screw (2-M8) on the motor flange.

[NOTICE] King pins (13), (29) are fitted by shrinkage fitting, space (14) is fitted by caulking.

[NOTICE] Support the hydraulic motor, 20kg (44.1lbf), firmly to prevent falling.

2. Remove snap ring (8) and retainer-B (7), and remove output shaft (1) from casing (5) by using a press.

[NOTICE] Sleeve (32) shrinkage fit, can not be removed.

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W511-0280E

D-2 .

D-2 .

Swing Speed Reducer 4. Assembly of reducer

5. Installation of hydraulic motor

1. Press-fit retainer-A (4) and roller bearing (30) to

1. Tighten hydraulic motor by bolt (2).

output shaft (1).

[NOTICE]

[NOTICE] Apply lithium type grease between retainer-A (4) and oil seal (31).

Apply THREE BOND 1104 on the mating surface between the hydraulic motor casing and the swing reducer.

2. Build output axis Assy into the casing (５).

2. Apply THREE BOND 1215 on the mating surface between the hydraulic motor casing and the swing

[NOTICE]

reducer.

Apply THREE BOND 1215 on the mating surface between the casing (5) and retainer-A (4).

3. Supply gear oil into the reducer via plug (9).

3

(about 1.2L (73.2 in )) 4.Press-fit ball bearing (6), install retainer-B (7), and hold it in position with snap ring (8).

5. Hereafter, assemble carrier-B(10) to sun gear-A (20) in reverse order of

"Disassemly of reducer."

[NOTICE] Confirm sun gear-A (20) turns lightly by your hand.

0 360-814-51000 △

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W511-0280E

D-3

D-3

Swing Bearing D-3

Swing Bearing

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Swing bearing

3. Plain washer

5. Plain washer

7. Bolt (M18x55)

2. Bolt (M20x70)

4. Bolt (M22x90)

6. Swing Assy

8. Plain washer

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W512-0200E

D-3 .

D-3 .

Swing Bearing 2. Notes for installation When installing the inner ring of the swing bearing, face the soft zone (stop plug) to the R position shown in the figure on the previous page.

To tighten the bolts•2,4,7, follow the procedures below.

Tighten all the bolts temporarily with approximately half the specified tightening torque.

Then tighten the bolts securely. After tightening one bolt in this case, tighten the diagonally opposite bolt.

Thread size and tightening torque Sign / Port

Thread size

2

Tightening torque N-m

ft-lbf

M20

466 - 505

343.7 – 372.4

4

M22

628 - 672

463.2 – 495.6

7

M18

372 - 412

274.3 – 303.9

Note

Apply a torque control agent to the threaded sections of the bolts.

1 313-015-20000 △

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W512-0200E

E Boom Elevating System E Contents E-1

Boom Elevating Cylinder ........ 1

1.

Structure ................................................... 1

2.

Pressure detector for AMA ........................ 2

E-2 Counterbalance Valve (Elevating) ................................ 3 1.

Structure ................................................... 3

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E -1

E -1

Boom Elevating Cylinder E-1

Boom Elevating Cylinder

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1. Grease nipple

7. O-ring

13. Damper ring

19. Backup ring

2. Spring pin

8. Backup ring

14. O-ring

20. Plug

3. Piston

9. Cylinder

15. Packing

21. Orifice

4. Plain bearing

10. Rod

16. Backup ring

5. Packing

11. Rod cover assy

17. Dust seal

6. Backup ring

12. O-ring

18. Retaining ring

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W155-0310E

E -1 .

E -1 .

Boom Elevating Cylinder 2. Pressure detector for AMA [NOTE] The adjustment of pressure detector is unnecessary.

Cylinder side

Rod side

1 361-500-70000 △ 1 361-801-10000 △ 0 360-275-80000 △

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W155-0310E

E -2

E -2

Counterbalance Valve (Elevating) E-2

Counterbalance Valve (Elevating)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Body

5. Spring

9. Plug

2. Spool

6. O-ring

10. Poppet

3. Plug

7. Plug

11. Spring

4. Backup ring

8. Plug

12. O-ring

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13. O-ring

W119-0282E

E -2 .

E -2 .

Counterbalance Valve (Elevating)

Thread size and tightening torque Sign / Port

Thread size

Mounting bolt

Tightening torque N-m

ft-lbf

M10

34.3 - 39.2

25.3 - 28.9

G 3/8

44.1 - 53.9

32.5 - 39.8

G 1/2

53.9 - 63.7

39.8 - 47

A-B port Plug-3.9 Plug - 7

1 366-065-50000 △ 2 366-055-20000 △

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W119-0282E

F Winch System FF Contents F-1 Winch ................................................ 1 1.

Structure ................................................... 1

F-2 Hydraulic Motor(Winch) .................. 5 1.

Operational explanation ............................ 5

2.

Structural explanation ............................... 5

3.

Structure ................................................... 6

F-3 Counterbalance Valve(Winch) ........ 7 1.

Structure ................................................... 7

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F-1

F-1

Winch F-1

Winch

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

[NOTICE] ※1：The amount of the projection in the bolt thread should be 5mm(0.2in) or less. ※2：A proper oil quantity is shown by the oil level line in the drum state for checking, refueling, and draining(as shown). ※3：If plate-15 can not be inserted between winch assy-1 and support-9, discard plate-15.

1.Winch ASSY

5.Cover

9.Support

13.Spring washer

2.Bolt

6.Bolt

10.Bolt

14.Spring washer

3.Spring washer

7.Plain washer

11.Hexagon socket head bolt

15.Plate

4.Wedge

8.Spring washer

12.Hexagon socket head bolt

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W526-0350E

F-1

F-1

Winch 1 Winch ASSY

1.Winch ASSY

3.Hydraulic motor

5.Spring washer

2.Support

4.Bolt

6.O-ring

Thread size and tightening torque Sign / Port

Thread size

4

M16

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Tightening torque N-m

ft-lbf

132-154

97-114

2

W526-0350E

7.Plug ASSY

F-1

F-1

Winch 1 Winch ASSY

1.Bracket

14.Needle roller bearing

27.Sun gear(B)

40.Ball bearing

2.Plug ASSY

15.Hexagon socket head plug

28.Carrier(A)

41.Input shaft

3.O-ring

16.O-ring

29.Internal gear

42.Piston

4.Spindol

17.Steel bearing ring

30.Kingpin(B)

43.Lock washer

5.Hexagon socket head plug

18.Kingpin(A)

31.Idle gear

44.O-ring

6.Snap ring

19.Snap ring

32.Steel bearing ring

45.Backup ring

7.O-ring

20.Hexagon socket head bolt

33.Ball bearing

46.O-ring

8.Oil seal

21.Ball bearing

34.Ball bearing

47.Backup ring

9.Snap ring

22.Steel bearing ring

35.Sleeve

48.Partner plate

10.Carrier(B)

23.Housing

36.Clip

49.Friction plate

11.Steel bearing ring

24.Sun gear(A)

37.Hexagon socket head bolt

50.Fixation plate(S)

12.Steel bearing ring

25.Drum

38.O-ring

51.Hexagon socket head bolt

13.Planetary gear

26.Slust plate

39.Spring

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W526-0350E

F-1.

F-1.

Winch

Thread size and tightening torque Sign / Port

Thread size

20

Tightening torque N-m

ft-lbf

M12

78.5

58

37 ※3

M14

108-126

80-93

37 ※4

M14

118

87

51

M14

108-126

80-93

[NOTICE]: ※1：Caulking. ※2：Apply THREE BOND 1373N. ※5：Apply lithium grease or spindle oil. ※6：wrap sealing tape. Plug must not project from the surface. ※7：Apply THREE BOND 1215 when shrinkage fitting. ※8：Apply lithium grease between lips. Apply THREE BOND 1215 on outer side. ※9：Adjust the space with piston to L=1.1 to 1.3mm(0.04 to 0.05in).

0 313-114-90000 △ 0 360-736-70000 △ 0 360-736-00000 △

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W526-0350E

F-2

F-2

Hydraulic Motor(Winch) F-2 Hydraulic Motor(Winch)

2. Structural explanation

1. Operational explanation

Cylinder block-9 is maintained rotatably with the center pin and the control plate.

When pressure oil is supplied from the other slit in the control plate, half of pistons in the cylinder block

Cylinder block-9

receive the pressure and are pushed out.

plate by the corned disc springs at no-load running.

is pressed against the control

The pistons pushed out push the flange portion of

The pressure rises up between the cylinder block 9

the drive shaft upward, and rotate the drive shaft.

and the control plate, balances cylinder block-9 and the control plate, and a oil film is always formed

At this time, the cylinder block slide on the control

between them.

plate.

Bearings-16 and 17 are combined with bearing

When rotating, each of seven pistons reciprocates

case-11, and installed in drive shaft-10 .

between top dead center (OT) and bottom dead center (UT), and then obtains strokes of (h)

These bearings receive the load caused in axially

according to inclination (a).

and the radial.

The amount of oil that corresponds to the sectional

Oil seal-24, O rings-6 and 19 are used for the seal of

area of the piston (F) × piston stroke (h) is supplied

the driving mechanism to the outside.

from one of slits in the control plate at the process of the piston of UT to OT.

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W102-0581E

F-2.

F-2.

Hydraulic Motor(Winch) 3. Structure [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1.Piston motor

7.Hexagon socket head bolt

13.Shim

19.O-ring

2.Counterbalance valve

8.Plug

14.Plate

20.Shim

3.Housing

9.Cylinder block

15.Retaining ring

21.Shim

4.Cover

10.Shaft

16.Bearing

22.Shim

5.Parallel pin

11.Case

17. Bearing

23.Screw

6.O-ring

12.Seal case

18.Retaining ring

24.Oil seal

Thread size and tightening torque Sign / Port

Thread size

7 8

Tightening torque N-m

ft-lbf

M12

98-123

72-91

G1/4

19-23

14-17 1 366-630-10000 △

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W102-0581E

F-3

F-3

Counterbalance Valve(W inch) F-3

Counterbalance Valve(W inch)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1.Body

7.Cover

13.Hexagon socket head bolt

19.O-ring

2.Spool

8.Plunger

14.Hexagon socket head bolt

20.O-ring

3.Piston

9.Bushing

15.Hexagon head bolt

21.Spring

4.Orifice

10.Plug

16.O-ring

22.Spring

5.Cover

11.Plug

17.O-ring

23.Spring

6.Cover

12.Hexagon socket head bolt

18.O-ring

24.Relief valve

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W119-0540E

F-3.

F-3.

Counterbalance Valve(W inch)

Thread size and tightening torque Sign / Port

Thread size

12

Tightening torque N-m

ft-lbf

M6

12-15

9-11

13

M8

28-35

21-26

14

M10

55-69

41-51

15

M12

88

65

A

M10

43-49

32-36

B

M10

43-49

32-36

0 366-053-70000 △

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W119-0540E

G Boom Telescoping System G

Contents G-1 General description of telescoping system ................. 1 1.

2.

G-2 Boom (Five-section boom) ..............5 1.

Structure ................................................... 5

2.

Dismounting the boom assembly and preparation of the boom disassembly...... 7

Functions of units...................................... 1 1.1

Telescoping cylinder ................................... 1

1.2

Counterbalance valve................................. 1

Wire rope mechanism ............................... 1 2.1

Wire rope mechanism A

2.2

Wire rope mechanism B

2.3

Wire rope mechanism C (for extending

3.

(for extending the 3rd boom section) ... 1 (for retracting the 4th boom section) .... 2

2.4

2.1

Dismounting the boom assembly................7

2.2

Preparation of the boom disassembly ........8

Disassembling the boom ......................... 10 3.1

Detaching the base boom section.............10

3.2

Pulling out the boom telescoping cylinder ............ 11

the 4th boom section /retracting

3.3

Detaching the 2nd boom section ..............13

the 3rd boom section) .......................... 2

3.4

Detaching the 3rd boom section ...............13

3.5

Detaching the 4th boom section and

Wire rope mechanism D

disassembling the top boom section........14

(for extending the top boom section) ... 3 2.5

Wire rope mechanism E

4.

(for retracting the top boom section) .... 3

3.

4.

Relation between boom extending/retracting operations and wire rope mechanisms ... 4 3.1

Boom extension.......................................... 4

3.2

Boom retraction .......................................... 4

Inspection................................................ 15 4.1

Boom.........................................................15

4.2

Slide plate .................................................15

4.3

Sheave ......................................................15

4.4

Wire rope for boom telescoping ................15

5.

Structure of the adjuster assy .................. 16

6.

Tools needed for boom assembling operation ......... 17

Boom telescoping order ............................ 4 4.1

Extending.................................................... 4

4.2

Retracting ................................................... 4

7.

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6.1

Tool A ........................................................17

6.2

Tool B ........................................................18

Assembling the boom.............................. 19 7.1

Assembling the top boom section .............19

7.2

Assembling the 4th boom section .............21

7.3

Assembling the 3rd boom section ............ 25

7.4

Assembling

7.5

Assembling the 2nd boom section ........... 29

7.6

Assembling the base boom section ......... 34

the boom telescoping cylinder.......... 28

8.

Mounting the boom assy......................... 37

G-3 Telescoping Cylinder..................... 38 1.Structure ......................................................... 38

G-4 Counterbalance Valve (Telescoping) ....................... 40 1.Structure ......................................................... 40

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G -1

G -1

General description of telescoping system G-1

General description of telescoping system

1. Functions of units 1.1 Telescoping cylinder This cylinder is located inside the boom.

It is connected to the base boom section and the 2nd boom section with pins to extend and retract the 2nd boom section.

1.2 Counterbalance valve This valve serves to prevent the telescoping cylinder from spontaneously retracting by a load during a boom retracting operation, and to make it retract at a speed in proportion to the oil quantity supplied to the telescoping cylinder.

This valve further serves to prevent the telescoping cylinder from retracting when the piping between this valve and the manual control valve is damaged.

2. Wire rope mechanism The 3rd, 4th and top boom sections are extended/retracted by the following five wire rope mechanisms.

2.1 Wire rope mechanism A (for extending the 3rd boom section) This mechanism extends the 3rd boom section at the same time when the 2nd boom section is extended.

The wire ropes are passed within the boom in the following order. ・Base boom section → sheave at the front end of the telescoping cylinder → rear end of the 3rd boom section

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WG02-0480E

G -1

G -1

General description of telescoping system 2.2 Wire rope mechanism B (for retracting the 4th boom section) This mechanism retracts the 4th boom section at the same time when the 2nd boom section is retracted.

The wire rope is passed within the boom in the following order. ・Rear end of the 4th boom section → rear end of the 2nd boom section → base boom section (adjuster assy) → equalizer sheave (on the upper surface of the 2nd boom section) → rear end of the 2nd boom section → rear end of the 4th boom section

2.3 Wire rope mechanism C (for extending the 4th boom section /retracting the 3rd boom section) The wire rope mechanism C serves for both extending and retracting operations. ・Extending operation: This mechanism extends the 4th boom section at the same time when the 3rd boom section is extended. ・Retracting operation: This mechanism retracts the 3rd boom section at the same time when the 4th boom section is retracted.

The wire ropes are passed within the boom in the following order. ・Front end of the base boom section → front end of the 3rd boom section → rear end of the 4th boom section → front end of the 3rd boom section

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WG02-0480E

G -1

G -1

General description of telescoping system 2.4 Wire rope mechanism D (for extending the top boom section) This mechanism extends the top boom section at the same time when the 4th boom section is extended.

The wire ropes are passed within the boom in the following order. ・Front end of the 3rd boom section → front end of the 4th boom section → rear end of the top boom section

2.5 Wire rope mechanism E (for retracting the top boom section) This mechanism retracts the top boom section at the same time when the 4th boom section is retracted.

The wire ropes are passed within the boom in the following order. ・Front end of the 3rd boom section → rear end of the 4th boom section → rear end of the top boom section

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WG02-0480E

G -1 .

G -1 .

General description of telescoping system 3. Relation between boom extending/retracting operations and wire rope mechanisms

4. Boom telescoping order 4.1 Extending 1. When the 2nd boom section is extended, the 3rd boom section is also extended at the same time by the wire rope mechanism A.

3.1 Boom extension ・2nd boom section: This has no relation to any of the wire rope mechanisms.

This is extended by the telescoping cylinder.

2. When the 3rd boom section is extended, the 4th boom section is also extended at the same time by the wire rope mechanism C.

・3rd boom section: This is extended by the wire rope mechanism A.

3. When the 4th boom section is extended, the top boom section is also extended at the same time by the wire rope mechanism D.

・4th boom section: This is extended by the wire rope mechanism C.

As a result, all of the 2nd, 3rd, 4th and top boom sections are extended all together.

・Top boom section: This is extended by the wire rope mechanism D.

4.2 Retracting

3.2 Boom retraction

1. When the 2nd boom section is retracted, the 4th boom section is also retracted at the same time by the wire rope mechanism B.

・2nd boom section: This has no relation to any of the wire rope mechanisms.

This is retracted by the telescoping cylinder.

2. When the 4th boom section is retracted, the 3rd boom section is also retracted at the same time by the wire rope mechanism C. Additionally the top boom is retracted at the same time by the wire rope mechanism E as well.

・3rd boom section: This is retracted by the wire rope mechanism C. ・4th boom section: This is retracted by the wire rope mechanism B.

As a result, all of the 2nd, 3rd, 4th and top boom sections are retracted all together.

・Top boom section: This is retracted by the wire rope mechanism E.

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WG02-0480E

G -2

G -2

G -2

Boom (Five-section boom) G-2 Boom (Five-section boom) 1. Structure General View

3 312-049-90100 △

5

W536-1040E

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5

G -2

G -2

Boom (Five-section boom) [NOTICE] ◆There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. ---------

43. Plate

85. Slide plate

127. Bolt

2. ---------

44. Roller assembly

86. Plate

128. Plain washer

3. ---------

45. Roller assembly

87. Plate

129. Sheave assembly

4. ---------

46. Pin

88. Slide plate

130. Pin

5. ---------

47. Pin

89. Plate

131. Retaining ring

6. Pin

48. Spacer

90. Support assembly

132. Support

7. Snap pin

49. Pin

91. Hexagon socket head bolt

133. Bolt

8. Pin

50. Snap pin

92. Slide plate

134. Shim

9. Plate

51. Sheave assembly

93. Slide plate

135. Pin

10. Sheave assembly

52. Pin

94. Shim

136. Bolt

11. Spacer

53. Retaining ring

95. Shim

137. Spring washer

12. Spacer

54. Lock washer

96. Bolt

138. Support

13. Pin

55. Nut

97. Plain washer

139. Bolt

14. Plate

56. Sheave assembly

98. Support

140. Bolt

15. Sheave assembly

57. Pin

99. Hexagon socket head bolt

141. Pin

16. Spacer

58. Bolt

100. Bolt

142. Retaining ring

17. Wire rope

59. Support

101. Spring washer

143. Slide plate

18. Nut

60. Bolt

102. Bolt

144. Slide plate

19. Wire rope

61. Sheave assembly

103. Bolt

145. Nut

20. Nut

62. Spacer

104. Bolt

146. Bolt

21. Nut

63. Spacer

105. Bolt

147. Plate

22. Wire rope

64. Button bolt

106. Bolt

148. Plate

23. Wire rope

65. Pin

107. Bolt

149. Plate

24. Wire rope

66. Plate

108. Bolt

150. Plate

25. Hexagon socket head bolt

67. Slide plate

109. Bolt

151. Slide plate

26. Support

68. Machine screw

110. Bolt

152. ---------

27. Plug

69. Plain bearing

111. Spring washer

153. ---------

28. Nameplate

70. Plate

112. Hexagon socket head bolt

154. ---------

29. Tapping screw

71. Retainer

113. Hexagon socket head bolt

155. ---------

30. Cap

72. Retainer

114. Bolt

156. Shim

31. Grease nipple

73. Slide plate

115. Spring washer

157. Shim

32. Grease nipple

74. Retainer

116. Pin

158. Plate

33. Pin

75. Retainer

117. Spacer

159. Plate

34. Plate

76. Slide plate

118. ---------

160. Bolt

35. Cover

77. Slide plate

119. Sheave assembly

161. Bolt

36. Pin

78. Support

120. Pin

162. Set screw

37. Support

79. Slide plate

121. Retaining ring

163. Cover

38. Sheave assembly

80. Plate

122. Pin

39. Spacer

81. Plate

123. Retaining ring

40. Pin

82. Slide plate

124. Adjuster assembly

41. Spacer

83. Shim

125. Bolt

42. Guide

84. Shim

126. Spring washer

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G -2

Boom (Five-section boom) 2. Dismounting the boom assembly and preparation of the boom disassembly 2.1 Dismounting the boom assembly 1. Extend the outrigger and set the crane level.

2. Confirm all the crane functions.

3. Swing the boom over the rear.

4. Unwind the winch wire rope enough to lay down the hook block on the ground.

5. Prepared wooden spacer of the thickness of "5in.".

(For disassembly and assembly) 1,2,3,4

6. Put the "5 in." spacer between the elevating cylinder and the swing frame.

7. Lower the boom until the elevating cylinder comes in contact with the spacer.

6

8. Stop the engine.

9. Relieve the pressure in the circuit by operating all control levers back and forth.

13

10. Remove hydraulic hoses for winch and tel. cylinders. * Put plugs to all connectors.

11. Disconnect all electric wires between boom and swing frame.

12. Remove hook block and rope socket.

13. Slightly hoist the boom assy to relieve the boom’s weight on the pivot pins. * Boom Assy weight: Approx. 3,000 lbs. (1350kg) 14. Remove elevating cylinder's upper pivot pin.

15. Remove Boom bottom pivot pin.

16. Dismount Boom Assy. * This boom's bottom is V-shaped. * Boom Assy must be placed level for easy disassembling.

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Boom (Five-section boom) 2.2 Preparation of the boom disassembly [NOTICE] ◆Refer to the boom length and angle detector replacement procedures in Chapter H before disassembling the boom.

1. Dismount Winch Assy.

2. Prepare 30’ 6” (9300mm) electric cable. - Dummy cable 2

3. Lock the Boom Length Detecter (BLD) cable drum to prevent it from turning. * If BLD drum is over-wound, potentiometer may be damaged.

4. Disconnect BLD cable at top boom head inside.

5. Connect dummy cable to BLD cable.

6. Pull out BLD Cable from back side of boom.

4

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Boom (Five-section boom)

7. Disconnect dummy cable from BLD cable. * Leave dummy cable inside boom.

7

8. Disconnect Hose Joint from tel. cylinder. * Put plug.

8

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W536-1040E

G -2

G -2

Boom (Five-section boom) 3. Disassembling the boom

3. Remove the wire ropes for extending the 3rd

[NOTICE]

boom section from the rear end of the base boom

Follow the disassembling procedure described here only after removing the winch and the boom length/angle detector.

Refer to Chapter H “boom length/detector replacement procedure” for the removing procedure.

section.

[NOTICE] Before removing the wire ropes, measure and record the dimension La, which can be used for reference during reassembly.

3.1 Detaching the base boom section 1. Fully retract the boom.

2. Remove the adjuster assy from the front end of the base boom section.

[NOTICE] Before removing the wire rope, measure and record the dimension Lb, which can be used for reference during reassembly.

4. Remove the wire ropes for extending the 4th boom section from the front end of the base boom section and fix them at the front end of the 4th boom section with a wire etc.

[NOTICE] Before removing the wire ropes, measure and record the dimension Lc, which can be used for reference during reassembly.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 3.2 Pulling out the boom telescoping cylinder

5. Pull out the pin fxing the boom telescoping

1. Remove the sheaves for extending the top boom

cylinder to the base boom section.

section and the wire rope guide from the front end of the 4th boom section.

2. Remove the wire ropes for extending the top boom section from the front end of the 3rd boom section and fix them at the front end of the top boom section with a wire etc.

