Tadano Faun Cargo Crane TM-ZR300XL Service Manual SN EU2255 - PDF DOWNLOAD

Publication No.

TM-ZR300JXL-4/S1(U)-1E

Service Manual

01 TM-ZR300JXL-4/S1 (U)-1E

ｃ ◯2005 PRINTED IN JAPAN 0512

K

Cargo Crane Model

TM-ZR300XL Applicable Serial No.

EU2255 ～

Safety Safety [NOTICE]

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.

[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.

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.

1

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

2

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 & 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 & 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 & remounting and disassembling & 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.

3

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.

4

WA01-0041E

Foreword Foreword

1.1 Unit No. of the TM-ZR300XL series

This manual contains information on the systems

1.1.1

TM-ZR300XL series Standard

and components of TM-ZR300XL 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.

Whenever a part need to be replaced, check the

Model

Boom nameplate Unit No.

ZR303XL (TM-30Z-4-442)

311-140-20170

ZR304XL (TM-30Z-4-443)

311-140-20180

ZR305XL (TM-30Z-4-444)

311-140-20190

Frame nameplate Unit No.

311-140-10261

311-140-10271

part sales unit in the parts catalog.

2. Separate Service Manual Separate Service Manual

Publication No.

General Caution

SA01-01-2E

Boom nameplate

–

–

(1) Unit No.

–

–

1. Applicable Unit No.

(2) Lot No.

（1）ユニット番号 （2）ロット番号 UNIT

NO.

LOT

NO.

IWA04-062001

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

(1) (2)

SPEC.

NO.

Please note that, for product improvement, some

SERIAL. NO.

changes may have been incorporated in the

MFG. DATE.

KAGAWA,JAPAN

(3)

machine that are not covered in this manual.

IWA04-062002

1

WA04-1880E

Foreword 3. Outline of specifications Outline of Specifications Spec. No. TM-30Z-4-442

TM-30Z-4-443

TM-30Z-4-444

TM-ZR303XL

TM-ZR304XL

TM-ZR305XL

3-section

4-section

5-section

Item

No.of boom sections Winch Outriggers Extended width

Safety devices

Hydraulic motor driven spur gear speed reduction Min.6' 6-3/4''

Mid.8' 9-1/2''

Max.10' 5-3/16''

Antitwo-block with alarm Hook safety latch Level gauge Hydraulic safety valves, check valves and holding valves Over load alert with load indicator Load indication Load moment ratio to rated load indication Audible warning External warning lamps

2

WA04-1880E

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 -3

1 3

1

1X10

6

1X10

3

9.80665X10 6895

4

1

9.80665X10

9.80665X10

6.895

0.006895

3

2

lb/in , psi

-3

1X10

1X10

2

1.01972X10

1X10

1X10

kgf/cm

-6

-5

14.5X10

1.01972X10

-2

14.5X10

1.01972X10

14.5X10

1

14.22

0.07031

1

-2

WA04-1880E

-5 -2

Foreword Torque N-cm

N-m

1

1X10

kgf-cm

-2

2

1X10

9.80665X10 2

0.00737

-1

0.7376

8.851

1X10

0.0723

0.868

foot-pound, ft-lb

1.01972X10

1.01972X10 -2

9.80665 9.80665X10

-1

1.01972X10

1

-3

inch-pound, in-lb 0.0885

kgf-m

1.01972X10 -2

1 2

9.80665

1X10

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

1.01972X10

2.24809X10

9.80665

1

2.20461

4.44822

0.45359

1

-1

-1

4

WA04-1880E

GROUP INDEX A B

Hydraulic Power Generating System

C

Outrigger System

D

Swing System

E

Boom Elevation 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 W X Y

Data, Adjustment and Checks

Z

System Diagrams 5

WA04-1880E

Foreword ZR300XLSeries Chapter

Section

TM-30Z-4-442

TM-30Z-4-443

TM-30Z-4-444

General Refer to separate manual SA01-01-2E

General Cautions A

Hydraulic Pressure Generating System

B

Manual Control Valve

B-1

Rotary Joint

B-2

Hydraulic Pump

B-3

Outrigger System Jack Cylinder

C-1

Pilot Check Valve (Jack)

C-2

C

Swing System

D

Hydraulic Motor (Swing)

D-1

Swing Speed Reducer

D-2

Swing Bearing

D-3

6

WA04-1880E

Foreword ZR300XLSeries Chapter

Section

TM-30Z-4-442

TM-30Z-4-443

Boom Elevation System

E

Elevating Cylinder

E-1

Counterbalance Valve

E-2

Winch System Hook-in Specifications

F-1

Hydraulic Motor

F-2

Winch

F-3

F

Boom Telescoping System 3-Section

G-1

4-Section

G-2

5-Section

G-3

3-Section Boom

G-5

4-Section Boom

G-6

5-Section Boom

G-7

Boom

G Telescoping Cylinder

Counterbalance Valve

G-9

7

WA04-1880E

TM-30Z-4-444

Foreword ZR300XLSeries Chapter

Section

TM-30Z-4-442

TM-30Z-4-443

Safety Devices

H

AMA (Load Moment Indicator)

H-1

Length Detector

H-2

Angle Detector

H-3

Outrigger Extension Detector

H-4

Data, Adjustment & Checks Sarvice data

Y-1

Y

System Diagrams Hydraulic Circuit

Z-1

Electric Circuit

Z-2

Z

8

WA04-1880E

TM-30Z-4-444

B Hydraulic Power Generating System

Contents

B-1 Manual Control Valve ...................... 1 1.

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

B-2 Rotary Joint ...................................... 6 1.

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

2.

Reassembly.............................................. 7

B-3 Hydraulic Pump................................ 8 1.

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

2.

Dismounting and remounting .................... 9

3.

Disassembly and reassembly ................... 9 3.1

Replacement of oil seal-2........................... 9

3.2

Replacement of backup strip-13 and gasket-3,12........................................... 9

4.

Cautions for starting the pump .................. 9

i

B

B-1

B-1

Manual Control Valve B-1

Manual 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 General View Pressure gauge

P

T

Pressure tapping hole

T

SOL-1

Pressure tapping hole Pressure gauge

Unload valve SOL-1

P

Unload valve

Boom telescoping

A1 B1

SOL-2

Winch

A2 B2

LRV

Boom elevation

A3 B3

Swing

A4 B4

Jack 2

A5 B5

Jack 1

A6 B6

A1

B1

SOL-2

Boom telescoping

A2

B2

LRV

Winch

A3

B3

Boom elevation

A4

B4

Swing

A5

B5

Jack 2

A6

B6

Jack 1

T = 21.6 - 23.5 N-m

Hydraulic circuit

IW113-003001E

Thread size and tightening torque Sign / Port

Thread size

A-B port

Tightening torque N-m

ft-lbf

G 3/8

39.2 – 49.0

28.9 – 36.1

P port

G 1/2

58.8 – 68.5

43.3 – 50.5

T port

G 1/2

58.8 – 68.5

43.3 – 50.5

Pressure gauge

G 1/4

24.5 - 29.4

18.0 – 21.6

1

W113-0031E

B-1

B-1

Manual Control Valve

Cross section

Unloading valve

A

A

Boom telescoping

Winch

Boom elevation

Swing

Jack 2

Jack 1

SOL-1

P T

A－A

2

IW113-003002

W113-0031E

B-1

B-1

Manual Control Valve

Unloading valve

3

W113-0031E

B-1

B-1

Manual Control Valve Boom telescoping

Tightening toque 68.6 - 78.4 N-m (50.6 - 57.8 ft-lbf)

A1

B1

Tightening toque 1.47 - 1.96 N-m (1.08 - 1.45 ft-lbf) (Loctite 270) Tightening toque 68.6 - 78.4 N-m (50.6 - 57.8 ft-lbf) SOL-2

Tightening toque 18 - 20 N-m (13.3 - 14.8 ft-lbs) (Loctite 242) IW113-003004E

Winch

A2

Tightening toque 20 N-m (14.8 ft-lbf) (Loctite 270) Tightening toque 39.2 N-m (28.9 ft-lbf)

B2

LRV

IW113-003005E

Boom elevation

A3

B3

IW113-003006

4

W113-0031E

B-1

B-1

Manual Control Valve

Swing

A4

B4

IW113-003007

Jack 2

A5

B5

IW113-003008

Jack 1

A6

B6

IW113-003009 0 366-382-10000 △

5

W113-0031E

B-2

B-2

Rotary Joint B-2

Rotary Joint

[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

6

W181-0410E

B-2 .

B-2 .

Rotary Joint 1. Body

6. Bolt

11. Connector

16. Bolt

2. Core

7. Spring washer

12. Plate

17. Cap

3. Packing

8. Bolt

13. Connector

4. Ring seal

9. Plain washer

14. Plate

5. Slip ring assembly

10. Spring washer

15. Support

2. Reassembly CAUTION When disassembling and reassembling, also observe “general cautions (hydraulic units)” in chapter A to work correctly.

Thread size and tightening torque Thread

The Union part of the pipe

Thread size

Tightening torque N-m

ft-lbf

R 1/8

8.8 - 11.8

6.5 - 8.7

G 1/4

24.5 - 29.4

18.1-21.7

G 3/8

44.1 - 53.9

32.5-39.8

7

W181-0410E

B-3

B-3

Hydraulic Pump

8

W101-0190E

B-3

B-3

Hydraulic Pump B-3

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.Retaining ring

5.Body

9.Front cover

13.Backup strip

2.Oil seal

6.Spring washer

10.Bush

14.Rear cover

3.Gasket

7.Hexagon socket head bolt

11.Driven gear

4.Side plate

8.Drive gear

12.Gasket

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

Suction port

G1

107.9±10.8

79.6±8.0

Delivery port

G1/2

32.4±2.9

23.9±2.1 0 316-313-20000 △

9

W101-0190E

B-3 .

B-3 .

Hydraulic Pump 3.2 Replacement of backup strip-13 and gasket-3,12

2. Dismounting and remounting [NOTE]

1. Front cover side

When replacing the pump, pay attention to the rotating direction of the new pump. (The rotating direction as viewed from the shaft end is stamped on the rear cover.)

Unscrew bolts-7 and remove front cover-9.

Remove backup strip-13 and gasket-3,12 from front cover-9.

3. Disassembly and reassembly

Install new backup strip-13 and gasket-3,12 and assemble in the reverse sequence of

CAUTION

disassembly.

Disassemble only the parts specified to do so, leaving all others intact. Maintain the present position of the bearings and the gears in the body. Removing the gears from the body could make the pump unusable, even if the parts can be reassembled.

2. Rear cover side Follow the same procedure as for the front cover side.

The covers, body and the bearings are made of aluminum alloy. Handle them carefully to avoid damage.

4. Cautions for starting the pump

Remove oil thoroughly from the mating surfaces of the covers, body, etc.

1. Before starting the pump,check the rotating direction of the pump, and the connection of the hydraulic lines. If the pump is driven in the wrong

3.1 Replacement of oil seal-2

direction, the suction and delivery sides are reversed,possibly resulting in the protrusion of the

1. Unscrew bolts-7, and remove front cover-9.

oil seal and other damage to the pump.

2. Remove retaining ring-1 from front cover-9;

2. Before starting the pump, fill the suction line with

remove oil seal-2.

hydraulic oil. First inch the pump, and then run it

3. Install new oil seal-2, and install retaining ring-1.

at a low speed and without load until all air is expelled from the hydraulic lines. Avoid running

4. Pack grease (LIMAX 3 or equivalent), between

the pump at high speeds and/or under heavy load

the lips of oil seal-2.

from the beginning.

