Tadano Faun Cargo Crane TM-ZR360-3 Service Manual SN EP7004 - PDF DOWNLOAD

Publication No.

TM-ZR360-3/S1-1E

Service Manual

01 TM-ZR360-3/S1 -1E

ｃ ◯2006 PRINTED IN JAPAN 0611

K

Cargo Crane Model

TM-ZR360-3 Applicable Serial No.

EP7004--

Safety Safety

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

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

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

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

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

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

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

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

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

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

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

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

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. Mark 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

Safety 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.

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.

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

8.Watch your step in the following cases: When stepping up to or stepping down from the upper surface of a boom for replacing wire ropes and applying grease. Be careful not to stumble on protrusions on the upper surface of a boom.

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

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

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

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

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

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

2.2 Dismounting and disassembling

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

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

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

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

3. Cautions in operation 3.1 Brake fluid replenishment

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

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

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

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

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

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

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

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

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

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

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

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

This service manual describes the systems and components of the TM-ZR360 series cranes, its repair, check and adjustment methods and other relevant

(1)

matters.

(2)

Read the separate operation and maintenance

UNI T

NO.

LOT

NO.

manual and the parts catalog for repair and

IWA04-062001

maintenance of the crane in conjunction with this manual.

Frame nameplate (1) Unit No. (2) Serial No. (3) Year and month of mounting

When carrying out repairs, check the parts catalog for structure and sales units of the parts beforehand.

(1)

1. Applicable unit No.

(2)

The unit Nos. of the cranes to which this manual is applicable are listed below. Check the unit No. of your SPEC.

crane on the nameplate attached to the crane before

NO.

SERIAL. NO.

MFG. DATE.

KAGAWA,JAPAN

using this manual.

(3)

Model (spec. No.) TM-ZR363 (TM-36Z-3-812) TM-ZR364 (TM-36Z-3-813) TM-ZR365 (TM-36Z-3-814) TM-ZR366 (TM-36Z-3-817)

IWA04-062002

Boom nameplate Frame nameplate Unit No. Unit No. 310-140-20620 310-140-20630 310-140-20640 310-140-20650

2. Separate service manual

411-023-10880 411-023-10881

The repair manual documents for your crane are comprised of this manual and the separate documents

411-023-10890 411-023-10891

listed below.

Separate Service Manual

Publication No.

1 General Cautions

SA01-01-2E

2 Radio Control Device

W307-0061E

Please note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual.

1

WA04-2110E

Foreword 3. Outline of specifications Model(Spec.No.) Item

No. of boom sections Winch Operation

Safety devices

TM-ZR363

TM-ZR364

TM-ZR365

TM-ZR366

(TM-36Z-3-812)

(TM-36Z-3-813)

(TM-36Z-3-814)

(TM-36Z-3-817)

3-section

4-section

5-section

6-section

Hydraulic motor driven spur gear speed reduction, provided with mechanical brake Radio remote controls Overload prevention device (AML) -Load indication -Load moment ratio to rated load indication -Warning lamps and alarm -Over load limiter Radius indicator Terminal for emergency stop switch Hook safety latch Level gauge Hydraulic safety valves, check valves and holding valves Over-winding alarm Hoisting limiter P.T.O. indicator lamp

2

WA04-2110E

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, mm2

square centimeter, cm2

square meter, m2

square inch, in2

square foot, ft2

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, cm3, cc 1

cubic meter, m3

cubic inch, in3

cubic foot, ft3

gallon, gal

cubic inch, in3

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

Mass

Pressure Pa

kPa

MPa

kgf/cm2

lb/in2, psi

1

1X10-3

1X10-6

1.01972X10-5

14.5X10-5

1X103

1

1X10-3

1.01972X10-2

14.5X10-2

1X106

1X103

1

1.01972X10

14.5X10

9.80665X10 6895

4

-2

9.80665X10

9.80665X10

1

14.22

6.895

0.006895

0.07031

1

3

WA04-2110E

Foreword

Torque N-cm

N-m

kgf-cm

kgf-m

1

1X10-2

1.01972X10-1

1.01972X10-3

0.00737

inch-pound, in-lb 0.0885

1.01972X10

-1

0.7376

8.851

1X10

0.0723

0.868

1

7.233

86.8

1X10

2

1

9.80665 9.80665X10

9.80665X10 2

-2

foot-pound, ft-lb

1.01972X10 -2

1 2

9.80665

1X10

135.58

1.3558

13.83

0.1383

1

12

11.3

0.113

1.1525

0.01153

0.08333

1

Centigrade-Fahrenheit ゜F

℃

゜F

℃

゜F

℃

゜F

℃

゜F

℃

゜F

℃

-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

10

100

37.78

150

65.56

200

93.33

0 o

-17.78 o

50 o

o

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

Force N

kgf

lbf -1

2.24809X10-1

1

1.01972X10

9.80665

1

2.20461

4.44822

0.45359

1

4

WA04-2110E

GROUP INDEX A B C D E F G

Boom Telescoping System

H

Safety System

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

Radio-control System

W X Y

Data, Adjustment and Checks

Z

System Diagrams 5

WA04-2110E

Foreword 5. Contents Model (Spec. No.) Chapter

Section

TM-ZR363 TM-ZR364 TM-ZR365 TM-ZR366 (TM-36Z-3-812) (TM-36Z-3-813) (TM-36Z-3-814) (TM-36Z-3-817) General

A

General Cautions

Refer to separate service manual

SA01-01-2E

Boom Telescoping System 3-Section

G-1

–

–

–

4-Section

–

G-2

–

–

5-Section

–

–

G-3

–

6-Section

–

–

–

G-4

3-Section Boom

G-5

–

–

–

4-Section Boom

–

G-6

–

–

5-Section Boom

–

–

G-7

–

6-Section Boom

–

–

–

G-8

Boom

G

Telescoping Cylinder

Safety Devices

H

AML

H-1

Length Detector

H-2

Angle Detector

H-3

6

WA04-2110E

Foreword Model (Spec. No.) Chapter

Section

TM-ZR363 TM-ZR364 TM-ZR365 TM-ZR366 (TM-36Z-3-812) (TM-36Z-3-813) (TM-36Z-3-814) (TM-36Z-3-817)

Radio-control System

V

Applicable serial No. --EP9035

Configurations of Radio-control System Radio-control Valve

V-1 V-2

Measures for Emergency Case Applicable serial No. EP9036--

V-3 Refer to separate service manual W307-0061E

Data, Adjustment and Checks

Y

Service Data

Y-1

Adjustment (Hydraulic)

Y-2

Adjustment (Electric)

Y-3 System Diagrams

Hydraulic Circuit

Z-1

Electric Circuit

Z-2

Z

7

WA04-2110E

G Boom Telescoping System G

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

G-4 Boom (Six-Section Boom) .............13

1.

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

1.

Structure .................................................. 13

2.

Notes for reassembly................................. 2

2.

Notes for reassembly............................... 15

3.

Boom adjustment procedures .................... 3

3.

Boom adjustment procedures.................. 17

3.1 3.2

Top slide plate installation procedure ......... 3 Adjustment of clearance between boom sections ................................................ 3

3.1 3.2 3.3 3.4

G-2 Boom (Four-Section Boom) ............ 5 1.

Grease application procedure...................17 Top slide plate installation procedure........17 Telescoping wire rope adjustment procedure............................................17 Adjustment of clearance between boom sections...............................................19

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

2.

Notes for reassembly................................. 6

G-5 Telescoping cylinder (Three-section boom) ............21

3.

Boom adjustment procedures .................... 7

1.

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

2.

Notes for reassembly of cylinder assembly...................................... 23

3.1 3.2

Top slide plate installation procedure ......... 7 Adjustment of clearance between boom sections ................................................ 8

G-3 Boom (Five-Section Boom) ............. 9 1.

Structure .................................................... 9

2.

Notes for reassembly............................... 10

3.

Boom adjustment procedures .................. 11 3.1 3.2

G-6 Telescoping Cylinder (Four-Section Boom) .............25 1.

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

2.

Description of operation........................... 28 2.1 2.2

Top slide plate installation procedure ....... 11 Adjustment of Clearance between Boom Sections.............................................. 12

i

Control of telescoping sequence ..............28 Shock-absorbing mechanism of No. 2 cylinder......................................29

3.

Notes for reassembly of cylinder assembly......................... 30

G-8 Telescoping Cylinder (Six-Section Boom)................49

4.

Notes for reassembly of telescoping cylinder......................................... 31

1.

Structure .................................................. 49

2.

Description of operation........................... 52

5.

Cautions about telescoping wire rope adjustment.................................... 33

6.

Telescoping wire rope adjustment procedure ..................................... 33 6.1 6.2

2.1 2.2

Wire rope adjustment with the telescoping cylinder out of the boom..................... 33 Wire rope adjustment with the telescoping cylinder installed in the boom............. 35

G-7 Telescoping Cylinder (Five-Section Boom).............. 36 1.

Structure .................................................. 36

2.

Description of operation........................... 39 2.1 2.2

Control of telescoping sequence .............. 39 Shock-absorbing mechanism of No. 3 cylinder ..................................... 41

3.

Notes for reassembly of cylinder assembly ...................................... 42

4.

Notes for reassembly of telescoping cylinder......................................... 44

5.

Telescoping wire rope adjustment procedure ..................................... 46 5.1 5.2

Wire rope adjustment with the telescoping cylinder out of the boom..................... 46 Wire rope adjustment with the telescoping cylinder installed in the boom............. 48

ii

Control of telescoping sequence ..............52 Shock-absorbing mechanism of No. 3 cylinder......................................54

3.