[NOTICE] Before removing the wire ropes, measure and record the dimension Ld, which can be used for reference during reassembly.

3. Remove the wire ropes for retracting the top boom section from the front end of the 3rd boom section and fix them at the front end of the 4th boom section with a wire etc.

6. To remove the slide plates from the base boom section, pull out the 2nd boom section about 400 to 600 mm (1.3 to 2 ft).

7. Remove the slide plates from the side and lower surfaces at the front end of the base boom section.

[NOTICE] When removing the slide plates from the lower surface, be sure to remove them with the retainers.

8. Draw out the 2nd boom section and others from the base boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

4. Pull and extend the 4th boom section about 200

[NOTICE]

mm (8 in).

When it is attempted to remove the support A, it will hit the wire rope for retracting the 4th boom section.

To avoid this, slacken the wire rope for retracting the 4th boom section as shown in the figure below and move it to one side within the boom.

[NOTICE] If step 5 and subsequent steps are performed without extending the 4th boom section, it will be impossible to pull out the boom telescoping cylinder from the boom.

Do not retract the 4th boom section until the 3rd boom section is removed.

8. Remove the pin fixing the boom telescoping cylinder to the 2nd boom section and pull out the boom telescoping cylinder about 1 m (3.3 ft).

9. Remove the support B from the rear end of the 3rd boom section and put it on the boom

5. Remove the two guide rollers for the boom length

telescoping cylinder.

detector cord.

10. Pull out the boom telescoping cylinder with the support B and the wire ropes for extending the 3rd boom section from the boom.

(Mass of cylinder: approx. 600 kg (1325 lbs)) 11. Remove the wire rope for retracting the 4th boom section from the rear end of the 4th boom section.

6. Remove the support for the wire rope guide at the rear end of the 2nd boom section.

7. Remove the bolts and disassemble the support A for the wire rope for extending the 3rd boom section.

Remove the parts on the support A from the rear end of the 3rd boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 3.3 Detaching the 2nd boom section

3.4 Detaching the 3rd boom section

1. Remove the slide plates from the side and lower

1. Remove the sheave (1) for extending the 4th

surfaces at the front end of the 2nd boom section.

boom section and the wire rope guide from the front end of the 3rd boom section.

2. Remove the wire ropes for extending the 4th boom section from the front end of the 3rd boom section and fix them at the front end of the 4th boom section with a wire etc.

[NOTICE] If the 4th boom section is in a retracted condition, the support at the front end of the wire rope may be caught by the 4th boom section. In such a case, pull out and extend the 4th boom section about 200 mm (8 in).

2. Draw out the 3rd boom and others from the 2nd boom section.

3. Remove the slide plates from the side and lower surfaces at the front end of the 3rd boom section.

4. Draw out the 4th boom and top boom from the 3rd boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 3.5 Detaching the 4th boom section and disassembling the top boom section

6. Remove the plates from the upper surface of the 4th boom section.

1. Remove the sheave (2) for extending the 4th boom section from the 4th boom section.

2. Release the wire ropes for extending the 4th boom section and pull out them from the 4th boom

7. Draw out the top boom section from the 4th boom

section.

section.

3. Remove the sheave for retractng the top boom

8. Remove the wire ropes for extending the top

section and the wire rope guide from the rear end

boom section from the top boom section.

of the 4th boom section.

9. Remove the wire ropes for retracting the top boom section from the top boom section.

4. Release the wire ropes for retracting the top boom section and pull out them to the rear of the 4th boom section.

5. Remove the slide plates from the side and lower surfaces at the front end of the 4th boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 4. Inspection 4.1 Boom Check the boom for torsion, deformation, warp, and/or cracks.

4.2 Slide plate Replace cracked or severely worn parts.

4.3 Sheave Replace damaged, deformed, or severely worn parts.

4.4 Wire rope for boom telescoping If any of the following conditions (1) through (5) are found, replace the wire rope.

[NOTICE] If the end of wire rope is not in proper condition, repair or cut.

1. In running ropes: six randomly distributed broken wires in one lay, or three broken wires in one strand in one lay.

2. Wear of one-third of the original diameter of outside individual wires. Evidence of kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure.

3. Evidence of any heat damage from any cause.

4. Reductions from nominal diameter of more than: 1/64 inch for diameters up to and including 5/16 inch 1/32 inch for diameters 3/8 to 1/2 inch inclusive 3/64 inch for diameters 9/16 to 3/4 inch inclusive 1/16 inch for diameters 7/8 to 1-1/18 inches inclusive 3/32 inch for diameters 1-1/4 to 1-1/12 inches inclusive 5. In standing ropes: more than two broken wires in one lay in sections beyond end connections, or more than one broken wire at an end connection.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 5. Structure of the adjuster assy [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

Use the illustration below for a reference when disassembling the adjuster assy.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 6. Tools needed for boom assembling operation The following tools are needed to assemble the boom. They should be prepared by yourself.

6.1 Tool A [NOTICE] All dimensions in the drawings are in millimeters.

The materials, thread sizes and pitches are described based on JIS (Japanese Industrial Standard).

- Assembly drawing

- Tool main body Material: SS400

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W536-1040E

G -2

G -2

Boom (Five-section boom) - Tool fixing pin and plate Material: SS400

6.2 Tool B [NOTICE] The thread size is based on JIS (Japanese Industrial Standard).

Bolt: M12 coarse thread with thread length 50 mm (2 in) or more Nut: M12 coarse thread, height less than 13 mm (1/2 in)

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7. Assembling the boom

4. Install protective covers on the top boom section.

7.1 Assembling the top boom section 1. To facilitate installaton of the cord of the boom length/angle detector, prepare the following cord or wire (later called as “temporary cord”).

- 1.6 mm (1/16 in) to 4.8 mm (3/16 in) in diameter - 9300 mm (30 ft 6 in) or longer 2. Fix the temporary cord to the support at the front end of the top boom section and stretch it to the rear end of the top boom section.

5. Install the wire ropes for extending and retracting the top boom section.

[NOTICE] Make sure the retaining rings are securely put in place and the wire rope ends are secured.

3. Pass the temporary cord through the cord guide for the boom length/angle detector and pull it out to the rear of the top boom section.

[NOTICE] Pull out the temporary cord at least 1500 mm (4 ft 11 in) from the rear end of the top boom section.

6. Temporarily fix the other ends of the wire ropes for extending the top boom section at the end of the boom with a wire etc.

[NOTICE] Fix the wire ropes while pulling them to the front end of the boom to prevent them from hanging down.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

7. Measure the following internal widthwise

10.Adjust the clearances of the slide plates on the

dimension of the 4th boom section.

side surfaces of the boom based on the

- At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end

dimension measured at step 7.

(welded portion)

Adjust the clearances to the following by increasing or decreasing the number of shims.

[NOTICE]

- 0.5 mm (1/64 in) or less in total when the values

The measured dimension will be used when the clearances are adjusted at step 10.

at right and left are added [NOTICE] After this adjustment, apply thread locker (ThreeBond 1305) to screws that are used for fixing the slide plates.

Then lightly tighten the screw and back off a quarter turn.

11. Apply grease to the surfaces outside the top boom section on which the slide plates of the 4th boom section slide and the slide plates at the rear end of the top boom section.

12. While pulling the temporary cord and the wire ropes for retracting the top boom section to the rear of the boom, insert the top boom section into the 4th boom section to the point about 2 m (6.6 ft) before full retraction.

8. Apply grease to the surfaces inside the 4th boom section on which the slide plates of the top boom section slide.

9. Install the slide pates at the rear end of the top boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7.2 Assembling the 4th boom section

5. Release the wire ropes for extending the top

1. Install the slide plates to the lower surface at the

boom section and place them in the grooves of

front end of the 4th boom section.

the sheaves for extending the top boom section.

Then install the wire rope guide for the sheaves

2. Install the slide plates to the side surfaces at the

for extending the top boom section.

front end of the 4th boom section. Adjust the clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added [NOTICE] Try to minimize the difference between the right and left clearances.

When installing the slide plates, pass the wire ropes for extending the top boom section as shown below.

6. Fully retract the top boom section.

7. Pass the wire ropes for retracting the top boom section through the openings at the upper surface of the 4th boom section.

8. Place the wire ropes for retracting the top boom section in the grooves of the sheaves for retracting the top boom section.

Then insert the sheaves for retracting the top boom section through the openings at the upper surface of the 4th boom section and fix them with pins.

[NOTICE]

3. Retract the top boom section to the point about

Install the sheaves with their clinched sides facing outwardly.

100 mm (4 in) before full retraction.

After installing the sheave, bend one of tabs of the toothed washer over a slot of the lock nut.

4. Install the sheaves for extending the top boom section at the front end of the 4th boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 9. Temporarily fix the ends of the wire ropes for

10. Install the slide plates inside the 4th boom

retracting the top boom section at the front end of

section.

the 4thboom section with a wire etc.

Install the wire rope guides at the rear end of the 4th boom section.

11.Place the wire ropes for extending the 4th boom

[NOTICE]

section in the grooves of the sheaves (2) for

Fix the wire ropes while pulling them to the front end of the boom to prevent them from hanging down.

extending the 4th boom section.

12. Install the sheaves (2) for extending the 4th boom

If the right/left wire rope guides are reversed, they will hit the 3rd boom section when the 4th boom section is inserted into the 3rd boom section.

Make sure that the wire rope guides are installed in the following condition.

section to the 4th boom section.

[NOTICE] When installing the sheave pins, pay attention to the direction of the anti-rotation plate.

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G -2

G -2

Boom (Five-section boom)

13. Adjust the clearances for the sheaves (2) for

14. Fix both ends of the wire ropes for extending the

extending the 4th boom section.

4th boom section at the front end of the 4th boom

Adjust the clearances to the following by

section with a wire etc.

increasing or decreasing the number of plates that

[NOTICE]

are placed between the sheave and sheave pin.

Fix the wire ropes while pulling them to prevent them from hanging down.

- 0.6 mm (3/128 in) or less in total when the values at right and left are added

15. Measure the following internal widthwise

Tightening torque of fixing bolts of sheave pin:

dimension of the 3rd boom section.

- 49.0 – 58.8N・m {36.1 – 43.3 ft・lbf}

- At 1.0 to 1.4 m (3.3 to 4.5 ft)from the front end [NOTICE] The measured dimension will be used when the clearances are adjusted at step 18.

[NOTICE] After this adjustment, apply thread locker (ThreeBond 1305) to bolts that are used for fixing the sheave pins and tighten them.

16. Apply grease to the surfaces inside the 3rd boom section on which the slide plates of the 4th boom section slide.

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G -2

G -2

Boom (Five-section boom)

17. Install the slide pates at the rear end of the 4th

19. Apply grease to the surfaces outside the 4th

boom section.

boom section on which the slide plates of the 3rd boom section slide and the slide plates at the rear

18. Adjust the clearances of the slide plates on the

end of the 4th boom section.

side surfaces of the boom based on the

20. While pulling the temporary cord to the rear of the

dimension measured at step 15.

Adjust the clearances to the following by

boom, insert the 4th boom section into the 3rd

increasing or decreasing the number of shims.

boom section to the point about 2 m (6.6 ft)before

- 0.5 mm (1/64 in) or less in total when the values

full retraction.

at right and left are added

[NOTICE]

[NOTICE]

Be sure to insert the 4th boom section while changing the positions of the wire ropes for retracting the top boom section to prevent them from being pinched between the supports at the front end of the 3rd boom section and the 4th boom section.

After this adjustment, apply thread locker (ThreeBond 1305) to screws that are used for fixing the slide plates.

Then lightly tighten the screw and back off a quarter turn.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7.3 Assembling the 3rd boom section

4. Position the support with the wire rope by

1. Install the slide plates to the lower surface at the

pressing it against the stopper at the front end of

front end of the 3rd boom section.

the 3rd boom section and fix the support in that condition to the 3rd boom section. (for two wire

2. Install the slide plates to the side surfaces at the

ropes)

front end of the 3rd boom section. Adjust the clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added [NOTICE] Try to minimize the difference between the right and left clearances.

5. Pass the wire ropes for extending the 4th boom section from the other ends in the grooves of the sheaves (1) for extending the 4th boom section.

6. Install the wire rope guide for the sheaves (1) for extending the 4th boom section and temporarily fix the wire ropes for extending the 4th boom section.

3. Release the wire ropes for extending the 4th boom section.

Attach the support to an end of

the wire rope for extending the 4th boom section. (for two wire ropes) [NOTICE] Pay attention to the direction of the support.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

9. Measure the following internal widthwise

7. Retract the 4th boom section to the point about

dimension of the 2nd boom section.

200 mm (8 in) before full retraction.

- At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end

[NOTICE]

[NOTICE]

If the 4th boom section is fully retracted, it becomes impossible to install the boom telescoping cylinder.

The measured dimension will be used when the clearances are adjusted at step 12.

8. Release the wire ropes for retracting the top boom section and pass them through the supports at the front end of the 3rd boom section.

10. Apply grease to the surfaces inside the 2nd boom section on which the slide plates of the 3rd boom section slide.

11. Install the slide plates at the rear end of the 3rd boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

12. Adjust the clearances of the slide plates on the

14. Pass the temporary cord through the roller assy

side faces of the boom based on the dimension

and fix the roller assy at the rear end of the 3rd

measured at step 9.

boom section.

Adjust the clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added [NOTICE] After this adjustment, apply thread locker (ThreeBond 1305) to screws that are used for fixing the slide plates.

Then lightly tighten the screw and back off a quarter turn.

15. While pulling the temporary cord to the rear of the boom, insert the 3rd boom section into the 2nd boom section to the point about 2 m (6.6 ft) before full retraction.

13. Apply grease to the surfaces outside the 3rd boom section on which the slide plates of the 2nd boom section slide and the slide plates at the rear end of the 3rd boom section.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7.4 Assembling the boom telescoping cylinder

6. Pass the other (threaded) ends of the wire ropes for extending the 3rd boom section through the

1. Apply the following grease to the outer surface of

holes of the tool A and temporarily fix them with

the boom telescoping cyliner and the support at

nuts.

the front end of the cylinder.

Adjust the wire ropes so that the chamfered surface of the fitting is placed at the bottom.

[NOTICE] Apply Daphne Eponex SR No. 2 grease to the outer surface of the boom telescoping cylinder.

Apply Tadano genuine grease TNR to the support at the front end of the cylinder.

[NOTICE] Turn the wire ropes for extending the 3rd boom section while being careful not to cause them to kink.

2. Pass the wire ropes for extending the 3rd boom section through the sheaves for extending the 3rd boom section.

3. Install the sheaves for extending the 3rd boom section to the support at the front end of the boom telescoping cylinder.

7. Turn the nut until the wire rope becomes lightly tight.

8. Put a mark at the end of the wire rope showing the position of the chamfered surface of the wire rope fitting.

In the figure below, the white paint shows the position of the chamfered surface.

4. Install the tool A to the rear end of the boom telescoping cylinder.

5. Hook the unthreaded ends of the wire ropes for extending the 3rd boom section on the tool A.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7.5 Assembling the 2nd boom section

9. Install the support A around the wire ropes for

1. Install the slide plates to the lower surface at the

extending the 3rd boom section.

front end of the 2nd boom section.

2. Install the slide plates to the side surfaces at the front end of the 2nd boom section. Adjust the clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added

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W536-1040E

G -2

G -2

Boom (Five-section boom)

6. Pass the wire rope for retracting the 4th boom

3. Fully retract the 3rd boom section.

section through the adjuster assy.

4. Fix an end of the wire rope for retracting the 4th

Then pass the wire rope for retracting the 4th

boom section to the rear end of the 4th boom section.

boom section through the equalizer sheave and

Then pass the other end through the

install the wire rope guide support.

opening at the upper surface of the 2nd boom section.

[NOTICE] To prevent the wire rope from kinking, be sure to make it straight once before passing it through various guides.

[NOTICE] Make sure the retaining ring is securely put in place and the wire rope end is secured.

Pass the wire rope according to the following routing diagram.

5. Place the wire rope for retracting the 4th boom section in the groove of the sheave for retracting the 4th boom section.

Then insert the sheave through the opening at the upper surface of the 2nd boom section and fix it with a pin.

Install the wire rope guide.

[NOTICE] Install the sheave with its clinched side facing outwardly.

7. With the same procedure as step 5, fix the sheave for retracting the 4th boom section to the 2nd boom section.

8. With the same procedure as step 4, fix the other end of the wire rope for retracting the 4th boom section to the rear end of the 4th boom section.

[NOTICE] Make sure the retaining ring is securely put in place and the wire rope end is secured.

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G -2

G -2

Boom (Five-section boom)

12. Fix the support A to the rear end of the 3rd boom

9. Pull the adjuster assy to the front end of the 2nd

section.

boom section and place it on the 2nd boom section.

[NOTICE] To make room necessary for this work, slacken the wire rope for retracting 4th boom section and put it to the end of the 2nd boom section.

[NOTICE] Pull the adjuster assy while keeping it straight.

(Refer to the figure for step 5.)

To protect the boom, spread a sheet of corrugated cardboard under the adjuster assy.

13. Remove the tool A from the rear end of the boom telescoping cylinder.

10. Put the support B on the cylinder tube and insert the boom telescoping cylinder into the boom to the point as shown in the figure below.

(Mass of the cylinder: approx. 600 kg (1325 lbs)) [NOTICE] Be careful not to pinch the wire ropes for extending the 3rd boom section between the boom telescoping cylinder and the boom.

Be careful not to drop the side with the support A in the boom. If the wire rope is dropped in the boom, the cylinder has to be drawn to return the wire rope to its original state.

11. Fix the support B to the 3rd boom section with bolts.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

14. Put an electric lamp in at the front end of the top

16. Pass the wire ropes for extending top boom

boom section to illuminate the inside of the boom.

section through the openings at the upper surface

Look into the boom from the rear end of the boom

of the 3rd boom section.

and make sure that the wire ropes for extending

[NOTICE]

the 3rd boom section are positioned as shown

As the wire ropes for extending the top boom section do not have enough length, pass them through the openings by retracting the boom little by little.

below.

17. Fully retract the 4th boom section.

18. Fix the wire ropes for extending the top boom section to the front end of the 3rd boom section.

[NOTICE] The dimension Ld that was measured during disassembly can be used as the reference target when screwing nuts.

[NOTICE] If it is difficult to visually check the wire ropes, pull one end of the wire rope for extending the 3rd boom section and make sure that the other end moves at the timing when the wire rope is pulled.

If the other end does not move, the wire rope for extending the 3rd boom section is pinched between the boom and the boom telescoping cylinder.

Cautiously pull out the support A,B and the boom telescoping cylinder while being careful not to damage the wire ropes, and then install the boom telescoping cylinder again.

19. Fix the wire ropes for retracting the top boom section to the front end of the 3rd boom section.

15. Fully insert the boom telescoping cylinder into the 2nd boom section and fix it with two pins.

Put retaining rings to the pins.

[NOTICE] Make sure the retaining rings are securely put in place and the pins are secured.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

23. Install the slide pates at the rear end of the 2nd

20. Pass the temporary cord through the roller assy

boom section.

and fix the roller assy at the rear end of the 2nd boom section.

21. Measure the following internal widthwise dimension of the base boom section.

- At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end [NOTICE] The measured dimension will be used when the clearances are adjusted at step 24.

24. Adjust the clearances of the slide plates on the side faces of the boom based on the dimension measured at step 21.

Adjust the clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added [NOTICE] After this adjustment, apply thread locker (ThreeBond 1305) to screws that are used for fixing the slide plates.

Then lightly tighten the screw and back off a quarter turn.

22. Apply grease to the surfaces inside the base

25. Apply grease to the surfaces outside the 2nd

boom section on which the slide plates of the 2nd

boom section on which the slide plates of the

boom section slide.

base boom section slide and the slide plates at the rear end of the 2nd boom section.

26. While pulling the temporary cord to the rear of the boom, insert the 2nd boom section into the base boom section to the point about 1 to 2 m (3.3 to 6.6 ft) before full retraction.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 7.6 Assembling the base boom section

5. Fix the adjuster assy to the front end of the base

1. Install the slide plates to the lower surface at the

boom section.

front end of the base boom section.

[NOTICE] 2. Install the slide plates to the side surfaces at the front end of the base boom section.

The dimension Lb that was measured during disassembly can be used as the reference target when screwing nuts.

Adjust the

clearances to the following by increasing or

Before screwing the nuts, loosen the adjusting bolts about one turn. After fixing the adjuster assy, tighten the adjusting bolts as before.

decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values at right and left are added

6. Fully retract the 2nd boom section.

7. Install the slide plates to the side surfaces at the front end of the base boom section.

Adjust the

clearances to the following by increasing or decreasing the number of shims.

- 0.5 mm (1/64 in) or less in total when the values

3. Insert the 2nd boom section into the base boom

at right and left are added

section to the point about 200 mm (8 in) before full retraction.

4. Apply molybdenum disulfide grease to the adjusting screw at the front end of the adjuster assy.

[NOTICE] Be sure to remove the nuts at the front end of the adjuster assy and apply molybdenum disulfide grease to the whole area of the adjusting screw.

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W536-1040E

G -2

G -2

Boom (Five-section boom)

8. Fix the boom telescoping cylinder to the base boom section with a pin.

Put a retaining ring to the pin.

[NOTICE] Make sure the retaining rings are securely put in place and the pins are secured.

10. Pass the ends of the wire ropes for extending the 3rd boom section through the opening at the rear end of the base boom section.

11. Pass the wire ropes for extending the 3rd boom section through the opening for the support at the rear end of the base boom section.

And install the support to the base boom section.

[NOTICE] Install the wire ropes with the chamfered surface of the fitting placed at the bottom.

9. Poke the upper ends of the wire ropes for extending the 3rd boom section with a bar to make them touch the support A. Pull the lower wire ropes at the same time until the lower rope ends come out of the boom as much as shown in the figure below.

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W536-1040E

G -2

G -2

Boom (Five-section boom) 14. Remove the tool B.

12.Screw a nut on the wire rope for extending the

Screw a locknut to lock the wire rope for

3rd boom section.

extending the 3rd boom section.

Then screw the tool B on the wire rope end.

[NOTICE]

[NOTICE]

The dimension La that was measured during disassembly can be used as the reference target when screwing nuts.

The figure below is reference only.

13. While fixing the tool B with a wrench, tighten the nut.

15. Fix the wire ropes for extending the 4th boom section to the front end of the base boom section.

[NOTICE] The dimension Lc that was measured during disassembly can be used as the reference target when screwing nuts.

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W536-1040E

G -2 .

G -2 .

Boom (Five-section boom)

16. Adjust the wire ropes for boom telescoping according to Chapter Y “Adjustment procedure of boom telescoping wire ropes”.

17. Install the boom length/angle detector according to Chapter H “Boom length/angle detector replacement procedure”.

8. Mounting the boom assy Reverse the “2.1 Dismounting the boom assembly” in sequence.

0 312-049-90000 △

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W536-1040E

G -3

G -3

Telescoping Cylinder G-3

Telescoping Cylinder

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1.Roller assy

9.Plain bearing

17.Damper ring (*1)

25.Spring washer

2.Retaining ring

10.Packing

18.Packing

26.Counterbalance valve (*3)

3.Pin

11.Backup ring

19.Backup ring

27.Plug

4.Split pin

12.O-ring

20.Plain bearing

5.Plug

13.Piston

21.O-ring

6.Cylinder

14.Rod

22.Dust seal

7.Nut

15.O-ring

23. Rod cover assy (*2)

8.Setscrew

16.Backup ring

24.Bolt

*1: Face the notch or the lip toward the pressurized side. *2: Apply NEVER SEEZ or equivalent (rust prevention oil) to the threaded portion of the rod cover assy・23. *3: For detail, refer to “Counterbalance Valve (Telescoping)”.

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W157-480E

G -3 .

G -3 .