5. With the spline of drive gear-8 wound with a tape

3. After allowing a sufficient brake-in time, check for

to protect the lips of oil seal-2 from damage, install

leakage, vibration, excentricity of the shaft,

front cover-9, and tighten bolts-7.

change in oil temperature,etc., before gradually increasing the speed and the load up to the full power operation.

1 366-522-90000 △

10

W101-0190E

C Outrigger System

Contents

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

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

2.

Check Valve Mounting Bolt ....................... 1

C-2 Pilot Check Valve (Jack).................. 2 1.

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

i

C

C-1 .

C-1 .

Jack Cylinder C-1

Jack Cylinder

[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. Cylinder

4. Plain bearing (＊)

7. Packing

2. Piston

5. Rod cover

8. Backup ring

3. O-ring

6. O-ring

9. Dust seal

10. Rod

＊：This part is the set of the plain bearing and packing.

2. Check Valve Mounting Bolt Check Valve

0 360-347-80000 △

1

W151-0210E

C-2 .

C-2 .

Pilot Check Valve (Jack) C-2

Pilot Check Valve (Jack)

[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 △

2

W115-0351E

D Swing System D

Contents

D-1 Hydraulic Motor................................ 1 1.

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

2.

Disassembly ............................................. 2

3.

Reassembly.............................................. 2

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

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

2.

Dismounting And Remounting................... 4

3.

Disassembly ............................................. 4

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

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

2.

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

i

D-1

D-1

Hydraulic Motor D-1

Hydraulic Motor

[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. Shaft

11. Thrust bearing

15. Bottom cover

21-5. Backup ring

2. Bearing

12-1. Thrust plate

16. Needle bearing

21-6. O-ring

3. Housing

12-2. Spherical ring

17. Pin

21-7. O-ring

4. O-ring

13. Spring

18. O-ring

21-8. O-ring

5. Oil seal cover

14-1. Cylinder barrel

19. Valve plate

22. Plug

6. Oil seal

14-2. Plunger

20. Bolt

23. Plug

7. Retaining ring

14-3. Plunger spring

21-1. Lock body

8. C-ring

14-4. Steel ball

21-2. Piston

9. Retainer

14-5. Center spring

21-3. Cap

10. Thrust plate

14-6. C-ring

21-4. Spring

1

W102-0590E

D-1 .

D-1 .

Hydraulic Motor Thread size and tightening torque Sign / Port

Thread size

Port･A

Tightening torque N･m

ft･lbf

G3/8

39.2 - 49.0

28.9 - 36.1

Port･B

G3/8

39.2 - 49.0

28.9 - 36.1

Port･L

G1/4

19.6 - 29.4

14.5 – 21.7

Hydraulic motor mounting bolt

M12×35

68.6 - 82.4

50.6 – 60.8

2. Disassembly

3. Reassembly

1. Loosen the bolts (20) to separate the bottom

1. Make sure that the O-rings (4) and (18) are placed

cover (15) about 10 mm. This is necessary to

in position.

prevent the shaft (1) from popping out by the force

2. Apply grease to the lip area of the oil seal (6).

of the center spring (14-5).

Install the oil seal (6), together with the oil seal

2. Remove the retaining ring (7).

cover (5), into the housing (3).

3. Insert the flat blade of a screwdriver into the slot

3. Securely put the retaining ring (7) into the groove

of the oil seal cover (5) to remove the oil seal

of the housing (3).

cover (5), together with the oil seal (6).

[NOTICE]

[NOTICE]

When putting the retaining ring (7), be sure to place the rounded edge inside (next to the bearing).

If the rounded edge is place outside, there is a possibility that the retaining ring may come off because of an internal force such as spring force and hydraulic force.

Do not pull out the shaft (1).

As it is difficult to engage the male spline teeth of the shaft (1) with the female ones of the cylinder barrel (14-1), reassembly will be troublesome.

4. Install the bottom cover (15) as before.

1 366-625-90000 △

2

W102-0590E

D-2

D-2

Swing Speed Reducer D-2

Swing Speed Reducer

[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. Nut

8. ------

15. Oil seal

22.Case

2. ------

9. ------

16. Case

23. Bearing

3. Spacer

10. Oil gauge

17. Bearing

24. Nut

4. Bearing

11. Seal washer

18. Bolt

25. ------

5. Worm

12. Plug

19. Pin

26. ------

6. ------

13. Drive gear

20. Key

27. Snap ring

7. ------

14. Sleeve

21.Worm wheel

28. Needle bearing

3

W511-0150E

D-2

D-2

Swing Speed Reducer 2. Dismounting And Remounting [NOTE] When the swing speed reducer is removed, the swing post is freed. Before removing the reducer, fasten the swing post to the lower frame with a wire rope to prevent its rotarion.

Fill the reducer with gear oil (Mobil 632) to the middle point on the oil gauge. (To check the oil level, just place the gauge on the gauge hole) Quantity: 0.5 lit.

3. Disassembly 1. Remove plug-12 , and drain the oil.

2. Remove oil gauge-10.

3. Remove snap ring-1 and remove spacer-2 and thim set-3.

To facilitate extracting worm-5, turn the spur gear-10 while shaking it slightly.

4. Extract worm-5 together with bearing-4 and-6 toward the motor side.

5. Separate the spur gear-10 and gear case-13 from the gear case-19.

Use the separating tap (M12, coarse thread) to separate them following the procedure below because the pin-22 is tightly fit. (The separating tap is made on the hole for the bolt-16.)

Put a spacer on the bottom of the separating tap to prevent damage to the hole in the gear case-19 for the bolt-16.

Then screw a bolt into a separating tap in the gear case-13 to separate the gear case-13 from the gear case-19.

6. Remove bolt-16, then remove spur gear-10 together with gear case-13 and bearings-14, 15 and 20.

7. Remove nut-21, then remove bearing-20, worm wheel-18, and key-17 from spur gear-10.

8. Remove spur gear-10 from gear case-13, then remove bearings-14 and-15, oil seal-12 and sleeve-11.

Notes for Reassembly With regard to the handling of oil seals and bearings, refer to the separate REPAIR MANUAL, GENERAL CAUTIONS ("Sealing Parts" and "Mechanical Elements" sections).

Maintenance Standards Item

Maintenance standards

Bearing damage/wear

No vibration/shakiness caused by damage/wear

Backlash between worm

Standard value

and worm wheel

0.11 – 0.19 mm (0.004 – 0.007 in.)

4

W511-0150E

Correction Replace Replace

D-2 .

D-2 .

Swing Speed Reducer

Thread size and tightening torque Sign / Port

Thread size

7

Tightening torque N-m

ft-lbf

Oil gauge

88.3-147

65.1-108.4

9

R 3/8

32.4-35.3

23.9-26

16

M 10

57

42

21

AN 11

167-216

123.2-159.3

Remarks

Seal tape

Apply adhesive (Threebond 1305)

2 360-813-80000 △ 1 360-815-50000 △

5

W511-0150E

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

4. Bolt (M8x16)

7. Swing Assy

10. Spring washer

2. Bolt (M18x70)

5. Bolt (M14x35)

8. O –ring

11. Hydraulic motor

3. Bolt (M16x50)

6.Spring washer

9. Hexagon socket head bolt

6

W512-0210E

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 position shown in the figure on the previous page.

To tighten the bolts•2,3,5, 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

M18

343 - 382

253.0 – 281.8

3

M16

255 - 284

188.1 – 209.5

5

M14

116 - 133

85.6 – 98.1

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

1 313-011-00000 △

7

W512-0210E

E Boom Elevating System

Contents

E-1 Boom Elevating Cylinder ................ 1 1.

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

E-2 Counterbalance Valve (elevating)... 2 1.

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

2.

Pressure detector for AMA ........................ 3

i

E

E -1 .

E -1 .

Boom Elevating Cylinder E-1

Boom Elevating Cylinder

[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. Plain bearing

5. Cylinder

9. Packing

2. Piston

6. Rod

10. Backup ring

3. Plain bearing

7. O-ring

11. Dust seal.

4. O-ring

8. Rod cover

12. Retaining ring

Sign / Port

Piston-2

Rod cover-8

Thread size

M78

M121

13. Grease nipple

Tightening torque N-m

72

Before installing Piston-2, apply Loctite 638 from 1st crest to 2nd crest of thread on Rod-6. Application area is shown by ※※ marks in drawing.

398

Before installing Rod cover-8, apply Threebond 1104 to thread portion shown by ※ mark. After installation, bend edge of Cylinder-5 at notch (one place) to prevent rotation.

98

539

Note

ft-lbf

0 360-259-60000 △

1

W155-0280E

E -2

E -2

Counterbalance Valve (elevating) E-2

Counterbalance Valve (elevating)

[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

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

2

13. O-ring

W119-0321E

1 366-225-40000 △

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

A-B port

G 3/8

44.1 - 53.9

32.5 - 39.8

Plug-3.9

G 3/8

44.1 - 53.9

32.5 - 39.8

Plug - 7

G 1/2

53.9 - 63.7

39.8 - 47

2. Pressure detector for AMA

Pressure detector [NOTE] The adjustment of pressure detector is nnecessary.

2 366-051-80000 △

3

W119-0321E

F Winch System F Contents F-1 Explanation of winch system (Hook-in Specifications) ......... 1 1.

2.

General..................................................... 1 1.1

Electrical Circuit.......................................... 1

1.2

Hydraulic Circuit ......................................... 1

Principle of operation ................................ 3 2.1

Hoisting up.................................................. 3

2.2

Automatic stop & overwinding cutout release switch....................................... 5

2.3

Hook stowing .............................................. 7

F-2 Hydraulic motor (Winch) ................. 8 1.

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

2.

Thread size and tightening torque............. 9

F-3 Winch .............................................. 10 1.

Structure ................................................. 10

2.

Principle of Operation ..............................11 2.1

Hoisting up.................................................11

2.2

Hoisting down ............................................11

i

F-1

F-1

Explanation of winch system (Hook-in Specifications) F-1

1.2 Hydraulic Circuit

Explanation of winch system (Hook-in Specifications)

1.When the unloading solenoid (SOL1) is energized, the unloading valve works as a main relief valve.

1. General

On the other hand when de-energized, the

[NOTICE]

operations such as hook hoisting-up, boom

hydraulic circuit serves to automatically stop extension, and boom raising. In the automatic

The circuit diagrams in this chapter are used only for the purpose of explaining the operation principle.

As there is a possibility that some portions may differ from the actual circuits, please refer to the circuit diagrams in Chapter Z when conducting service or repairs.

stop condition, the vent circuit of the unloading valve is connected to the tank circuit and the unloading valve is in unloaded condition.

2. In a hook stowing operation, the vent circuit pressure of the unloading valve is controlled by

1.1 Electrical Circuit

the low-pressure relief valve (LRV) and the unloading valve works as a low-pressure relief

1. When the hook is hoisted up too high and touches

valve.

the weight of the overwinding cutout device, the buzzer will be activated and the unloading solenoid (SOL1) will be de-energizes at the same time. (Operations such as hook hoisting-up, boom extension, and boom raising will be automatically stopped.)

If the buzzer switch is set to the off position, the buzzer will not be activated.

2.While the overwinding cutout release switch is pushed, the unloading solenoid (SOL1) is energized. (Operations such as hook hoisting-up, boom extension, and boom raising will not be automatically stopped.)

3. In a hook stowing operation the unloading solenoid (SOL1) is de-energized and the low-pressure solenoid (SOL2) is energized at the same time. (The operating pressure for hook hoisting-up becomes low.)

1

WF02-0350E

F-1

F-1

Explanation of winch system (Hook-in Specifications) Winch System [NOTICE] These circuit diagrams are for the ZR500-4 series (standard specifications). As some portions may differ from your machine, please refer to the circuit diagrams in Chapter Z at the same time.