Notes for reassembly of cylinder assembly...................................... 55

4.

Notes for reassembly of telescoping cylinder......................................... 57

G-1

G-1

G-1

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

0 312-041-50100 △

1

W536-1060E

1

G-1

G-1

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

1. Base boom section 2. 2nd boom section 3. Top boom section 4. Cover 5. Grease nipple 6. Cap 7. Cover 8. Flange bolt 9. Flange bolt 10. Pin 11. Retaining ring 12. Plain bearing 13. Slide plate 14. Button bolt

15. Slide plate 16. Pin 17. Cover 18. Plate 19. Pin 20. Bolt 21. Grease nipple 22. Pin 23. Retaining ring 24. Nameplate 25.---------26.Roller assembly 27. Pin

28. Nut 29. Set screw 30. Slide plate 31. Shim 32. Shim 33. Shim 34. Slide plate 35. Sheave 36. Pin

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.

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

4. Seal up the sections shown below (2 places) with 3M Drip-check Sealer or equivalent.

2

W536-1060E

G-1

G-1

Boom (Three-Section Boom)

5. Before performing assembly, apply a line of

3.2

grease of about 40 mm (1.57 in) in width to the bottom part of the top boom section’s inside surface in the longitudinal direction (see area marked by “*” in Fig.5)

Adjustment of clearance between boom sections

1. Adjust dimension "a" (see Fig. 7) to the following values: ・With boom fully retracted: a =2mm (0.08in) And it locks with the nut. ・Over entire boom telescoping stroke : "a" = max 3mm (0.12in) 2. Adjust dimension "b" (see Fig. 7) using shims ･ 31, ･32, ･33, 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.(0.79in) (see Fig.8) ・Boom lateral play: max. 50mm (1.97in). (see Fig. 9)

Fig. 5

3. Boom adjustment procedures to each slide plate and to each grease cup.

3.1 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. 6).

a

[NOTICE] Install the slide plates before assembling the boom.

Shim･31 serves to retain the other shims, so it must be installed last.

Before performing this work, supply grease (TNR)

A

Slide plate

b

Button bolt 31 Shim (For the fixation) 32 Shim (For the adjustment) 33 Shim (For the adjustment)

Slide plate IW536-0272E02

Fig. 6

View A

Fig. 7

3

W536-1060E

IW536-0272E03

G-1

G-1

Boom (Three-Section Boom)

Fig. 8

Fig. 9

4

W536-1060E

G-2

G-2

G-2

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

5 312-026-30100 △ 0 312-041-60100 △

5

W536-0991E

5

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 2. 2nd boom section 3. 3rd boom section 4. Top boom section 5. Grease nipple 6. Cap 7. Cover 8. Flange bolt 9. Pin 10. Retaining ring 11. Plain bearing 12. Slide plate 13. Button bolt 14. Flange bolt

15. Cover 16. Plate 17. Pin 18. Bolt 19. Grease nipple 20. Pin 21. Retaining ring 22. Bolt 23. Nut 24. Roller assembly 25. Pin 26. Nut 27. Set screw 28. Slide plate

29. Shim 30. Shim 31. Shim 32. Slide plate 33. Sheave 34. Pin 35. Retaining ring 36. Pin 37. Roller assembly 38. Hexagon socket head bolt 39. Spring washer 40. Slide plate 41. Bolt 42. Slide plate

43. Spring washer 44. Button bolt 45. Slide plate 46. Roller assembly 47. Pin 48. Cover 49. Nameplate

3. Bend down the plate on the boom elevating

2. Notes for reassembly

cylinder pivot pin after installing the bolts. (see Fig. 3).

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 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. (see Fig. 3).

boom with their grease grooves on the outside (see Fig. 2).

Fig.2 Fig.3

6

W536-0991E

G-2

G-2

Boom (Four-Section Boom) 3. Boom adjustment procedures

4. Install the top boom telescoping support in accordance with the following steps (see Fig. 4):

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

• Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts and use them to loosely fit the top boom telescoping support.

3.1 Top slide plate installation procedure Apply thread locking compound (Threebond 1305

• Tighten the bolts until the top boom telescoping support's longitudinal play is eliminated, then lock them in position with the nuts.

Verify through the inspection holes that the top boom telescoping support is pressed firmly against the stopper.

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).

Button bolt

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

Slide plate IW536-0272E02

Fig. 5

Fig. 4

7

W536-0991E

G-2.

G-2.

Boom (Four-Section Boom)

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

a

3.2 Adjustment of clearance between boom sections

A

values:

Slide plate

With boom fully retracted: a = 2 mm (0.08 in.)

b

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

31 Shim (For the fixation)

2. Adjust dimension "b" (see Fig. 6) using shims-31, -32, and 33 such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values:

32 Shim (For the adjustment) 33 Shim (For the adjustment)

Boom lateral bending: max. 35mm (1.38 in) (see Fig. 7)

View A

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

IW536-0272E03

Fig. 6

(see Fig. 8) [NOTE] Install the slide plates before assembling the boom.

Shim-31 serves to retain the other shims, so it must be installed last.

Boom fully retracted Max. 35 mm (1.38 in)

Boom fully extended

Adjustment of boom lateral bending IW536-0272E05

Fig. 7

100 N (22 lbf) Max. 80 mm (3.15 in) 100 N (22 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0272E06

Fig. 8

5 312-026-30100 △ 0 312-041-60100 △

8

W536-0991E

G-3

G-3

G-3

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

1 312-029-40100 △ 0 312-041-70100 △

9

W536-1001E

9

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 2. 2nd boom section 3. 3rd boom section 4. 4th boom section 5. Top boom section 6. Cap 7. Cover 8. Flange bolt 9. Flange bolt 10. Pin 11. Retaining ring 12. Plain bearing 13. Slide plate 14. Button bolt 15. Cover

16. Spacer 17. Cover 18. Plate 19. Pin 20. Bolt 21. Grease nipple 22. Pin 23. Retaining ring 24. Bolt 25. Nut 26. Roller assembly 27. Pin 28. Nut 29. Set screw 30. Slide plate

31. Shim 32. Shim 33. Shim 34. Slide plate 35. Sheave 36. Pin 37. Grease nipple 38. Pin 39. Roller assembly 40. Hexagon socket head bolt 41. Spring washer 42. Pin 43. Retaining ring 44. Spring washer 45. Slide plate

2. Notes for reassembly

46. Bolt 47. Button bolt 48. Slide plate 49. Slide plate 50. Roller assembly 51. Pin 52. Plate 53. Slide plate 54. Nameplate

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

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

against slide plates.

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

10

W536-1001E

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 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. (see Fig. on back page)

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

3.1 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).

6. Install the top boom telescoping support in accordance with the following steps (see Fig. 4): • Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts and use them to loosely fit the top boom telescoping support.

Button bolt

• Tighten the bolts until the top boom telescoping support's longitudinal play is eliminated, then lock them in position with the nuts.

Verify through the inspection holes that the top boom telescoping support is pressed firmly against the stopper.

Slide plate IW536-0272E02

• Tighten the button bolts to a torque of 24.5 N-m

Fig.5

(18.1 ft-lbf).

Fig. 4

11

W536-1001E

G-3.

G-3.

Boom (Five-Section Boom)

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

a

3.2 Adjustment of Clearance between Boom Sections

A

values:

Slide plate

With boom fully retracted: a = 2 mm (0.08 in.)

b

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

31 Shim (For the fixation)

2. Adjust dimension "b" (see Fig. 6) using shims-31, -32, and 33 such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values:

32 Shim (For the adjustment) 33 Shim (For the adjustment)

Boom lateral bending: max. 35mm (1.38 in.) (see Fig. 7)

View A

Boom lateral play: max.80mm (3.15in.) (see Fig. 8)

IW536-0272E03

Fig.6

[NOTE] Install the slide plates before assembling the boom.

Shim-31 serves to retain the other shims, so it must be installed last.

Boom fully retracted Max. 35 mm (1.38 in)

Boom fully extended

Adjustment of boom lateral bending IW536-0272E05

Fig. 7 100 N (22 lbf) Max. 80 mm (3.15 in) 100 N (22 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0272E06

Fig. 8

0 312-029-25000 △

12

W536-1001E

G-4

G-4

G-4

Boom (Six-Section Boom) G-4 Boom (Six-Section Boom) 1. Structure General View

1 312-041-80100 △

13

W536-1070E

13

G-4

G-4

Boom (Six-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 2. 2nd boom section 3.3rd boom section 4.4th boom section 5.5th boom section 6. Top boom section 7. Cover 8. Flange bolt 9. Spring washer 10. Pin 11. Retaining ring 12. Plain bearing 13. Slide plate 14. Button bolt 15. Flange bolt 16. Shim 17. Cover 18. Plate 19. Pin 20. Bolt 21. Grease nipple 22. Pin 23. Retaining ring 24. Bolt

25. Nut 26. Roller assembly 27. Pin 28. Nut 29. Set screw 30. Slide plate 31. Shim (for the fixation) 32. Shim (for the adjustment) 33. Shim (for the adjustment) 34. Slide plate 35. Sheave 36. Pin 37. Grease nipple 38. Pin 39. Roller assembly 40. Hexagon socket head bol 41. Spring washer 42. Pin 43.----------44. Spacer 45. Slide plate 46. Sheave assembly 47. Pin 48. Retaining ring

49. Slide plate 50. Spacer 51. Slide plate 52. Slide plate 53. Roller assembly 54. Plate 55. Pin 56. Sheave assembly 57. Pin 58. Slide plate 59. Plate 60. Cap 61. Bolt 62. Spacer 63. Sheave assembly 64. Pin 65. Slide plate 66. Retainer 67. Plate 68. Roller assembly 69. Spacer 70. Spacer 71. Pin 72. Cover assembly

14

W536-1070E

73. Wire rope 74. Nut 75. Nut 76. Wire rope 77. Nut 78. Wire rope 79. Wire rope 80. Support 81. Flange bolt 82. Nut 83. Nameplate

G-4

G-4

Boom (Six-Section Boom) 2. Notes for reassembly

4. Apply thread locking compound (Threebond 1305 or equivalent) to the bolts provided for mounting of the slide plates at the bottom of the 4th and 5th boom sections (see Figs. 4 and 5).