Telescoping Cylinder Thread size and tightening torque Tightening torque N-m ft-lbf

Thread

Thread size

7

–

515 – 721

380– 531

8

M8

13.2 – 16.2

9.7 – 11.9

23

–

1030 – 1442

760 – 1063

24

M10

34.3 – 39.2

25.3 – 28.9

1 360-181-40000 △

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W157-480E

G -4

G -4

Counterbalance Valve (Telescoping) G-4

Counterbalance Valve (Telescoping)

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure General View

1. Body

5. Spring

9. Plug

2. Spool

6. O-ring

10. Poppet

3. Plug

7. Plug

11. Spring

4. Backup ring

8. Plug

12. O-ring

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13. O-ring

W119-0282E

G -4 .

G -4 .

Counterbalance Valve (Telescoping)

Thread size and tightening torque Sign / Port

Thread size

Mounting bolt

Tightening torque N-m

ft-lbf

M10

34.3 - 39.2

25.3 - 28.9

G 3/8

44.1 - 53.9

32.5 - 39.8

G 1/2

53.9 - 63.7

39.8 - 47

A-B port Plug-3.9 Plug - 7

1 366-065-50000 △ 2 366-055-20000 △

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W157-480E

H Safety System

Contents H-1 AMA (Load Moment Indicator) ........ 1

H-2 Boom Length/Angle Detector........17

1.

Structure ................................................... 1

1.

Construction and function........................ 17

2.

Function of Components........................... 2

2.

Disassembly and reassembly.................. 18

3.

Caution About Installing Length Detector............................. 3

4.

2.1

Disassembly of cord..................................18

2.2

Reassembly of cord ..................................19

2.3

Replacing spiral spring..............................20

2.4

Disassembly of potentiometer

AMA adjustment........................................ 4

(for boom length detection).................20

4.1

Attention for adjustment work..................... 4

2.5

Reassembling of potentiometer ................21

4.2

AMA components ....................................... 4

2.6

Replacing boom angle detector ................21

4.3

Selecting the crane model

4.4

Zero-point and span adjustments

4.5

Zero-point and span adjustments

4.6

Confirming Accuracy .................................. 6

1.

Check of Outrigger Extension Detector ... 22

5.

List of Error Nos. Related to AMA ............. 7

2.

Adjustment Procedure............................. 22

6.

Adjustment items when parts are exchanged ............ 9

3.

and capacity data ................................. 5

Adjustment .............................................. 21

of length detector . ............................... 5

H-3 Outrigger Extension Detector .......22

of angle detector................................... 6

2.1

adjustment procedure (upper surface of frame)........................................................22 2.2

7.

Boom length/angle detector replacement procedure................ 10 7.1

Pulling out cord from boom ...................... 10

7.2

Passing cord through boom ..................... 13

Middle extension detection switch adjustment procedure (side surface of frame)........................................................22

3.

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Maximum extension detection switch

Rear stabilizer Extension Detector.......... 23

H

H-1

H-1

AMA (Load Moment Indicator) H-1

AMA (Load Moment Indicator)

1. Structure

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W301-0270E

H-1

H-1

AMA (Load Moment Indicator) 2. Function of Components

4. Display alteration

1. Outrigger state indicator lamp Lighting condition of these lamps indicates the

Only the display on the AMA main body can be

extension width of right and left outriggers.

altered.

When both outriggers are fully extended, the MAX indicator lamp (green) is lit.

Usually the real load is shown on the display

When both outriggers are extended to minimum,

window. As the display alteration switch is pressed,

the MIN indicator lamp (red) is lit.

the real load display alternates with the moment display.

2. Over-front area state indicator lamp While the boom is in over-front area, this lamp is lit. When the boom is swung out on the over-front area, this lamp goes out.

3. Display window, display alteration switch The display windows usually display the weight of the load. You can change them into the moment ratio display as necessary, using the display alteration switch.

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W301-0270E

H-1

H-1

AMA (Load Moment Indicator) 3. Caution About Installing Length Detector

2. A stopper is attached to the cord. Do not remove the stopper from the cord when installing the detector on the boom, other wise the cord will be

1. Adjust the cord for length detector assy so that the

reeled in all the way, leading to damage to the

yellow tape on the cord is located as shown in the

potentiometer.

drawing when the boom is fully retracted.

After installing the detector, attach the stopper to the end of the cord for next maintenance work.

Refer to chapter Z-5

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W301-0270E

H-1

H-1

AMA (Load Moment Indicator) 4. AMA adjustment

3. Run the engine at an idling speed when performing adjustment.

AMA stores capacity data for plural models of cranes. After mounting of a crane is completed,

4. Shift the Dip switches and the Rotary switch using

you must select the capacity data that correspond

an extra thin screwdriver.

to the actual model and confirm accuracy of the

5. Do not let water enter inside of the AMA during

data.

adjustment.

4.1 Attention for adjustment work

6. Keep off the buttons other than the specified

1. Set the machine level on a firm level ground with

switches.

the outriggers extended as specified.

[NOTE]

(See the Table 1.on the next page.)

For more information, refer to the next page.

2. Remove the cover from the AMA main unit and select the crane model and the capacity data before confirming accuracy.

4.2 AMA components

1 361-930-14000 △

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H-1

H-1

H-1

AMA (Load Moment Indicator) 4.3 Selecting the crane model and capacity data

4.4 Zero-point and span adjustments of length detector .

Swing the boom to over-front before adjustment.

Select the data according to the flowchart below.

( Exclude the case where the direction of the boom has been decided by the inspection system etc.)

START START

Set the Dip switches according to the actual crane model and capacity type.

(For the Dip switch setting that corresponds to each crane model and capacity type, see the Table 1.)

Turn the rotary switch to the "2" position.

Retract the boom fully and press the zero-point adjustment button.

Turn on the power supply.

Extend the boom fully and press the span adjustment button.

Shift the rotary switch to "1".

No

Retract the boom fully again.

Does the displayed value match the one in the "Indication 1" column in the Table 1?

No

Turn ON the select button. (Keep pressing it.)

No

Is the displayed valve within the zero-point adjustment range shown in the Table 2 ?

Yes

Does the displayed value match the one in the "Indication 2" column in the Table 1?

Completed

IW301-017007

Shift the rotary switch to "5".

No

Does the displayed value match the one in the "Indication 3" column in the Table 1?

Yes Completed

IW301-017005

Table 1 Crane model

Specifications Non-continuous 375° rotation Continuous rotation

TM-20110

Non-continuous 375° rotation Continuous rotation

Location of AMA

Capacity type

Dip switch setting DS1

Frame

DS3

Indication 1

Indication 2

00100000

Post Frame Frame

Indication

DS2

10100000 C

00000000

11100000 00110000

Indication 3 005 006

0000

243

001

Outrigger extension Maximum Maximum

Condition for accuracy confirmation Boom Load to be Angle lifted (Ibf.) o 44 1454 44

o

1454

R1(ft.)

R2(ft.)

70.01

73.52

70.01

73.52

008

–

–

–

–

–

013

Maximum

44o

1454

70.01

73.52

Post

10110000

014

Maximum

44o

1454

70.01

73.52

Frame

11110000

016

–

–

–

–

–

Remarks

Serial No.: EX0069 and onward

Serial No.: EX0141 and onward

Table 2 Crane model TM-20110

Zero-point adjustment range Boom length detector

Boom angle detector

8.29 – 8.37

-0.2 – 0.2

[NOTE] For Dip switch setting, “0” means OFF position and “1” means ON position.

For “Indication”, “0” means that no segments are marked up.

For the current capacity type, see the rated lifting capacity chart.

The load includes the weight of the hoisting accessory to hook block.

5

W301-0320E

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5

H-1

H-1

H-1

AMA (Load Moment Indicator) 4.5 Zero-point and span adjustments of angle detector.

4.6 Confirming Accuracy Swing the boom to over-right and make sure that the over-front indication lamp is not lit. ( Exclude the case where the direction of the boom has been decided by the inspection system etc.)

Retract the boom fully and swing it to over-right before adjustment. ( Exclude the case where the direction of the boom has been decided by the inspection system etc.)

START

Measure the elevating angle with the angle meter.

START

Shift the rotary switch to "6".

Set the elevating angle to zero by lower operation with the boom retracted fully, and depress the Zero-point adjustment button.

Set the elevating angle to the specified angle by lower operation, and the load radius to R1(m) by telescoping operation.

Pushing the override SW, lift up the specified load.

The specified angle, R1, and the specified load depend on the table 1.

Set the elevating angle to the specified angle ±1゜.

Set the elevating angle to zero by raise operation with the boom retracted fully, and depress the Span adjustment button. Press the span-adjustment button.

Is the moment displayed value within the range of 95.0-104 % ?

Turn the rotary switch to the "3" position.

No

Yes Extend the boom until the boom stops.

Again, set the elevating angle to zero by lower operation.

No To adjustment " 4.4 "

Is the displayed valve within the Zero-point adjustment range shown in the Table 2 ?

Is the load radius within the range of R1-R2 shown in the table 1 when stops ?

Yes

Yes Completed

IW301-0270E02

No

Turn the rotary switch to "0" position.

Completed

IW301-0270E03

Table 1 Crane model

Specifications Non-continuous 375° rotation Continuous rotation

TM-20110

Non-continuous 375° rotation Continuous rotation

Location of AMA

Capacity type

Dip switch setting DS1

Frame

DS3

Indication 1

Indication 2

00100000

Post Frame Frame

Indication

DS2

10100000 C

00000000

11100000 00110000

Indication 3 005 006

0000

243

001

Outrigger extension Maximum Maximum

Condition for accuracy confirmation Boom Load to be Angle lifted (Ibf.) o 44 1454 44

o

1454

R1(ft.)

R2(ft.)

70.01

73.52

70.01

73.52

008

–

–

–

–

–

013

Maximum

44o

1454

70.01

73.52

Post

10110000

014

Maximum

44o

1454

70.01

73.52

Frame

11110000

016

–

–

–

–

–

Remarks

Serial No.: EX0069 and onward

Serial No.: EX0141 and onward

Table 2 Crane model TM-20110

Zero-point adjustment range Boom length detector

Boom angle detector

8.29 – 8.37

-0.2 – 0.2

[NOTE] For Dip switch setting, “0” means OFF position and “1” means ON position.

For “Indication”, “0” means that no segments are marked up.

For the current capacity type, see the rated lifting capacity chart.

The load includes the weight of the hoisting accessory to hook block.

2 361-930-14000 △

6

W301-0320E

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6

H-1

H-1

AMA (Load Moment Indicator) 5. List of Error Nos. Related to AMA No.

Description

E01 Error in other-side AMA E02 E14 E15

Improper setting of model selection Dip switch

E16 E17 E18

Improper setting of function selection Dip switch

Cause

Measures

An error among E21-27, E29, E65 and E66 occurring in other-side AMA

Refer to canceling method corresponding to each error code.

An error among E14-18 and E28 occurring in other-side AMA

Refer to canceling method corresponding to each error code.

Boom length value or boom angle value left unadjusted

Adjust.

Improper setting of Dipswitch

Set property.

Improper setting of Dipswitch

Set property.

Maladjusted boom full retraction detector switch

Defective cable.

E19

E20

Faulty boom full retraction detector switch

Abnormal load display

Faulty boom length detector

Fully retract the boom and measure the resistance of the potentiometer.

[1-2 of CN3 : 5000±750Ω 1-3 of CN3 : 460±40Ω] If a measured value is out of the standard range, replace the boom length detector.

Faulty AMA main body

Replace the AMA main body if check result is normal.

Maladjusted boom length value

Compare the actual boom length with the boom length value displayed on the display window on the AMA main unit.

Adjust boom length value and check precision. [To make the boom length value appear on the display window, turn the rotary switch to the “2” position.]

Maladjusted boom angle value

Compare the actual boom angle with the boom angle value displayed on the display window on the AMA main unit.

Adjust the boom angle value and check precision. [To make the boom angle value appear on the display window, turn the rotary switch to the “3” position.]

Faulty pressure detector on the cylinder side or the rod side

Compare the actual load with the load value displayed on the display window on the AMA main unit.

Replace the pressure detector on the cylinder side or the rod side if check result is fault.

Faulty AMA main body

Replace the AMA main body if check result is normal.

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Fully retract the boom and make sure that the contact point of the boom full retraction detector switch is CLOSED. If the contact point is OPEN, adjust so that it is CLOSED. Check if there is any broken wire or short circuit between AMA main unit and boom full retraction detector switch.

Replace or repair the cable.

W301-0320E

H-1

H-1

AMA (Load Moment Indicator) No. E21 E29 E22 E23

E24

E25

E26 E27

Description

Cause

Measures

Faulty CPU Faulty AMA main body

Replace the AMA main body.

Connector (CN3) disconnected

Connect.

Maladjusted cord of the boom length detector when installed

Make sure that the error occurs on the occasions that the boom is almost fully extended or almost fully retracted.

Adjust the cord so that the yellow tape on the cord is located close to the opening when the boom is fully retracted. Then adjust the boom length value and check precision.

Faulty boom length detector

Fully retract the boom and measure the resistance of the potentiometer.

[1-2 of CN3 : 5000±750Ω 1-3 of CN3 : 460±40Ω] If a measured value is out of the standard range, replace the boom length detector.

Faulty AMA main body

Replace the AMA main body if check result is normal.

Connector (CN4) disconnected

Connect.

Boom angle value adjustment performed while it is maladjusted (i, e, the crane is inclined).

Make sure that the error occurs on the occasions that the boom is almost fully raised or almost fully lowered.

Adjust the boom angle value and check precision.

Faulty boom angle adjuster.

Measure the resistance of the potentiometer while the boom angle is at minimum (1°).

[2-4 of CN4 : 1000±200Ω 2-3 of CN4 : 150±20Ω] If a measured value is out of the standard range, replace the boom angle detector.

Faulty AMA main body.

Replace the AMA main body.

Defective cable.

Check if there is broken wire or short circuit between the AMA main body and a pressure detector (on cylinder’s/ rod’s side).

Replace or repair the cable.

Faulty pressure detector on the cylinder’s side or the rod’s side.

Measare the output voltage of the pressure detectors on the cylinder’s side or the rod’s side. They should be 0.5-4.5V DC. Measure 2-3 of CN8 (while CN7 is disconnected) and 2-3 of CN7 (while CN8 is disconnected).

Faulty AMA main body.

Replace the AMA main body if check result is normal.

Faulty hardware

Faulty length detector

Faulty angle detector

Faulty pressure detector (on cylinder’s side) Faulty pressure detector (on rod’s side)

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator) No.

Description

Cause

Measures

E28

Boom high/low angle restriction switch position inconsistent with AMA memory

When the power is turned ON, the boom high angle restriction switch or boom low angle restriction switch is in ON position though the position of the corresponding switch stored in the AMA memory is OFF.

Make sure that the boom high angle restriction switch and boom low angle restriction switch are turned off.

Error caused by broken wiring of the serial circuit or noise.

Check the cable between the AMA main body and control unit.

Repair or replace the cable.

Boom angle reaching to the upper or lower limit.

Lower or raise the boom.

E65 E66 ――

Broken wiring for receiving serial data Faulty serial data received “‐‐‐” is displayed

6. Adjustment items when parts are exchanged Exchange parts names Boom length detector Boom angle detector Pressure detector (Cylinder side and rod side)

Executed adjustment item ・”4.4 Boom length detector adjustment” ・”4.6 Confirming accuracy” ・”4.5 Boom angle detector adjustment” ・”4.6 Confirming accuracy” ・”4.6 Confirming accuracy” ・”4.3 Selecting the crame model and capacity data”

AMA itselt

・”4.4 Boom length detector adjustment” ・”4.5 Boom angle detector” ・”4.6 Comfirming accuracy”

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator) 7. Boom length/angle detector replacement procedure When it is needed to replace the boom length/angle detector, refer to the following steps as a guide.

This replacement procedure describes the following steps. ・Pulling out cord from boom ・Passing cord through boom

・Tools and materials needed - Pipe To be passed from the rear end of the base boom section to the rear end of the top boom section. This should be longer than 900 mm (3 ft), with approx. 6mm (1/4 in) O.D. and approx. 4mm (5/32 in) I.D. - Wire To be passed through the above pipe to the front end of the top boom section. m (29.5 ft) with a diameter of approx. 2mm (5/64 in).

- Fastener (2 pieces) To be used for fixing the cord at the boom front end.

- Others Wrench, pliers, etc.

7.1 Pulling out cord from boom

1) Removing the winch at the boom rear end The winch weighs about 280 kg (620 lbs) without a wire rope around it.

1. Remove the piping for the winch and put blank caps.

2. Wind a nylon sling around the winch drum, and support the winch by suspending it with a crane etc.

3. Remove the fixing bolts. (8 pieces) It is difficult to remove the bolts if there are too many layers of winch wire rope around the drum.

In such a case, unwind some of the wire rope to reduce the number of layers.

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W301-0320E

This should be longer than 9

H-1

H-1

AMA (Load Moment Indicator) 2) Removing the sheave inside of the boom front end 1. Remove the bolts. (2 pieces) 2. Remove the plate (1 piece) 3. Pull out the pin.

Pull out the pin from the side opposite to where the bolts are removed.

4. Remove the sheave.

3) Disconnecting the cord terminals 1. Disconnect the terminals.

2. Remove the fastener fixing the cord.

4) Pulling out the cord from the boom 1. Remove the fastener for fixing the cord, and remove the cord from the support.

2. Pull out the cord from the boom rear end.

Before pulling out the cord, put the terminals at the cord end together with tape etc. so that they should not be caught while the cord is being pulled out.

The space at the upper portion of the top boom section through which the cord passes is about 10 mm (3/8 in) high.

If the cord is cut halfway, pull out the portion of the cord with the terminals from the side of the boom front end.

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator) 5) Pulling out the cord along the rollers at the boom end If the terminals are not detached from the cord end, the cord cannot be pulled out through the rollers C and D. Then, the following steps will be needed.

If the cord is cut halfway and the portion of the cord with the terminals can be pulled out from the side of the boom front end, the following steps 1, 2 and 3 are not necessary.

1. Remove the split pin from the pin for the roller.

2. Pull out the pin.

3. Remove the roller.

4. Pull out the cord.

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator) 7.2 Passing cord through boom

1) Removing the rollers etc.

Pass the cord only when no roller or pin is installed.

If they are in position, remove them according to the following steps.

1. Remove the split pin from the pin for the roller.

2. Pull out the pin.

3. Remove the roller.

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator) 2) Passing a pipe from the boom rear end 1. Pass a pipe from the rear end of the base boom section to the rear end of the top boom section.

Pass the pipe from the rear end of the base boom section, via the roller C and the shaded areas of the rollers B and A, to the support at the rear end of the top boom section. It may be difficult to do this as the inside of the boom is dark.

As the support at the rear end of the top boom section is painted in white, use it as a guide for this operation.

3) Passing a wire from the rear end of the base boom section Pass a wire through the pipe from the rear end of the boom section to the front end of the top boom section.

Try to pass the wire as straight as possible, or it may be caught within the boom.

4) Removing the pipe Remove only the pipe from the boom rear end while leaving the wire in the boom.

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W301-0320E

H-1

H-1

AMA (Load Moment Indicator)

5) Pass the cord from the rear end of the base boom section.

1. Pass the cord from the cord reel over the roller D and install the roller D in the reverse order of the steps 1 to 3 of 1) above.

Then pass the cord through the hole and into the boom.

2. Pass the cord over the roller C and install the roller C in the reverse order of the steps 1 to 3 of 1) above.

Then join the cord to the end of the wire with tape or something.

Put the terminals together and fix them to the cord so that they should not be caught by the support, rollers, pipes, etc.

3. Slowly pull out the wire from the boom front end.

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W301-0320E

H-1 .

H-1 .

AMA (Load Moment Indicator) 6) Securing the cord on the boom front end 1. Pull out the wire from the support at the top surface of the top boom section. Once the cord is pulled into the boom for about 400 mm (1.3ft) from the grommet, temporarily fix the cord to the support.

2. Fix the cord to the support as follows.

Hook the cord by passing its portion covered with a poly tube through the support and tie a bowline.

Then tie the poly tube portion that is looped back with a fastener.

3. Fix the support with bolts to the upper surface of the boom. (2 places) 4. Fix the cord with a fastener inside the boom.

(1 place) 5. Plug the cord terminals that are of the same color.

7) Restoring the original condition - Install the winch and the sheave at the upper side of the boom front end to return to the original condition.

Tightening torque for the bolts to install the winch: 126 ± 7N-m (93 ± 5 ft-lbf)

0 361-934-70000 △

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W301-0320E

H-2

H-2

Boom Length/Angle Detector H-2

Boom Length/Angle Detector

2. The cord wound on the drum is unwound and rewound by the spiral spring as the boom extends

[NOTICE]

and retracts. The resultant drum rotation is

There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

reduced by the reduction gear, which in turn rotates the shaft of the potentiometer.

3. The electric resistance of the potentiometer shaft varies proportional to the reduction of the shaft rotation, and the change in electric resistance is

1. Construction and function

transmitted to the AML main body to detect the boom length.

1. The boom length/angle detector consists of a spiral spring, cord, reduction gear, potentiometer (for boom length detection), and boom angle detector.

23

3

2

36

24 10 34 15 8

40,44

36

35

16

1

14

7

39

13

6,42

43

4

18

11

37

41

13 43

32

9

33 52

31

38

30

17

22

5,42 50

29

20,25 39

20,25 53,54,55

19 21

Reel-out Derection

46

After sealing with high-bonding tape, wrap with insulating tape.

26,47,48,51

28

Shield wire 0.85Y

27,47,49,51

1Ｗ

0.85W(Core wire) 0.85W

2Ｙ

12 56,57,58 45

0.85Y(Shield wire)

Main cord end

Electric symbols

Potentiometer Resistance: 5000 ± 750Ω (for boom length detection) Electrical turning angle: 350° Mechanical turning angle: 360°continuous rotation Potentiometer (for boom angle detection)

Resistance: 1000 ± 200Ω Electrical angle: 120 ± 1.5%

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W305-0490E

1W 2Y

IW305-0130E01

H-2

H-2

Boom Length/Angle Detector 1. Plate

16. Spring

31. Terminal

46. Cable

2. Case

17. Cover

32. Nut

47. Holder

3. Drum assembly

18. Clip

33. Washer

48. Terminal

4. Slip ring assembly

19. Clip

34. Screw

49. Terminal

5. Contact assembly

20. Clamp

35. Bolt

50. Angle detector

6. Contact assembly

21. Cord guide

36. Bolt

51. Plug

7. Bearing case

22. Collar

37. Screw

52. Thrust bearing

8. Bearing

23. Packing

38. Screw

53. Bolt

9. Retaining ring

24. Packing

39. Screw

54. Spring washer

10. Retaining ring

25. Packing

40. Screw

55. Washer

11. Reducer

26. Connector

41. Screw

56. Bolt

12. Support

27. Connector

42. Screw

57. Plain washer

13. Gear

28. Cord lock

43. Set screw

58. Spring washer

14. Bracket

29. Screw

44. Nut

15. Potentiometer

30. Terminal

45. Connector

2. Disassembly and reassembly Retaining case

2.1 Disassembly of cord

Case

1. Remove connector and cord lock on the end of cord. Allow drum to slowly wind cord until the spiral spring does not effect any force.

Bolt

2. Loosen clamp (2 places), and remove cover.

3. Disconnect the connection between cable and

Sub cord

potentiometer and angle detector at the pin terminals, and remove cover and cable together.

Plate

[NOTICE]

Match marks IW305-0130E03

Remove speed reducer straight upward without twisting or tilting it.

6. Remove nut, and separate drum assembly from

4. Loosen setscrew and remove gear.

plate

Then remove screws 38 and speed reducer.

Drum assembly

[NOTICE] Put match marks on case and plate to clearly indicate the position where sub-cord passes.