These circuit diagrams show the de-energized condition.

2

WF02-0350E

F-1

F-1

Explanation of winch system (Hook-in Specifications) 2. Principle of operation 2.1 Hoisting up 1. When the PTO is turned on: First, the contact of the power supply relay is closed. Second, DC 24V (12V) is outputted to the following relays and switch from the No.3 terminal of the power supply relay.

- No. 2 terminal of the overwinding detection relay (for SOL1) - No.2 & 4 terminals of the overwinding detection relay (for buzzer) - No.1 terminal of the hook stowing operation detection switch - No.1 terminal of the overwinding cutout release switch 2. When the hook does not touch the weight of the overwinding cutout device: As the contact of the overwinding detection swich is closed, the contact of the overwinding detection relay (for buzzer) becomes open, which does not activate the buzzer. And the contact of the overwinding detection relay (for SOL1) is closed, which energizes the unloading solenoid (SOL1).

In this condition the hook can be hoisted up.

3

WF02-0350E

F-1

F-1

Explanation of winch system (Hook-in Specifications) Hoisting up

4

WF02-0350E

F-1

F-1

Explanation of winch system (Hook-in Specifications)

2.2 Automatic stop & overwinding cutout release switch (When the overwinding cutout device is activated during a hoisting-up operation.)

1. When the PTO is turned on: First, the contact of the power supply relay is closed.

Second, DC 24V (12V) is outputted to the following relays and switch from the No.3 terminal of the power supply relay.

- No.2 terminal of the overwinding detection relay (for SOL1) - No.2 & 4 terminals of the overwinding detection relay (for buzzer) - No.1 terminal of the hook stowing operation detection switch - No.1 terminal of the overwinding cutout release switch 2. When the hook touches the weight of the overwinding cutout device: First, the contact of the overwinding detection switch is opened.

Second, the contact of the overwinding detection relay (for buzzer) is closed, which activates the buzzer.

Third, the contact of the overwinding detection relay (for SOL1) is opened, which de-energizes the unloading solenoid (SOL1).

Then hoisting-up operation of the hook will be automatically stopped.

3. While the overwinding cutout release switch is pushed, the unloading solenoid (SOL1) is energized and hoisting-up of the hook will not be automatically stopped.

5

WF02-0350E

F-1

F-1

Explanation of winch system (Hook-in Specifications)

6

WF02-0350E

F-1.

F-1.

Explanation of winch system (Hook-in Specifications) 2.3 Hook stowing 1. When the hook storage lever is operated, the main circuit pressure is controlled with the low-pressure relief valve,therefore the hook is stored with an appropriate wire tension.

First, the hook stowing operation detection switch is changed and the low-pressure solenoid (SOL2) is energized. (the electrical circuit is constructed so that the unloading solenoid (SOL1) is de-energized at the same time.)

Second, the winch lever is changed to the hoisting-up position in connection with the hook stowing lever, and the directional control valve is switched over. Then the hook is hoisted up and stowed.

7

WF02-0350E

F-2

F-2

Hydraulic motor (Winch) F-2

Hydraulic motor (Winch)

[NOTICE] 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. Front case

8. Spherical socket pin

17. Needle bearing

25. Hexagon socket head bolt

2. Rear case

10. Collar

19. Thrust roller bearing

27. O-ring

3. Shaft

12. Spring

20. Plate

32. Piston assembly

4. Cylinder block

13. Key

21. Hexagon socket head bolt

5. Piston retainer

14. Washer

22. Bearing

7. Spherical head retainer

16. Oil seal

23. C-ring

8

W102-0300E

F-2.

F-2.

Hydraulic motor (Winch)

2. Thread size and tightening torque Sign / Port

Thread size

Oil entrance port

G 3/8 (PF3/8)

Drain port

Rc 1/8

Hydraulic motor mounting bolt

M8

Tightening torque N-m

ft-lbf

39.2±4.9

1.54±0.19

Tightening is to stop without being here once from the place where a torque reached 6.9N-m after tightening stars.

11.8 - 16.7

0.46 - 0.66

0 366-631-00000 △

9

W102-0300E

F-3

F-3

Winch F-3

Winch

[NOTICE] ◆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 17 4 9

7

8 6 23 28 27

12 10 11 24

18

35, 34 13 14

A－A

B－B

15

7

26 8

25

B

2 10

5 20

A

A

B

21 19

32

33

16 31

3 1 29

IW526-013001

1. Gear case

10. Ratchet

19. Ball bearing

28. Spring washer

2. Gear case

11. Shaft

20. Oil seal

29. Plug

3. Spur gear

12. Spring

21. Retaining ring

30. ----------------------

4. Spur gear

13. Cap

22. ----------------------

31. Nameplate

5. Spur gear

14. Pin

23. O-ring

32. Pin

6. Break disk

15. Nut

24. O-ring

33. Oil gauge

7. Ratchet wheel

16. Ball bearing

25. Split pin

34. Round head screw

8. Link

17. Ball bearing

26. Key

35. Spring washer

9. Disk ass'y

18. Ball bearing

27. Bolt

Thread size and tightening torque Sign / Port

Thread size

27

M10×28

Tightening torque N-m

ft-lbf

43.1 - 49.0

1.7 - 1.93

10

W526-0200E

F-3.

F-3.

Winch 2. Principle of Operation 2.1 Hoisting up 1. The torque of the winch hydraulic motor is transmitted to the winch drum through the clutch facing.

2.2 Hoisting down 1. When no load is applied to the winch, the torque of the winch hydraulic motor is transmitted to the winch drum without passing through the clutch facing.

2. When a load is applied to the winch, the winch drum tends to rotate in the hoisting-down direction by the load. If the rotational speed of the winch drum becomes higher than the supposed speed when rotated by the torque of the winch hydraulic motor, the mechanical brake will be applied to reduce the speed. Once the speed becomes lower than the supposed one, the mechanical brake will be released. In the hoisting-down operation, these two operations described above are repeated.

Lef t -handed quadr upl e-st ar t t hr ead

when hoi st i ng up

when hoi st i ng down

hoi st i ng up hoi st i ng down

IW526-013002

11

W526-0200E

G Boom Telescoping System G

Contents

G-1 Boom (Three-Section Boom) .......... 1

3.

Boom Adjustment Procedures ................. 14 3.1

Top Slide Plate Installation Procedure ......14

1.

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

2.

Top Slide Plate Installation Procedure....... 4

3.

Adjustment of Clearance between Boom Sections ........................................ 4

1.

Structure ................................................. 16

4. Telescoping wire rope adjusting procedure .. 5

2.

Notes for Reassembly of Cylinder Assembly .................................................... 17

3.

Notes for Reassembly of Telescoping Cylinder ....................................... 18

5.

G-4 Telescoping cylinder (Three sections boom)......................................16

Telescoping wire rope readjusting procedure ...................................................... 6

G-2 Boom (Four-Section Boom) ............ 8 1.

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

G-5 Telescoping Cylinder (Four-Section Boom) .....................................19

2.

Notes for Reassembly............................... 9

1.

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

3.

Boom Adjustment Procedures................. 10

2.

Description of Operation.......................... 22

3.1

Top Slide Plate Installation Procedure...... 10

2.1

Control of Telescoping Sequence .............22

3.2

Adjustment of Clearance between Boom

2.2

Shock-Absorbing Mechanism of No. 2

Sections.............................................. 10

Cylinder...............................................23

3.

Notes for Reassembly of Cylinder Assembly .................................................... 24

4.

Notes for Reassembly of Telescoping Cylinder ....................................... 25

G-3 Boom (Five-Section Boom) ........... 12 1.

Structure ................................................. 12

2.

Notes for Reassembly............................. 13

i

5.

Cautions about Telescoping Wire Rope Adjustment .................................. 27

6.

Telescoping Wire Rope Adjustment Procedure.................................... 27 6.1

Wire rope adjustment with the telescoping

6.2

Wire rope adjustment with the telescoping

cylinder out of the boom..................... 27 cylinder installed in the boom............. 29

G-6 Telescoping Cylinder (Five-Section Boom) ..................................... 30 1.

Structure ................................................. 30

2.

Description of Operation ......................... 33 2.1

Control of Telescoping Sequence............. 33

2.2

Shock-Absorbing Mechanism of No. 3 Cylinder .............................................. 36

3.

Notes for Reassembly of Cylinder Assembly .................................................... 37

4.

Notes for Reassembly of Telescoping Cylinder ....................................... 39

5.

Telescoping Wire Rope Adjustment Procedure.................................... 41 5.1

Wire rope adjustment with the telescoping

5.2

Wire rope adjustment with the telescoping

cylinder out of the boom..................... 41 cylinder installed in the boom............. 42

G-7 Counterbalance Valve (Telescoping) ................................................ 44 1.

Structure ................................................. 44

ii

G -1

G -1

G -1

Boom (Three-Section Boom) G-1 Boom (Three-Section Boom) 1. Structure General View

7 312-026-10100 △

1

W536-0980E

1

G -1

G -1

Boom (Three-Section Boom) [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 parts sales unit described in the parts catalog before starting disassembling operations.

1. Base boom section

15. Cover

28. Slide plate

42. Spring washer

2. 2nd boom section

16. Plate

29. Shim

43. Button bolt

3. Top boom section

17. Pin

30. Shim

44. Support

4. Cover

18. Bolt

31. Shim

45. Plain washer

5. Grease nipple

19. Grease nipple

32. Nut

46. Spacer

6. Cap

20. Pin

33. Sheave

47. Nut

7. Cover

21. Retaining ring

34. Pin

48. Wire rope

8. Flange bolt

22. Sheave Ass’y

35. Support

49. Nameplate

9. Pin

23. Hexagon socket head

36. Support

50. Nameplate

37. Slide plate

51. Tapping screw 52. Nameplate

10. Retaining ring

bolt

11. Plain bearing

24. Roller assembly

38. Slide plate

12. Slide plate

25. Pin

39. Slide plate

13. Button bolt

26. Nut

40. Support

14. Flange bolt

27.Set screw

41. Bolt

Notes for Reassembly 1. Apply grease to the boom inside surfaces that rub 3. Bend down the plate on the boom elevating

against slide plates.

cylinder pivot pin after installing the bolts.

2. Press-fit the plain bearings at the base of the boom with their grease grooves on the outside.

2

W536-0980E

G -1

G -1

Boom (Three-Section Boom)

4. Before installing the wire rope support on the inside surface of the top boom section’s top plate, install the retracting wire rope and bend the plates (three places).

Install the wire rope support after installing the retracting wire rope.

6. Check that the support is not upside-down.

7. Install the sheave assembly at the rear end of the 2nd boom section after installing the telescoping cylinder in the 2nd boom section.

Install the sheave assembly with the clinched part on the inside.

Install the hexagon soket head bolt after installing the sheave assembly with the pin.

Apply thread locking compound (Loctite 262T or

5. Install the wire rope support in accordance with

equivalent) to the hexagon socket head bolt.

the following steos.

Tightening torque: 13.7 N-m (10.1 ft-lbf).

(1) Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts and use them to loosely fit the wire support.

(2) Tighten the bolts until the wire rope support’s longitudinal play is eliminated, then lock them in position with nuts.

Verify through the inspection holes that the wire rope support is pressed firmly against the stopper.

(3) Tighten the button bolts to a torque of 24.5 N-m (18.07 ft-lbf).

3

W536-0980E

G -1

G -1

Boom (Three-Section Boom) 3.

8. Before performing assembly, apply a line of grease of about 40 mm (1.57 inch) in width to the bottom part of the top boom section’s inside

Adjustment of Clearance between Boom Sections

1) Adjust dimension "a" (see Fig. 6) to the following

surface in the longitudinal direction (see area

values:

marked by “*” in Fig.)