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

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

4th boom section

Slide plate mounting bolt IW536-040004E

Fig. 4

Fig. 2

5th boom section

3. Bend the plate on the boom elevating cylinder pivot pin after installing the bolts (see Fig. 3).

Slide plate mounting bolt

IW536-040005E

Fig. 5

Fig. 3

15

W536-1070E

G-4

G-4

Boom (Six-Section Boom)

5. When installing the sheave assemblies at the rear

6. Bend the plates on the wire rope guides on the

end of the 5th boom section, play attention to the following instructions:

top of the 5th and top boom sections after installing the extending wire rope (see Figs. 8 and 9).

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

Plate

• After installing the top boom section’s retracting wire rope, bend the plate onto the mounting surface such that the clearance between the plate and the sheave assembly is 1 - 2 mm (0.04 - 0.08 in) (see Fig. 7).

5th boom section IW536-040008E

Sheave assembly (with clinched part on inside)

Fig. 8 Plate

5th boom section

Top boom section

IW536-040006E

Fig . 6

IW536-040009E

fig. 9

5th boom section retracting wire rope

7. Install the sheave assembly at the top of the 5th boom section with the clinched part on the inside (see Fig. 10).

Top boom section retracting wire rope 1 - 2 mm (0.04 - 0.08 in) Bend after installing wire rope Detail W

Plate

Sheave assembly (with clinched part on inside)

Mounting surface

Section X-X

IW536-0451E03

5th boom section

Fig. 7

IW536-0451E04

Fig. 10

16

W536-1070E

G-4

G-4

Boom (Six-Section Boom) 3. Boom adjustment procedures

3.3 Telescoping wire rope adjustment procedure

3.1 Grease application procedure

1. Loosen the respective lock nuts of the extending wire rope and retracting wire rope (see Fig. 12).

Before performing this work, supply grease (TNR)

Extending wire rope

to each slide plate and to each grease cup.

Retracting wire rope

3.2 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. 11).

Adjusting nut

Button bolt

Lock nut

Slide Plate

Extending wire rope thread (detail)

Lock nut Adjusting nut

Support and shim retaining nut

Retracting wire rope thread (detail) IW536-040012E

Fig. 12 2. Position the boom horizontally, then extend the 4th, 5th, and top boom sections by 500 mm (19.7 in) each.

With the idling condition (with a flow rate of approx.

15 L/min (4 gal/min)), fully retract the boom and lock the 3rd boom section and 4th 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. 13.

Top slide plate installation procedure IW536-040011E

Fig. 11

• Dimension “B” : approx. 15 mm (0.59 in) (for reference)

Fig. 13

IW536-040013E

17

W536-1070E

G-4

G-4

Boom (Six-Section Boom)

3. Tighten the retracting wire rope’s adjusting nut until the stopper of the 5th boom section touches the end of the 4th boom section and the stopper of the top boom section touches the end of the 5th boom section (see Fig. 14).

5th boom section stopper Top boom section stopper (located on rear surface of top boom section) IW536-040015E

Fig. 15 5th boom section stopper

7. If the boom conditions stated in step 6. are not

Top boom section stopper (located on rear surface of top boom section)

satisfied, make adjustments again.

8. Readjustment method 1

IW536-040014E

Fig. 14

• Dimension “B” is not same as measured previously.

4. After 5th and top boom sections touch their

• The stoppers for the 5th boom section and top boom section are in contact with the 4th boom section head and 5th boom section head respectively.

corresponding stoppers, tighten each retracting wire rope's adjusting nut for 6 turns.

5. Tighten the adjusting nut for top boom extending wire rope until the stopper is 1 - 2 mm (0.04 - 0.08 in) away from the 5th boom section; then tighten the adjusting nut for 5th boom extending wire rope until the stopper is 1 - 2 mm (0.04 - 0.08 in) away from the 4th boom section. After that, tighten each extending wire rope's adjusting nut for a turn.

In this case, first loosen the retracting wire rope's adjusting nut slightly.

Then tighten the extending wire ropes' adjusting nuts slightly until dimension “B” becomes same as measured in step 2.

6. Position the boom horizontally, then extend the 4th, 5th, and top boom sections by 500 mm (19.7 in) each.

With the idling condition (with a flow rate of approx.

15 L/min (4 gal/min)), fully retract the boom.

Check whether the following boom conditions are satisfied (see Fig. 15).

• The stopper of the 5th boom section is touching the end of the 4th boom section, and the stopper of the top boom section is touching the end of the 5th boom section. (The boom is fully retracted.)

• Dimension “B” is the same as when measured in step 2).

9. Readjustment method 2 • The stoppers for the 5th boom section and top boom section are clear of the 4th boom section head and 5th boom section head respectively.

• Dimension “B” is same as measured previously.

In this case, first tighten the retracting wire rope's adjusting nut slightly.

Then loosen the extending wire ropes' adjusting nuts slightly to let the stoppers for the 5th boom section and top boom section touch the 4th boom section head and 5th boom section head respectively.

10. The adjusting nut of the wire rope for each telescoping is locked with the lock nut.

18

W536-1070E

G-4

G-4

Boom (Six-Section Boom) 3.4 Adjustment of clearance between boom sections

3. Adjust dimension "b" (see Fig. 16) using shims-31, -32, and 33 such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values:

1. Adjust dimension "a" (see Fig. 16) to the following values: • With boom fully extended: a = 2 mm (0.08 in) And locks it with the nut.

• Boom lateral bending: max. 45 mm (1.77 in) (see Fig. 18) • Boom lateral play: max. 100 mm (3.94 in) (see Fig. 19) [NOTICE] Install the slide plates before assembling the boom.

Shim-31 serves to retain the other shims, so it must be installed last.

Boom fully retracted Max. 45 mm (1.77 in)

Boom fully extended

Fig. 16

Adjustment of boom lateral bending IW536-0451E06

2. If the gate retainer is a plate, use a shim to adjust

Fig. 18

demension "a" to 2 - 3 mm (0.08 - 0.12 in) (see Fig. 17).

100 N (22 lbf) Max. 100 mm (3.94 in) 100 N (22 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0451E07

Fig. 19

Fig. 17 [NOTICE] Ensure that the upper plate is clear of the slide plate at any length of the boom. If the upper plate touches the slide plate, adjust to arrange clearance.

19

W536-1070E

G-4

G-4

Boom (Six-Section Boom)

4. Adjust dimension ”C” (see Fig. 20) to 0 - 0.5 mm (0 - 0.02 in) using the support-89 and shim-90.

89 90

Top boom section

D detail

IW536-040020E

Fig. 20

0 312-029-60500 △

20

W536-1070E

G-5

G-5

Telescoping cylinder (Three-section boom) G-5

Telescoping cylinder (Three-section boom)

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

1. Structure General view

1. Cylinder assembly

2. Spring washer

3. Bolt

4. Counterbalance valve

0 312-115-60000 △

21

W157-0281E

G-5

G-5

Telescoping cylinder (Three-section boom) Cylinder assembly

1. O-ring 2. Hexagon socket head bolt 3. Packing 4. Backup ring 5. Dust seal 6. O-ring 7. Rod cover 8. Cylinder 9. Rod

10. Piston 11. O-ring 12. Plain bearing 13. Nut 14. Check valve assembly 15. O-ring 16. Check valve assembly 17. Stopper 21. Plain bearing

23. Piston 24. Pipe 25. Rod 26. Cylinder 27. Rod cover 28. O-ring 29. Plain bearing 30. Packing 31. Backup ring

33. Dust seal 34. Bearing 35. Pin 36. Retaining ring 37. Retaining ring 38. Pin 39. Roller 42. Plain bearing

2 360-163-50000 △

22

W157-0281E

G-5

G-5

Telescoping cylinder (Three-section boom) 2. Notes for reassembly of cylinder assembly

Check valve assembly (cylinder assembly part-14)

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)

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

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

Check valve assembly (cylinder assembly part-16)

3. Before installing the piston, apply adhesive (Loctite 638) to the three consecutive crests of the rod's external fourth starting with the thread crest (see the areas marked with "※" in Fig. 4).

• Tightening torque: 98 N-m (72.3 ft-lbf)

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

23

W157-0281E

G-5.

G-5.

Telescoping cylinder (Three sections boom)

4. Before fitting the rod cover, apply rust inhibitor

6. Apply thread locking compound to the items listed

(Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover (see Fig. 5).

below before tightening those items.