5. Remove retaining ring and bolts, and separate

Plate

case from drum assembly.

IW305-0130E04

Nut

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W305-0490E

H-2

H-2

Boom Length/Angle Detector 7. Remove the slip ring assembly from the drum

4. Wind new cord arround drum assembly while

assembly. Then, remove the connection

preventing slack. After zero marker (at 7.0 m)

(soldered) of the slip ring and cord.

{22.97 ft} from the end of cord appears on drum, wind cord 1 turn additionally and fix it with

Slip ring assembly

gummed tape to prevent it from loosening.

Slip ring assembly Core wire

Slip ring

Cord Shield wire IW305-0130E05

Gummed tape

8. Remove all the old cord from the drum assembly.

IW305-0130E08

5. Insert the shaft of the drum assembly into the

2.2 Reassembly of cord

boss hole in the plate, and secure the shaft with

1. Mark the new cord with yellow tape as shown.

the nut .

6. Put case over drum assembly while passing

Yellow tape To drum

sub-cord through hole of case and cord through 9700mm(31.82ft)

opening of cord guide.

42170mm(138.35ft)

7. Secure the case and plate with the bolt, and install

IW305-0490E02

the retaining ring.

8. Apply a thin coat of sealant over the bottom of the

[NOTICE]

reduction gear and install the reduction gear on

Connect cord core wire to the inner slip ring.

Connect shield wire to the outer slip ring.

case.

Completely insulate the soldered portions.

[NOTICE] If the potentiometer is faulty, refer to “Replacing potentiometer (for boom length detection)” described later and replace the potentiometer at that point.

2. Pass new cord through holes of drum assembly.

Solder new cord to slip ring assembly in the reverse procedure for disassembly.

Core wire

9. Set the gear on the shaft of the reduction gear

Cord

and loosen the set screw of the gear on the potentiometer side to allow both gears to idle.

Shield wire

Turn the gear of the potentiometer about a 1/4 Vinyl tube

turn with your finger and confirm that the gear

Drum assembly

returns to its original position by the force of the

IW305-0130E07

spring. If not, loosen the bolt and adjust the position of the bracket.

3. Install slip ring assembly while preventing slack

10. Fix the gear in the notched section of the shaft of

of cord.

the reduction gear, using the set screw. Apply

[NOTICE]

screw-locking compound to the set screw.

Wind the cord around the drum assembly clockwise as seen from the slip ring.

Tightening torque: 118 N•cm {0.87ft•lbf}

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W305-0490E

H-2

H-2

Boom Length/Angle Detector Completely insulate soldered connections.

11. Take out new cord through the guide hole of the cord reel, and pull out new cord to the end

9700 mm (31.82ft) 50 mm (0.16ft)

completely.

Then allow cord to be wound slowly on drum until the zero marker appears at the edge of guide hole. Then fix cord at that position as shown in

0-marker

IW305-0490E03

figure.

"0-marker"

18. Check continuity between terminals of sub-cord connector and cord connector, and absence of short circuit.

Sub cord

Gummed tape

Cord

IW305-0130E09

IW305-0130E12

12. Take out new cord through the guide hole of the cord reel, and pull out new cord to the end

2.3 Replacing spiral spring

completely.

[NOTICE]

Then allow cord to be wound slowly on drum until

If the spiral spring is broken, replace the drum assembly. For disassembly and reassembly of the spiral spring, follow the above instructions pertaining to the cord.

the zero marker appears at the edge of guide hole. Then fix cord at that position as shown in figure.

Tightening torque: 118 N•cm {0.87ft•lbf} Driver

2.4 Disassembly of potentiometer (for boom length detection)

Gear B

Gear A

Set screw Bracket Spring White

Red Black

[NOTICE] When both the cord and spiral spring are faulty, remove the detector assembly from the boom before replacement.

If only the potentiometer is faulty, it is not necessary to remove the detector.

+ Multimeter Power for + ipmressing

1. Loosen clamp (2 places), and remove bolts 35 and cover.

IW305-0130E10

13. Draw out the cord slightly from the drum and

[NOTICE]

confirm that the resistance between the red and

As the leads (red and black) are also connected to the boom angle detector, disconnect the wiring to the boom angle detector at the pin terminals prior to replacement.

white leads increases smoothly.

14. Connect terminals of cable, potentiometer, and angle detector.

2. Disconnect the three potentiometer lead terminals

15. Install cover.

and the cable terminals, and remove the potentiometer and the bracket together.

16. Pull cable to eliminate slack, and tighten clamp.

(2 places) 17. Install cord lock on the end of cord, and install lead wires and connector to the end of cord.

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W305-0490E

H-2 .

H-2 .

Boom Length/Angle Detector original position by spring. If not, loosen bolts and

Gear

adjust the position of bracket.

Gear B

Spring

Gear A

Bracket

Bracket Spring

Lead wire

Bolt

Black Red

Potentiometer

To boom angle detector Terminal

IW305-0130E15

IW305-0130E13

3. Fix gear on the shaft of speed reducer with setscrew that is screwed on the flat surface of

3. Remove gear and spring, and remove

shaft after screw locking agent is applied.

potentiometer from bracket.

Tightening torque: 118 N•cm{12kgf•cm}

4. Remove connector and cord lock on the end of

4. From here on, perform the reassembly procedure

cord. Allow drum to slowly wind cord until the

from step 12 on in the above cord assembly

spiral spring does not effect any force.

instructions.

2.5 Reassembling of potentiometer

2.6 Replacing boom angle detector

[NOTICE]

Remove the leads to the boom angle detector

In order not to expose the potentiometer to unnecessary heat, solder the potentiometer terminals and leads as quickly as possible.

from the pin terminals, and replace the boom angle detector assembly.

Fix the potentiometer terminals including leads to the bracket by insulating sealant.

3. Adjustment

Recommended sealant: Shin-etsu Silicone KE45RTV made by Shin-etsu Chemical industries

1. With the boom fully retracted, adjust the cord lock so that the zero marker of the cord is located on

1. Install a new potentiometer.

the edge of the cord guide.

Bracket

Potentiometer

Insulating sealant IW305-0130E14

2. Loosen setscrews of gear on the shaft of speed reducer and gear on potentiometer shaft to allow 2. Adjust the boom length display of the AML.

both gears to rotate freely.

(Refer to the service manual for the AML.)

Rotate gear on potentiometer shaft about 1/4 turn by hand, and confirm that gear is returned to its

0 361-321-80000 △

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W305-0490E

H-3

H-3

Outrigger Extension Detector H-3

Outrigger Extension Detector

2. Retract the outriggers, and check the switch

1. Check of Outrigger Extension Detector

indicator to confirm that there is no detection error.

When shipped, the proximity switch is secured so that the switch tip is recessed loosened from the

Check if the outrigger extension detector switch

frame internal surface by one turn 1/16 inches

detects the extended condition of the outrigger

(1mm).

exactly.

2.2 Middle extension detection switch adjustment procedure (side surface of frame)

Adjust the outrigger extension detector switch if the lighting condition of the indicator lamp is out of order.

Secure the proximity switch at the position in

2. Adjustment Procedure of Outrigger Extension Detector

which the switch tip becomes flush for the frame

2.1 Maximum extension detection switch adjustment procedure (upper surface of frame)

is no detection error.

internal surface.

Operate the outrigger slides to confirm that there

1. With the outrigger beams fully extended and jack cylinders fully retracted, screw the proximity switch in until it contacts the upper surface of the outrigger box. Then loosen the switch 2.5 turns (3/32") and lock the switch in place.

Outrigger extension condition Max

Maximum extension detection indicator lamp Lit

Middle extension detection indicator lamp Lit

Middle Min

Not lit Not lit

Lit Not lit

0 313-612-21001 △

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W313-0210E

H-3 .

H-3 .

H-3 .

Outrigger Extension Detector 3. Rear stabilizer Extension Detector

0 314-803-36200 △

23

W313-0210E

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23

V Remote Control System

Contents V-1 Configurations of Radio-control System...................................... 1

V-4 Measures for Emergency Case .....12 1.

1.

Structure ................................................... 1

When radio-control operation is impossible.................................... 12 1.1

1.1 Names and functions of each part............. 2

If the LED of the transmitter flashes .........12

1.2 When the mode indicator lamp of the controlunit displays an error number ...13

2.

Safety Functions of Radio-control System .................... 3 2.1

Auto power-off function .............................. 3

2.2

Switch failure detection function................. 3

2.3

Continual operation restriction function...... 4

2.4

Instant stop alarm function ......................... 4

2.5

Alarm function ............................................ 5

2.

If the radio-control is not possible............ 14

3. Troubleshooting Guide ............................... 15

V-2 Radio-control Valve ......................... 6 1.

Structure ................................................... 6 1.1

Hydraulic circuit .......................................... 6

1.2

Electric circuit ............................................. 7

1.3

General View .............................................. 8

1.4

Cross section.............................................. 9

1.5

Unloading valve ........................................ 10

V

V-3 Accelerator Cylinder...................... 11 1.

Structure ..................................................11

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V -1

V -1

Configurations of Radio-control System V-1

Configurations of Radio-control System

[NOTICE] !There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

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ＷV02-0021E

V -1

V -1

Configurations of Radio-control System 1.1 Names and functions of each part

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ＷV02-0021E

V -1

V -1

Configurations of Radio-control System 2. Safety Functions of Radio-control System The radio-control system has the following functions to realize safety operations.

2.1 Auto power-off function When the motion selection switch is not operated for approximately one hour, the power of the transmitter is automatically turned off to save battery consumption. ! The power LED of the transmitter is turned off. ! To resume the radio-control operation, press the power switch once again to turn on the power LED.

2.2 Switch failure detection function Error is displayed when the power of the transmitter is turned on while the switches or speed control lever is operated. ! Four LEDs on the transmitter flash to show the failure condition. ! To perform a radio-control operation, press the power switch while releasing your finger from the other switches and the speed control lever.

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ＷV02-0021E

V -1

V -1

Configurations of Radio-control System 2.3 Continual operation restriction function Error is displayed when any of the motion selection switches is kept in the operation state for approximately five minutes due to a failure, trapped dirt or the like. ! Four LEDs on the transmitter flash to show the failure condition. ! To resume the radio-control operation, turn the power on once again after confirming the position of the motion selection switches.

2.4 Instant stop alarm function If the radio wave from the transmitter is hindered during the radio-control operations due to changing surrounding conditions and the like, the speaker outputs a “beep” alarm. ! Condition of the crane is as follows according to the number of beeps of the alarm.

(1) “Beep” The crane continues to work although there is a warning of poor radio wave transmission.

(2) “Beep,Beep” The crane operation stops when two continual alarms sound.

In either case the warning is of poor radio wave transmission condition. Take measures such as reducing the distance between the transmitter and the communication unit.

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ＷV02-0021E

V -1 .

V -1 .

Configurations of Radio-control System 2.5 Alarm function The following alarms sound when the system has a problem, when a wrong operation is made, or to call attention for proper operations.

(1) At the time of abnormal stop of the radio-control system: Warning sound Beep (Three times) Warning timing When the computer judges that serious trouble has occurred to the system Crane operation The radio-control operation is disabled.

Measure

Refer to the chapter of “Measures for Emergency Case”

(2) At the time of a problem occurring when the operation lever is at the neutral position Warning sound Beep (Three times) Warning timing When the operation lever of the crane does not return to the neutral position even after the motion selection switch of the transmitter is returned to the neutral position.

Crane operation The radio-control operation is disabled.

Measure Refer to the chapter of “Measures for Emergency Case” (3) Battery exhaustion warning Warning sound Two-tone alarm (once) Warning timing When the motion selection switch of the transmitter is operated under the low battery-voltage condition of the transmitter.

Measure

Refer to the chapter of “Battery Replacement for Transmitter”

(4) At the set of emergency stop state Warning sound Beep (Once) Warning timing When the operation to set the emergency stop state is made.

(5) At the release of emergency stop state Warning sound Two-tone alarm (once) Warning timing When the operation to release the emergency stop state is made.

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ＷV02-0021E

V -2

V -2

Radio-control Valve V-2

Radio-control Valve

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure 1.1 Hydraulic circuit

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W135-0180E

V -2

V -2

Radio-control Valve 1.2 Electric circuit

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W135-0180E

V -2

V -2

Radio-control Valve 1.3 General View

Thread size and tightening torque Sign / Port

Thread size

– P, T port

Tightening torque N-m

ft-lbf

G 1/4

24.5 - 29.4

18 - 22

G 1/2

53.9 - 63.7

40 - 47

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W135-0180E

V -2

V -2

Radio-control Valve 1.4 Cross section

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W135-0180E

V -2 .

V -2 .

Radio Control Valve 1.5 Unloading valve

Relif valve :C

19.61- 20.10 Mpa

(2843.45- 2914.45 psi)

Relif valve :F

2.06 - 2.65 Mpa

( 298.70 - 384.30 psi)

Reducing valve :E

1.86 - 1.96 Mpa

(270 - 284.5 psi)

at 60L/min at 1.5L/min P : at 5L/min

Pilot : at 0.4L/min

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W135-0180E

V -3 .

V -3 .

Accelerator Cylinder V-3

Accelerator Cylinder

[NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1. Flange

7. O-ring

13. Body

19. Solenoid assy

2. Differential transformer assy

8. O-ring

14.O-ring

20. Machine screw

3. Shim

9. Seal cover

15. Rod assy

21.O-ring

4.Shim

10. Steel ball

16. Scraper

22. Solenoid valve assy

5.Shim

11.O-ring

17. Spring B

23. Steel ball

6. Machine screw

12.O-ring

18. Spring A

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.W165-0040E

V -4

V -4

Measures for Emergency Case V-4

Measures for Emergency Case

1. When radio-control operation is impossible 1.1 If the LED of the transmitter flashes 1. If the power of the transmitter is turned on while the motion selection switch is operated, indications (2) as shown in the table are displayed.

If the power of the transmitter is turned on while the speed control lever is operated, indications (4) as shown in the table are displayed.

If the power of the transmitter is turned on while the motion selection switch and speed control lever are operated, indications (1) as shown in the table are displayed.

In either case, once again turn the power on.

2. If the power of the transmitter is turned on while the push switch (the horn, engine start and speed mode) is operated, indications (3) as shown in the table are displayed.

After confirming the switch, once again turn the power on.

3. If the motion selection switch is kept under the operation state approximately for five minutes due to a failure, trapped dirt or the like, indications (2) as shown in the table are displayed. After confirming the switch, once again turn the power on.

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W307-0051E

V -4

V -4

Measures for Emergency Case 1.2 When the mode indicator lamp of the control unit displays an error number The mode indicator lamp of the control unit displays indications as are shown in the figure to the right according to the operational conditions.

If the mode indicator lamp displays the indications not listed in the figure to the right, the radio-control system has a problem.

Take an appropriate measure according to the following table.

[NOTICE] !If more than two problems occur, each error number flashes in turn.

Error number 13

30-33

Trouble and measures After releasing your fingers from the switch of the transmitter and speed control lever, turn on the power of the transmitter.

If the above does not restore the normal operation, the radio-control operation is impossible.

Change to the manual operation and operate the crane.

After the operation lever that corresponds to the error number is manually returned to the neutral position, check if the error number disappears. When the mode indicator lamp displays “L1” and when the error number does not reappear after operation is started, the operation can be continued.

If the operation lever cannot be returned to the neutral position or if the error number does not disappear, the radio-control operation of the part that has a problem is not possible.

Change to the manual operation and then operate the crane.

WARNING It is dangerous to make other operations when the operation lever of the part that has a problem cannot be returned to the neutral position, since this would cause the part that has a problem to move at the same time. Do not make such operations.

“30”: Telescoping operation “32”: Winching operation “31”: Elevation operation “33”: Swing operation 34

The auto acceleration cannot be controlled with the radio-control operation. Although the radio-control operation is possible, the operation should be made carefully when the engine is revved up. Or, change to the manual operation and then operate the crane.

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W307-0051E

V -4

V -4

Measures for Emergency Case 45-49

The part that has a problem cannot be operated with the radio-control operation.

Change to the manual operation and then operate the crane.

WARNING It is dangerous to make other operations when the operation lever of the part that has a problem cannot be returned to the neutral position, since this would cause the part that has a problem to move at the same time. Do not make such operations.

“45”: Telescoping operation “47”: Winching operation “46”: Elevation operation “48”: Swing operation “49”: Accelerating operation 50-59

The part that has a problem cannot be operated with the radio-control operation.

Change to the manual operation and then operate the crane.

“50” “55”: Telescoping operation “52” “57”: Winching operation “51” “56”: Elevation operation “53” “58”: Swing operation “54” “59”: Accelerating operation

60-63

First change to the manual operation. Then, after the operation lever that corresponds to the error number is manually returned to the neutral position, change to the radio-control mode and check that the error number disappears.

When the mode indicator lamp displays the normal number and when the error number does not reappear after operation is made, the operation can be continued. If the operation lever cannot be moved or if the error number does not disappear, then radio-control operation is impossible. Change to the manual operation and then operate the crane.

“60”: Telescoping operation “62”: Winching operation “61”: Elevation operation “63”: Swing operation

70-89

The radio-control operation is impossible. Change to the manual operation and then operate the crane.

2. If the radio-control is not possible [NOTICE] !This is a measure to stow the crane in an emergency case. Do not make any crane operation.

Fastening the screw too tight may cause operation failures. Make sure to lightly tighten the screw.

1. The unloading solenoid of the radio-control valve should be fastened so that the crane can be manually stowed.

(1) Remove the cap nut.

(2) Loosen the lock nut and lightly tighten the screw inside until it cannot be turned any longer.

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W307-0051E

V -4

V -4

Measures for Emergency Case 3. Troubleshooting Guide First check the following when a problem occurs during the radio-control operation.

Trouble Power LED does not light up.

Power LED flashes.

After the power is turned on, four LEDs flash.

The power of the transmitter spontaneously turned off.

The power is turned off during the radio-control operation.

The accelerator cannot be revved up.

Batteries are exhausted in a short time The crane stops with two-tone sound.

Checkpoints • Are batteries inserted?

• Are batteries inserted in the correct manner?

• Are batteries exhausted?

Are batteries exhausted?

• Was the power turned on while the switch on the transmitter was operated?

• Was the power turned on while the speed control lever was pulled?

• When no operation is made for approximately one hour, the power of the transmitter is automatically turned off to save battery consumption.

• When the motion selection switch is under operational state continuously for approximately five minutes, transmission from the transmitter is automatically cut off to prevent accidents.

• Is the low-speed mode (with the speed mode LED lighting in red) selected?

• Battery longevity is shortened under the conditions with extremely cold temperatures.

• Are cables of the reception unit or control unit loose?

• Is the crane used in the situation as shown on the next page?

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Measures • Insert batteries.

• Insert batteries in the correct manner.

• Replace batteries.

Replace batteries • After releasing your finger from the switch, turn on the power.

• After releasing your finger from the speed control lever, turn on the power.

• Turn on the power again.

• After confirming that the motion selection switches are returned to the neutral positions, turn on the power again.

• Change to the medium-speed or high-speed mode.

• Replace batteries.

• Connect the cable properly.

• Refer to the next page.

W307-0051E

V -4 .

V -4 .

Measures for Emergency Case

Radio wave transmission is hindered under the following conditions, which may stop the crane operation.

Take an appropriate measure according to the operational condition. !If the appropriate measure does not improve the situation, use the manual operation.

Operation example

Appropriate measures

Distance between the transmitter and reception unit is too far.

•Too large a distance between the transmitter and reception unit may not only hinder the radio wave transmission but also increase noise influences.

Normally, make the operations within the operating radius of the crane.

•When a noise generating device such as a revolving light, electric fan or vehicle’s air conditioner is used nearby, the radio-control operation is influenced by the source.

Turn off the noise-generating device when it is possible to refrain from using it.

Since a motorcycle also generates a noise, pay attention to motorcycles passing through.

Operation is made near the noise-generating source.

Operation is made in a place with an intensive radio wave interference causing noise to the radios and to television screens.

•Approach the transmitter to the reception unit and operate the transmitter.

A large metal cargo is lifted with the crane.

Or, there are obstacles between the transmitter and reception unit such as wire netting or metal doors.

•Metal products between the transmitter and reception unit hinder the radio wave transmission.

Move yourself to the location where the reception unit can be seen and then operate the transmitter.

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W307-0051E

Y Data, Adjustment and Checks

Contents Y-1 Service Data ..................................... 1 1.

Hydraulic Pressure Setting Table .............. 1 1.1

Manual Control Valve(Boom elevating, telescoping, swing, outrigger high/low shift).............................................. 1

2.

3.

1.2

Manual Control Valve(Outrigger)................ 2

1.3

Manual Control Valve(Winch)..................... 3

Hydraulic Units.......................................... 4 2.1

Swing Motor................................................ 4

2.2

Swing Speed Reducer................................ 4

2.3

Winch Motor ............................................... 4

2.4

Winch Speed Reducer................................ 4

2.5

Winch Motor ............................................... 4

2.6

Winch Speed Reducer................................ 4

Pump ...................................................... 4 3.1

Check Items................................................ 4

3.2

Engine rpm at rated flow ............................ 4

Y-2 Adjustment and Checks .................. 5 1.

Adjustment procedure of boom telescoping wire ropes ......... 5

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Y-1

Y-1

Service Data Y-1 Service Data 1. Hydraulic Pressure Setting Table 1.1 Manual Control Valve(Boom elevating, telescoping, swing, outrigger high/low shift) [NOTE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG1, PG2 ports.

Engine Set pressure Item Note speed -1 MPa psi min 1.Connect a pressure gauge to the PG2 port.

2.Turn the PTO switch ON. Relief valve 3.Swing while the connecter for solenoid valve(for 12.0-12.5 1740-1813 1960 (RV1) swing bake release) is removed to apply swing at 25L / min brake.

4.Check the pressure at engine speed 1960 rpm.

Over load relief 1.Pressure adjustment is not necessary because the 12.5-13.0 1813-1885 pressure is set in factory. valve(RV3) Relief valve (RV2) at 95L / min

21.1-21.6

3060-3132

1960

Port relief valve (PR1) at 95L / min

15.6-17.6

2263-2553

1960

1.Connect a pressure gauge to the PG1 port.

2.Turn the PTO switch ON. 3.Extend the elevating cylinder fully.

4.Operate the boom elevating lever toward the boom raise position until the lever reaches the full stroke.

5.Check the pressure at engine speed 1960 rpm.

1.Connect a pressure gauge to the PG1 port.

2.Turn the PTO switch ON. 3.Retract the elevating cylinder fully.

4.Operate the boom elevating lever toward the boom down position until the lever reaches the full stroke.

5.Check the pressure at this condition.

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WY01-0900E

Y-1

Y-1

Service Data 1.2 Manual Control Valve(Outrigger) [NOTE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG port.

Engine Set pressure Item Note speed -1 MPa psi (min ) 1.Connect a pressure gauge to the PG port.

2.Turn the PTO switch ON. 3.Set the outrigger extension / jack selection levers of Relief valve the right and left to JACK. 20.6-21.1 2987-3060 1960 (RV5) 4.Set the rear stabilizer jack levers of the right and left to JACK. at 95L / min 5.Set the outrigger extend/retract lever to RETRACT, and retract the jack cylinder fully.

6.Check the pressure at engine speed 1960 rpm.

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WY01-0900E

Y-1

Y-1

Service Data 1.3 Manual Control Valve(Winch) [NOTE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG port.

Engine Set pressure Item Note speed -1 MPa psi (min ) 1.Plug the hoses connected to the hoist-up and hoist-down ports.

2.Connect a pressure gauge to the PG port.

Relief valve 3.Turn the PTO switch ON. 20.1-20.6 2915-2987 1960 (RV4) 4.Push on the winch high-speed switch continuously. at 216L / min 5.Operate the winch lever toward the hoist-up position until the lever reaches the full stroke.