・With boom fully retracted: a =2mm (0.079in.)

And it locks with the nut. ・Over entire boom telescoping stroke : "a" = max 3mm (0.12in.)

2) Adjust dimension "b" (see Fig. 6) using shims ･ 1, ･2, ･3, such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values: ・Boom lateral bending: max. 20mm.(0.787in.) ・Boom lateral play: max. 50mm (1.969in.).

[NOTE]

Boom Adjustment Procedures

Install the slide plates before assembling the boom.

Before performing this work, supply grease (TNR)

Shim･1 serves to retain the other shims, so it must be installed last.

to each slide plate and to each grease cup.

2. Top Slide Plate Installation Procedure Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts before using them to secure the slide plate. After tightening the button bolts, loosen each of them by half a turn and make sure the slide plate can move longitudinally (see Fig. 5).

[

4

W536-0980E

G -1

G -1

Boom (Three-Section Boom) 4. Telescoping wire rope adjusting procedure 1) With the top boom section’s stopper touching the end of the 2nd boom section, use the specified jig to lock the top boom section and 2nd boom section in position.

Make sure the telescoping cylinder is fully retracted.

2) Tighten the extending wire rope’s adjusting nut.

Tightening torque : 4.9N-m (3.61ft-lbf)

3) Fit the extending wire rope lock nut’s locking support.

4) Tightening torque : 37.8 N-m (27.88ft-lbf) 5) Bend the plate of each of the locking supports to prevent the lock nuts from working loose.

6) Remove the jig that was fitted in step 1) to hold the boom sections in their fully retracted positions. The wire rope’s tension will create a clearance between the end of the 2nd boom section and the stopper of the top boom section.

5

W536-0980E

G -1

G -1

Boom (Three-Section Boom)

4) Position the boom horizontally, then extend

7) Fit the assembly formed through step 6) into

the 2nd boom section and top boom section by

the base boom section.

500 mm (19.68 inch) each.

8) Tighten the adjusting nut of the boom

With the hydraulic motor idling (with a flow rate

retracting wire rope until the stopper of the top

of approximately 15 L/min.), fully retract the

boom section touches the end of the 2nd

boom and lock the base boom section and 2nd

boom section.

boom section in position. (It is not necessary to lock them in position if pressure remains on the retraction side of the telescoping cylinder.)

Measure dimension “B” shown in Fig. Dimension “B” : approx. 13mm (0.51 inch) (for reference)

9) Tighten the lock nut of the retracting wire rope.

Tightening torque : 37.8 N-m (27.88ft-lbf)

5. Telescoping wire rope readjusting procedure 1) Unbend the bent parts of the locking supports on 5) Tighten the retracting wire rope’s adjusting nut

the extending wire rope’s lock nuts.

until the stopper of the top boom section touches the end of the 2nd boom section.

Refer to Fig. in step 4-8).

6) Tighten the extending wire rope’s adjusting nut until the stopper of the top boom section is 4 – 5 mm (0.16 – 0.20 inch) away from the end of the 2nd boom section.

Refer to Fig. in step 4-1).

7) Once again tighten the retracting wire rope’s

2) Remove the extending wire rope’s lock nuts

adjusting nut until the stopper of the top boom

and locking supports.

section touches the end of the 2nd boom section.

3) Loosen the retracting wire rope’s lock nut.

8) Position the boom horizontally, then extend the 2nd boom section and top boom section by 500 mm (19.68 inch) each.

With the hydraulic motor idling (with a flow rate of approximately 15L/min.), fully retract the boom.

6

W536-0980E

G -1 .

G -1 .

Boom (Three-Section Boom)

Check whether the following boom conditions are satisfied.

- The stopper of the top boom section is touching the end of the 2nd boom section.

(The top boom section is fully retracted.)

- Dimension “B” is the same as when measured in step 4).

9) If the boom conditions stated in step 8) are not satisfied, make adjustments again in accordance with the following steps.

Refer to Fig. in step 4-1) and step 4-8).

- If the stopper of the top boom section is touching the end of the 2nd boom section but dimension “B” is not the same as when measured in step 4), perform these steps : (1) Slightly loosen the retracting wire rope’s adjusting nut.

(2) Slightly tighten the extending wire rope’s adjusting nut until dimension “B” is the same as when measured in step 4).

- If dimension “B” is the same as when measured in step 4) but the stopper of the top boom section is not touching the end of the 2nd boom section, perform these steps : (1) Slightly tighten the retracting wire rope’s adjusting nut.

(2) Slightly loosen the extending wire rope’s adjusting nut until the stopper of the top boom section touches the end of the 2nd boom section.

10) Fit the locking supports over the extending wire rope’s lock nuts. If the supports are damaged, replace them with new ones.

11) Tighten the extending wire rope’s lock nuts Refer to Fig. in step 4-1).

Be careful not to deform the locking supports.

Tightening torque : 37.8N-m (27.88 ft-lbf) 12) Bend the plate of each of the supports to prevent the nuts from working loose.

Refer to Fig. in step 4-1).

13) Tighten the retracting wire rope’s lock nuts.

7 312-026-10100 △

Tightening torque : 37.8N-m (27.88 ft-lbf)

7

W536-0980E

G -2

G -2

G -2

Boom (Four-Section Boom) G-2 Boom (Four-Section Boom) 1. Structure General View

5 312-026-30100 △

8

W536-0990E

8

G -2

G -2

Boom (Four-Section Boom) [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. Base boom section

15. Cover

29. Shim

43. Spring washer

2. 2nd boom section

16. Plate

30. Shim

44. Button bolt

3. 3rd boom section

17. Pin

31. Shim

45. Slide plate

4. Top boom section

18. Bolt

32. Slide plate

46. Roller assembly

5. Grease nipple

19. Grease nipple

33. Sheave

47. Pin

6. Cap

20. Pin

34. Pin

48. Cover

7. Cover

21. Retaining ring

35. Retaining ring

49. Nameplate

8. Flange bolt

22. Bolt

36. Pin

9. Pin

23. Nut

37. Roller assembly

10. Retaining ring

24. Roller assembly

38. Hexagon socket head bolt

11. Plain bearing

25. Pin

39. Spring washer

12. Slide plate

26. Nut

40. Slide plate

13. Button bolt

27. Set screw

41. Bolt

14. Flange bolt

28. Slide plate

42. Slide plate

2. Notes for Reassembly 3. Bend down the plate on the boom elevating

1. Apply grease to the boom inside surfaces that rub

cylinder pivot pin after installing the bolts.

against slide plates.

4. After installing the telescoping cylinder, turn back

2. Press-fit the plain bearings at the base of the

the bolt at the bottom of the telescoping cylinder

boom with their grease grooves on the outside

until all play in the telescoping cylinder pivot pin

(see Fig. 2).

on the 2nd boom section side is eliminated.

Then, lock the bolt in position with the nut.

9

W536-0990E

G -2

G -2

Boom (Four-Section Boom)

5. Install the wire rope support in accordance with the following steps (see Fig.): Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts and use them to loosely fit the wire rope support.

Tighten the bolts until the wire rope support's longitudinal play is eliminated, then lock them in position with the nuts.

Verify through the inspection holes that the wire rope support is pressed firmly against the stopper.

Tighten the button bolts to a torque of 24.5 N-m (18.1 ft-lbf).

3.2 Adjustment of Clearance between Boom Sections 1. Adjust dimension "a" (see Fig. 6 on next page) to the following values: With boom fully retracted: a = 2 mm (0.08 in.)

Over entire boom telescoping stroke : a=max 3 mm (0.118in.)

2. Adjust dimension "b" (see Fig. 6 on next page) using shims-1, -2, and 3 such that the boom's

3. Boom Adjustment Procedures

degree of lateral bending and the boom's degree of lateral play comply with the following values:

Before performing this work, supply grease (TNR) to each slide plate and to each grease cup.

Boom lateral bending: max. 35mm (1.38 in.) (see Fig. 8 on next page)

3.1 Top Slide Plate Installation Procedure

Boom lateral play: max.80mm (3.15in.)

Apply thread locking compound (Threebond 1305

(see Fig. 9 on next page)

or equivalent) to the button bolts before using

[NOTE]

them to secure the slide plate. After tightening the button bolts, loosen each of them by half a turn

Install the slide plates before assembling the boom.

and make sure the slide plate can move

Shim-1 serves to retain the other shims, so it must

longitudinally (see Fig. 5).

be installed last.

10

W536-0990E

G -2 .

G -2 .

Boom (Four-Section Boom)

Boom fully retracted Max. 35mm (1.38 in.)

Boom fullyextended

Adjustment of boom lateral bending IW536-043002E

Fig. 8

10kgf (22.1 lbf) Max. 80mm (3.15 in.)

10kgf (22.1 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0990E03

Fig. 9

5 312-026-30100 △

11

W536-0990E

G -3

G -3

G -3

Boom (Five-Section Boom) G-3 Boom (Five-Section Boom) 1. Structure General View

1 312-029-40100 △

12

W536-1000E

12

G -3

G -3

Boom (Five-Section Boom) [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. Base boom section

16. Spacer

31. Shim

46. Bolt

2. 2nd boom section

17. Cover

32. Shim

47. Button bolt

3. 3rd boom section

18. Plate

33. Shim

48. Slide plate

4. 4th boom section

19. Pin

34. Slide plate

49. Slide plate

5. Top boom section

20. Bolt

35. Sheave

50. Roller assembly

6. Cap

21. Grease nipple

36. Pin

51. Pin

7. Cover

22. Pin

37. Grease nipple

52. Plate

8. Flange bolt

23. Retaining ring

38. Pin

53. Slide plate

9. Flange bolt

24. Bolt

39. Roller assembly

54. Nameplate

10. Pin

25. Nut

40. Hexagon socket head bolt

11. Retaining ring

26. Roller assembly

41. Spring washer

12. Plain bearing

27. Pin

42. Pin

13. Slide plate

28. Nut

43. Retaining ring

14. Button bolt

29. Set screw

44. Spring washer

15. Cover

30. Slide plate

45. Slide plate

2. Notes for Reassembly 3. Bend down the plate on the boom elevating cylinder pivot pin after installing the bolts.

1. Apply grease to the boom inside surfaces that rub against slide plates.

4. After installing the telescoping cylinder, turn back

2. Press-fit the plain bearings at the base of the

the bolt at the bottom of the telescoping cylinder

boom with their grease grooves on the outside.

until all play in the telescoping cylinder pivot pin on the 2nd boom section side is eliminated.

Then, lock the bolt in position with the nut.

13

W536-1000E

G -3

G -3

Boom (Five-Section Boom) 3. Boom Adjustment Procedures

5. After installing the telescoping cylinder, turn back the bolt at the bottom of the telescoping cylinder

Before performing this work, supply grease (TNR)

until all play in the telescoping cylinder pivot pin

to each slide plate and to each grease cup.

on the 2nd boom section side is eliminated.

3.1 Top Slide Plate Installation Procedure

Then, lock the bolt in position with the nut. (see Fig. on back page)

Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts before using

6. Install the wire rope support in accordance with

them to secure the slide plate. After tightening the

the following steps (see Fig.4):

button bolts, loosen each of them by half a turn

Apply thread locking compound (Threebond 1305

and make sure the slide plate can move

or equivalent) to the button bolts and use them to

longitudinally (see Fig. 5).

loosely fit the wire rope support.

Tighten the bolts until the wire rope support's longitudinal play is eliminated, then lock them in position with the nuts.

Verify through the inspection holes that the wire rope support is pressed firmly against the stopper.

Tighten the button bolts to a torque of 24.5 N-m (18.1 ft-lb).