• Check valve mounting bolts-N

• Tightening torque: 343 - 392 N-m (253 - 289 ft-lbf)

• Hexagon socket head bolts-2

5. After installing the cylinder, bend the end of the cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

24

W157-0281E

G-6

G-6

Telescoping Cylinder (Four-Section Boom) G-6

Telescoping Cylinder (Four-Section Boom)

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

1. Structure General view

3 312-115-70000 △

25

W157-0291E

G-6

G-6

G-6

Telescoping Cylinder (Four-Section Boom) Cylinder assembly

360-163-60000

26

W157-0291E

4 △

26

G-6

G-6

Telescoping Cylinder (Four-Section Boom) 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 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 24. Plate

25. ---------------------26. Support 27 Machine screw 28.Nut 29. Plate

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. ---------------------32. ---------------------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 44. Spring pin 45. Plain washer

Cylinder assembly 1. Hexagon socket head bolt 2. Spring washer 3. Support 4. O-ring 5. Hexagon socket head bolt 6. Roller 7. Retaining ring 8. Plunger 9. O-ring 10. Backup ring 11. Retaining ring 12. Seal

Check valve assembly (cylinder assembly part-23)

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

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

Check valve assembly (cylinder assembly part-26)

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

27

W157-0291E

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

G-6

G-6

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.

28

W157-0291E

G-6

G-6

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 1 mm (0.04 in). 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).

29

W157-0291E

G-6

G-6

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 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 areas marked with "※" in Fig. 3).

• Tightening torque: 98 N-m (72.3 ft-lbf)

5. Before fitting the rod cover, apply rust inhibitor

Fig. 3

(Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover.

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

• Tightening torque: 343-392 N-m (253-289 ft-lbf) 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.

• Tightening torque: 98 N-m (72.3 ft-lbf) 4. Apply thread locking compound to the items listed below before tightening those items.

• Check valve mounting bolts-N • Hexagon socket head bolts-5 • Slide plate mounting bolts-40 and 42

30

W157-0291E

G-6

G-6

Telescoping Cylinder (Four-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. 2 cylinder with the clinched part on the inside.

Fig. 8 8. Tighten each of the hexagon socket head bolts on

2. Install the sheave assembly at the front end of the

the top of the cylinder assembly to a torque of 23.5-27.4 N-m (17.3-20.2 ft-lbf).

No. 2 cylinder with the clinched part on the outside.

Fig. 9 3. Before installing the extending wire rope, install the retracting wire rope end loop support and the plate.

31

W157-0291E

G-6

G-6

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 to follow these instructions:

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

• 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.

A 5. When passing the retracting wire rope through the retracting wire rope end loop support, be sure to follow these instructions:

IW157-0291E07

Fig. 14

• Align the retracting wire rope's center mark with

8. Apply grease to the surface that rubs against the

the center of the retracting wire rope end loop support.

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

• After passing the retracting wire rope through the retracting wire rope end loop support, apply thread locking compound to the machine screws and use the machine screws to install the wire rope guides.

Fig. 12

32

W157-0291E

G-6

G-6

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 rope guide supports-26 after applying screw locking agent to the threaded portion of the machine screw-27.

1. To prevent the nut of the extending wire rope from hitting the sheave assy-6 and the nut of the retracting wire rope from hitting the sheave assy-18, adjust the wire rope so that the projecting length of the extending wire rope is 108 mm (4.25 in) or shorter and the one of thhe retracting wire rope is 72 mm (2.83 in) or shorter (See the Fig. 15).

Fig. 17 3. With the heads of the extending wire rope adjusting bolts-16 pressing firmly against the adjusting bolt mounting surface, adjust dimension "E" (see Fig. 18) to 120 - 121 mm (4.72 - 4.76 in).

(The bolts-16 should be tightened for a turn from the position where the pin-20 becomes forced against cylinder assembly.)

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

Fig. 15

6. Telescoping wire rope adjustment procedure 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": 152.5 mm (6 in)

Fig. 18

33

W157-0291E

G-6

G-6

Telescoping Cylinder (Four-Section Boom)

7. With the jig fitted, tighten the retracting wire rope

4. With the heads of the retracting wire rope

adjusting nut until the jig slightly comes off.

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.

• 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-22 close to the boom head.

8. After 7., secure the nuts-4 and 28 using the lock nuts.

9. After adjustment is completed, thrust the adjusting bolt locking plate-29 against the horizontal face of the extending wire rope adjusting bolt and secure the plates-15 and 29 using the hexagon socket head bolts-13 and the spring washers-14 (see the Fig. 21).

5. Use the specified jig to retain the top boom telescoping support in the position at which dimension "C" (see Fig. 20) is 294 mm (11.57 in).

Fig. 21 10. After adjustment is completed, thrust the adjusting bolt locking plate-29 against the horizontal face of the retracting wire rope adjusting bolt and secure the plates-15 and 29 using the hexagon socket head bolts-13 and the spring washers-14 (see the Fig. 22).

Fig. 20 6. With the jig still fitted, tighten the extending wire rope adjusting nut (see Fig. 20).

Adjusting nut tightening torque： 4.9 N-m (3.6 ft-lbf) • 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-16 on the right and left close to the boom head equally.

Adjusting bolt tightening torque： 9.8 N-m (7.2 ft-lbf)

Fig. 22

34

W157-0291E

G-6.

G-6.

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

3. When "F" is longer than 4 mm (0.16 in)

Telescope the boom for several strokes and check

Perform the "6.1 Wire rope adjustment with the

the dimension of "F" (clearance between the top boom section and 3rd boom section).

telescoping cylinder out of the boom" again.

1. When "F" is 2 mm (0.08 in) or shorter re-adjustment is not necessary.

2. When "F" is longer than 2 mm (0.08 in) and does not exceed 4 mm (0.16 in) Make adjustment in the following order: • Remove the top cover. (Take care not to damage the cord on the cord reel.)

• Remove the adjusting bolt locking plates-15 and 29, hexagon socket head bolts-13 and the spring washers-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 plates-15 and 29, hexagon socket head bolts-13 and the spring washers-14, and tighten the retracting wire rope adjusting bolt-22 until "F" is 2 mm (0.08 in) or shorter (see the Fig. 22).

• Attach the adjusting bolt locking plates-15 and 29, hexagon socket head bolts-13 and spring washers-14 (both for the retracting wire rope and for the extending wire rope). Then attach the top cover.

0 312-115-71000 △

35

W157-0291E

G-7

G-7

Telescoping Cylinder (Five-Section Boom) G-7

Telescoping Cylinder (Five-Section Boom)

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

1. Structure 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 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 24. Plate 25. Support 26. Machine screw 27. ---------------------28. Plate 3 312-115-80000 △

36

W157-0301E

G-7

G-7

G-7

Telescoping Cylinder (Five-Section Boom) Cylinder assembly

4 360-163-70000 △

37

W157-0301E

37

G-7

G-7

Telescoping Cylinder (Five-Section Boom)

Cylinder assembly 1. Roller 2. Retaining ring 3. Plunger 4. Backup ring 5. O-ring 6. Retaining ring 7. Seal 8. Piston 9. O-ring 10. Plain bearing 11. Cylinder 12. Rod 13. Rod cover 14. O-ring 15. Packing

16. Backup ring 17. Dust seal 18. Check valve assembly 19. O-ring 20. O-ring 21. Rod cover 22. Roller assembly 23. Roller assembly 24. Check valve assembly 25. Stopper 26. Pipe 27. Plain bearing 28. Plain bearing 29. O-ring 30. Piston

31. Plain bearing 32. ---------------------33. ---------------------34. Piston 35. Rod 36. Cylinder 37. Rod 38. Cylinder 39. O-ring 40. Rod cover 41. Plain bearing 42. Packing 43. Backup ring 44. Dust seal 45. Plate

Check valve assembly (cylinder assembly part-18)

1. O-ring 2. Backup ring 3. Check valve 4. O-ring 5. Valve seat

6. O-ring 7. Spring 8. Plug 9. O-ring 10. Plug

46. Hexagon socket head bolt 47. Spring washer 48. O-ring 49. Hexagon socket head bolt 50. Slide plate 51. Machine screw 52. Slide plate 53. Button bolt 54. Slide plate 55. Machine screw 56. Spring pin 57. Plain washer

Check valve assembly (cylinder assembly part-24)

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

38

W157-0301E

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

G-7

G-7

Telescoping Cylinder (Five-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 extended, the No. 3 cylinder is extended.

39

W157-0301E

G-7

G-7

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.

40

W157-0301E

G-7

G-7

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 (0.04 in). 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).

41

W157-0301E

G-7

G-7

Telescoping Cylinder (Five-Section Boom) 3. Notes for reassembly of cylinder assembly

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

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

• Check valve mounting bolts-N

correctly aligned.

• Machine screws-51 and button bolts-53 used to mount slide plates at front ends of No.1 and No.2 cylinders

2. Before installing the pistons of the No. 2 and No. 3 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: 98.1 N-m (72.4 ft-lbf)

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).

Fig. 4

• Tightening torque: 98.1 N-m (72.4 ft-lbf)

42

W157-0301E

G-7

G-7

Telescoping Cylinder (Five-Section Boom)

• Machine screws-55 used to mount slide plate at

• Hexagon socket head bolts-46 on top of No. 3

rear end of No. 2 cylinder

cylinder's front end

Fig. 7 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: 343 - 392 N-m (253 - 289 ft-lbf) 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-49 at rear end of cylinder assembly

Fig. 8

Fig. 6

43

W157-0301E

G-7

G-7

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.

44

W157-0301E

G-7

G-7

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 (marked with a "A") in the outside of the sheave at the rear end of the No. 3 cylinder.

ropes through their respective wire rope end loop support, be sure to follow these instructions: • 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

Fig. 15

After passing the retracting wire rope through the

7. Apply grease to the surface that rubs against the slide plate (see Figs. 4 and 5). At the same time, apply grease to the top surface of the No. 3 cylinder.

retracting wire rope end loop support, apply thread locking compound to the machine screws and use the machine screws to install the wire rope guide supports.