6.Check the pressure at engine speed 1960 rpm.

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WY01-0900E

Y-1 .

Y-1 .

Service Data 2. Hydraulic Units 2.1 Swing Motor 3

3

・Displacement : 43.0cm / rev(2.6in / rev)

2.2 Swing Speed Reducer ・Reduction ratio : 34.98:1

2.3 Winch Motor 3

3

・Displacement : 90cm / rev(5.5in / rev)

2.4 Winch Speed Reducer ・Reduction ratio : 29.25:1

2.5 Winch Motor 3

3

・Displacement : 125cm / rev(7.6in / rev)

2.6 Winch Speed Reducer ・Reduction ratio : 19.011:1

3. Pump 3.1 Check Items ・Check the indicated engine speed is 1960 rpm or more on a tachometer, when PTO is in OFF position and the accelerator pedal is depressed from driver's seat.

3.2 Engine rpm at rated flow Pump

Engine

Pump

revolution

revolution

Volumetric efficiency

Flow rate

Pump displacement

P1

1960min

-1

2430min

-1

0.95

121L / min

52.6cm / rev (3.2in / rev)

P2

1960min

-1

2430min

-1

0.95

95L / min

41.1cm / rev (2.5in / rev)

P3

1960min

-1

2430min

-1

0.96

25L / min

10.7cm / rev (0.65in / rev)

・PTO

Reduction ratio

1.24

[NOTE] The specification of the pump is Max 2500 rpm.

Note that the engine does not overrun when PTO is in ON position.

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WY01-0900E

3

3

3

3

3

3

Y-2 .

Y-2 .

Y-2 .

Adjustment and Checks Y-2 Adjustment and Checks 1. Adjustment procedure of boom telescoping wire ropes

0 312-049-90970 △

5

WY05-1510E

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Z System Diagrams

Contents Z-1 Hydraulic Circuit : Spec.TM-2000-1-104,114,204,214 (Manual spec.).............................. 1

Z-6 Electric Circuit : Spec.TM-2000-1-314, 414 (Continuous rotation, Radio-controls spec.) ............6a

Z-2 Hydraulic Circuit : Spec.TM-2000-1-304,314,404,414 ( Radio-controls spec.)................ 2

1.

Applicable serial No. --EX0309................ 6a

2.

Applicable serial No. EX0310--................ 6b

Z-3 Electric Circuit : Spec.TM-2000-1-104, 204 (Non-continuous 375° rotation, Manual spec.) ............................... 3

Z-7 Location of Hydraulic Parts.............7 1.

2.

Z-5 Electric Circuit : Spec.TM-2000-1-304, 404 (Non-continuous 375° rotation, Radio-controls spec.) ................ 5a Applicable serial No. --EX0309 ................ 5a

2.

Applicable serial No. EX0310-- ................ 5b

Boom ....................................................... 8 2.1 2.2

Z-4 Electric Circuit : Spec.TM-2000-1-114, 214 (Continuous rotation, Manual spec.) ............................... 4

1.

Frame ....................................................... 7

With 375° non-continuous swing ................8 With 360° continuous swing........................9

3.

Outrigger.................................................. 10

4.

Lower ......................................................11

Z-8 Location of Electrical Parts ...........12 1.

2.

Boom ..................................................... 12 Post and Boom-point ............................... 13 2.1 2.2

Non-continuous 375° rotation spec...........13 Continuous rotation spec. .........................14

Z Revised Nov. 2009

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i

3.

Frame ..................................................... 15

4.

Operation box .......................................... 16

5.

Radio-control system ............................... 17 5.1 5.2

Main harness ............................................ 17 Sub harness ............................................. 18

6.

Frame (Rear) ........................................... 19

7.

Vehicle ..................................................... 20

8.

Angle limit alarm ...................................... 21

Z-9 Harness........................................... 22 1.

2.

Harness (Post and Boom-point) .............. 22 Harness (Operation box) ......................... 23 2.1 2.2 2.3

3.

Harness 1 ................................................. 23 Harness 2 ................................................. 24 Switch ....................................................... 25

Harness (Radio-controls)......................... 26

Revised Nov. 2009

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ii

Z-1.

Z-1.

Z-1.

Hydraulic Circuit Z-1

Hydraulic Circuit : Spec.TM-2000-1-104,114,204,214 (Manual spec.)

1 314-022-60200 △

1

WZ01-1351E

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1

Z-2.

Z-2.

Z-2.

Hydraulic Circuit Z-2

Hydraulic Circuit : Spec.TM-2000-1-304,314,404,414 ( Radio-controls spec.)

1 314-022-90200 △

2

WZ01-1501E

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2

Z-3.

Z-3.

Z-3.

Electric Circuit Z-3 Electric Circuit : Spec.TM-2000-1-104, 204 (Non-continuous 375°rotation, Manual spec.)

No CN No.,Metal L400 361−323−20000

Emergency switch Horn switch Hoisting speed selector switch High-speed hoisting indicator lamp

Emergency stop switch

Emergency stop lamp

Br 1 B

Detecting relay for winch operation up Detecting relay for telescoping operation extended Detecting relay for elevating operation down

Detecting relay for swing operation

CN30,AMP L125〜200 313−612−22302

8 R 3 O Y 7 B 6 R 4 R Y 2 YG

8 O 3 B 7 6 R 4 YG 2

F CN28 M R 1 YG

M CN28 F YG 1 R

F CN29 M B 1 B

M CN29 F B 1 B

M CN31 F Y 3 R G 4 Br R 1 LO W 2 GL Br 5 Br B 6 B

F CN31 M R 3 Y Br 4 G R 1 R GL 2 W Br 5 Br B 6 B

R

R

CN67 F 4 GB 3 Y 2 R 1 WB

R

CN66 F 4 R 3 YW 2 R 1 WG

R

CN54 F 4 GB 3 Y 2 R 1 L

R

CN53 F 4 WL 3 Y 2 R 1 L

R

CN52 F 5 R 4 WL 3 G 2 R 1 W

R

CN51 F 4 O 3 B 2 R 1 BL

R

CN19 F 4 LgB 3 B 2 R 1 LgR

R

CN18 F 4 R 3 LG 2 LO 1 B

R

CN17 F 4 LY 3 LW 2 LG 1 B

R

CN16F 4 RW 3 R 2 RB 1 B

Detecting relay for overwind

Rear outrigger relay

Emergency stop relay

Power supply relay

Emergency switch L150 Angle detector Horn switch L75

R Y

Hoisting speed selector switch L125

Shield Power supply GND Out put

G R B W

Shield Power supply GND Out put

G R B W

F CN63 M G E Shield R C R B D B W B W W A G No CN No.,Metal L3150 313−612−24200 CN62,AMP

No CN No.,AMP L400 361−500−70000

Pressure detector (rod side)

No CN No.,SWP L100 423ー521−30100

M CN57 F B 3 B W 2 Y R 1 R

COM Pr Vcc

No CN No.,SWP L300 361−801−10000

Hoisting speed indicator lamp

Pressure detector (cylinder side)

(Full retraction detecting switch from boom section)

Emergency stop switch 1 Br

Emergency stop lamp

B 2 R 1

CN40,AMP L200 319−314−41400

F CN26 M B 2 * WR 1 *

CN40,AMP L200 319−314−41400

F CN27 M B 2 * WB 1 *

CN40,AMP L200 319−314−41400

F CN42 M B 2 * WG 1 *

CN42,AMP L70 821−085−01180

F CN42 M B 2 * WG 1 *

CN42,AMP L70 821−085−01180

F CN38 M 3 R 2 * BY 1 *

No CN No.,SWP L250 821−045−01120

F CN37 M 3 BY 2 * YB 1 *

No CN No.,SWP L250 821−045−01120

F CN36 M YB 2 * B 1 *

No CN No.,AMP 367−405−50000

F CN35 M YW 2 * B 1 *

No CN No.,AMP 367−401−90000

F CN34 M YG 2 * B 1 *

No CN No.,AMP 367−401−90000

F CN33 M YR 2 * B 1 *

No CN No.,SWP L500 367−402−00000

F CN32 M YR 2 * B 1 *

No CN No.,SWP L500 367−402−10000

Detection switch for winch up (Up:open) Detection switch for telescoping extended (Extension:open)

W Y

W Y

CN59,AMP L3350 316−558−14300 CN60,AMP

Code reel

F CN61 M BR 4 BR W 3 W G 2 GY B 1 B

Top boom section

AMA lamp (base boom section)

G

AMA lamp (base boom section)

G

Detection switch for elevating down (Down:open)

Detection switch for swing operation (close when operating)

F CN61 M BR 4 BR W 3 W GY 2 GY B 1 B

Detection switch for swing operation (close when operating)

F CN3 M W 1 LR 2 R 3

M CN62 F YW 1 G GW 2 W GB 3 B GR 4 R GL 5 Shield

F CN2 M RY 2 RG 1

Detection switch for front stabilizer jack operation (closed at neutrality)

6

F CN83 Gy 4 W 3 R 2 P 1

Detection switch for extending and retracting operation (closed at neutrality) Solenoid for jack valve change (when it is energized, the jack cannot be operated)

SOL5

F CN70 R 4 GY 3 R 2 Y 1

Solenoid for swing brake release (released when valve is energized)

SOL4

Buzzer(AMA)

Unloading solenoid (telescoping, elevating) (loading when energized)

SOL2

Unloading solenoid (winch) (loading when energized)

SOL1

R

Spare power supply C/J spare terminal

Front outrigger MAX. relay R

Relay for AMA buzzer R

CN51,AMP L1200 313−601−91600

Hoisting speed selector solenoid (increasing hoisting speed when energized)

SOL3

LR

M CN51 F R 2 GY B 1 B

Controller AMA−PDⅡ (12V)

CN42,AMP L230 821−085−01060

(Left)

(Right)

M CN42 F L 2 B Br 1 W

M CN43 F B 2 B W 1 P

M CN42 F L 2 B Br 1 W

M CN46 F B 2 B W 1 Gy

1 M CN63 F RG 10 RG RY 9 RY GY 8 GY Lg 7 Lg P 6 P Gy 5 W BW 4 BW BR 3 BR RL 2 RL BrW 1 BrW

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 316−520−30200

Anti-twoblock device alarm buzzer

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

GR 2 DET1SRC GB 1 DET1GND GW 12 LENSIG YW 21 ANGSIG LW 14 RODPR LR 4 PRSRC LY 13 SYLPR LB 3 PRGND GL 11 DET1SLD

F CN60 M B 6 LW R 5 LR W 4 LY G 3 LB L 2 GL

Outrigger extension detecting switch (Maximum extension)

CN42,AMP L230 821−085−01060

F CN11 M G 2 R B 1 B

M CN56 F W 2 BR Y 1 W

B Y

Detection switch for overwinding F CN25 M B 2 * GR 1 *

1

No CN No.,SWP L250 361−323−20000

W B

B

F CN59 M Y 6 B R 5 R W 4 W B 3 G 2 L

M CN58 F R 3 R B 2 B W 1 W

Vcc COM Pc

CN31,SWP L150 313−612−23400

1

CN68 F 4 GW 3 GB 2 R 1 WR

Length detector

Angle display switch

R Y

1 CN69 F 4 R 3 GW 2 R 1 GR

Stop relay for AMA

Emergency stop engine stop relay

CN4,AMP L100 316−533−03300

F CN30 M R 1 R Y 5 Y

R

Stop relay for AMA

Detecting relay for front stabilizer jack operation

F CN4 M BW 2 W B 1 B M CN30 F R 1 R Y 5 Y

M CN5 F 6 B 5 B Y 1 WG R 3 R W 2 WL G 4 WR

10A

AMA display window

B

M CN4 F W 2 BW B 1 B

Boom angle display switch

F CN20 M 6 LG 5 Y 4 YR 3 RB 2 O 1 B

F CN64 M L 4 L R 3 R B 2 B G 1 G

23 DET2SRC 33 SANGSIG 22 DET2GND RG 29 TXD RY 28 RXD Y 9 Do1(100mA) Lg 36 DI9 BY 25 DI8 Gy 26 DI7 BW 15 DI5 BR 5 DI3 RL 6 DI2 BrW 7 DI1 20 RSRXD 19 RSTXD 30 BOOT B 35 MBGND WG 32 Do10(200mA) R 10 MBSRC WL 31 Do9(200mA) WR 37 Do8(1.5A) 24 ENCA 34 ENCB L 18 Do3(100mA) YG 39 Do7(1.5A) LO 38 Do6(1.5A) LG 40 Do5(1.5A) YB 17 Do4(100mA) YR 8 Do2(100mA) LgB 27 DI6 LgR 16 DI4

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger Basket O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

(Machine equipped with front jack) M CN72 F 4 3 RW 2 Br 1 R

KEY SW

Fuse box

PTO SW

F CN1 M R 3 RW RB 2 RB G 1 O

(17.7MPa)

Vehicle battery 12V

F CN81 M R 3 BL 1 B 2

R G W

Power supply Output Common

Relay for angle limit warning lamp

CN42,AMP L450 821−085−01080

Horn relay

Engine start relay

CN 74 F 4 R 3 Y 2 YG R 1 B

R

1

Y R

9

5

5SEC 14

T 13

BW

F CN71 M GB 2 LW GW 1 LY

F CN82 M B B LgR 4 LgR LgB 3 LgB Lg 2 Lg 1

KEY SW (engine stop circuit) (stopped when circuit is open)

F CN42 M B L LgR 2 Br 1

(Left)

F CN42 M LgB L Lg 2 Br 1

(Right)

Angle limit warning lamp

Low angle set indicator (Rear jack with slide)

Frame

CN 73 F 4 BW 3 B 2 W 1 B

R

CN92 F 4 R 3 RY 2 R 1 LG

R B

Rear jack extention detection switch (Closed when jack extends)

H B S

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

F CN65 M RY 6 G R 5 R B 4 B LG 3 LG YB 2 LgB YR 1 LgR

NoCN No.,SWP L240 366−828−90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

High angle set indicator

RY

R YB R YR

M CN6 F W 4 B R 2 LgB W 3 B R 1 LgR

Low angle set switch High angle set switch

CN42,AMP L230 821−085−01060

Outrigger extention detection switch (Closed when jack extends)

Alternator (12V while the engine is idling) Ground when the alternator stops F CN82 M B 4 B LgR 3 W LgB 2 B Lg 1 W

F CN47 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Left)

F CN48 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Right)

(Machine for rear mounting)

Basket (Option for radio-control specification)

M CN84 F 8 7 R 6 YG 5 LO 4 YB 3 YR 2 BY 1 B

IWZ03-3430E01

314-025-40100 2

3

WZ03-3430E

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3

Z-4.

Z-4.

Z-4.

Electric Circuit Z-4 Electric Circuit : Spec.TM-2000-1-114, 214 (Continuous rotation, Manual spec.)

Emergency switch Horn switch Hoisting speed selector switch High-speed hoisting indicator lamp Emergency stop switch Emergency stop lamp

Detecting relay for winch operation up Detecting relay for telescoping operation extended Detecting relay for elevating operation down Detecting relay for swing operation

Br B

M CN28 F YG R 1

No CN No.,SWP L100 423ー521−30100

F CN29 M B B 1

M CN29 F B B 1

M CN31 F Y R G 3 Br R 4 LO W 1 GL Br 2 Br B 5 B 6

F CN31 M R Y Br 3 G R 4 R GL 1 W Br 2 Br B 5 B 6

R

CN68 F GW 4 GB 3 R 2 WR 1

R

CN67 F GB 4 Y 3 R 2 WB 1

R

CN66 F R 4 YW 3 R 2 WG 1

R

CN54 F GB 4 Y 3 R 2 L 1

R

CN53 F WL 4 Y 3 R 2 L 1

R

CN52 F R 5 WL 4 G 3 R 2 W 1

R

CN51 F O 4 B 3 R 2 BL 1

R

CN19 F LgB 4 B 3 R 2 LgR 1

R

CN18 F R 4 LG 3 LO 2 B 1

R

CN17 F LY 4 LW 3 LG 2 B 1

R

CN16F RW 4 R 3 RB 2 B 1

Rear outrigger relay

Emergency stop relay

Emergency stop engine stop relay

F CN28 M R 1 YG

CN69 F R 4 GW 3 R 2 GR 1

Stop relay for AMA

Detecting relay for front stabilizer jack operation

1

CN30,AMP L125〜200 313−612−22302

R

Stop relay for AMA

Detecting relay for overwind

1

CN4,AMP L100 316−533−03300

F CN30 M R R Y 1 Y 5 O 8 R B 3 Y 7 R 6 R 4 YG Y 2

Power supply relay

Angle display switch

Length detector

Shield Power supply GND Out put

Angle detector

Shield Power supply GND Out put

Emergency switch L150 Horn switch L75

F CN26 M B * WR 2 * 1 F CN27 M B * WB 2 * 1

F CN42 M B * WG 2 * 1 F CN42 M B * WG 2 * 1 F CN38 M R 3 BY 2 1

No CN No.,SWP L300 361−801−10000

Hoisting speed indicator lamp

Vｃｃ COM Pｃ

Pressure detector (cylinder side)

BY 3 YB 2 1

F CN35 M YW * B 2 * 1 F CN34 M YG * B 2 * 1 F CN33 M YR * B 2 * 1 F CN32 M YR * B 2 * 1 R LR

F CN59 M Y B R 6 R W 5 W B 4 G 3 L 2 1

M CN58 F R R B 3 B W 2 W 1

1

B R 2 1

B

W Y

W Y

Code reel

CN40,AMP L200 319−314−41400

Detection switch for telescoping extended (Extension:open)

G

AMA lamp (base boom section)

G

AMA lamp (base boom section)

CN40,AMP L200 319−314−41400

Detection switch for elevating down (Down:open)

CN42,AMP L70 821−085−01180

Detection switch for swing operation (close when operating)

F CN61 M BR 4 W 3 GY 2 B 1

F CN3 M W W LR 1 L R 2 R 3

Non-continuous swing spec.

CN42,AMP L70 821−085−01180

Detection switch for swing operation (close when operating)

Detection switch for front stabilizer jack operation (closed at neutrality)

Fuse box

PTO SW

F CN83 Gy W 4 R 3 P 2 1

Solenoid for jack valve change (when it is energized, the jack cannot be operated) 6 GL 5 GR 4 GB 3 GW 2 YW 1

CN51,AMP L1200 313−601−91600

Hoisting speed selector solenoid (increasing hoisting speed when energized)

SOL3

R

R

CN 73 F BW 4 B 3 W 2 B 1

Engine start relay

1

Y R

9

5

5SEC 14

T 13

BW

F CN70 R GY 4 R 3 Y 2 1

F CN62 M

Solenoid for swing brake release (released when valve is energized)

SOL4

No CN No.,AMP 367−401−90000

Buzzer(AMA)

M CN51 F R 2 GY B 1 B

Unloading solenoid (telescoping, elevating) (loading when energized)

SOL2

CN42,AMP L230 821−085−01060

Unloading solenoid (winch) (loading when energized)

SOL1

(Left)

Spare power supply (Right)

C/J spare terminal

F CN60 M LW 6 LR 5 LY 4 LB 3 GL 2 1

Outrigger extension detecting switch (Maximum extension)

No CN No.,SWP L500 367−402−10000

M CN42 F L 2 B Br 1 W

M CN43 F B 2 B W 1 P

M CN42 F L 2 B Br 1 W

M CN46 F B 2 B W 1 Gy

M CN63 F RG RG RY 10 RY GY 9 GY Lg 8 Lg P 7 P Gy 6 W BW 5 BW BR 4 BR RL 3 RL BrW 2 BrW 1

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 316−520−30200

Anti-twoblock device alarm buzzer

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

M CN5 F B 6 B Y 5 WG R 1 R W 3 WL G 2 WR 4

AMA display window

M CN4 F W BW B 2 B 1

Boom angle display switch F CN64 M L L R 4 R B 3 B G 2 G 1

F CN1 M R RW RB 3 RB G 2 O 1

F CN65 M RY G R 6 R B 5 B LG 4 LG YB 3 LgB YR 2 LgR 1

No CN No.,SWP L240 366−828−90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

(17.7MPa)

F CN81 M R 3 BL 1 B 2

R G W

Power supply Output Common

Relay for angle limit warning lamp

R

CN92 F R 4 RY 3 R 2 LG 1

Front outrigger MAX. relay R

Relay for AMA buzzer R

Controller AMA−PDⅡ (12V)

No CN No.,SWP L500 367−402−00000

CN42,AMP L450 821−085−01080

Horn relay

GR GB 2 DET1SRC GW 1 DET1GND YW 12 LENSIG LW 21 ANGSIG LR 14 RODPR LY 4 PRSRC LB 13 SYLPR GL 3 PRGND 11 DET1SLD 23 DET2SRC 33 SANGSIG RG 22 DET2GND RY 29 TXD 28 RXD Y Do1(100mA) Lg 9 BY 36 DI9 Gy 25 DI8 BW 26 DI7 BR 15 DI5 RL 5 DI3 BrW 6 DI2 7 DI1 20 RSRXD 19 RSTXD 30 BOOT B WG 35 MBGND R 32 Do10(200mA) MBSRC 10 WL WR 31 Do9(200mA) 37 Do8(1.5A) 24 ENCA 34 ENCB L YG 18 Do3(100mA) LO 39 Do7(1.5A) LG 38 Do6(1.5A) YB 40 Do5(1.5A) YR 17 Do4(100mA) Do2(100mA) LgB 8 LgR 27 DI6 16 DI4

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger O/R MAX O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

R B

Rear jack extention detection switch (Closed when jack extends)

H B S

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

B

Detection switch for extending and retracting operation (closed at neutrality) SOL5

No CN No.,AMP 367−401−90000

10A

Vehicle battery 12V

CN 74 F R 4 Y 3 YG 2 B 1

R R F CN2 M RY 2 RG 1

No CN No.,AMP 367−405−50000

(Machine equipped with front jack)

KEY SW

W

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger Basket O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

No CN No.,SWP L250 821−045−01120

F CN20 M LG 6 Y 5 YR 4 RB 3 O 2 B 1

4 RW 3 Br 2 R 1

C/J

F CN2 M RY G RG 2 RG 1

No CN No.,SWP L250 821−045−01120

B

M CN72 F

F CN61 M BR BR W 4 W G 3 GY B 2 B 1

Top boom section

CN40,AMP L200 319−314−41400

Detection switch for winch up (Up:open)

M CN56 F W BR Y 2 W 1

B Y

CN42,AMP L230 821−085−01060

F CN11 M G 2 R B 1 B

GR GB 2 DET1SRC GW 1 DET1GND YW 12 LENSIG LW 21 ANGSIG LR 14 RODPR LY 4 PRSRC LB 13 SYLPR GL 3 PRGND 11 DET1SLD 23 DET2SRC 33 SANGSIG RY 22 DET2GND RG 29 TXD Y 28 RXD 9 Do1(100mA) 36 DI9 25 DI8 26 DI7 BR 15 DI5 5 DI3 6 DI2 7 DI1 20 RSRXD 19 RSTXD B 30 BOOT 35 MBGND R 32 Do10(200mA) 10 MBSRC 31 Do9(200mA) 37 Do8(1.5A) 24 ENCA 34 ENCB 18 Do3(100mA) 39 Do7(1.5A) 38 Do6(1.5A) 40 Do5(1.5A) 17 Do4(100mA) 8 Do2(100mA) 27 DI6 16 DI4

F CN60 M B LW R 6 LR W 5 LY G 4 LB L 3 GL 2 1

No CN No.,SWP L250 361−323−20000

W B

Emergency stop lamp

* *

F CN36 M YB * B 2 * 1

M CN57 F B B W 3 Y R 2 R 1

Relay for AML buzzer R

Controller AMA−PDⅡ (12V)

CN59,AMP L1350 316−558−04300 CN60,AMP

(Full retraction detecting switch from boom section)

Emergency stop switch 1 Br

F CN70 R 4 GY 3 R 2 Y 1

No CN No.,Metal L1150 313−613−74200 CN62,AMP

CN31,SWP L150 313−612−23400

* *

F CN37 M

G R B W

COM Pr Vc

Pressure detector (rod side)

Detection switch for overwinding F CN25 M B * GR 2 * 1

G R B W

No CN No.,AMP L400 361−500−70000

Hoisting speed selector switch L125

F CN62 M Shield 6 GL R 5 GR B 4 GB W 3 GW G 2 YW 1

F CN63 M Shield G R E R B C B W D W W B G A

No CN No.,Metal L400 361−323−20000

F CN4 M BW W B 2 B 1 M CN30 F R R Y 1 Y 5 R 8 O Y 3 B 7 R 6 R 4 Y YG 2

F CN71 M GB LW GW 2 LY 1

F CN82 M B B LgR 4 LgR LgB 3 LgB Lg 2 Lg 1

KEY SW (engine stop circuit) (stopped when circuit is open)

F CN42 M B L LgR 2 Br 1

(Left)

F CN42 M LgB L Lg 2 Br 1

(Right)

Angle limit warning lamp

Low angle set indicator (Rear jack with slide)

Frame

High angle set indicator

RY

R YB R YR

M CN6 F W B R 4 LgB W 2 B R 3 LgR 1

Low angle set switch High angle set switch

CN42,AMP L230 821−085−01060

Alternator (12V while the engine is idling) Ground when the alternator stops

Outrigger extention detection switch (Closed when jack extends)

F CN82 M B B LgR 4 W LgB 3 B Lg 2 W 1

F CN47 M B B W 2 W 1

F CN42 M B L W 2 Br 1

(Left)

F CN48 M B B W 2 W 1

F CN42 M B L W 2 Br 1

(Right)

(Machine for rear mounting) Basket (Option for radio-control specification)

M CN84 F 8 R 7 YG 6 LO 5 YB 4 YR 3 BY 2 B 1

IWZ03-3460E01

314-024-90100 2

4

WZ03-3460E

Downloaded from www.Manualslib.com manuals search engine

4

Z-5

Z-5

Z-5

Electric Circuit Z-5 Electric Circuit : Spec.TM-2000-1-304, 404 (Non-continuous 375°rotation, Radio-controls spec.)