3.2

Adjustment of Clearance between Boom Sections

1. Adjust dimension "a" (see Fig. 6 on next page) to the following values: With boom fully retracted: a = 2 mm (0.08 in.)

Over entire boom telescoping stroke : a=max 3 mm (0.118in.)

2. Adjust dimension "b" (see Fig. 6 on next page) using shims-1, -2, and 3 such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values: Boom lateral bending: max. 35mm (1.38 in.) (see Fig. 8 on next page) Boom lateral play: max.80mm (3.15in.) (see Fig. 9 on next page) [NOTE] Install the slide plates before assembling the boom.

Shim-1 serves to retain the other shims, so it must be installed last.

14

W536-1000E

G -3 .

G -3 .

Boom (Five-Section Boom)

Boom fully retracted Max. 35mm (1.38 in.)

Boom fullyextended

Adjustment of boom lateral bending IW536-043002E

Fig. 8

10kgf (22.1 lbf) Max. 80mm (3.15 in.)

10kgf (22.1 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0990E03

Fig. 9

1 312-029-40100 △

15

W536-1000E

G -4

G -4

Telescoping cylinder (Three sections boom) G-4

Telescoping cylinder (Three sections 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. Structure General View

1. Cylinder assembly 2. Wire rope

4. Hexagon socket head bolt

3. Counterbalance valve assembly

7. Retaining ring

11. Bolt

8. Spader

12. Spring washer

5. -----------

9. Spader

13. Plate

6. Pin

10. Sheave assembly

Thread size and tightening torque Sign / Port

Thread size

Bolt-4 Bolt-11

Tightening torque N-m

ft-lbf

M10×45

34.3 – 39.2

25.3 – 28.9

M8×12

14

10.3

16

W157-0440E

G -4

G -4

Telescoping cylinder (Three sections boom)

Cylinder assembly

1. Cylinder

5. O-ring

9. Dust seal

13. Retaining ring

2. Nut

6. Rod cover

10. Rod

14. Pin

3. Plain bearing

7. O-ring

11. Roller Assy

15. Roller

4. Piston

8. Packing

12. Retaining ring

2. Notes for Reassembly of Cylinder Assembly 1. Make sure each seal, O-ring, and plain bearing is correctly aligned.

2. Before fitting the nut, apply adhesive (Loctite 638) to the thread on the rod as shown below. ・Application area: From third crest to sixth crest (counting from end of piston) (see area marked with ※ in Fig. 3) ・Nut tightening torque: 98 N-m (72.3 ft-lbf)

17

W157-0440E

G -4 .

G -4 .

Telescoping cylinder (Three sections boom)

3. Before fitting the rod cover, apply rust inhibitor (Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover. (see Fig. 5) ・Tightening torque: 392 - 441 N･m (289- 325 ft-lbf) 4. After installing the cylinder, bend the end of the cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

Pass the extending wire rope through the part that is labeled “N” in Fig..

Then, apply thread locking compound (Threebond 1305 or equivalent) to the bolts and use the bolts to retain the plate.

Tightening torque : 14 N-m (10.3 ft-lbf)

3. Notes for Reassembly of Telescoping Cylinder 1. Install the sheave assembly with the clinched part on the inside.

5. When passing the extending wire rope through the extending wire rope end loop support, be sure to follow these instructions: Align the extending wire rope's center mark with the center of the extending wire rope end loop support.

After passing the extending wire rope through the extending wire rope end loop support, bend down the wire rope guides.

18

W157-0440E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) G-5

Telescoping Cylinder (Four-Section Boom)

1. Structure General View

1 312-115-70000 △

19

W157-0290E

G -5

G -5

G -5

Telescoping Cylinder (Four-Section Boom) Cylinder assembly

0 360-163-60000 △

20

W157-0290E

20

G -5

G -5

Telescoping Cylinder (Four-Section Boom) [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.

General View 1. Cylinder assembly 2. Wire rope 3. Support 4. Nut 5. Wire rope 6. Sheave assembly

7. Hexagon socket head bolt 8. Spring washer 9. Support 10. Spring washer 11. Bolt 12. Counterbalance valve assembly (※)

13. Hexagon socket head bolt 14. Spring washer 15. Support 16. Bolt 17. Support 18. Sheave assembly

19. Retaining ring 20. Pin 21. Plate 22. Bolt 23. Support

※ For details, refer to "Counterbalance Valve" section in chapter G. Cylinder Assembly 1. Hexagon socket head bolt 2. Spring washer 3. Support 4. O-ring 5. Hexagon socket head bolt 6. Roller assembly 7. Retaining ring 8. Plunger 9. O-ring 10. Backup ring 11. Retaining ring

12. Seal 13. O-ring 14. Plain bearing 15. Piston 16. Cylinder 17. Rod 18. Rod cover 19. O-ring 20. Packing 21. Backup ring 22. Dust seal

23. Check valve assembly 24. ---------------------25. Roller assembly 26. Check valve assembly 27. Stopper 28. Plain bearing 29. Piston 30. Plain bearing 31. Packing 32. Backup ring 33. O-ring

34. Pipe 35. Rod 36. Cylinder 37. O-ring 38. Plain bearing 39. Rod cover 40. Machine screw 41. Slide plate 42. Machine screw 43. Slide plate

1. Plug 2. Valve seat 3. Spring 4. Check valve

5. O-ring 6. O-ring 7. O-ring 8. Backup ring

1. O-ring 2. Spring 3. Check valve 4. Rod 5. O-ring 6. Backup ring 7. Cap

8. Body 9. O-ring 10. O-ring 11. Hexagon socket head bolt 12. Plug 13. Spacer

21

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 2. Description of Operation 2.1 Control of Telescoping Sequence 1. When the No. 1 cylinder has been fully extended, the No.2 cylinder is extended.

2. When the No.2 cylinder has been fully retracted, the No.1 cylinder is retracted.

22

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 2.2 Shock-Absorbing Mechanism of No. 2 Cylinder 1. Just before the No. 2 cylinder reaches the end of its retracting stroke, the return flow rate is progressively reduced by four chokes that each have a diameter of 0.04inch. The chokes serve to reduce the retracting speed and to minimize shock at the end of the stroke.

Oil flows at maximum rate.……

Oil flows through four chokes.……

Oil flows through three chokes.……

Oil flows through two chokes.……

Oil flows at minimum rate …… (through one choke).

23

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 3. Notes for Reassembly of Cylinder Assembly 1. Make sure each seal, O-ring, and plain bearing is correctly aligned.

2. Before installing the pistons of the No.1 and No.2 cylinders, apply adhesive (Loctite 638) to the three consecutive crests of each rod's external thread, starting with the second crest (see the areas marked with "※" in Fig.3).

Tightening torque: 98 N-m (10 kgf-m)

4. Before fitting the rod cover, apply rust inhibitor (Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover.

Tightening torque: 253-289.1 ft-lb (343-392 N-m) 3. Apply thread locking compound to the items listed

5. After installing the cylinder, bend the end of the

below before tightening those items.

cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

For any tightening torque not shown in the drawings, refer to the "Mechanical Elements" chapter in the separate repair manual, "General Cautions".

Check valve mounting bolts (N) (four) Hexagon socket head bolts (three) and nut (one) Slide plate mounting bolts (M4) (two)

24

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 4. Notes for Reassembly of Telescoping Cylinder

6. When reassembling each roller assembly, apply grease to the pin.

1. Install the sheave assembly at the rear end of the No.2 cylinder with the clinched part on the inside.

7. Tighten each of the hexagon socket head bolts on the top of the cylinder assembly to a torque of 17.3 ft-lb (23.5 N-m)

2. Install the sheave assembly at the front end of the No.2 cylinder with the clinched part on the outside.

3. Before installing the extending wire rope, install the retracting wire rope end loop support and the plate.

25

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 4. When passing the extending wire rope through

6. Tighten each of the support mounting bolts shown

the extending wire rope end loop support, be sure

in Fig.13 to a torque of 14.5 ft-lb (19.6 N-m)

to follow these instructions: Align the extending wire rope's center mark with the center of the extending wire rope end loop support.

After passing the extending wire rope through the extending wire rope end loop support, bend down the two wire rope guides.

7. When installing the telescoping cylinders in the boom, align as shown in Fig.14 the groove (marked with a "A") in the outside of the sheave at the rear end of the No.2 cylinder.

5. When passing the retracting wire rope through the retracting wire rope end loop support, be sure to follow these instructions: Align the retracting wire rope's center mark with the center of the retracting wire rope end loop support.

After passing the retracting wire rope through the retracting wire rope end loop support, apply thread locking compound to the machine screws

8. Apply grease to the surface that rubs against the

and use the machine screws to install the wire

slide plate (the bottom surface of the No.2

rope guides.

cylinder) (see Fig.4). At the same time, apply grease to the top surface of the No.2 cylinder.

26

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom) 5. Cautions about Telescoping Wire Rope Adjustment

2. Attach the extending wire rope-2 and retracting wire rope-5, and fold the four wire rope guides.

Then attach the two wire guide supports-26 after

1. To prevent the nut of the extending wire rope from

applying screw locking agent to the threaded

hitting the sheave ass'y-6 and the nut of the

portion of the machine screw-27.

retracting wire rope from hitting the sheave ass'y-18, adjust the wire rope so that the projecting length of the extending wire rope is 4.25 in. or shorter and the one of thhe retracting wire rope is 2.83 in. or shorter (See the Fig.15)

3. With the heads of the extending wire rope adjusting bolts pressing firmly against the adjusting bolt mounting surface, adjust dimension "E" (see Fig.18) to 4.72-4.76 inch.

At this time, make sure the most external flats of

6. Telescoping Wire Rope Adjustment Procedure

the adjusting bolts are horizontal as shown in Fig.18.

6.1 Wire rope adjustment with the telescoping cylinder out of the boom 1. Fully retract the telescoping cylinder. At this time, maintain pressure on the retraction side of the telescoping cylinder to prevent dimension "D" (see Fig. 16) from changing.

Dimension D: 6 in.

4. With the heads of the retracting wire rope adjusting bolts pressing firmly against the adjusting bolt mounting surface, tighten the adjusting bolts until the plate is slightly separated from the cylinder support.

At this time, make sure the most external flats of the adjusting bolts are horizontal as shown in Fig.19.

27

W157-0290E

G -5

G -5

Telescoping Cylinder (Four-Section Boom)

8. After secure the nuts-4 and 28 using the lock nuts.

9. After adjustment is completed, thrust the adjusting bolt locking support against the horizontal face of the extending wire rope adjusting bolt and secure the support using the hexagon head bolts-13 and the spring washers-14. (see the Fig.21) 5. Use the specified jig to retain the top boom

10. After adjustment is completed, thrust the

stretch support in the position at which dimension

adjusting bolt locking support against the

"C" (see Fig.20) is 11.57 inch.

horizontal face of the retracting wire rope adjusting bolt and secure the support using the hexagon head bolts-13 and the spring washers-14. (see the Fig.22)

6. With the jig still fitted, tighten the extending wire rope adjusting nut and lock it in position using the lock nut. (see Fig.20).

Adjusting nut tightening torque： 3.6 ft-lb (4.9 N-m) (If the length of the wire rope projecting from the adjusting nut is too short to tighten the nut using the jig, tighten the extending wire rope adjusting bolts on the right and left close to the boom head equally.)

Adjusting bolt tightening torque： 7.2 ft-lb (9.8 N-m) 7. With the jig fitted, tighten the retracting wire rope adjusting nut until the jig slightly comes off.

(If the length of the wire rope projecting from the adjusting nut is too short to tighten the nut using the jig, tighten the retracting wire rope adjusting bolt close to the boom head.)

28

W157-0290E

G -5 .