• Retracting wire rope: two wire rope guide supports

Fig. 13 5. Tighten each of the support mounting bolts shown in Fig. 14 to a torque of 19.6 N-m (14.5 ft-lbf).

45

W157-0301E

G-7

G-7

Telescoping Cylinder (Five-Section Boom) 5. Telescoping wire rope adjustment procedure

3. With the heads of the extending wire rope adjusting bolts-16 pressing firmly against the adjusting bolt mounting surface, adjust dimension "E" (see Fig. 18) to 111.5 - 112.5 mm (4.39 - 4.43 in).

(The bolts-16 should be tightened for a turn from the position where the pin-20 becomes forced against cylinder assembly.)

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

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": 146 mm (5.75 in)

Fig. 18 4 With the head of the retracting wire rope adjusting 2. Attach the extending wire rope-2 and retracting

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.

wire rope-5, and fold the two wire rope guides.

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

Fig. 17

46

W157-0301E

G-7

G-7

Telescoping Cylinder (Five-Section Boom)

9. After adjustment is completed, thrust the adjusting

5. Use the specified jig to retain the top boom

bolt locking plate-28 against the horizontal face of the extending wire rope adjusting bolt and secure the plates-15 and 28 using the hexagon socket head bolts-13 and the spring washers-14 (see the Fig. 21).

telescoping support in the position at which dimension "C" (see Fig. 20) is 338 mm (13.31 in).

Fig. 20 6. With the jig still fitted, tighten the extending wire rope adjusting nut (see Fig. 20).

Adjusting nut tightening torque: 4.9 N-m (3.6 ft-lbf) Fig. 21

• 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-16 on the right and left close to the boom head equally.

Adjusting bolt tightening torque: 9.8 N-m (7.2 ft-lbf)

10.After adjustment is completed, thrust the adjusting bolt locking plate-28 againt the horizontal face of the retracting wire rope adjusting bolt and secure the plates-15 and 28 using the hexagon socket head bolts-13 and the spring washers-14. (see Fig. 22)

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-22 close to the boom head.

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

Fig. 22

47

W157-0301E

G-7.

G-7.

Telescoping Cylinder (Five-Section Boom) 5.2 Wire rope adjustment with the telescoping cylinder installed in the boom

3. When "F" is longer than 4 mm (0.16 in)

Telescope the boom for several strokes and check

Perform the "5.1 Wire rope adjustment with the

the dimension of "F" (clearance between the top boom section and 3rd boom section).

telescoping cylinder out of the boom" again.

1. When "F" is 2 mm (0.08 in) or shorter re-adjustment is not necessary.

2. When "F" is longer than 2 mm (0.08 in) and does not exceed 4 mm (0.16 in) Make adjustment in the following order: • Remove the top cover. (Take care not to damage the cord on the cord reel.)

• Remove the adjusting bolt locking plates-15 and 28, hexagon socket head bolts-13, and the spring washers-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 plates-15 and 28, hexagon socket head bolts-13 and the spring washers-14, and tighten the retracting wire rope adjusting bolt-22 until "F" is 2 mm (0.08 in) or shorter (see the Fig. 22).

• Attach the adjusting bolt locking plates-15 and 28, hexagon socket head bolts-13 and spring washers-14 (both for the retracting wire rope and for the extending wire rope). Then attach the top cover.

0 312-115-81000 △

48

W157-0301E

G-8

G-8

Telescoping Cylinder (Six-Section Boom) G-8

Telescoping Cylinder (Six-Section Boom)

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

1. Structure General view

1. Cylinder assembly 2. Sheave assembly

3. Hexagon socket head bolt 4. Spring washer

5. Support 6. Spring washer

7. Bolt 8. Counterbalance valve

1 312-115-90000 △

49

W157-0311E

G-8

G-8

G-8

Telescoping Cylinder (Six-Section Boom) Cylinder assembly

2 360-163-80001 △

50

W157-0311E

50

G-8

G-8

Telescoping Cylinder (Six-Section Boom)

Cylinder assembly 1. Roller assembly 2. Retaining ring 3. Support 4. Plunger 5. Backup ring 6. O-ring 7. Retaining ring 8. Seal 9. Piston 10. O-ring 11. Plain bearing 12. Plain bearing 13. Plain bearing 14. O-ring

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. O-ring 25. O-ring 26. Packing 27. Backup ring 28. Dust seal

29. Rod cover 30. Roller assembly 31. Check valve assembly 32. Stopper 33. Pipe 34. ---------------------35. ---------------------36. ---------------------37. Piston 38. Rod 39. Cylinder 40. Rod 41. Cylinder 42. Rod cover

Check valve assembly (cylinder assembly part-23)

1. O-ring 2. Backup ring 3. Check valve 4. O-ring 5. Valve seat

6. O-ring 7. Spring 8. Plug 9. O-ring 10. Plug

43. Plain bearing 44. Hexagon socket head bolt 45. Spring washer 46. Roller assembly 47. O-ring 48. Hexagon socket head bolt 49. Slide plate 50. Machine screw 51. Button bolt 52. Slide plate 53. Slide plate 54. Machine screw

Check valve assembly (cylinder assembly part-31)

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

51

W157-0311E

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

G-8

G-8

Telescoping Cylinder (Six-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 extended, the No. 3 cylinder is extended.

52

W157-0311E

G-8

G-8

Telescoping Cylinder (Six-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.

53

W157-0311E

G-8

G-8

Telescoping Cylinder (Six-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 (0.04 in). 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).

54

W157-0311E

G-8

G-8

Telescoping Cylinder (Six-Section Boom) 3. Notes for reassembly of cylinder assembly

5. Apply thread locking compound to the items listed below before installing the items (see Figs. 4 - 6).

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

• Check valve mounting bolts-N

correctly aligned.

• Machine screws-50 and button bolts-51 used to mount slide plates at front ends of No. 1 and No. 2 cylinders

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

• Tightening torque: 98.1 N-m (72.4 ft-lbf)

3. Before installing the piston of the No. 2 cylinder, apply adhesive (Loctite 638) to the three consecutive crests of the rod's external thread, starting with the second crest (see the area marked with "※※" in Fig. 3).

• Tightening torque: 98.1 N-m (72.4 ft-lbf) 4. Before installing the piston of the No. 3 cylinder, apply adhesive (Loctite 638) to the three consecutive crests of the rod's external thread, starting with the second crest (see the area marked with "※※※" in Fig. 3).

Fig. 4

• Tightening torque: 98.1 N-m (72.4 ft-lbf)

55

W157-0311E

G-8

G-8

Telescoping Cylinder (Six-Section Boom)

• Machine screws-54 used to mount slide plate at

• Hexagon socket head bolts-48 at rear end of

rear end of No. 2 and No. 3 cylinder

cylinder assembly

Fig. 6 6. Before fitting the rod cover, apply rust inhibitor (Threebond 1104 or equivalent) to the thread.

Perform this step with each rod cover.

• Tightening torque: 343 - 392 N-m (253 - 289 ft-lbf) 7. After installing the cylinder, bend the end of the cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

56

W157-0311E

G-8

G-8

Telescoping Cylinder (Six-Section Boom)

below before installing the item.

4. Notes for reassembly of telescoping cylinder

• Hexagon socket head bolts-44 on top of No. 3

1. Install the sheave assembly at the rear end of the

8. Apply thread locking compound to the item listed

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

cylinder’s front end

Fig. 8

Fig. 10

9. When reassembling each roller assembly, apply

2. When passing the retracting wire ropes through their respective wire rope end loop support, be sure to follow these instructions:

grease to the pin.

• 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 (6 places).

Fig. 11

57

W157-0311E

G-8.

G-8.

Telescoping Cylinder (Six-Section Boom)

3. Tighten each of the support mounting bolts shown in Fig. 12 to a torque of 19.6 N-m (14.5 ft-lbf).

Fig. 12 4. When installing the telescoping cylinders in the boom, align as shown in Fig. 13 the groove (marked with a "A") in the outside of the sheave at the rear end of the No. 3 cylinder.

Fig. 13 5. Apply grease to the surface that rubs against the slide plate (see Figs. 4 and 5). At the same time, apply grease to the top surface of the No. 3 cylinder.

58

W157-0311E

H Safety System

Contents H-1 Overload Prevention Device (AML) ........................................ 1 1.

H-2 Length Detector (Boom) ................12 1.

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

2.

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

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

2.

Function of components............................. 2

3.

Caution about installing length detector..... 3

H-3 Angle Detector (Boom) ..................13

AML adjustment ......................................... 4

1.

Structure .................................................. 13

2.

Specifications (potentiometer) ................. 13

4.

4.1 4.2 4.3 4.4 4.5 4.6

Attention for adjustment work..................... 4 AML components........................................ 5 Selecting the crane model and capacity data ........................................ 6 Zero-point and span adjustments of length detector...................................... 8 Zero-point and span adjustments of angle detector....................................... 8 Confirming accuracy................................... 9

5.

List of error Nos. related to AML .............. 10

6.

Adjustment items when parts are exchanged.................................... 11

i

H

H-1

H-1

Overload Prevention Device (AML) H-1

Overload Prevention Device (AML)

[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

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 2. Function of components Applicable serial No.: -- EP9035

Applicable serial No.: EP9036 --

Outrigger state indicator lamps These lamps indicate the state of the right and left outriggers.

When both outriggers are extended to the maximum length, the max. extension lamp (green) lights.

When both outriggers are extended to the minimum length, the min. extension lamp (red) lights.

When the right and the left outriggers are extended to different lengths: 1. When the boom is directed toward the outrigger that is extended to the maximum length, the max. extension lamp(green) flashes.