1. Applicable serial No. --EX0309 F CN63 M G Shield E R C R B D B W B W W A G

No CN No.,Metal L400 3６1－323－20000

Radio control valve (STD、SANWA)

Controller (RCS-FC1 12V) RSTXD w RSRXD x BOOT n RXD F TXD E 8 SA1 L 9 SB1 M 6 SA2 N 7 SB2 P 4 SA3 R 5 SB4 S 10 SA4 T 11 SB4 U 12 OUT2 g 13 OUT1 h 14 SA5 V 15 SB5 W 16 OSC1 q 17 OSC2 r 18 FBG s 19 FB1-2 y Telescoping 20 FB1-1 z Telescoping 21 FB2-2 AA Winch 22 FB2-1 BB Winch 23 FB3-2 CC Elevating 24 FB3-1 DD Elevating 25 FB4-2 EE Swing 26 FB4-1 FF Swing 27 FB5-2 GG Accelerator 28 FB5-1 HH Accelerator SW13 X Jack neutrality SW12 Y Hook-in B SW11 Z Hook-in state detection SW10 a Over winding cutout release SW9 b AA accelerator cutoff SW8 ｃ Valve state detection LW AUDIO1 t Speaker GW AUDIO2 u Speaker LO Emergency stop lamp (Output at emergency stop) OUT4 d GR Horn (Output when horin SW is pressed) HORN f YG OUT6 K Engine start (Output at engine start) LY OUT5 J Engine stop (Output at emergency stop) WB M unload (Output when crane is operated) OUT8 H WR Unload (Output when crane is operated) UNLOD i LOW j Low-pressure relief RL MBSRC e Battery(+) RL MBSRC k Battery(+) B MBGND m Battery(-) B MBGND p Battery(-) B SW3 v Overwinding OUT7 G BrY Spare SW4 D LR Overturning alarm right SW5 C LgW Overturning alarm left SW6 B WY Outrigger right SW7 A Outrigger left Maintenance terminal Maintenance terminal Maintenance terminal Serial input Serial output Telescoping Telescoping Winch Winch Elevating Elevating Swing Swing SL jack SL jack Accelerator Accelerator

F CN85 M YR 1 WY YB 2 LgW LO 3 LR YG 4 BrY

F CN7 M 1 2

F CN14 M WG 1 2 B 3 B 4 8 5 9 6 4 7 5 8 6 9 7 10 10 11 11 12 12 13 13 14 14 15 15 16

SV1

M CN8 F 1 2

Unloading (loading when energized)

Emergency switch

Telescoping

Hoisting speed selector switch

M CN30 F R 1 R Y 5 Y

SA3

SB3

Elevating

SA2

SB2

Winch

SA4

SB4

Swing

High-speed hoisting indicator lamp Emergency stop switch

Telescoping

M CN15 F 16 1 17 2 18 3 19 4 20 5 23 6 24 7 21 8 22 9 25 10 26 11 27 12 28 13 14

Emergency stop lamp

Br 1 B

Elevating Winch Swing

Integrated with radio control harness

M CN13 F 10 B 9 WG 8 WR 7 WG 6 BrW 5 WG 4 WB 3 BrW 2 LY 1 LG

F CN6 M F CN6 M YB 1 1 Lg 2 2 BL 3 3 YW 4 4 4 M CN5 F M CN5 F GL 1 1 GY 2 2 GB 3 3 LgR 6 6 BY 5 5 4 4

SA5 SB5

Detecting relay for swing operation

F CN10 M LW 2 R BW 1 W

Speaker switch

F CN11 M BW 2 BW GW 1 G

Speaker

3 1

2

Radio control/Manual switch Up：Radio control (2-3) Down：Manual(1-2) Emergency stop lamp

F CN23 R 4 Br 3 LO 2 B 1

R

F CN24 O 4 B 3 GR 2 B 1

R

F CN21 RW 4 R 3 RB 2 B 1

R

Detecting relay for front stabilizer jack operation

Emergency stop lamp relay

Rear outrigger relay

Horn relay

Emergency stop relay

Power supply relay

Emergency stop engine stop relay

Unload relay

B

M CN29 F B 1 B F CN31 M R 3 Y Br 4 G R 1 R GL 2 W Br 5 Br B 6 B

R

CN67 F 4 GB 3 Y 2 R 1 WB

R

CN66 F 4 R 3 YW 2 R 1 WG

R

CN54 F 4 GB 3 Y 2 R 1 L

R

CN53 F 4 WL 3 Y 2 R 1 L

R

CN52 F 5 R 4 WL 3 G 2 R 1 W

R

CN51 F 4 O 3 B 2 R 1 BL

R

CN19 F 4 LgB 3 B 2 R 1 LgR

R

CN18 F 4 R 3 LG 2 LO 1 B

R

CN17 F 4 LY 3 LW 2 LG 1 B

R

CN16F 4 RW 3 R 2 RB 1 B

Power supply relay

R

Hoisting speed selector switch L125

M CN28 F YG 1 R

R

Stop relay for AMA

Horn switch L75

R Y

M CN31 F Y 3 R G 4 Br R 1 LO W 2 GL Br 5 Br B 6 B

CN68 F 4 GW 3 GB 2 R 1 WR

Angle display switch

Length detector

Shield Power supply GND Output

Angle detector

Shield Power supply GND Output

Emergency switch L150

R Y

F CN29 M B 1 B

CN69 F 4 R 3 GW 2 R 1 GR

Stop relay for AMA

CN30,AMP L125～200 313－６12－22302

F CN28 M R 1 YG

R

Detecting relay for overwind

Br

F CN22 YR 4 Y 3 BrW 2 B 1

Detecting relay for telescoping operation extended Detecting relay for elevating operation down

Accelerator cylinder

F CN9 M RL 3 W BrW 1 B R 2 R

20A

Detecting relay for winch operation up

1

CN4,AMP L100 31６－533－03300

8 O 3 B 7 6 R 4 YG 2

8 R 3 O Y 7 B 6 R 4 R Y 2 YG

Horn switch SA1

SB1

F CN4 M BW 2 W B 1 B F CN30 M R 1 R Y 5 Y

Pressure detector (cylinder side)

F CN26 M B 2 * WR 1 * F CN27 M B 2 * WB 1 *

F CN42 M B 2 * WG 1 * F CN42 M B 2 * WG 1 * F CN38 M 3 R 2 * BY 1 * F CN37 M 3 BY 2 * YB 1 * F CN36 M YB 2 * B 1 * F CN35 M YW 2 * B 1 * F CN34 M YG 2 * B 1 * F CN33 M YR 2 * B 1 * F CN32 M YR 2 * B 1 *

Emergency stop lamp

B 2 R 1

CN40,AMP L200 319－314－41400

F CN59 M Y B 6 R R 5 W W 4 B G 3 L 2 1

R B W

CN59,AMP L3350 31６－558－14300 CN６0,AMP No CN No.,SWP L250 3６1－323－20000

W Y

W Y

Code reel M CN56 F

Top boom section

AMA lamp (base boom section)

Detection switch for winch up (Up:open)

G

AMA lamp (base boom section) Detection switch for telescoping extended (Extension:open)

G

CN40,AMP L200 319－314－41400

Detection switch for elevating down (Down:open)

CN42,AMP L70 821－085－01180

Detection switch for swing operation (close when operating)

F CN61 M BR 4 BR W 3 W GY 2 GY B 1 B

CN42,AMP L70 821－085－01180

Detection switch for swing operation (close when operating)

F CN3 M W 1 LR 2 R 3

No CN No.,SWP L250 821－045－01120

Detection switch for extending and retracting operation (closed at neutrality) No CN No.,AMP 3６7－405－50000 SOL5

Solenoid for jack valve change (when it is energized, the jack cannot be operated)

No CN No.,AMP 3６7－401－90000 SOL4

Solenoid for swing brake release (released when valve is energized)

No CN No.,AMP 3６7－401－90000 SOL3

CN51,AMP L1200 313－６01－91６00

Buzzer(AMA) Hoisting speed selector solenoid (increasing hoisting speed when energized)

No CN No.,SWP L500 3６7－402－00000 SOL2

Unloading solenoid (telescoping, elevating) CN42,AMP L230 821－085－010６0 (loading when energized) Outrigger extension detecting switch (Maximum extension) M CN42 F M CN43 F L 2 B B 2 B Unloading solenoid (winch) (Left) Br 1 W W 1 P (loading when energized)

F CN60 M B 6 LW R 5 LR W 4 LY G 3 LB L 2 GL

No CN No.,SWP L500 3６7－402－10000 SOL1

R

Spare power supply C/J spare terminal

M CN42 F L 2 B Br 1 W

(Right)

1

M CN46 F B 2 B W 1 Gy

M CN63 F RG 10 RG RY 9 RY GY 8 GY Lg 7 Lg P 6 P Gy 5 W BW 4 BW BR 3 BR RL 2 RL BrW 1 BrW

CN42,AMP L230 821－085－010６0

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 31６－520－30200

Anti-twoblock device alarm buzzer

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

10A

M CN5 F 6 B 5 B Y 1 WG R 3 R W 2 WL G 4 WR

AMA display window

Boom angle display switch

Fuse box

(Machine equipped with front jack)

F CN1 M R 3 RW RB 2 RB G 1 O

PTO SW

(17.7MPa)

F CN81 M R 3 BL 1 B 2

R G W

Power supply Output Common

Relay for angle limit warning lamp

CN42,AMP L450 821－085－01080

Horn relay

Engine start relay

R

CN 73 F 4 BW 3 B 2 W 1 B

Y R

5

5SEC 14

T 13

Rear jack extention detection switch (Closed when jack extends)

H B S

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

1 9

BW

F CN65 M RY 6 G R 5 R B 4 B LG 3 LG YB 2 LgB YR 1 LgR

No CN No.,SWP L240 36６－828－90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

Vehicle battery 12V

CN 74 F 4 R 3 Y 2 YG R 1 B

M CN4 F W 2 BW B 1 B

F CN64 M L 4 L R 3 R B 2 B G 1 G

For no-radio-control specification, loop 4 and 5.

KEY SW

F CN71 M GB 2 LW GW 1 LY

F CN42 M B L 2 LgR 1 Br

F CN82 M B B 4 LgR LgR 3 LgB LgB 2 Lg Lg 1

KEY SW (engine stop circuit) (stopped when circuit is open)

(Right)

F CN47 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Left)

F CN48 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Right)

R YB R YR

High angle set indicator

CN42,AMP L230 821－085－01060

Outrigger extention detection switch (Closed when jack extends) F CN82 M B B 4 LgR W 3 LgB B 2 Lg W 1

RY

Low angle set indicator

(Rear jack with slide)

Frame Alternator (12V while the engine is idling) Ground when the alternator stops

R

CN92 F 4 R 3 RY 2 R 1 LG

Angle limit warning lamp

(Left)

F CN42 M LgB 2 L Lg 1 Br

F CN83 Gy 4 W 3 R 2 P 1

R

F CN70 R 4 GY 3 R 2 Y 1

R

Front outrigger MAX. relay

Relay for AMA buzzer

Controller AMA－PDⅡ(12V)

M CN51 F R 2 GY B 1 B

B

M CN72 F

M CN62 F YW 1 G GW 2 W GB 3 B GR 4 R GL 5 Shield 6

F CN2 M RY 2 RG 1

Detection switch for front stabilizer jack operation (closed at neutrality) No CN No.,SWP L250 821－045－01120

F CN20 M LG 6 LG Y 5 Y YR 4 YR RB 3 RB O 2 O B 1 B

RW 4 RW 3 YG 2 Br R 1 R

F CN61 M BR BR 4 W W 3 G GY 2 B B 1

W 2 BR Y 1 W

B Y

CN40,AMP L200 319－314－41400

LR

F CN11 M G 2 R B 1 B

R 3 B 2 W 1

Vｃｃ COM Pｃ

W B

Detection switch for overwinding F CN25 M B 2 * GR 1 *

No CN No.,Metal L3150 313－６12－24200 CN６2,AMP

M CN57 F B B 3 W Y 2 R R 1

(Full retraction detecting switch from boom section)

Emergency stop switch B

COM Pr Vc

No CN No.,SWP L300 3６1－801－10000 M CN58 F

Hoisting speed indicator lamp CN31,SWP L150 313－６12－23400

1

G R B W

No CN No.,AMP L400 3６1－500－70000

Pressure detector (rod side)

No CN No.,SWP L100 423ー521－30100

1 Br

G R B W

GR 2 DET1SRC GB 1 DET1GND GW12 LENSIG YW 21 ANGSIG LW 14 RODPR LR 4 PRSRC LY 13 SYLPR LB 3 PRGND GL 11 DET1SLD 23 DET2SRC 33 SANGSIG 22 DET2GND RG 29 TXD RY 28 RXD Y 9 Do1(100mA) Lg 36 DI9 BY 25 DI8 Gy 26 DI7 BW 15 DI5 BR 5 DI3 RL 6 DI2 BrW 7 DI1 20 RSRXD 19 RSTXD 30 BOOT B 35 MBGND WG32 Do10(200mA) R 10 MBSRC WL 31 Do9(200mA) WR 37 Do8(1.5A) 24 ENCA 34 ENCB L 18 Do3(100mA) YG 39 Do7(1.5A) LO 38 Do6(1.5A) LG 40 Do5(1.5A) YB 17 Do4(100mA) YR 8 Do2(100mA) LgB 27 DI6 LgR 16 DI4

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger O/R MAX O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

R B

M CN6 F W 4 B R 2 LgB W 3 B R 1 LgR

Low angle set switch High angle set switch

(Machine for rear mounting) Connect to main harness CN3 M 1 W 2 LR 3 R

Relay for overwind cutout cancellation by basket installation

R

CN88 F 4 W 3 B 2 R 1 YG

F CN3 1 LR 2 R 3

Relay for basket lamp Basket mode lamp

Basket switch

BY 2 B 1

R

CN86 F 4 R 3 RY 2 R 1 YG RY

M CN84 F 8 R 7 R YG 6 YG LO 5 LO YB 4 YB YR 3 YR BY 2 BY B 1 B

M CN87 F

IWZ03-3440E01

314-024-80100 2

Revised Nov. 2009

5a

WZ03-3441E

Downloaded from www.Manualslib.com manuals search engine

5a

Z-5.

Electric Circuit : TM-2000-1-304, 404

Z-5.

Z-5.

2. Applicable serial No. EX0310-No CN, Metal L400 361-323-20000

Length detector

Radio control valve (STD, SANWA) Controller (RCS-FC1 12V) Maintenance terminal Maintenance terminal Maintenance terminal Serial input Serial output Telescoping Telescoping Winch Winch Elevating Elevating Swing Swing SL jack SL jack Accelerator Accelerator

RSTXD w RSRXD x BOOT n RXD F TXD E 8 SA1 L SB1 M 9 6 SA2 N 7 SB2 P SA3 R 4 5 SB4 S SA4 T 10 SB4 U 11 12 OUT2 g OUT1 h 13 SA5 V 14 15 SB5 W OSC1 q 16 17 OSC2 r 18 FBG s 19 Telescoping FB1-2 y Telescoping FB1-1 z 20 Winch FB2-2 AA 21 22 Winch FB2-1 BB Elevating FB3-2 CC 23 Elevating FB3-1 DD 24 25 Swing FB4-2 EE Swing FB4-1 FF 26 Accelerator FB5-2 GG 27 28 Accelerator FB5-1 HH Jack neutrality SW13 X Hook-in SW12 Y B Hook-in state detection SW11 Z Over winding cutout release SW10 a AA accelerator cutoff SW9 b Valve state detection SW8 c LW Speaker AUDIO1 t Speaker AUDIO2 u GW LO Emergency stop lamp (Output at emergency stop) OUT4 d GR Horn (Output when horin SW is pressed) HORN f Engine start (Output at engine start) OUT6 K YG LY Engine stop (Output at emergency stop) OUT5 J M unload (Output when crane is operated) OUT8 H WB Unload (Output when crane is operated) UNLOD i WR Low-pressure relief LOW j RL Battery(+) MBSRC e Battery(+) MBSRC k RL B Battery(-) MBGND m B Battery(-) MBGND p B Overwinding SW3 v Spare OUT7 G Overturning alarm right SW4 D BrY Overturning alarm left SW5 C LR LgW Outrigger right SW6 B Outrigger left SW7 A WY F CN85 M YR 1 WY YB 2 LgW LO 3 LR YG 4 BrY

F CN7 M 1 2

F CN14 M WG 1 2 B 3 B 4 8 5 9 6 4 7 5 8 6 9 7 10 10 11 11 12 12 13 13 14 14 15 15 16

SV1

Unloading (loading when energized) Emergency

M CN30 F R 1 R Y 5 Y 8 R 3 O Y 7 B 6 R 4 R Y 2 YG

switch Horn switch

M CN8 F 1 2

SA1

SB1 SB3 SB2 SB4

Hoisting

Telescoping speed selector switch

SA3

Elevating

SA2

Winch

SA4

Swing

Telescoping Emergency stop lamp

Br 1 B 1

Elevating Winch Swing

F CN6 M F CN6 M 1 1 YB Lg 2 2 3 3 BL 4 4 YW 4 M CN5 F GL M CN5 F 1 1 2 2 GY GB 3 3 6 LgR 6 5 5 BY 4 4

M CN13 F 10 B 9 WG 8 WR 7 WG 6 BrW 5 WG 4 WB 3 BrW 2 LY 1 LG

F CN9 M RL 3 W BrW 1 B R 2 R

20A

R

R

CN53 F 4 WL 3 Y 2 R 1 L

R

CN52 F 5 R 4 WL 3 G 2 R 1 W

Radio control/Manual switch Up:Radio control (2-3) Down:Manual(1-2)

Emergency stop lamp

F CN23 R 4 Br 3 LO 2 B 1 R

Emergency stop lamp relay

Rear outrigger relay

F CN24 O 4 B 3 GR 2 B 1 R

Horn relay

R

CN51 F 4 O 3 B 2 R 1 BL

R

CN19 F LgB 4 3 B 2 R LgR 1

R

CN18 F 4 R 3 LG 2 LO 1 B

R

CN17 F 4 LY 3 LW 2 LG 1 B

R

CN16F 10A 4 RW 3 R 2 RB 1 B

Emergency stop

F CN21 RW 4 R 3 RB 2 B 1 R

Power supply relay

F CN22 YR 4 Y 3 BrW 2 B 1 R

Unload relay

CN40,AMP L200 319-314-41400

CN54 F 4 GB 3 Y 2 R 1 L

Detecting relay for front stabilizer jack operation

Br

CN40,AMP L200 319-314-41400

F CN27 M B 2 * WB 1 *

R

Detecting relay for overwind 2

F CN26 M B 2 * WR 1 *

CN66 F 4 R 3 YW 2 R 1 WG

Speaker

3 1

CN40,AMP L200 319-314-41400

R

Stop relay for AMA

F CN11 M BW 2 BW GW 1 G

F CN25 M B 2 * GR 1 *

CN69 F 4 R 3 GW 2 R 1 GR CN68 F 4 GW 3 GB 2 R 1 WR

Speaker switch

F CN10 M LW 2 R BW 1 W

Emergency stop engine stop relay

Power supply relay

B

M CN29 F 1 B

F CN42 M B 2 * WG 1 *

1 Br 1 B

F CN63 M G E Shield R C R B D B W B W W A G No CN, Metal L3150 313-612-24200 CN62,AMP

M CN57 F B 3 B W 2 Y R 1 R

COM Pr Vcc

No CN, SWP L300 361-801-10000

Pressure detector (cylinder side)

L125

F CN59 M Y 6 B R 5 R W 4 W B 3 G 2 L 1

M CN58 F R 3 R B 2 B W 1 W

Vcc COM Pc

CN59,AMP L3350 316-558-14300 CN60,AMP

No CN, SWP L250 361-323-20000

(Full retraction detecting switch from boom section)

W B

W Y

B 2 B R 1 Y

Detection switch for overwinding

Emergency stop lamp

W Y

Code reel

AMA lamp (base boom section)

G

AMA lamp (base boom section)

G

Detection switch for winch up (Up:open) Detection switch for telescoping extended (Extension:open)

F CN61 M BR 4 BR W 3 W GY 2 GY B 1 B

Detection switch for elevating down (Down:open)

Detection switch for swing operation (close when operating)

CN42,AMP L70 821-085-01180

F CN38 M 3 2 * 1 *

No CN, SWP L250 821-045-01120

Detection switch for swing operation (close when operating) Detection switch for front stabilizer jack operation (closed at neutrality)

Detection switch for extending and retracting operation (closed at neutrality)

F CN36 M YB 2 * B 1 *

No CN, AMP 367-405-50000

F CN35 M YW 2 * B 1 *

AMP 367-401-90000

F CN34 M YG 2 * B 1 *

No CN, AMP 367-401-90000

F CN33 M YR 2 * B 1 *

No CN, SWP L500 367-402-00000

F CN32 M YR 2 * B 1 *

No CN, SWP L500 367-402-10000

R

Spare power supply

SOL5

SOL4

SOL3

SOL2

SOL1

LR

CN76 F 4 G 3 L 2 R 1 GR

R

(Left)

(Right)

L 2 B Br 1 W

B 2 G W 1 R

M CN42 F L 2 B Br 1 W

M CN50 F B 2 B W 1 W

Solenoid for jack valve change (when it is energized, the jack cannot be operated) Solenoid for swing brake release (released when valve is energized)

390Ω Resistance

M CN79 F G 4 B R 3 YW B 2 B W 1 GR

M CN78 F 6 B 5 B R 4 R O 3 O Br 2 Br G 1 GO

M CN77 F 2 O 1 Br

Buzzer(AMA)