G -5 .

Telescoping Cylinder (Four-Section Boom) 6.2 Wire rope adjustment with the telescoping cylinder installed in the boom

3. When F is longer than 4mm Perform the "6.1 Wire rope adjustment with the telescoping cylinder out of the boom" again.

1. Telescope the boom for several strokes and check the dimension of F (clearance between the top boom section and 3rd boom section). If F is 0.08in. or shorter re-adjustment is not necessary.

2. When F is longer than 0.08in. and does not exceed 0.16in.

Remove the top cover. (Take care not to damage the cord on the cord reel.)

Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and loosen the extending wire rope adjusting bolts-16 on the right and left fot one turn.(see the Fig.21) Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and tighten the retracting wire rope adjusting bolts until F is 0.08in. or shorter. (see the Fig.22) Attach the adjusting bolt locking support-15, hexagon head bolt 13-and spring washers-14 (both for the retracting wire rope and for the extending wire rope).Then attach the top cover.

29

W157-0290E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) G-6

Telescoping Cylinder (Five-Section Boom)

1. Structure General View

2 312-115-80000 △

30

W157-0300E

G -6

G -6

G -6

Telescoping Cylinder (Five-Section Boom) Cylinder assembly

0 360-163-70000 △

31

W157-0300E

31

G -6

G -6

Telescoping Cylinder (Five-Section Boom) [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.

General View 1. Cylinder assembly

8. Spring washer

14. Spring washer

21. Plate

2. Wire rope

9. Support

15. Support

22. Bolt

3. Support

10. Spring washer

16. Bolt

23. Support

4. Nut

11. Bolt

17. Support

24. Plate

5. Wire rope

12. Counterbalance valve

18. Sheave assembly

25. Support

19. Retaining ring

26. Machine screw

20. Pin

27. ----------------------

6. Sheave assembly 7. Hexagon socket head bolt

assembly(※) 13. Hexagon socket head bolt

※For details, refer to "Counterbalance Valve" section in chapter G. Cylinder Assembly 1. Roller assembly

15. Packing

29. O-ring

43. Backup ring

2. Retaining ring

16. Backup ring

30. Piston

44. Dust seal

3. Plunger

17. Dust seal

31. Plain bearing

45. Support

4. Backup ring

18. Check valve assembly

32. Packing

46. Hexagon socket head bolt

5. O-ring

19. O-ring

33. Backup ring

47. Spring washer

6. Retaining ring

20. O-ring

34. Piston

48. O-ring

7. Seal

21. Rod cover

35. Rod

49. Hexagon socket head bolt

8. Piston

22. Roller assembly

36. Cylinder

50. Slide plate

9. O-ring

23. Roller assembly

37. Rod

51. Machine screw

10. Plain bearing

24. Check valve assembly

38. Cylinder

52. Slide plate

11. Cylinder

25. Stopper

39. O-ring

53. Button bolt

12. Rod

26. Pipe

40. Rod cover

54. Slide plate

13. Rod cover

27. Plain bearing

41. Plain bearing

55. Machine screw

14. O-ring

28. Plain bearing

42. Packing

32

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 1. O-ring 2. Spring

9. O-ring

3. Check valve

10. O-ring

4. Rod

11. Hexagon socket head bolt

5. O-ring

12. Plug

6. Backup ring

13. Spacer

7. Cap

Check Valve Assembly (Cylinder Assembly Part24) Detail

2. Description of Operation 2.1 Control of Telescoping Sequence 1. When the No.1 cylinder has been fully extended, the No.2 cylinder is extended.

33

8. Body

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 2. When the No.2 cylinder has been fully extended, the No.3 cylinder is extended.

34

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 3. When the No.3 cylinder has been fully retracted, the No.2 cylinder is retracted.

4. When the No.2 cylinder has been fully retracted, the No.1 cylinder is retracted.

35

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 2.2 Shock-Absorbing Mechanism of No. 3 Cylinder 1. Just before the No. 3 cylinder reaches the end of its retracting stroke, the return flow rate is progressively reduced by four chokes that each have a diameter of 1 mm. The chokes serve to reduce the retracting speed and to minimize shock at the end of the stroke.

Oil flows at maximum rate.……

Oil flows through four chokes.……

Oil flows through three chokes.……

Oil flows through two chokes.……

Oil flows at minimum rate …… (through one choke).

36

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 3. Notes for Reassembly of Cylinder Assembly

4. Apply thread locking compound (Threebond 1305) to the items listed below before installing the items (see Figs. 4 - 7).

1. Make sure each seal, O-ring, and plain bearing is correctly aligned.

For any tightening torque not shown in the drawings, refer to the "Mechanical Elements"

2. Before installing the pistons of the No.2 and No.3

chapter in the separate repair manual, "General

cylinders, apply adhesive (Loctite 638) to the

Cautions".

three consecutive crests of each rod's external thread, starting with the second crest (see the

Check valve mounting bolts (N) (eight)

areas marked with "※" in Fig. 3).

Machine screws (M4x2) and button bolts (M6x2)

Tightening torque: 72.4 ft-lb (98.1 N-m)

used to mount slide plates at front ends of No.1 and No.2 cylinders

3. Before installing the piston of the No.1 cylinder, apply adhesive (Loctite 638) to the four consecutive crests of the rod's external thread, starting with the third crest (see the area marked with "※※" in Fig.3).

Tightening torque: 72.4 ft-lb (98.1 N-m)

37

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) Machine screws (M4x2) used to mount slide plate

Hexagon socket head bolts (M8x4) on top of No.3

at rear end of No.2 cylinder

cylinder's front end

5. Before fitting the rod cover, apply rust inhibitor (Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover.

Tightening torque: 253-289.1 ft-lb (343-392 N-m) 6. After installing the cylinder, bend the end of the cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

Hexagon socket head bolts (M12x8) at rear end of cylinder assembly

38

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 4. Notes for Reassembly of Telescoping Cylinder

7. When reassembling each roller assembly, apply grease to the pin.

1. Install the sheave assembly at the rear end

of

the No. 3 cylinder with the clinched part on the inside.

2. Install the sheave assembly at the front end of the No.3 cylinder with the clinched part on the outside.

3. Before installing the extending wire rope, install the retracting wire rope end loop support and the plate.

39

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 6. When installing the telescoping cylinders in the

4. When passing the extending and retracting wire

boom, align as shown in Fig.15 the groove

ropes through their respective wire rope end loop

(marked with a "A") in the outside of the sheave at

support, be sure to follow these instructions:

the rear end of the No.3 cylinder.

Align the wire rope's center mark with the center of the wire rope end loop support.

After passing each wire rope through the wire rope end loop support, bend down the wire rope guides.

Extending wire rope: two wire rope guides After passing the retracting wire rope through the retracting wire rope end loop support, apply

7. Apply grease to the surface that rubs against the

thread locking compound to the machine screws

slide plate (see Fig.4,Fig.5). At the same time,

and use the machine screws to install the wire

apply grease to the top surface of the No.3

rope guides.

cylinder.

Retracting wire rope: six wire rope guides.

5. Tighten each of the support mounting bolts shown in Fig.14 to a torque of 14.5 ft-lb (19.6 N-m).

40

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 5. Telescoping Wire Rope Adjustment Procedure 5.1 Wire rope adjustment with the telescoping cylinder out of the boom 1. Fully retract the telescoping cylinder. At this time, maintain pressure on the retraction side of the telescoping cylinder to prevent dimension "D" (see Fig.16) from changing.

Dimension D: 5.75 in.

4 With the head of the retracting wire rope adjusting bolt pressing firmly against the adjusting bolt mounting surface, tighten the adjusting bolt until the plate is slightly separated from the cylinder support (see Fig.19).

At this time, make sure the most external flat of the adjusting bolt is horizontal as shown in Fig.19.

2. Attach the extending wire rope-2 and retracting wire rope-5, and fold the two wire rope guides.

Then attach the two wire guide supports-25 after applying screw locking agent to the threaded portion of the machine screw-26.

5. Use the specified jig to retain the top boom stretch in the position at which dimension "C" (see Fig.20) is 13.31 inch.

3. With the heads of the extending wire rope adjusting bolts pressing firmly against the adjusting bolt mounting surface, adjust dimension "E" (see Fig.18) to 4.39 - 4.43 inch.

At this time, make sure the most external flats of the adjusting bolts are horizontal as shown in Fig.18.

41

W157-0300E

G -6

G -6

Telescoping Cylinder (Five-Section Boom) 6. With the jig still fitted, tighten the extending wire

10.After adjustment is completed, thrust the

rope adjusting nut and lock it in position using the

adjusting bolt locking support againt the horizontal

lock nut (see Fig.20).

face of the retracting wire rope adjusting bolt and secure the support using the hexagon head

Adjusting nut tightening torque:

bolts-13 and the spring washers-14. (see Fig.22)

3.6 ft-lb (4.9 N-m) (If the length of the wire rope projecting from the adjusting nut is too short to tighten the nut using the jig, tighten the extending wire rope adjusting bolts on the right and left close to the boom head equally.)

Adjusting bolt tightening torque: 7.2 ft-lb (9.8 N-m) 7. With the jig fitted, tighten the retracting wire rope adjusting nut until the jig slightly comes off.

(If the length of the wire rope projecting from the adjusting nut is too short to tighten the nut using the jig, tighten the retracting wire rope adjusting bolt close to the boom head.

8. After 7., secure the nuts-4 using the lock nuts.

5.2 Wire rope adjustment with the telescoping cylinder installed in the boom

9. After adjustment is completed, thrust the adjusting bolt locking support against the horizontal face of the extending wire rope adjusting bolt and secure the support using the hexagon head bolts-13 and the spring washers-14. (see the Fig.21)

1. Telescope the boom for several strokes and check the dimension of F (clearance between the top boom section and 3rd boom section). If F is 0.08in. or shorter re-adjustment is not necessary.

2. When F is longer than 0.08 in. and does not exceed 0.16 in.

Remove the top cover. (Take care not to damage the cord on the cord reel.)

42

W157-0300E

G -6 .

G -6 .

Telescoping Cylinder (Five-Section Boom) Remove the adjusting bolt locking support-15, hexagon head bolt-13, and the spring washer-14, and loosen the extending wire rope adjusting bolts-16 on the right and left for one turn. (see the Fig.21) Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and tighten the retracting wire rope adjusting bolts until F is 0.08 in. or shorter. (see the Fig.22) Attach the adjusting bolt locking support-15, hexagon head bolt-13 and spring washers-14 (both for the retracting wire rope and for the extending wire rope). Then attach the top cover.

3. When F is longer than 0.16 in.

Perform the "5.1 Wire rope adjustment with the telescoping cylinder out of the boom" again.

2 312-115-80000 △

43

W157-0300E

G -7

G -7

Counterbalance Valve (Telescoping) G-7

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

44

13. O-ring

W119-0281E

G -7 .

G -7 .

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

2 366-055-20000 △

45

W119-0281E

H Safety System

Contents

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

4.

Assembly ................................................ 13

1.

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

5.

Replacing the Potentiometer ................... 15

2.

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

3.

Caution About Installing Length Detector .. 3

4.

AMA Adjustment ....................................... 4

H-3 Angle Detector (Boom) ..................16

4.1

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

4.2

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

4.3

Selecting the crane model and capacity data

1.

Structure ................................................. 16

2.

Specifications (Potentiometer)................. 16

H-4 Outrigger Extension Detector .......17

............................................................. 5 4.4 Zero-and span-adjustment of length detector . ............................................................. 6 4.5

Zero-and span-adjustment of angle detector.

4.6

Confirming Accuracy .................................. 8

1.

Procedure to adjust outrigger extension detector switch and uninstalled outrigger warning switch .............. 17

............................................................. 7 1.1

5.