2. When the boom is directed toward the outrigger that is extended to the minimum length, the min. extension lamp (red) flashes.

Over-front area state indicator lamp This lamp is lit while the boom is in the over-front area and goes out when the boom is out of the over-front area.

Working height limit indicator lamp, Working height limit setting switch The working height limit cannot be set if the power switch of the radio-control transmitter is ON. The switch is used for setting a working height limit, and the lamp is used for confirming the setting.

Display window, Display alteration switch Normally, the actual load of the lifted load is displayed, but the moment or working height limit can also be displayed by pressing the display alteration switch. Also, if an error occurs in the system, the corresponding error code is displayed.

2

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 3. Caution about installing length detector 1. Adjust the cord for length detector assy so that the yellow tape on the cord is located as shown in the drawing when the boom is fully retracted.

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 reeled in all the way, leading to damage to the potentiometer.

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

3

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 4. AML adjustment AML stores capacity data for plural models of cranes.

After mounting of a crane is completed, you must select the capacity data that corresponds to the actual model and confirm accuracy of the data.

4.1 Attention for adjustment work 1. Set the machine level on a firm level ground with the outriggers extended as specified.

(See the Table 1.)

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

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

4. Shift the dip switches and the rotary switch using an extra thin screwdriver.

5. Do not let water enter inside of the AML during adjustment.

6. Keep off the buttons other than the specified switches.

4

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 4.2 AML components Applicable serial No.: -- EP9035

Display window

OPERATION SWITCH

SPAN

5 6 7

15

8

16

8

4

14

A

0

3

13

F

2

12

6 7 8

MOOD

ZERO

Span adjustment button

SPAN

Rotary switch

6

2 4

CODE

SELECT

ON

1

9

4

12

5

13

6

14

7

15

8

16

8

3

11

C A

0

10

F

2

Dip switch (DS2)

MODE

Select button

2

6

1

ON

11

5

C

9 10

4

ZERO

4

8

8

8

7

7

3

7

6

6

6

5

5

5

4

4

4

3

3

2

3

2

2

Zero-point adjustment button

1

2

1

ON

1

ON

1

Dip switch (DS1)

OPERATION SWITCH

CODE

SELECT

AML main unit with the cover removed

IW301-0330E05

Applicable serial No.: EP9036 --

5

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 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 the "1" position.

No

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

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

No No

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

Yes Shift the rotary switch to the "5" position.

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

Yes Completed

IW301-0330E07

6

W301-0340E

H-1

H-1

Overload Prevention Device (AML)

Table 1

(*1): For dip switch setting, “0” means OFF position and “1” means ON position.

Setting of DS3 is applicable to serial No. EP9036 and onward. (*2): For indication 2 and 3, “ ” means that no segments are marked up. (*3): For the current capacity type, see the rated lifting capacity chart.

7

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 4.4 Zero-point and span adjustments of length detector Swing the boom to over-rear before adjustment.

START

Turn the rotary switch to the "2" position.

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

Extend the boom fully and press the span adjustment button.

Retract the boom fully again.

No

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

Yes Completed

IW301-0330E08

4.5 Zero-point and span adjustments 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-point adjustment button.

Raise 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 value within the zero-point adjustment range shown in the Table 2 ?

Yes IW301-0330E09

Completed

Table 2 Crane model

Zero-point adjustment range Boom length detector

Boom angle detector

ZR363

3.18 - 3.38

0.8 - 1.2

ZR364

3.25 - 3.45

0.8 - 1.2

ZR365

3.43 - 3.63

0.8 - 1.2

ZR366

3.55 - 3.75

0.8 - 1.2

8

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 4.6 Confirming accuracy Swing the boom to over-right and make sure that the over-front area state indicator lamp is not lit.

Then confirm data accuracy according to the flowchart below.

START Shift the rotary switch to the "0" position.

Lift up the specified load, lower the boom to the specified boom angle, and telescope the boom to make the load radius within R1.

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

(Set the boom angle to the specified angle ± 1°.)

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

Extend the boom until the boom stops.

Is the load radius between R1 and R2 in the table 1 when stops?

Yes

NO To adjustment "4.4" (length detctor)

Completed

IW301-0330E10

0 368-053-60200 △ 0 368-058-60200 △

9

W301-0340E

H-1

H-1

Overload Prevention Device (AML) 5. List of error Nos. related to AML No.

Description

E14 E15

Improper setting of model selection dip switch

Cause

Measures

Boom length value or boom angle value left unadjusted

Adjust.

Improper setting of dip switch

Set property.

Improper setting of dip switch

Set property.

Maladjusted boom length value

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

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

Faulty pressure detector on the cylinder side or the rod side

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

Faulty AML main body

Replace the AML main body if check result is normal.

Faulty AML main body

Replace the AML 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±250 Ω 1-3 of CN3: 300±50 Ω] If a measured value is out of the standard range, replace the boom length detector.

Faulty AML main body

Replace the AML main body if check result is normal.

E16 E17 E18

E20

E21

Improper setting of function selection dip switch

Abnormal load display

Faulty CPU

E29 E22

Faulty hardware

E23

E24

Faulty length detector

10

W301-0340E

H-1.

H-1.

Overload Prevention Device (AML)

No.

E25

E26 E27

Description

Cause

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 detector

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

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

Faulty AML main body

Replace the AML main body.

Defective cable

Check if there is broken wire or short circuit between the AML 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 AML main body

Replace the AML main body if check result is normal.

Error caused by broken wiring of the serial circuit or noise

Check the cable between the AML 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)

E65

Broken wiring for receiving serial data

E66

Faulty serial data received

–––

” – – – ” is displayed

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

Executed adjustment item

• ”4.4 Zero-point and span adjustments of length detector” • ”4.6 Confirming accuracy” • ”4.5 Zero-point and span adjustments of angle detector” • ”4.6 Confirming accuracy” • Nothing • ”4.3 Selecting the crane model and capacity data”

AML main body

• ”4.4 Zero-point and span adjustments of length detector” • ”4.5 Zero-point and span adjustments of angle detector” • ”4.6 Confirming accuracy”

11

W301-0340E

H-2.

H-2.

Length Detector (Boom) H-2

Length Detector (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 Connection diagram Potentiometer

Cable 0.5B (black) 0.5R (red)

R

0.5W (white)

W

B

1

Shield

(Length detector portion)

Connector 2

15 16

3 4

IW305-0172E01

1

7 2 3

4

12 9

19

6 10

20

Water cutout hole

8

5

18

11

Yellow tape

GND(B)

Air vent

Power supply(R)

Water cutout hole

Shield(G)

Output(W)

14 13 17 IW305-0172E02

1. Base plate 2. Case 3. Drum assembly 4. Slip ring assembly 5. Contactor assembly

6. Case 7. Packing 8. O-ring 9. Bracket 10. Potentiometer

11. Cord clamp 12. Gear 13. Terminal 14. Sleeve 15. Terminal

16. Sleeve 17. Cord guide 18. Cord assembly 19. Cord lock 20. Stopper

2. Specifications Speed reducer

Reduction ratio: 3/10

Potentiometer

Resistance: 5000 ± 250Ω Mechanical turning angle: 3600° (10 turns type)

0 361-317-40000 △ 0 361-317-50000 △

12

W305-0172E

H-3.

H-3.

Angle Detector (Boom) H-3

Angle Detector (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 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 2. Cover 3. Potentiometer

4. Weight 5. Arm 6. Terminal

7. O-ring 8. Oil 9. -

10. 11. 12. Connector

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

0 361-404-70000 △

13

W305-0181E

V Radio Control System

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

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

2.

Safety functions of radio-control system .... 3 2.1 2.2 2.3 2.4

Automatic power off function ...................... 3 Fail-safe function ........................................ 3 Receiving condition alarm .......................... 3 Alarm function............................................. 4

V-2 Radio-control Valve ......................... 6 1.

Structure .................................................... 6 1.1 1.2 1.3 1.4

Hydraulic circuit .......................................... 6 Electric circuit ............................................. 7 General View .............................................. 8 Cross section.............................................. 9

V-3 Measures for Emergency Case..... 11 1.

When radio-control mode operation is not available ....................................... 11

2.

When neither radio nor manual control mode operations are available ............... 13

3.

Troubleshooting guide ............................. 14

V

i

V-1

V- 1

Configurations of Radio-control System V-1

Configurations of Radio-control System

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

1. Structure

1

WV02-0050E

V-1

V- 1

Configurations of Radio-control System

1. Antenna 2. Inching mode lamp 3. Inching mode switch 4. Hook-IN switch 5. Horn switch 6. Power lamp 7. Power switch

8. Boom telescoping switch 9. Hoisting switch 10. Boom elevation switch 11. Swing switch 12. Strap 13. Battery lid 14. Battery lid lock screw

2

15. Grip 16. Speed control lever 17. Remote control connector 18. Mode display lamp 19. Receiving lamp 20. Antenna cable (1) 21. Antenna cable (2)

WV02-0050E

V-1.

V-1.

Configurations of Radio-control System 2. Safety functions of radio-control system 2.1 Automatic power off function If none of the control switches is operated for approximately 10 minutes, the power supply of the transmitter is automatically turned off to prevent the batteries from running down.

To resume operation, press the power switch again; the power indicator lamp lights up, indicating that the control system is ready for operation.

2.2 Fail-safe function If any of the control switches remains in an activating position for approx. five minutes due to a failure of the switch or dust deposits blocking its movement, the power supply of the transmitter will be automatically turned off to prevent potential hazard. To resume operation, press the power switch again. When the power lamp lights up, the crane is ready for operation.