Unloading solenoid (telescoping, elevating) (loading when energized) Unloading solenoid (winch) (loading when energized)

C/J spare terminal

CN42,AMP L230 821-085-01060

F CN60 M B 6 LW R 5 LR W 4 LY G 3 LB L 2 GL 1

Outrigger extension detecting switch (Maximum extension) (Left)

M CN42 F L 2 B Br 1 W

M CN43 F B 2 B W 1 P

(Right)

M CN42 F L 2 B Br 1 W

M CN46 F B 2 B W 1 Gy

M CN63 F RG 10 RG RY 9 RY GY GY Lg 8 Lg 7 P P Gy 6 W 5 BW 4 BW BR 3 BR RL 2 RL BrW 1 BrW

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 316-520-30200

Anti-twoblock device alarm buzzer

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

B Y R W G

AMA display window

B

Fuse box

PTO SW

(Machine equipped with front jack)

Horn relay

R

R

CN 73 F 4 BW 3 B 2 W 1 B

Engine start relay

1

R

9

5

(17.7MPa)

F CN81 M R 3 R BL 1 G B 2 W

Power supply Output

Relay for angle limit warning lamp

Common

R

5SEC 14

Rear jack extention detection switch (Closed when jack extends)

H B S

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

T 13 BW

F CN65 M RY 6 G R 5 R B 4 B LG 3 LG YB 2 LgB YR 1 LgR

No CN, SWP L240 366-828-90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

CN42,AMP L450 821-085-01080

Y

F CN71 M GB 2 LW GW 1 LY

F CN82 M B B LgR 4 LgR LgB 3 LgB 2 Lg Lg 1

KEY SW (engine stop circuit) (stopped when circuit is open)

F CN42 M B L LgR 2 Br 1

(Left)

F CN42 M LgB L Lg 2 Br 1

(Right)

Angle limit warning lamp

Low angle set indicator High angle set indicator

(Rear jack with slide)

Frame

CN42,AMP L230 821-085-01060

Alternator (12V while the engine is idling) Ground when the alternator stops

Outrigger extention detection switch (Closed when jack extends) F CN82 M G B LgR 4 R LgB 3 B 2 Lg 1 W

B W

F CN47 M B G 2 B WR 1 W

F CN42 M B 2 L W 1 Br

(Left)

F CN48 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Right)

(Machine for rear mounting)

F CN32 M 2 YW 1 BW

R

CN89 F 4 BW 3 BR 2 R 1 YG

RY

Low angle set switch High angle set switch

R YB R YR

R B

M CN6 F W 4 B R 2 LgB W 3 B R 1 LgR

F CN3 M 1 W 2 LR 3 L

F CN3 M 1 LR 2 L 3

When optional basket is not installed

F CN32 M YW 2 BR 1

Relay for overwind cutout cancellation by basket installation

CN92 F 4 R 3 RY 2 R 1 LG

GR 2 DET1SRC Detector power supply output GB 1 DET1GND GND GW 12 LENSIG Length detector input YW 21 ANGSIG Angle detector input LW 14 RODPR Rod pressure detector input LR 4 PRSRC Detector power supply output LY 13 SYLPR Cylinder pressure detector input LB 3 PRGND GND GL 11 DET1SLD Shield O 23 DET2SRC Spare(detector power supply) Br 33 SANGSIG Spare(swing detector) GO 22 DET2GND Spare(GND) RG 29 TXD Serial output RY 28 RXD Serial input Y Warning lamp 9 Do1(100mA) Lg 36 Rear outrigger DI9 P 25 DI8 Basket W 26 DI7 O/R MAX BW 15 DI5 Angle display BR 5 DI3 Full retraction RL 6 DI2 O/R MID BrW 7 DI1 O/R MID 20 RSRXD Maintenance terminal 19 RSTXD Maintenance terminal Maintenance terminal 30 BOOT B 35 MBGND GND WG 32 Do10(200mA) Display R Power supply input 10 MBSRC WL 31 Do9(200mA) Display WR 37 Display Gy 24 Do8(1.5A) ENCA Drum REV detector 1 BY 34 ENCB Drum REV detector 2 L 18 Do3(100mA) AMA stop (open when it stops) YG 39 Do7(1.5A) Spare LO 38 Do6(1.5A) Spare LG 40 Do5(1.5A) Spare YB 17 Do4(100mA) Spare YR 8 Do2(100mA) Spare LgB 27 Spare LgR 16 DI6 Spare DI4

Connect to main harness

Connect to main harness

Relay for winch unload by basket installation

M CN4 F W 2 BW B 1 B

F CN64 M L 4 L R 3 R B 2 B G 1 G

Vehicle battery 12V

CN 74 F 4 R 3 Y 2 YG 1 B

M CN5 F 6 5 B 1 WG 3 R 2 WL 4 WR

Boom angle display switch

F CN1 M R 3 RW RB 2 RB G 1 O

Relay for AMA buzzer

Controller AMA-PDⅡ(12V)

M CN51 F R 2 GY B 1 B

CN42,AMP L230 821-085-01060

For no-radio-control specification, loop 4 and 5.

KEY SW

F CN70 R 4 GY 3 R 2 Y 1 R

CN51,AMP L1200 313-601-91600

Hoisting speed selector solenoid (increasing hoisting speed when energized)

F CN20 M LG 6 LG Y 5 Y YR 4 YR RB 3 RB O 2 O B 1 B

M CN72 F 4 RW 3 RW YG 2 Br R 1 R

M CN62 F YW 1 G GW 2 W GB 3 B GR 4 R GL 5 Shield 6

F CN2 M RY 2 RG 1

CN75 F 4 L 3 Br 2 R 1 YW

R Relay for front outrigger extension detecting switch (closed at the middle extension) M CN49 F M CN42 F (Left)

No CN, SWP L250 821-045-01120

BY YB

F CN3 M W 1 LR 2 R 3

Crane mounted on chassiis tail Relay for front outrigger extension detecting switch (Middle extension) (Right)

CN42,AMP L70 821-085-01180

R BY

F CN11 M G 2 R B 1 B

F CN61 M BR 4 BR W 3 W G 2 GY B 1 B

M CN56 F W 2 BR Y 1 W

Top boom section

Emergency stop switch

F CN42 M B 2 * WG 1 *

F CN37 M 3 2 * 1 *

Shield Power GND Output

G R B W

No CN, AMP L400 361-500-70000

Hoisting speed indicator lamp CN31,SWP L150 313-612-23400

CN67 F 4 GB 3 Y 2 R 1 WB

Stop relay for AMA

Hoisting speed selector switch

G R B W

Pressure detector (rod side)

Horn switch L75

F CN31 M R 3 Y Br 4 G R 1 R GL 2 W Br 5 Br B 6 B

R

Accelerator cylinder

No CN, SWP L100 423ー521-30100

M CN31 F Y 3 R G 4 Br R 1 LO W 2 GL Br 5 Br B 6 B

Detecting relay for telescoping operation extended

Detecting relay for swing operation

Integrated with radio control harness

M CN28 F YG 1 R

Angle detector

Angle display switch L150 Emergency switch L150

B

R

SB5

CN30,AMP L125～200 313-612-22302

F CN29 M B 1 B

Detecting relay for winch operation up

Detecting relay for elevating operation down

SA5

CN4,AMP L100 316-533-03300

F CN30 M 1 R 5 Y 8 O 3 R B 7 Y 6 R 4 R YG 2 Y

F CN28 M R 1 YG

High-speed hoisting indicator lamp Emergency stop switch

16M CN15 F 1 17 2 18 3 19 4 20 5 23 6 24 7 21 8 22 9 25 10 26 11 27 12 28 13 14

F CN4 M BW 2 W B 1 B R Y

Shield Power GND Output

Basket operation indicator lamp

R

CN88 F 4 W 3 B 2 R 1 YG

Selector switch (basket operation)

YG R

M CN19 F BY 4 BL 3 B 2 B 1

M CN84 F B 8 7 6 5 4 3 B 2 B 1 M CN84 F BL 8 Gy R 7 R YG 6 YG LO 5 LO YB 4 YB YR 3 YR BY 2 BY B 1 B

IWZ03-3441E01

Revised Nov. 2009

5b

WZ03-3441E

Downloaded from www.Manualslib.com manuals search engine

314-024-80100 5

5b

Z-6

Z-6

Z-6

Electric Circuit Z-6 Electric Circuit : Spec.TM-2000-1-314, 414 (Continuous rotation, Radio-controls spec.)

1. Applicable serial No. --EX0309

F CN14 M WG 1 2 B 3 B 4 8 5 9 6 4 7 5 8 6 9 7 10 10 11 11 12 12 13 13 14 14 15 15 16

RSTXD w RSRXD x BOOT n RXD F TXD E 8 SA1 L 9 SB1 M 6 SA2 N 7 SB2 P 4 SA3 R 5 SB4 S 10 SA4 T 11 SB4 U 12 OUT2 g 13 OUT1 h 14 SA5 V 15 SB5 W 16 OSC1 q 17 OSC2 r 18 FBG s 19 FB1-2 y Telescoping 20 FB1-1 z Telescoping 21 FB2-2 AA Winch 22 FB2-1 BB Winch 23 FB3-2 CC Elevating 24 FB3-1 DD Elevating 25 FB4-2 EE Swing 26 FB4-1 FF Swing 27 FB5-2 GG Accelerator 28 FB5-1 HH Accelerator SW13 X Jack neutrality SW12 Y Hook-in B SW11 Z Hook-in state detection SW10 a Over winding cutout release SW9 b AA accelerator cutoff SW8 ｃ Valve state detection LW AUDIO1 t Speaker GW AUDIO2 u Speaker LO Emergency stop lamp (Output at emergency stop) OUT4 d GR HORN f Horn (Output when horin SW is pressed) YG OUT6 K Engine start (Output at engine start) LY OUT5 J Engine stop (Output at emergency stop) WB OUT8 H M unload (Output when crane is operated) WR UNLOD i Unload (Output when crane is operated) LOW j Low-pressure relief RL MBSRC e Battery(+) RL MBSRC k Battery(+) B MBGND m Battery(-) B MBGND p Battery(-) B SW3 v Overwinding OUT7 G Spare SW4 D BrY Overturning alarm right LR SW5 C Overturning alarm left SW6 B LgW Outrigger right SW7 A WY Outrigger left Maintenance terminal Maintenance terminal Maintenance terminal Serial input Serial output Telescoping Telescoping Winch Winch Elevating Elevating Swing Swing SL jack SL jack Accelerator Accelerator

F CN85 M YR 1 WY YB 2 LgW LO 3 LR YG 4 BrY

F CN7 M 1 2

Unloading (loading when energized)

SV1

M CN8 F 1 2

M CN30 F R 1 R Y 5 Y

Emergency switch

SA1

SB1

Telescoping

SA3

SB3 SB2

Winch

SA4

SB4

Hoisting speed selector switch

Elevating

SA2

Swing

High-speed hoisting indicator lamp Emergency stop switch

Telescoping

M CN15 F 16 1 17 2 18 3 19 4 20 5 23 6 24 7 21 8 22 9 25 10 26 11 27 12 28 13 14

Emergency stop lamp

Br

1

B

1

Elevating Winch Swing

Integrated with radio control harness

M CN13 F 10 B 9 WG 8 WR 7 WG 6 BrW 5 WG 4 WB 3 BrW 2 LY 1 LG

F CN6 M F CN6 M YB 1 1 Lg 2 2 BL 3 3 YW 4 4 4 M CN5 F M CN5 F GL 1 1 GY 2 2 GB 3 3 LgR 6 6 BY 5 5 4 4

SA5 SB5

Detecting relay for swing operation

F CN10 M LW 2 R BW 1 W

Speaker switch

F CN11 M BW 2 BW GW 1 G

Speaker

3 1

2

Emergency stop lamp

F CN23 R 4 Br 3 LO 2 B 1

R

F CN24 O 4 B 3 GR 2 B 1

R

F CN21 RW 4 R 3 RB 2 B 1

R

Detecting relay for front stabilizer jack operation

Emergency stop lamp relay

Rear outrigger relay

Horn relay

Emergency stop relay

Power supply relay

Unload relay

Emergency stop engine stop relay

R

CN67 F 4 GB 3 Y 2 R 1 WB

R

CN66 F 4 R 3 YW 2 R 1 WG

R

CN54 F 4 GB 3 Y 2 R 1 L

R

CN53 F 4 WL 3 Y 2 R 1 L

R

CN52 F 5 R 4 WL 3 G 2 R 1 W

R

CN51 F 4 O 3 B 2 R 1 BL

R

CN19 F 4 LgB 3 B 2 R 1 LgR

R

CN18 F 4 R 3 LG 2 LO 1 B

R

CN17 F 4 LY 3 LW 2 LG 1 B

R

CN16F 4 RW 3 R 2 RB 1 B

Power supply relay

R

B

F CN31 M R 3 Y Br 4 G R 1 R GL 2 W Br 5 Br B 6 B

CN68 F 4 GW 3 GB 2 R 1 WR

Stop relay for AMA

Radio control/Manual switch Up：Radio control (2-3) Down：Manual(1-2)

M CN29 F B 1 B

M CN31 F Y 3 R G 4 Br R 1 LO W 2 GL Br 5 Br B 6 B

R

F CN26 M B 2 * WR 1 * F CN27 M B 2 * WB 1 *

B 2 R 1

B Y

Fuse box

PTO SW

G

Engine start relay

R

CN 73 F 4 BW 3 B 2 W 1 B

R

5

5SEC 14

T 13

G

Detection switch for elevating down (Down:open)

CN42,AMP L70 821－085－01180

No CN No.,SWP L250 821－045－01120

F CN37 M 3 BY 2 * YB 1 *

No CN No.,SWP L250 821－045－01120

F CN36 M YB 2 * B 1 *

No CN No.,AMP 367－405－50000

F CN35 M YW 2 * B 1 *

No CN No.,AMP 367－401－90000

F CN34 M YG 2 * B 1 *

No CN No.,AMP 367－401－90000

F CN33 M YR 2 * B 1 *

No CN No.,SWP L500 367－402－00000

F CN32 M YR 2 * B 1 *

No CN No.,SWP L500 367－402－10000

Detection switch for swing operation (close when operating)

F CN61 M 4 BR 3 W 2 GY 1 B

C/J

F CN3 M W 1 W LR 2 L R 3 R

Non-continuous swing spec.

Detection switch for swing operation (close when operating) Detection switch for front stabilizer jack operation (closed at neutrality)

W

R R

F CN2 M RY 2 G RG 1 RG

B

F CN2 M 2 RY 1 RG

Detection switch for extending and retracting operation (closed at neutrality) SOL5

SOL4

SOL3

SOL2

SOL1

Solenoid for jack valve change (when it is energized, the jack cannot be operated) F CN62 M 6 5 GL 4 GR 3 GB 2 GW 1 YW

Solenoid for swing brake release (released when valve is energized) CN51,AMP L1200 313－601－91600

Buzzer(AMA) Hoisting speed selector solenoid (increasing hoisting speed when energized)

M CN51 F R 2 GY B 1 B

Unloading solenoid (telescoping, elevating) CN42,AMP L230 821－085－01060 (loading when energized) Outrigger extension detecting switch (Maximum extension) Unloading solenoid (winch) (loading when energized)

(Left)

Spare power supply

(Right)

C/J spare terminal

M CN42 F L 2 B Br 1 W

M CN43 F B 2 B W 1 P

M CN42 F L 2 B Br 1 W

M CN46 F B 2 B W 1 Gy

Anti-twoblock device alarm buzzer

1

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

M CN5 F 6 B 5 B Y 1 WG R 3 R W 2 WL G 4 WR M CN4 F W 2 BW B 1 B

F CN64 M L 4 L R 3 R B 2 B G 1 G

(Machine equipped with front jack)

F CN1 M 3 RW RB 2 RB 1 O

F CN65 M RY 6 G R 5 R B 4 B LG 3 LG YB 2 LgB YR 1 LgR

No CN No.,SWP L240 366－828－90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

(17.7MPa)

F CN81 M R 3 BL 1 B 2

R G W

Power supply Output Common

Relay for angle limit warning lamp

Rear jack extention detection switch (Closed when jack extends)

F CN71 M GB 2 LW GW 1 LY

F CN82 M B 4 B LgR 3 LgR LgB 2 LgB Lg 1 Lg

KEY SW (engine stop circuit) (stopped when circuit is open)

F CN42 M B 2 L LgR 1 Br

(Left)

F CN42 M LgB 2 L Lg 1 Br

(Right)

Angle limit warning lamp

F CN47 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Left)

F CN48 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Right)

R YB R YR

High angle set indicator

CN42,AMP L230 821－085－01060

Outrigger extention detection switch (Closed when jack extends) F CN82 M B 4 B LgR 3 W LgB 2 B Lg 1 W

RY

Low angle set indicator

(Rear jack with slide)

Frame Alternator (12V while the engine is idling) Ground when the alternator stops

R

CN92 F 4 R 3 RY 2 R 1 LG

R

F CN70 R 4 GY 3 R 2 Y 1

R

Front outrigger MAX. relay

Relay for AMA buzzer

Controller AMA－PDⅡ (12V)

M CN63 F RG 10 RG RY 9 RY GY 8 GY Lg 7 Lg P 6 P Gy 5 W BW 4 BW BR 3 BR RL 2 RL BrW 1 BrW

CN42,AMP L230 821－085－01060

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 316－520－30200

F CN83 Gy 4 W 3 R 2 P 1

GR 2 DET1SRC GB 1 DET1GND GW 12 LENSIG YW 21 ANGSIG LW 14 RODPR LR 4 PRSRC LY 13 SYLPR LB 3 PRGND GL 11 DET1SLD

F CN60 M 6 LW 5 LR 4 LY 3 LB 2 GL

Boom angle display switch

H B S

BW

6 DI2 7 DI1 20 RSRXD 19 RSTXD 30 BOOT B 35 MBGND 32 Do10(200mA) R 10 MBSRC 31 Do9(200mA) 37 Do8(1.5A) 24 ENCA 34 ENCB 18 Do3(100mA) 39 Do7(1.5A) 38 Do6(1.5A) 40 Do5(1.5A) 17 Do4(100mA) 8 Do2(100mA) 27 DI6 16 DI4

G

CN42,AMP L450 821－085－01080

Horn relay

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

1 9

36 DI9 25 DI8 26 DI7 15 DI5 BR 5 DI3

CN40,AMP L200 319－314－41400

F CN38 M 3 R 2 * BY 1 *

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger Basket O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

23 DET2SRC 33 SANGSIG 22 DET2GND RY 29 TXD RG 28 RXD Y 9 Do1(100mA)

1

F CN61 M BR 4 BR W 3 W G 2 GY B 1 B

Top boom section

AMA display window

For no-radio-control specification, loop 4 and 5.

R

Y

M CN56 F W 2 BR Y 1 W

AMA lamp (base boom section) AMA lamp CN40,AMP L200 319－314－41400 (base boom section) Detection switch for telescoping extended (Extension:open)

10A

Vehicle battery 12V

CN 74 F 4 R 3 Y 2 YG R 1 B

1

CN59,AMP L1350 316－558－04300 CN60,AMP

W Y

Detection switch for winch up (Up:open)

CN42,AMP L70 821－085－01180

F CN11 M G 2 R B 1 B

R B W

Code reel

CN40,AMP L200 319－314－41400

F CN42 M B 2 * WG 1 *

R

F CN60 M B 6 LW R 5 LR W 4 LY G 3 LB L 2 GL

F CN59 M Y 6 B R 5 R W 4 W B 3 G 2 L

Relay for AMA buzzer R

Controller AMA－PDⅡ(12V)

GR 2 DET1SRC GB 1 DET1GND GW12 LENSIG YW 21 ANGSIG LW 14 RODPR LR 4 PRSRC LY 13 SYLPR LB 3 PRGND GL 11 DET1SLD

No CN No.,SWP L250 361－323－20000

W Y

W B

Emergency stop lamp

F CN42 M B 2 * WG 1 *

LR

B Y R

R 3 B 2 W 1

Vc COM Pｃ

(Full retraction detecting switch from boom section)

Detection switch for overwinding F CN25 M B 2 * GR 1 *

B 3 W 2 R 1

COM Pr Vc

Pressure detector (cylinder side)

Emergency stop switch

F CN70 R 4 GY 3 R 2 Y 1

No CN No.,Metal L1150 313－613－74200 CN62,AMP

No CN No.,SWP L300 361－801－10000 M CN58 F

Hoisting speed indicator lamp

B

G R B W

Pressure detector (rod side)

CN31,SWP L150 313－612－23400

1

Shield Power supply GND Output

No CN No.,AMP L400 361－500－70000 M CN57 F

Hoisting speed selector switch L125 No CN No.,SWP L100 423ー521－30100

1 Br

G R B W

F CN20 M LG 6 LG 5 Y YR YR 4 RB RB 3 O 2 B 1

O B

KEY SW

Angle detector

Horn switch L75

Shield Power supply GND Output

B

Y

M CN72 F RW 4 RW 3 YG 2 Br R 1 R

Emergency switch L150

R Y

F CN29 M B 1 B

Length detector

Angle display switch

R Y

M CN28 F YG 1 R

R

Stop relay for AMA

CN30,AMP L125～200 313－612－22302

F CN28 M R 1 YG

CN69 F 4 R 3 GW 2 R 1 GR

Detecting relay for overwind

Br

F CN22 YR 4 Y 3 BrW 2 B 1

Detecting relay for telescoping operation extended Detecting relay for elevating operation down

Accelerator cylinder

F CN9 M W RL 3 BrW 1 B R 2 R

20A

Detecting relay for winch operation up

CN4,AMP L100 316－533－03300

8 O 3 B 7 6 R 4 YG 2

8 R 3 O Y 7 B 6 R 4 R Y 2 YG

Horn switch

F CN4 M BW 2 W B 1 B F CN30 M R 1 R Y 5 Y

F CN62 M 6 Shield 5 GL R 4 GR B 3 GB W 2 GW G 1 YW

F CN63 M G E Shield R C R B D B W B W W A G

No CN No.,Metal L400 361－323－20000

Radio control valve (STD、SANWA)

Controller (RCS-FC1 12V)

23 DET2SRC 33 SANGSIG 22 DET2GND RG 29 TXD RY 28 RXD Y 9 Do1(100mA) Lg 36 DI9 BY 25 DI8 Gy 26 DI7 BW 15 DI5 BR 5 DI3 RL 6 DI2 BrW 7 DI1 20 RSRXD 19 RSTXD 30 BOOT B 35 MBGND WG 32 Do10(200mA) R 10 MBSRC WL 31 Do9(200mA) WR 37 Do8(1.5A) 24 ENCA 34 ENCB L 18 Do3(100mA) YG 39 Do7(1.5A) LO 38 Do6(1.5A) LG 40 Do5(1.5A) YB 17 Do4(100mA) YR 8 Do2(100mA) LgB 27 DI6 LgR 16 DI4

Detector power supply output GND Length detector input Angle detector input Rod pressure detector input Detector power supply output Cylinder pressure detector input GND Shield Spare(detector power supply) Spare(swing detector) Spare(GND) Serial output Serial input Warning lamp Rear outrigger Basket O/R MAX Angle display Full retraction O/R MID O/R MID Maintenance terminal Maintenance terminal Maintenance terminal GND Display Power supply input Display Display Drum REV detector 1 Drum REV detector 2 AMA stop (open when it stops) Spare Spare Spare Spare Spare Spare Spare

R B

M CN6 F W 4 B R 2 LgB W 3 B R 1 LgR

Low angle set switch High angle set switch

(Machine for rear mounting) Connect to main harness CN3 M 1 W 2 LR 3 R

Relay for overwind cutout cancellation by basket installation

R

CN88 F 4 W 3 B 2 R 1 YG

F CN3 1 LR 2 R 3

Relay for basket lamp Basket mode lamp

Basket switch

BY 2 B 1

R

CN86 F 4 R 3 RY 2 R 1 YG RY

M CN84 F 8 R 7 R YG 6 YG LO 5 LO YB 4 YB YR 3 YR BY 2 BY B 1 B

M CN87 F

IWZ03-3450E01

314-024-70100 2

Revised Nov. 2009

6a

WZ03-3451E

Downloaded from www.Manualslib.com manuals search engine

6a

Z-6.