List of Error Nos. Related to AMA ............. 9

6.

Adjustment items when parts are exchanged .................................................... 10

............................................................17 1.2

H-2 Length Detector (Boom)................ 11

Checking outrigger extension detector switch and uninstalled outrigger warning switch .......................................... 17 2.1

Structure and Function.............................11

2.

Specifications.......................................... 12

3.

Disassembly ........................................... 12

Adjusting uninstalled outrigger warning switch ..................................................17

2.

1.

Adjusting outrigger extension detector switch

Checking outrigger extension detector switch ............................................................17

2.2

Checking uninstalled outrigger warning switch ..................................................17

i

H-1

H-1

AMA (Load Moment Indicator) H-1

AMA (Load Moment Indicator)

1. Structure

Hook stowing device

Boom

Anti-twoblock device Wire rope

Load indicator Boom elevating cylinder Winch

Hook block

Post AMA device alarm buzzer

Power lamp Boom swing device PTO lever Frame Outrigger Hydraulic oil tank Control panel

Control lever

Warning light Boom length detector

Boom angle detector

Angle meter

Winch Cable follower AMA device

1

W301-0290E

M22409E

H-1

H-1

AMA (Load Moment Indicator) 2. Function of Components Over-front area state indicator lamp

Outrigger state

Display window

Display alteration switch

IW301-017002

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.

2

W301-0290E

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.

Warning light

Length detector

Boon angle detector

Yellow tape

Less than 0.98" 9.8"

Length detection vessel terminal treatment details

IW301-017003

3

W301-0290E

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

an extra thin screwdriver.

corresponds to the actual model and confirm

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

accuracy of the data.

adjustment.

4.1 Attention for adjustment work

6. Keeo off the buttons other than the specified

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

switvches.

the outriggers extended as specified.

(See the Table 1.)

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 Over-front indication lamp Display window

OPERATI ON SWI TCH OPERATI ON SWI TCH

1

ON

1

5 6 7

15

8

16

8

4

14

0

3

13

F

2

12

2 3 4 5 6 7 8

6

ZERO

MOOD

2 4

CODE

ON

1

ON

C

A

11

1

8

SPAN

9 10

Dip switch (DS1)

7

8

8

ZERO

6

7

7

5

6

6

4

5

5

3

4

4

2

3

3

1

2

2

SELECT

ON

1

9

4

12

5

13

6

14

7

15

8

16

8

3

11

MOOD

Select button

6

2

4

CODE

AMA main unit with the cover removed

Rotary switch

C A

0

10

F

2

Dip switch (DS2)

SPAN

SELECT

IW301-017004

4

W301-0290E

H-1

H-1

AMA (Load Moment Indicator) 4.3 Selecting the crane model and capacity data Select the data according to the flowchart below.

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 on the power supply.

Shift the rotary switch to "1".

NO

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

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

NO

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

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

ZR303XL ZR304XL ZR305XL

A

00000010

01001000

225

001

019

Minimum

Condition for accuracy confirmation Load to Boom be lifted Angle (Ibs.) 10o 2020

D

11000010

01001000

225

004

019

Minimum

10o

2020

8.40

9.28

A

00001010

01001000

226

001

019

Maximum

10o

1020

18.54

20.24

D

11001010

01001000

226

004

019

Maximum

10o

2020

12.80

14.70

A

00000110

01001000

227

001

019

Maximum

10o

1020

17.65

19.26

D

11000110

01001000

227

004

019

Maximum

10o

2020

12.30

14.11

Dip switch setting

Capa city type

DS1

DS2

Indication Indication 1

Indication 2

Indication 3

Outrigger extension

R1(ft.)

R2(tf.)

8.40

9.28

[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.

Capacity type

Capacity ; A

Capacity ; D

Gross Axle Weight Rating (GAWR), front

5,000 lbs. or more

5,500 lbs. or more

Gross Axle Weight Rating (GAWR), rear

10,000 lbs. or more

10,000 lbs. or more

Gross vehicle weight

15,000 to 26,000 lbs.

15,000 to 26,000 lbs.

5

W301-0290E

H-1

H-1

AMA (Load Moment Indicator) 4.4 Zero-and span-adjustment of length detector .

Swing the boom to over-front before adjustment.

START

Turn the rotary switch to the "2" position.

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

Extend the boom fully and press the span-adjustment button.

Retract the boom fully again.

No

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

Yes Completed

IW301-017007

Table 1 Crane model

DS1

DS2

A

00000010

01001000

225

001

019

Minimum

Condition for accuracy confirmation Load to Boom be lifted Angle (Ibs.) 10o 2020

D

11000010

01001000

225

004

019

Minimum

10o

2020

o

Dip switch setting

Capa city type

ZR303XL ZR304XL ZR305XL

Indication Indication 1

Indication 2

Indication 3

Outrigger extension

R1(ft.)

R2(tf.)

8.40

9.28

8.40

9.28

A

00001010

01001000

226

001

019

Maximum

10

1020

18.54

20.24

D

11001010

01001000

226

004

019

Maximum

10o

2020

12.80

14.70

A

00000110

01001000

227

001

019

Maximum

10o

1020

17.65

19.26

Maximum

o

2020

12.30

14.11

D

11000110

01001000

227

004

019

10

Table 2 Crane model

Zero-point adjustment range Boom length detector

Boom angle detector

ZR303XL

2.75 – 2.95

0.8 - 1.2

ZR304XL

3.07 - 3.27

0.8 - 1.2

ZR305XL

3.03 - 3.23

0.8 - 1.2

[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.

Capacity type

Capacity ; A

Capacity ; D

Gross Axle Weight Rating (GAWR), front

5,000 lbs. or more

5,500 lbs. or more

Gross Axle Weight Rating (GAWR), rear

10,000 lbs. or more

10,000 lbs. or more

Gross vehicle weight

15,000 to 26,000 lbs.

15,000 to 26,000 lbs.

6

W301-0290E

H-1

H-1

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

Retract the boom fully and swing it to over-right before adjustment.

START

Turn the rotary switch to the "3" position.

Retract the boom fully and lower it until the eleveting cylinder comes to its stroke end. Press the zero-adjustment button.

Lower the fully retracted boom until the elevating cylinder comes to its stroke end. Press the span-sdjustment button.

Lower the boom again until the elevating cylinder comes to its stroke end.

No

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

Yes Completed

IW301-017008

Table 1 Crane model

Dip switch setting

Capa city type A

ZR303XL ZR304XL ZR305XL

Indication

DS1

DS2

Indication 1

Indication 2

Indication 3

00000010

01001000

225

001

019

Outrigger extension

Minimum

Condition for accuracy confirmation Load to Boom be lifted Angle (Ibs.) 10o 2020 o

R1(ft.)

R2(tf.)

8.40

9.28

D

11000010

01001000

225

004

019

Minimum

10

2020

8.40

9.28

A

00001010

01001000

226

001

019

Maximum

10o

1020

18.54

20.24

D

11001010

01001000

226

004

019

Maximum

10o

2020

12.80

14.70

o

A

00000110

01001000

227

001

019

Maximum

10

1020

17.65

19.26

D

11000110

01001000

227

004

019

Maximum

10o

2020

12.30

14.11

Table 2 Crane model

Zero-point adjustment range Boom length detector

Boom angle detector

ZR303XL

2.75 – 2.95

0.8 - 1.2

ZR304XL

3.07 - 3.27

0.8 - 1.2

ZR305XL

3.03 - 3.23

0.8 - 1.2

[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.

Capacity type

Capacity ; A

Capacity ; D

Gross Axle Weight Rating (GAWR), front

5,000 lbs. or more

5,500 lbs. or more

Gross Axle Weight Rating (GAWR), rear

10,000 lbs. or more

10,000 lbs. or more

Gross vehicle weight

15,000 to 26,000 lbs.

15,000 to 26,000 lbs.

7

W301-0290E

H-1

H-1

AMA (Load Moment Indicator) 4.6 Confirming Accuracy Swing the boom to over-right and make sure that the over-front indication lamp is not lit. Then Confirm data accuracy according to the flowchart below.

START Shift the rotary switch to "0".

Lift up a load of the specified weight, lower the boom to the specified boom angle, and telescope the boom to make the load radius within R1 (m).

(For the R1, values and specified weight, see the Table 1.)

(Set the boom angle ± 0.1 of the specified angle.)

(Do not lower the boom below the angle of 2.5 to avoid boom angle lower limit alarm functioning.)

Extend the boom until the limit alarm functions (the alarm buzzer sounds and the warning buzzer lights up.)

Is the load radius between R1 and R2 when the limit alarm is output?

NO

Yes

Contact TAC

Completed

IW301-017006

Table 1 Crane model

A

00000010

01001000

225

001

019

Minimum

Condition for accuracy confirmation Load to Boom be lifted Angle (Ibs.) 10o 2020

D

11000010

01001000

225

004

019

Minimum

10o

2020

8.40

9.28

A

00001010

01001000

226

001

019

Maximum

10o

1020

18.54

20.24

D

11001010

01001000

226

004

019

Maximum

10o

2020

12.80

14.70

o

Dip switch setting

Capa city type

ZR303XL ZR304XL ZR305XL

DS1

DS2

Indication Indication 1

Indication 2

Indication 3

Outrigger extension

R1(ft.)

R2(tf.)

8.40

9.28

A

00000110

01001000

227

001

019

Maximum

10

1020

17.65

19.26

D

11000110

01001000

227

004

019

Maximum

10o

2020

12.30

14.11

Table 2 Crane model

Zero-point adjustment range Boom length detector

Boom angle detector

ZR303XL

2.75 – 2.95

0.8 - 1.2

ZR304XL

3.07 - 3.27

0.8 - 1.2

ZR305XL

3.03 - 3.23

0.8 - 1.2

[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.

Capacity type

Capacity ; A

Capacity ; D

Gross Axle Weight Rating (GAWR), front

5,000 lbs. or more

5,500 lbs. or more

Gross Axle Weight Rating (GAWR), rear

10,000 lbs. or more

10,000 lbs. or more

Gross vehicle weight

15,000 to 26,000 lbs.

15,000 to 26,000 lbs.

8

W301-0290E

H-1

H-1

AMA (Load Moment Indicator) 5. List of Error Nos. Related to AMA No. E14 E15

Description

Improper setting of model selection dipswitch

E16 E17 E18

E20

E21 E29 E22 E23

E24

Improper setting of function selection dipswitch

Cause

Measures

Boom length value or boom angle value left unadjusted

Adjust

Improper setting of dipswitch

Set property

Improper setting of dipswitch

Set property

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

Faulty AMA itself

Replace the AMA main body if check result is normal.

Faulty AMA itself

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 : 5,000±1,000Ω 1-3 of CN3 : 300±50Ω] If a measured value is out of the standard range, replace the boom length detector.

Faulty AMA itself

Replace the AMA main body if check result is normal.

Abnormal display of load

Faulty CPU Faulty hardware

Faulty length detector

9

W301-0290E

H-1 .

H-1 .

AMA (Load Moment Indicator)

No.

E25

E26 E27

Description

――

Measures

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 0 at minimum (1 ).

[2-4 of CN4 : 500±100Ω 2-3 of CN4 : 79±15Ω] If a measured value is out of the standard range, replace the boom angle detector.

Faulty AMA itself.

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 itself.

Replace the AMA main body if check result is normal.

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.

Faulty angle detector

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

Broken wiring E65

Cause

Abnormality “‐‐‐” 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 adjustment” ・”4.6 Confirming accuracy” ・”4.5 Boom angle adjustment” ・”4.6 Confirming accuracy” ・Nothing ・”4.3 Selecting the crame model and capacity data”

AMA itselt

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

10

W301-0290E

H-2

H-2

Length Detector (Boom) H-2

Length Detector (Boom)

1. Structure and Function This detector consists of recoil spring, wire gear

[NOTE]

and potentiometer.