2.3 Receiving condition alarm If the receiving condition of the wave from the transmitter becomes poor during radio control due to changed circumstance, beeping alarm is output from the speaker.

The frequency of beeping indicates as follows: (1) One or two time(s) The receiving condition of the wave is poor. The crane can be operated as usual.

(2) Three times Crane operation is halted.

Both cases warn of poor receiving condition. Reduce the distance between the transmitter and receiver to improve condition.

3

WV02-0050E

V-1.

V-1.

Configurations of Radio-control System 2.4 Alarm function The following alarm may be given during operation to indicate that an error exists in the system, wrong operation is being performed, or attention should be paid. If the alarm is given, take suitable measures referring to the tables below.

(1) Automatic stop due to failure of radio control system Alarm

Beep. (3 times repeated)

Cause

Computer diagnoses that a serious error has occurred in the system.

Crane

Radio-control operation and manual operation become unavailable.

Measure

Refer to the "Measures for Emergency Case" section.

(2) Stop due to overwinding Alarm

Beep. (1 time)

Crane

1. Hook block is overwound.

2. Boom extension, boom raising or hoist-up operation is attempted while the hook block is overwound.

Boom extension, boom raising and hoist-up operation become unavailable.

Measure

Retract the boom or hoist down the hook block to terminate the overwound condition.

Cause

(3) Unsetting of outriggers ・ Before setting the outriggers Alarm

Beep. (1 time)

Cause

Any operation other than jacking is attempted while the outriggers are unset.

Crane

Both radio-control operation and manual operation become unavailable.

Measure

Set the right and left outriggers.

・ After setting the outriggers Alarm Cause Measure

Beep. (1 time) Beep ... (repeated) Either or both outriggers leave the ground, or any operation other than jacking is attempted while they are off the ground.

Set the right and left outriggers.

(4) Boom angle restricted area Alarm Cause Measure

Beep. (1 time) Boom extension, boom lowering, hoist-up or swing operation is attempted while the boom is at the fully raised or lowered position.

Raise or lower the boom to terminate the restricted condition.

(5) Overload limit alarm Alarm

Beep. (1 time)

Beep ... (repeated)

Cause

The crane is in an overloaded condition.

Measure

Retract or raise the boom to terminate the overloaded condition.

4

WV02-0050E

V-1.

V-1.

Configurations of Radio-control System (6) Upon setting of a working height limit Alarm

Ding-dong. (1 time)

Cause

A working height limit is set.

(7) Upon cancellation of the working height limit Alarm

Ding-dong. (1 time)

Cause

The working height limit is canceled.

(8) Stop at the working height limit Alarm

Beep. (1 time)

Crane

The boom height reaches the limit value.

Boom extension or boom raising operation is attempted while the boom height is at the limit.

Boom extension and boom raising operation cannot be performed.

Measure

Retract or lower the boom to terminate the working height limited condition.

Cause

(9) Control lever out of neutral position ・ Immediately after the PTO is connected Alarm

Beep. (3 times repeated)

Cause

A control lever is out of the neutral position.

The operation on the defective location by radio-control and manual operation become unavailable.

Refer to the "Measures for Emergency Case" section.

Crane Measure

・ During radio-control or remote-control operation after the PTO is connected Alarm

Crane

Beep. (3 times repeated) A control lever does not return to the neutral position even though the corresponding control switch on the transmitter is returned to the neutral position.

Radio-control operation and manual operation become unavailable.

Measure

Refer to the "Measures for Emergency Case" section.

Cause

(10) Weak batteries (radio control) Alarm

Ding-dong. (1 time)

Cause

A control switch on the transmitter is operated while the battery voltage for the transmitter is low.

Measure

Replace the batteries.

(11) Hook block stowing operation Alarm

Ding-dong. (1 time)

Cause

Hook-in switch is pressed.

(12) Hook block take-out operation Alarm

Ding-dong. (1 time)

Cause

Hook-out operation is performed.

(13) Error in the AML-related system Alarm

Beep. (3 times)

Cause

An error exists in the AML-related system.

Measure

Refer to the "Measures for Emergency Case" section.

5

WV02-0050E

V-2

V- 2

Radio-control Valve V-2

Radio-control Valve

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

1. Structure 1.1 Hydraulic circuit

6

W135-0021E

V-2

V- 2

Radio-control Valve 1.2 Electric circuit

7

W135-0021E

V-2

V- 2

Radio-control Valve 1.3 General View

Thread size and tightening torque Sign / Port

Thread size

–

Tightening torque N-m

ft-lbf

G1/4

26.4 - 32.4

19.5 - 23.9

A, B port

G3/8

44.0 - 54.0

32.5 - 39.8

P, T port

G1/2

88.1 - 108.1

65.0 - 79.7

8

W135-0021E

V-2

V- 2

Radio-control Valve 1.4 Cross section Section (Telescoping, Winch, Elevating, Swing)

Section (Jack)

9

W135-0021E

V-2.

V-2.

Radio-control Valve

0 366-488-30000 △

10

W135-0021E

V-3

V- 3

Measures for Emergency Case V-3

Measures for Emergency Case

1. When radio-control mode operation is not available WARNING In some trouble circumferences, even shifted manual operation cannot bring about normal operation.

See the failure codes on the mode display lamp and take measures which comply with the failure codes.

Radio-controlled operation is electrically performed by means of radio-control system. If some trouble occurs, a part or all of the radio-control becomes inoperable.

When radio-controlled operation is conceived defective, see the mode display lamp. If it shows one of the below mentioned figures, the radio-control system itself has some troubles: (1) Showing other than "01" or "02" figures with the transmitter power supply ON. (2) Showing other than "00" figures with the transmitter power supply OFF. When the mode display lamp shows other failure codes than "00", "01" and "02", take proper measures in accordance with the table in the following pages. ◆When two or more failure codes are registered, the display repeatedly displays these codes in sequence.

11

W307-0120E

V-3

V- 3

Measures for Emergency Case

Failure code 11

12 86 87 13

14-29

30-33

Trouble and remedy In case of hook-in specifications, hook-in operation by means of the hook-in switch cannot be performed either on radio-control or manually.

To stow the hook block, hoist up the hook block manually, pressing the anti-twoblock disable switch.

[NOTICE] ◆Usually the hook block is stowed by low pressure to prevent damage on the crane. In this event, however, the hook block will be stowed by high pressure. The hook block, hoisted up too far, will give damage to the crane. Operate the hook block in the inching mode for stowing.

Radio control is not available. Manually operate the crane.

Release all the control switches and the speed control lever of the transmitter, and turn on the power supply of the transmitter again.

If the indication still persists, the radio controller cannot be used for controlling the crane.

Control the crane manually by using the levers.

The AML is faulty. The overload limiting and working height limiting functions will not work.

[NOTICE] ◆Failure code "20" may be displayed during boom lowering operation. In this case, stop operation and recheck that the failure code is displayed. If the failure code goes off, it is not a problem.

Return the control lever corresponding to the failure code manually to the neutral position and see whether the failure code goes off.

If the mode display lamp shows one of "00" or "03", and the failure code does not appear again, when operation is performed, you can resume crane operation.

If the control lever does not return to the neutral position or if the failure code does not disappear, radio control of the troubled component cannot be operated.

WARNING While one control lever does not return to the neutral position, do not operate other control levers. Otherwise the defective component can move simultaneously.

“30”: Telescoping “31”: Hoisting “32”: Elevation “33”: Swing 34

The automatic accelerator control is impossible in both the radio and manual control modes.

If the engine is stuck at the maximum speed, stow the crane carefully.

40-49

The operation for which the failure code has been displayed is impossible in both the radio and manual control modes.

WARNING While one control lever does not return to the neutral position, do not operate other control levers. Otherwise the defective component can move simultaneously.

"40", "45": Telescoping "41", "46": Hoisting "42", "47": Elevation "43", "48": Swing "44", "49": Acceleration

12

W307-0120E

V-3

V- 3

Measures for Emergency Case Failure code

Trouble and remedy

36,37, 50-59

The operation for which the failure code has been displayed is not available in the radio-control mode.

Manual operation is available.

“50” “55”: Extension “51” “56”: Hoisting “52” “57”: Elevation “53” “58”: Swing “54” “59”: Accelerating

60-63

Return the control lever corresponding to the failure code manually to the neutral position and see whether the failure code goes off.

If the mode display lamp shows the normal figure, and the failure code does not appear again when operation is performed, crane can be operated continuously.

In case control levers do not move or failure codes do not disappear, neither radio-controlled operation nor manual operation is operable. Follow the following section "When neither radio nor manual control mode operations are available", and stow the crane.

“60”: Telescoping operation “61”: Hoisting operation “62”: Elevation operation “63”: Swing operation The cable between the AML and control unit is faulty. The overload limiting and working height limiting functions will not work.

The cable between the antenna and control unit is faulty. Radio control is not available.

Manually operate the crane.

Neither radio-controlled operation nor manual operation is operable.

Follow the following section "When neither radio nor manual control mode operations are available", and stow the crane.

65,66, 75,76 77,78 70-74, 80-85, 88

2. When neither radio nor manual control mode operations are available WARNING The procedure described in this section is used to stow the crane in an emergency.

Do not perform this procedure during normal crane operation.

1. Manually shift the unloading solenoid valve for the radio control to enable the crane to be stowed.

(1) Remove the cap nut.

(2) Loosen the lock nut, and tighten the inner nut lightly until it does not turn. ◆Excessively tightening the inner nut causes malfunction.