Electric Circuit : TM-2000-1-314, 414

Z-6.

Z-6.

2. Applicable serial No. EX0310--

CN4,AMP L100 316-533-03300

Controller (RCS-FC1 12V)

F CN14 M WG 1 2 B 3 B 4 8 5 9 6 4 7 5 8 6 9 7 10 10 11 11 12 12 13 13 14 14 15 15 16

Maintenance terminal Maintenance terminal Maintenance terminal Serial input Serial output Telescoping Telescoping Winch Winch Elevating Elevating Swing Swing SL jack SL jack Accelerator Accelerator

RSTXD w RSRXD x BOOT n RXD F TXD E 8 SA1 L SB1 M 9 6 SA2 N 7 SB2 P SA3 R 4 5 SB4 S SA4 T 10 SB4 U 11 12 OUT2 g OUT1 h 13 SA5 V 14 15 SB5 W OSC1 q 16 17 OSC2 r 18 FBG s 19 Telescoping FB1-2 y Telescoping FB1-1 z 20 Winch FB2-2 AA 21 22 Winch FB2-1 BB Elevating FB3-2 CC 23 Elevating FB3-1 DD 24 25 Swing FB4-2 EE Swing FB4-1 FF 26 Accelerator FB5-2 GG 27 28 Accelerator FB5-1 HH Jack neutrality SW13 X Hook-in SW12 Y B Hook-in state detection SW11 Z Over winding cutout release SW10 a AA accelerator cutoff SW9 b Valve state detection SW8 c LW Speaker AUDIO1 t Speaker AUDIO2 u GW LO Emergency stop lamp (Output at emergency stop) OUT4 d GR Horn (Output when horin SW is pressed) HORN f Engine start (Output at engine start) OUT6 K YG LY Engine stop (Output at emergency stop) OUT5 J M unload (Output when crane is operated) OUT8 H WB Unload (Output when crane is operated) UNLOD i WR Low-pressure relief LOW j Battery(+) MBSRC e RL Battery(+) MBSRC k RL B Battery(-) MBGND m B Battery(-) MBGND p B Overwinding SW3 v Spare OUT7 G Overturning alarm right SW4 D BrY Overturning alarm left SW5 C LR LgW Outrigger right SW6 B Outrigger left SW7 A WY F CN85 M YR 1 WY YB 2 LgW LO 3 LR YG 4 BrY

F CN7 M 1 2

SV1

Unloading (loading when energized) Emergency

switch Horn switch

M CN8 F 1 2

M CN30 F R 1 R Y 5 Y 8 R 3 O Y 7 B 6 R 4 R Y 2 YG

F CN30 M R 1 R Y 5 Y 8 O 3 R B 7 Y 6 R 4 R YG 2 Y

CN30,AMP L125～200 313-612-22302

SA1

SB1 SB3 SB2 SB4

Hoisting

Telescoping speed selector switch

SA3

Elevating

SA2

Winch

SA4

Swing

High-speed hoisting indicator lamp

F CN28 M R 1 YG

M CN28 F YG 1 R

No CN, SWP L100 423ー521-30100

F CN29 M B 1 B

B

Emergency stop switch

M CN31 F Y 3 R G 4 Br R 1 LO W 2 GL Br 5 Br B 6 B

F CN31 M R 3 Y Br 4 G R 1 R GL 2 W Br 5 Br B 6 B

CN31,SWP L150 313-612-23400

Telescoping Emergency stop lamp

M CN15 F 16 1 17 18 2 3 19 4 20 5 23 6 24 21 7 8 22 9 25 26 10 27 11 12 28 13 14

Br 1 B 1

Elevating Winch Swing

F CN6 M F CN6 M YB 1 1 Lg 2 2 BL 3 3 YW 4 4 4 M CN5 F GL M CN5 F 1 1 GY 2 2 GB 3 LgR 3 6 6 BY 5 5 4 4

Detecting relay for telescoping operation extended Detecting relay for elevating operation down

SA5 SB5

F CN25 M B 2 * GR 1 *

CN40,AMP L200 319-314-41400

F CN26 M B 2 * WR 1 *

CN40,AMP L200 319-314-41400

F CN27 M B 2 * WB 1 *

CN40,AMP L200 319-314-41400

R

CN69 F 4 R 3 GW 2 R 1 GR

R

CN68 F 4 GW 3 GB 2 R 1 WR

R

CN67 F 4 GB 3 Y 2 R 1 WB

R

CN66 F 4 R 3 YW 2 R 1 WG

Detecting relay for swing operation

Integrated with radio control harness

Accelerator cylinder

Stop relay for AMA

Speaker switch

Stop relay for AMA

F CN10 M LW 2 R BW 1 W F CN11 M BW 2 BW GW 1 G

M CN13 F 10 B 9 WG 8 WR 7 WG 6 BrW 5 WG 4 WB 3 BrW 2 LY 1 LG

Detecting relay for winch operation up

R

CN54 F 4 GB 3 Y 2 R 1 L

R

CN53 F 4 WL 3 Y 2 R 1 L

R

CN52 F 5 R 4 WL 3 G 2 R 1 W

Speaker Detecting relay for overwind

F CN9 M RL 3 W BrW 1 B R 2 R

3 1

Br F CN23 4 3 2 1

R

F CN24 O 4 B 3 GR 2 B 1

R

R Br LO B

20A

2

Radio control/Manual switch Up:Radio control (2-3) Down:Manual(1-2)

Emergency stop lamp

Detecting relay for front stabilizer jack operation

Emergency stop lamp relay

Rear outrigger relay

R

F CN22 YR 4 Y 3 BrW 2 B 1

R

R

CN19 F LgB 4 3 B R 2 LgR 1

R

CN18 F 4 R 3 LG 2 LO 1 B

R

CN17 F 4 LY 3 LW 2 LG 1 B

R

CN16F 10A 4 RW 3 R 2 RB 1 B

Emergency stop relay

Horn relay

F CN21 RW 4 R 3 RB 2 B 1

R

CN51 F 4 O 3 B 2 R 1 BL

Power supply relay

Unload relay

Emergency stop engine stop relay

Power supply relay

B

Angle display switch

Emergency switch L150

Hoisting speed selector switch

Shield Power GND Output

G R B W

No CN, AMP L400 361-500-70000 COM Pr Vcc

No CN, SWP L300 361-801-10000

L125

Pressure detector (cylinder side)

Vcc COM Pc

M CN57 F B 3 B W 2 Y R 1 R

1 B

W B

M CN58 F R 3 R B 2 B W 1 W

CN42,AMP L70 821-085-01180

No CN, SWP L250 821-045-01120

Detection switch for front stabilizer jack operation (closed at neutrality) Detection switch for extending and retracting operation (closed at neutrality)

(Left)

F CN35 M YW 2 * B 1 *

No CN, AMP 367-401-90000

F CN34 M YG 2 * B 1 *

No CN, AMP 367-401-90000

F CN33 M YR 2 * B 1 *

No CN, SWP L500 367-402-00000

F CN32 M YR 2 * B 1 *

No CN, SWP L500 367-402-10000

R

Spare power supply

SOL2

SOL1

LR

(Right)

L 2 B Br 1 W

B 2 G W 1 R

M CN42 F L 2 B Br 1 W

M CN50 F B 2 B W 1 W

Solenoid for jack valve change (when it is energized, the jack cannot be operated) Solenoid for swing brake release (released when valve is energized)

390Ω Resistance

M CN79 F G 4 B R 3 YW B 2 B W 1 GR

F CN62 M 6 5 GL 4 GR 3 GB 2 GW 1 YW

CN51,AMP L1200 313-601-91600

Buzzer(AMA)

Hoisting speed selector solenoid (increasing hoisting speed when energized) Unloading solenoid (telescoping, elevating) (loading when energized) Unloading solenoid (winch) (loading when energized)

C/J spare terminal

M CN51 F R 2 GY B 1 B

F CN60 M 1 6 LW 5 LR 4 LY 3 LB 2 GL

CN42,AMP L230 821-085-01060

Outrigger extension detecting switch (Maximum extension) (Left)

M CN42 F L 2 B Br 1 W

M CN43 F B 2 B W 1 P

(Right)

M CN42 F L 2 B Br 1 W

M CN46 F B 2 B W 1 Gy

RG 10 RY 9 GY 8 Lg 7 P Gy 6 5 BW 4 BR 3 RL 2 BrW 1

Outrigger extension detecting switch (closed at the middle extension)

CN11,AMP L1100 316-520-30200

Anti-twoblock device alarm buzzer

(Left)

M CN42 F L 2 B Br 1 W

M CN44 F B 2 B W 1 RL

(Right)

M CN42 F L 2 B Br 1 W

M CN45 F B 2 B W 1 BrW

M CN5 F 6 5 B 1 WG 3 R 2 WL 4 WR

B

Fuse box

PTO SW

Boom angle display switch

(Machine equipped with front jack)

F CN1 M R 3 RW RB 2 RB G 1 O

Horn relay

R

R

CN 73 F 4 BW 3 B 2 W 1 B

Engine start relay

1

R

9

5

(17.7MPa)

F CN81 M R 3 R BL 1 G B 2 W

Power supply Output

Relay for angle limit warning lamp

Common

R

5SEC 14

Rear jack extention detection switch (Closed when jack extends)

H B S

Connect to the ingition line (position passed through the clutch switch) The starter is rotated when 12V is output.

T 13 BW

F CN65 M RY 6 G R 5 R B 4 B LG 3 LG YB 2 LgB YR 1 LgR

No CN, SWP L240 366-828-90000

Front jack pressure detection switch F CN80 M R 3 R BL 1 BL B 2 B

CN42, AMP L450 821-085-01080

Y

F CN71 M GB 2 LW GW 1 LY

F CN42 M B L LgR 2 Br 1

F CN82 M B B LgR 4 LgR LgB 3 LgB Lg 2 Lg 1

KEY SW (engine stop circuit) (stopped when circuit is open)

F CN42 M LgB L Lg 2 Br 1

Angle limit warning lamp

(Left) (Right)

Low angle set indicator High angle set indicator

(Rear jack with slide)

Frame

CN42,AMP L230 821-085-01060

Alternator (12V while the engine is idling) Ground when the alternator stops

Outrigger extention detection switch (Closed when jack extends) F CN82 M B G LgR 4 R LgB 3 B Lg 2 W 1

B W

F CN47 M B G 2 B WR 1 W

F CN42 M B 2 L W 1 Br

(Left)

F CN48 M B 2 B W 1 W

F CN42 M B 2 L W 1 Br

(Right)

(Machine for rear mounting)

F CN32 M 2 YW 1 BW

R

CN89 F 4 BW 3 BR 2 R 1 YG

RY

Low angle set switch High angle set switch

R YB R YR

Relay for AMA buzzer

Controller AMA-PDⅡ(12V) GR 2 DET1SRC Detector power supply output GB 1 DET1GND GND GW 12 LENSIG Length detector input YW 21 ANGSIG Angle detector input LW 14 RODPR Rod pressure detector input LR 4 PRSRC Detector power supply output LY 13 SYLPR Cylinder pressure detector input LB 3 PRGND GND GL 11 DET1SLD Shield O 23 DET2SRC Spare(detector power supply) Br 33 SANGSIG Spare(swing detector) GO 22 DET2GND Spare(GND) RG 29 TXD Serial output RY 28 RXD Serial input Y Warning lamp 9 Do1(100mA) Lg 36 Rear outrigger DI9 P 25 DI8 Basket W 26 DI7 O/R MAX BW 15 DI5 Angle display BR 5 DI3 Full retraction RL 6 DI2 O/R MID BrW 7 DI1 O/R MID 20 RSRXD Maintenance terminal 19 RSTXD Maintenance terminal Maintenance terminal 30 BOOT B 35 MBGND GND WG 32 Do10(200mA) Display R Power supply input 10 MBSRC WL 31 Do9(200mA) Display WR 37 Do8(1.5A) Display Gy 24 ENCA Drum REV detector 1 BY 34 ENCB Drum REV detector 2 L 18 Do3(100mA) AMA stop (open when it stops) YG 39 Do7(1.5A) Spare LO 38 Do6(1.5A) Spare LG 40 Do5(1.5A) Spare YB 17 Do4(100mA) Spare YR 8 Do2(100mA) Spare LgB 27 Spare LgR 16 DI6 Spare DI4

R B

M CN6 F W 4 B R 2 LgB W 3 B R 1 LgR

F CN3 M 1 W 2 LR 3 L

F CN3 M 1 LR 2 L 3

When optional basket is not installed

F CN32 M YW 2 BR 1

Relay for overwind cutout cancellation by basket installation

CN92 F 4 R 3 RY 2 R 1 LG

F CN70 R 4 GY 3 R 2 Y R 1

Connect to main harness

Connect to main harness

Relay for winch unload by basket installation

M CN4 F W 2 BW B 1 B

F CN64 M L 4 L R 3 R B 2 B G 1 G

Vehicle battery 12V

CN 74 F 4 R 3 Y 2 YG 1 B

RG RY GY Lg P W BW BR RL BrW

B Y R W G

AMA display window

For no-radio-control specification, loop 4 and 5.

KEY SW

R

M CN78 F 6 B 5 B R 4 R O 3 O Br 2 Br G 1 GO

M CN77 F 2 O 1 Br

F CN20 M LG 6 LG Y 5 Y YR 4 YR RB 3 RB O 2 O B 1 B

M CN72 F 4 RW 3 RW YG 2 Br R 1 R

F CN2 M 2 RY 1 RG

B

CN42,AMP L230 821-085-01060

F CN11 M G 2 R B 1 B

W

R

F CN2 M RY 2 G RG 1 RG

CN75 F 4 L 3 Br 2 R 1 YW

R Relay for front outrigger extension detecting switch (closed at the middle extension) M CN42 F M CN49 F (Left)

No CN, SWP L250 821-045-01120

No CN, AMP 367-405-50000

CN76 F 4 G 3 L 2 R 1 GR

R

C/J

F CN3 M W 1 W LR 2 L R 3 R

Crane mounted on chassiis tail Relay for front outrigger extension detecting switch (Middle extension) (Right)

Detection switch for swing operation (close when operating)

F CN36 M YB 2 * B 1 *

F CN61 M BR 4 BR W 3 W G 2 GY B 1 B

G

F CN61 M 4 BR Non-continuous 3 W 2 GY swing spec.

1 B

Detection switch for swing operation (close when operating)

F CN38 M 3 R 2 * BY 1 *

M CN56 F W 2 BR Y 1 W

G

AMA lamp (base boom section)

CN42,AMP L70 821-085-01180

SOL3

CN59, AMP L1350 316-558-04300 CN60,AMP

Code reel

AMA lamp (base boom section)

Detection switch for elevating down (Down:open)

SOL4

W Y

Top boom section

Emergency stop lamp

Detection switch for telescoping extended (Extension:open)

SOL5

W Y

Relay for AMA buzzer

Controller AMA-PDⅡ(12V)

GR 2 DET1SRC Detector power supply output GB 1 DET1GND GND GW 12 LENSIG Length detector input YW 21 ANGSIG Angle detector input LW 14 RODPR Rod pressure detector input LR 4 PRSRC Detector power supply output LY 13 SYLPR Cylinder pressure detector input LB 3 PRGND GND GL 11 DET1SLD Shield 23 DET2SRC Spare(detector power supply) 33 SANGSIG Spare(swing detector) Spare(GND) 22 DET2GND RY 29 TXD Serial output RG 28 RXD Serial input Y Warning lamp 9 Do1(100mA) Rear outrigger 36 DI9 25 DI8 Basket 26 DI7 O/R MAX Angle display 15 DI5 BR 5 DI3 Full retraction 6 DI2 O/R MID 7 DI1 O/R MID Maintenance terminal 20 RSRXD Maintenance terminal 19 RSTXD Maintenance terminal 30 BOOT B 35 MBGND GND Display 32 Do10(200mA) R 10 MBSRC Power supply input Display 31 Do9(200mA) Display 37 Do8(1.5A) 24 ENCA Drum REV detector 1 Drum REV detector 2 34 ENCB 18 Do3(100mA) AMA stop (open when it stops) Spare 39 Do7(1.5A) Spare 38 Do6(1.5A) Spare 40 Do5(1.5A) 17 Do4(100mA) Spare Spare 8 Do2(100mA) Spare 27 DI6 Spare 16 DI4

F CN60 M B 6 LW R 5 LR W 4 LY G 3 LB L 2 GL 1

B 2 B R 1 Y

Detection switch for overwinding

Detection switch for winch up (Up:open)

BY YB

F CN59 M Y 6 B R 5 R W 4 W B 3 G 2 L 1

No CN, SWP L250 361-323-20000

(Full retraction detecting switch from boom section)

Emergency stop switch 1 Br

F CN70 R 4 GY 3 R 2 Y R 1

No CN, Metal L1150 313-613-74200 CN62,AMP

Hoisting speed indicator lamp

F CN42 M B 2 * WG 1 *

F CN37 M 3 2 * 1 *

G R B W

Pressure detector (rod side)

Horn switch L75

M CN29 F 1 B

F CN42 M B 2 * WG 1 *

Angle detector

Shield Power GND Output

F CN62 M 6 Shield 5 GL R 4 GR B 3 GB W 2 GW G 1 YW

F CN63 M G E Shield R C R B D B W B W W A G

No CN, Metal L400 361-323-20000

Length detector F CN4 M BW 2 W B 1 B

Radio control valve (STD, SANWA)

Basket operation indicator lamp

R

CN88 F 4 W 3 B 2 R 1 YG

Selector switch (basket operation)

YG R

M CN19 F BY 4 BL 3 B 2 B 1

M CN84 F B 8 7 6 5 4 3 B 2 B 1

M CN84 F BL 8 Gy R 7 R YG 6 YG LO 5 LO YB 4 YB YR 3 YR BY 2 BY B 1 B

IWZ03-3451E01

Revised Nov. 2009

6b

WZ03-3451E

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314-024-70100 5

6b

Z-7

Z-7

Z-7

Location of Hydraulic Parts Z-7 Location of Hydraulic Parts 1. Frame

4 316-484-20000 △

7

WZ07-1810E

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7

Z-7

Z-7

Location of Hydraulic Parts 2. Boom 2.1 With 375° non-continuous swing Connect the 7 hoses from the hose assembled section of the swing frame, and the winch drain hoses.

Connect the hoses with the same marks.

Arrange clearance of at least 1/2 inch between clamps or bolts and high-pressure hoses.

2 313-429-50000 △

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WZ07-1810E

Z-7

Z-7

Location of Hydraulic Parts 2.2 With 360° continuous swing Notice 1. Connect the hose between same marks.

2. Cover the hoses with spiral tube wraps on the position shown in figure at the passage part of the post side face, and secure both ends with fasteners.

1 313-429-60000 △

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WZ07-1810E

Z-7

Z-7

Z-7

Location of Hydraulic Parts 3. Outrigger

4 316-481-21001 △

10

WZ07-1810E

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10

Z-7.

Z-7.

Z-7.

Location of Hydraulic Parts 4. Lower

0 319-233-61000 △ 1 316-134-30300 △ 0 319-233-63000 △

11

WZ07-1810E

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11

Z-8

Z-8

Z-8

Location of Electrical Parts Z-8 Location of Electrical Parts 1. Boom

Note: 1. Reduce size X as much as possible within the range where the switch can be smoothly rotated.

2. Never apply grease to pins 1 and 2.

3. Clamp the wiring of the metal connector. ( In upper part, fix the wiring from the post.)

4. Tighten both wirings for the SWP connector and the wirings for the metal connector.

5. Adjust the switch to operate at 5 – 8mm (0.2 – 0.32in) before the top boom retracted completely.

Apply LOCKTITE 262T on threads when install bolts.

6. Tighten the ground terminal and the flange bolt together.

(Only on right-side of boom) 7. Connect plug of lamp assy harness to the plug receptacles of post side, and clamp remainder materials with fasteners.

3 313-618-50000 △

12

WZ02-3270E

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12

Z-8

Z-8

Z-8

Location of Electrical Parts 2. Post and Boom-point 2.1 Non-continuous 375° rotation spec.

0 316-558-14000 △

13

WZ02-3270E

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13

Z-8

Z-8

Z-8

Location of Electrical Parts 2.2 Continuous rotation spec.

1 316-558-04000 △

14

WZ02-3270E

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14

Z-8

Z-8

Z-8

Location of Electrical Parts Adjustment Procedure of Outrigger Extension Detector

3. Frame

1. Maximum extension detection switch adjustment procedure (upper surface of frame) 1-1.With the outrigger beams fully extended and jack cylinders fully retracted, screw the proximity switch in until it contacts the upper surface of the outrigger box. Then loosen the switch 2.5 turns (3/32") and lock the switch in place.

1-2.Retract the outriggers, and check the switch indicator to confirm that there is no detection error. When shipped, the proximity switch is secured so that the switch tip is recessed loosened from the frame internal surface by one turn 1/16 inches (1mm).

2. Middle extension detection switch adjustment procedure (side surface of frame) Secure the proximity switch at the position in which the switch tip becomes flush for the frame internal surface.

Operate the outrigger slides to confirm that there is no detection error.

0 313-612-21001 △

15

WZ02-3270E

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15

Z-8

Z-8

Z-8

Location of Electrical Parts 4. Operation box

4 316-558-02000 △

16

WZ02-3270E

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16

Z-8

Z-8

Z-8

Location of Electrical Parts 5. Radio-control system 5.1 Main harness

2 316-558-03000 △

17

WZ02-3270E

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17

Z-8

Z-8

Z-8

Location of Electrical Parts 5.2 Sub harness

1 316-557-30000 △

18

WZ02-3270E

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18

Z-8

Z-8

Z-8

Location of Electrical Parts 6. Frame (Rear)

0 314-803-36000 △

19

WZ02-3270E

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19

Z-8

Z-8

Z-8

Location of Electrical Parts 7. Vehicle 0 319-329-00000 △

20

WZ02-3270E

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20

Z-8.

Z-8.

Z-8.

Location of Electrical Parts 8. Angle limit alarm 0 314-803-40000 △

21

WZ02-3270E

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21

Z-9

Z-9

Z-9

Harness Z-9 Harness 1. Harness (Post and Boom-point)

0 313-612-24100 △ 1 313-612-24200 △ 0 316-558-14300 △ 0 316-558-14400 △ 0 313-613-74200 △ 0 316-558-04300 △ 2 316-558-04400 △ 0 316-558-04500 △

22

WZ04-2600E

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22

Z-9

Z-9

Z-9

Harness 2. Harness (Operation box) 2.1 Harness 1

3 316-558-02300 △

23

WZ04-2600E

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23

Z-9

Z-9

Z-9

Harness 2.2 Harness 2

3 316-558-02100 △

24

WZ04-2600E

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24

Z-9

Z-9

Harness 2.3 Switch

3 313-612-23400 △

25 Downloaded from www.Manualslib.com manuals search engine

WZ04-2600E

Z-9.

Z-9.

Z-9.

Harness 3. Harness (Radio-controls)

0 316-558-03600 △

26

WZ04-2600E

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26

Head Office

Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group Tadano Ryogoku Bldg.

4-12, Kamezawa 2-chome, Sumida-ku, Tokyo, Japan Tel. 81 (3) 3621-7765 Tel fax 81 (3) 3621-7785

History of revision 1 2 3 4 5

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