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.

When the wire wound on the drum is unwound or rewound by the recoil spring, the resultant drum rotation is increased or reduced according to the gear ratio, which in turn rotates the potentiometer shaft. The electric resistance of the potentiometer changes in proportion to the shaft rotation.

Connection diagram Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W

Connector 1 2 3

Shield

(Length detector portion)

4

Knob-type terminal IW305-017001

Overall plan 15 16 15 16 77 11

22 3

19 19

66 10 4 12 12 9 9 10

21 21

20 20

Water cutout hole

8 8

55

11 11 18 18

Yellow tape

GND(B)

Power supply(R)

Water cutout hole

Shield(G)

Output(W)

14 14 13 13

Air vent

17 17 IW305-017002

1.Plate

6. Case

11.Seal

16.Sleeve

2.Case

7.Packing

12.Gear A

17.Cord guide

3.Drum ass’y

8.O-ring

13. Knob-type terminal

18.Connector

4.Contact point circle

9.Bracket

14.Sleeve

19.Super lock

5.Contact ass’y

10.Potentiometer

15. Knob-type terminal

20.Cord lock

11

W305-0171E

H-2

H-2

Length Detector (Boom) Potentiometer

2. Specifications

Bracket

Speed reducer

Reduction ratio : 1/35

Potentiometer

Resistance : 5000 ± 1000Ω

(for boom length detection)

Electrical turning angle : 340

Gear B

o

Set potentiometer (at fully retracted boom) : 237 – 368Ω

IW305-011004E

3. Disassembly 4. Remove the setscrew. Then remove the gear A.

[NOTE] If the spring in the drum and the wire is broken, replace the whole drum assy and wire assy.

Setscrew

Gear A

1. Loosen the cord clamp and remove the cover.

Cable Cord clamp Cover Potentiometer IW305-011005E

Knob-type terminal

5. Remove the nut securing the case and the base plate and relieve the tension on the recoil spring in the drum assy. Then remove the drum assy from the case.

IW305-011003E

[NOTE] To facilitate assembly work, put alignment marks on the case and the base plate after the tension on the recoil spring in the drum assy is relieved.

2. Disconnect the Knob-type terminals for the cable and the potentiometer.

Remove the cover and table from the main body.

3. Remove the bracket with the potentiometer and the gear B on it.

12

W305-0171E

H-2

H-2

Length Detector (Boom) 4. Assembly

6. Pull the end of the wire out of the opening in the case until the portion of the yellow tape comes to

1. Put a marker on the new wire assy by winding

the opening.

yellow tape.

Then remove the gummed tape that fixes the wire.

7. Align the alignment marks that have been put on

Yellow tape To drum

the base plate and the case during disassembly.

Attach the case.

4.02m (11.84 ft) 3-4 sec. Boom : 12.54m (41.14 ft) 5-6 sec. Boom : 16.24m (53.28 ft)

8. To take in the slack, pull the wire fully out of the case and rewind it.

IW305-0171E02

Then pull the end of the wire out of the opening in the case until the portion of the yellow tape comes 2. Put new wire ass’y around a groove in the drum

to the opening and fix the wire with gummed tape.

ass’y and reel it in until the portion of the yellow

Yellow tape

tape comes onto the drum.

Gummed tape IW305-011009E

Wire ass'y Drum ass'y

9. Attach the gear A to the gear mounting shaft temporarily with the setscrew.

IW305-011007E

Setscrew

Gear A

3. Fix the wire with gummed tape to prevent it from loosening.

[NOTIC] Wind the cord around the counterclockwise when viewed from the gear mounting shaft.

IW305-011005E

10. Attach the bracket with the potentiometer and the gear B on it to the case temporarily with a setscrew.

Gummed tape

Potentiometer Drum assy

Bracket IW305-011008E

Gear B

4. Attach the base plate to the drum assy.

5. To make the wire tense, rotate the drum for 4 turns in the same direction that the wire is wound while the base plate is secured.

IW305-011004E

13

W305-0171E

H-2

H-2

Length Detector (Boom)

15. Attach the length detector to the original position.

11. While applying a D.C. at 5 V between the connector terminals 1 and 2, rotate the gear B of

In this time, cut the wire to adjust the wire length if

the potentiometer by hand so that the output

necessary.

voltage between the terminals 2 and 3 is 0.3 ±

For how to cut the wire, see the Y section.

0.05 V. When the output voltage is within the

[NOTE]

above range, put the gear A in mesh with the gear

Attach the length detector so that the portion of the yellow tape comes to the end of the wire.

B and secure the bracket.

Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W Shield

(Length detector portion)

Connector 1 2 3 4

Knob-type terminal IW305-017001

[NOTE] If the meshing condition is too strong, the gears may scratch each other. It it is weak, the gears may be disengaged.

12. After adjustment is completed, secure the gear A with the setscrew. Apply thread locking agent to the setscrew.

[NOTE] When tightening the setscrew, take care that the output voltage stays within the allowable range checking the gauging equipment.

13. Connect the knob-type terminal of the cable to the potentiometer.

14. Attach the cover while checking the position of the cord clamp.

Cable Cord clamp Cover Potentiometer

Knob-type terminal

IW305-011003E

14

W305-0171E

H-2

H-2

Length Detector (Boom) 5. Replacing the Potentiometer 1. Attach a new potentiometer to the bracket. Solder the leads and the potentiometer terminals.

[NOTE] Solder the potentiometer terminals and the leads quickly to prevent exposing the potentiometer to unnecessary heat.

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

Recommended sealant: Shin-etsu KE45RTV (Shin-etsu Chemical Industries) Orient the potentiometer terminals as shown in the figure. potentiometer

Insulating sealant

IW305-011010E

2. Attach the gear B to the potentiometer shaft and secure it with a setscrew. Apply thread locking agent to the setscrew.

3. Pull the wire from the drum a little and make sure that the resistance 1-3 (red-white) smoothly increases.

Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W

(Length detector portion)

Shield

Connector 1 2 3 4

Knob-type terminal IW305-017001

4. Assemble a length detector following the steps 9. and below in the "3. Assembly".

0 361-317-40000 △

15

W305-0171E

H-3 .

H-3 .

Angle Detector (Boom) H-3

Angle Detector (Boom)

[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 The boom angle detector attached on the side face of the base boom section incorporates a pendulum-driven potentiometer inside and converts the angle between the boom and the ground into electrical resistance.

1. Case

4. Weight

7. O-ring

10. Binding band

2. Cover

5. Arm

8. Oil

11. -

3. Potentiometer

6. Terminal

9. -

12. Connector

2. Specifications (Potentiometer) Resistance : 500 ± 100Ω Effective electrical angle : 120±1.5°

0 361-404-70000 △

16

W305-0180E

H-4

H-4

Outrigger Extension Detector H-4

Outrigger Extension Detector

2. Checking outrigger extension detector switch and uninstalled outrigger warning switch

1. Procedure to adjust outrigger extension detector switch and uninstalled outrigger warning switch

Check the switches in the following procedure.

1.1 Adjusting outrigger extension detector switch

2.1 Checking outrigger extension detector switch

1. Measure the clearance C shown in the right figure

1. Make sure that the lateral play of on outrigger in

when it becomes smallest due to lateral play of

the frame does not affect outrigger extension

the outrigger in the frame.

detection.

2. Make the protrusion length of D equal to the minimum dimension of the clearance C (2.5mm (0.1 inch)).

O/R extension

Indicator lamp

Max

Lit

Min

Unlit

1.2 Adjusting uninstalled outrigger warning switch 2.2 Checking uninstalled outrigger warning switch

1. Extend the outriggers fully 2. Make the clearance between the inner case and

1. Check the switch when the outriggers are fully

the roller 1.0-1.5mm (0.04-0.06 inch) using shims.

extended and when they are extended to

(In the usual service condition, the clearance is

minimum.

0.3-1.0mm (0.01-0.04 inch) due to adjusted vertical play of the outrigger.)

3. Make the outrigger beams extended approx, 100 mm (3.94 inch) than the minimum extension width with the outrigger jacks retracted.

Outrigger

Indicator lamp

Extended

Lit

No extended

Unlit

2. Make sure that the uninstall outrigger warning

4. Attach E (2.5mm (0.1 inch) thick) on the bottom of

alarm does not sound when the crane is in a

each outrigger inner case.

configuration given in the Table 1.

(Check both cases when the boom is in the

5. Secure each switch while it is in contact with E.

over-right area and when the boom is in the over-left area.)

[NOTE] If uninstalled outrigger condition is detected even though the outriggers are extended, check the clearance between the inner case and the roller.

In installed outrigger condition is detected even though the outriggers are not extended, check the thickness of E. If the installed outrigger condition still remains detected even after the check and adjustment of E, make E 2.3mm (0.09 inch) thick.

For the part No. of the Table 1, see “1” and “2” in the part list in the drawing.

17

W313-0190E

H-4

H-4

Outrigger Extension Detector

2.5mm

Side of outrigger

(0.1")

C

Outrigger inner case

E D

Confir mation lamp Confirmation Side of frame View A

Section B

18

W313-0190E

IW313-0150E02

H-4 .

H-4 .

Outrigger Extension Detector

0 316-546-41001 △

19

W313-0190E

Y Data, Adjustment and Checks

Contents

Y-1 Service data...................................... 1 1.

Set pressure ............................................. 1

2.

Hydraulic units .......................................... 1

3.

Hydraulic circuit ........................................ 2

Y i

Y-1

Y-1

Service data Y-1

Service data

[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. Set pressure (1) Hook - in Set Pressure

Item

MPa

psi

Main relief valve

17.2 – 17.69

2494 - 2565

Low - pressure relief valve

2.94 - 4.9

426 - 710

2. Hydraulic units 1. Swing motor 3

3

3

3

Displacement : 25.0 cm / rev (1.52 in /rev) 2. Winch motor Displacement : 24.0 cm / rev (1.48 in /rev) 3. Swing speed reducer Reduction ratio : 30 : 1 4. Winch speed reducer Reduction ratio : 20.4 : 1

1

WY01-1020E

Y-1 .

Y-1 .

Service data 3. Hydraulic circuit Pressure setting Set Pressure

Part Control valve Main circuit (Flow rate)

MPa

psi

17.2-17.69 (53L/min)

2494-2565 (14.0gal/min)

Note Relief valve RV1

Pressure adjustment o

Conditions : Oil temperature 45 to 55℃ (113-131 F) 1. Control valve (Relief valve RV1) Connect a pressure gauge to the PG port of the control valve.

Measure the pressure with the jack cylinder fully retracted and the control lever placed in the retracting position.

RV1 PG(G1/4)

Hook stowing

Boom elevation

Winch

Boom telescoping

Swing

Jack 2

Jack 1

IWY01-0750E01

2

WY01-1020E

Z System Diagrams

Contents

Z-1 Hydraulic Circuit .............................. 1

Z-2 Electrical Circuit............................... 2

Z i

Z-1.

Z - 1.

Z-1.

Hydraulic Circuit Z-1

Hydraulic Circuit

0 314-009-10200 △

1

WZ01-0500E

1

Z-2.

Z-2.

Z-2.

Electrical Circuit

Z-2

1. This diagram shown the circuit with the power supply off and the winch overwound.

Electrical Circuit

2. The vehicle circuit shown here is typical. It may differ from the circuit of your vehicle.

3. Color codes in parentheses apply to switches made by Matsushita Electric Works Ltd.

0 314-017-10100 △

2

WZ03-3000E

2

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