2. Stow the crane. ◆If shifting the unloading solenoid valve for the radio control fails to make the manual stowing of the crane possible, shift the unloading solenoid valve for the outrigger slide and re-try.

13

W307-0120E

V-3

V- 3

Measures for Emergency Case 3. Troubleshooting guide First check the following when a problem occurs during the radio-control operation.

Trouble Power indicator lamp does not steadily light.

Power indicator lamp continues to flash.

Power supply is interrupted while any operation is not performed.

Power supply is interrupted during switch operation.

Engine speed does not increase.

Batteries run down quickly.

Beeping sound is output from the speaker and the crane stops.

Possible causes • No batteries in position.

• Batteries installed incorrectly.

• Low battery voltage.

• Power switch turned on with any control switches activated.

• Power switch turned on with the speed control lever pulled.

• Low battery voltage.

Remedy • Install batteries in the transmitter.

• Reinstall batteries correctly.

• Replace the batteries with new ones.

• Release all control switches, and then turn on the power supply.

• Release the speed control lever, and then turn on the power supply.

• Replace the batteries with new one.

• After the radio controller is not • Press the power switch again. used for 10 minutes or longer, the automatic power off function cuts off the power supply.

• If any control switch is kept • Press the power switch again. pressed for 5 minutes or longer, the fail-safe function will automatically cuts off the power supply.

• Inching mode selected.

• Cancel the mode.

• In a very cold area, the battery life tends to be shortened.

• Receiver antenna connected incorrectly.

• Receiver antenna or cable bent or damaged.

• Transmitter antenna set incorrectly.

• Crane is used in conditions described in the subsequent pages.

14

• Replace the batteries with new ones.

• Reconnect the antenna correctly.

• Repair the defective antenna and/or cable.

• Set the antenna correctly.

• See subsequent pages.

W307-0120E

V-3

V- 3

Measures for Emergency Case In the cases listed below, a poor radio transmission could cause unintended stops of the crane operation. Take proper steps, depending on the cases encountered. !If the remedy described below does not improve the situation, perform manual operation or use the remote-control system (option).

Causes

Remedy

The transmitter operated too far from the receiver.

• A too long distance between the transmitter and receiver results in not only poor radio signal reception but also ready disturbance by noise.

Ordinarily operate the radio-control system within the working radius range.

Operated near the source of noise.

• Electric apparatus generating noise, such as turning light, electric fan, air conditioner on vehicle, etc., affect this control.

If possible switch off such noise generating devices.

Motorcycles also generate noise.

Another TADANO radio-controlled crane is used in the same place.

• Change frequencies.

The transmitter is used in an environment where the radio or TV programs are impaired by noise.

• Change frequencies.

• Reduce the distance between the transmitter and receiver and face the antennas toward each other.

When the crane is lifting a large metallic object.

• A metallic object placed between the transmitter and receiver will block or disturb the radio transmission.

Move the transmitter to a location where the receiver is directly visible.

15

W307-0120E

V-3.

V-3.

Measures for Emergency Case Causes

Remedy

An obstacle like a metal netting or metal fence exists between the transmitter and receiver.

• A metal net or metal fence will block or disturb The radio transmission.

Reduce the distance between the transmitter and receiver to 5 meters or less.

• Position a portable antenna (option) on the obstacle or some other thing where operators can see, and then operate the crane.

The transmitter is in use in a manhole or cave.

• Position a portable antenna (option) near operating position. Place it on an iron plate.

16

W307-0120E

Y Data, Adjustment and Checks

Contents Y-1 Service Data ..................................... 1 1.

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

2.

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

Y-2 Adjustment (Hydraulic) ................... 2 1.

Adjusting relief valve pressure................... 2 1.1

Main relief valve ......................................... 2

Y-3 Adjustment (Electric)....................... 3 1.

Adjustment of outrigger part detecting switch ............................................. 3 1.1 1.2

2.

Checking outrigger extension state and installing state detecting switches ........ 3 Adjustment of outrigger extension state and installing state detecting switches ........ 3

Adjustment of right and left zone detecting ranges ............................................ 5

Y i

Y- 1 .

Y-1.

Service Data Y-1

Service Data

1. Set pressure Item

Set pressure

Flow rate

MPa

psi

Main relief valve

19.6 - 20.1

2843 - 2914

at 60 L/min (16 gal/min)

Low-pressure relief valve

2.94 - 4.9

426 - 710

at 20 L/min (5 gal/min)

Back pressure valve

1.57 - 1.97

228 - 286

at 5 L/min (1.3 gal/min)

Reducing valve

1.37 - 1.57

199 - 228

at 5 L/min (1.3 gal/min) Pilot at 0.4 L/min (0.1 gal/min)

For the measuring points and measuring methods, refer to Y-2 “Adjustment (Hydraulic).”

2. Hydraulic units 1. Swing motor Displacement: 39.3 cm3/rev (2.40 in3/rev) 2. Winch motor Displacement: 24.0 cm3/rev (1.46 in3/rev) 3. Swing speed reducer Reduction ratio: 42 : 1 4. Winch speed reducer Reduction ratio: 3.3 : 1

1

WY01-1380E

Y- 2 .

Y-2.

Adjustment (Hydraulic) Y-2

Adjustment (Hydraulic)

[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. Adjusting relief valve pressure 1.1 Main relief valve [NOTICE] Hydraulic oil temperature: 45 to 55°C (113 to 131°F)

Part

Main relief valve

Set pressure

Flow rate

MPa

psi

19.6 - 20.1

2843 - 2914

at 60 L/min (16 gal/min)

Connect a pressure gauge to the pressure outlet port (PG) of the control valve.

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

• Control valve (SANWA)

• Control valve (NACHI)

2

WY02-0750E

Y- 3

Y- 3

Adjustment (Electric) Y-3

1.2 Adjustment of outrigger extension state and installing state detecting switches

Adjustment (Electric)

[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.

A. Outrigger extension state detecting switch 1. Measure a dimension when dimension C on the figure on the next page is minimized by lateral looseness between the outrigger outer case and inner case.

2. Protrusion of the switch (dimension D) should be

1. Adjustment of outrigger part detecting switch

the "minimum value of the dimension C -2.5 mm (0.1 in)."

3. Check whether the detecting state has become

1.1 Checking outrigger extension state and installing state detecting switches

normal.

B. Outrigger installing state detecting switch

Check the following, and if not properly detected, make an adjustment according to “1.2 Adjustment of outrigger extension state and installing state detecting switches.”

1. Fully extend the outrigger and install.

2. Adjust the clearance between the bottom of the outrigger inner case and the roller with a shim to be 1.0 to 1.5 mm (0.04 to 0.06 in).

(Adjust the clearance to 0.3 to 1.0 mm (0.01 to 0.04 in) in general.)

A. Outrigger extension state detecting switch 1. Check that false detection is not made even if the outrigger inner case is swung to the right and left both at maximum extension and minimum extension states.

Outrigger extension state

Check lamp

Maximum extension

Light up

Minimum extension

Light off

3. Retract the outrigger.

4. Extend the outrigger by 100 mm (4 in). However, do not install.

5. Place a plate [a] with a thickness of 2.5 mm (0.1 in) at the bottom of the outrigger inner case bottom face.

B. Outrigger installing state detecting switch

6. Fix the switch by slightly contacting to the plate

1. Check both at maximum extension and minimum extension states.

Outrigger installing state

[a].

7. Draw out [a].

Check lamp

Installing

Light up

Not yet installed

Light off

8. Check whether the detecting state has become normal.

[NOTICE]

2. Check that the not yet installed warning does not sound in the operating state of Table 1. In addition, check boom direction both on right and left sides.

If the check lamp does not light up even in the installed state, return to step 2 to re-adjust. If the check lamp does not turn off in the not yet installed state, return to step 5 to re-adjust. Even if normal detection is not made even by the above adjustment, change the plate [a] to that of a thickness of 2.3 mm (0.09 in) to re-adjust.

3

WY04-1070E

Y- 3

Y- 3

Adjustment (Electric)

Table 1 Crane model ZR363 ZR364 ZR365 ZR366

(*1)

Outrigger extension state

A

Max.

D

Max.

When checking not yet installed accuracy Boom Lifting load (t) Load radius (m) telescoping Max. 0.5 7.50 Max. 1.0 5.50

A

Max.

3-section

0.5

7.48

D

Max.

3-section

1.0

5.25

Capacity type

A

Max.

3-section

0.5

7.21

D

Max.

3-section

1.0

5.08

A

Max.

3-section

0.5

7.00

D

Max.

3-section

1.0

5.08

(*1): For the current capacity type, see the rated lifting capacity chart.

3 313-607-44010 △

4

WY04-1070E

Y- 3 .

Y-3.

Adjustment (Electric) 2. Adjustment of right and left zone detecting ranges • When the dimension A is smaller than the reference value, move the swing right side switch in direction D. • When the dimension B is larger than the reference value, move the swing left side switch in direction E. • When the dimension B is smaller than the reference value, move the swing left side switch in direction F. (When the swing switch is moved by 4 mm (0.16 in), the difference between the dimensions A and B is reduced by approximately 60 mm (2.4 in). However, the dimension A changes only, and the dimension B does not change.)

1. Fully retract the boom to measure the dimensions A and B in the figure below.

(A detecting point should be a point where the proximity switch shifts from ON (check lamp lights up) to OFF.) Dimension A, B

Standard specification Reference value

Allowable value

215 mm (8.5 in)

160 to 270 mm (6.3 to10.6 in)

2. When the dimensions A and B are not within the allowable value, or when the difference between the dimensions A and B is 90 mm (3.5 in) or larger, make adjustment as follows.

• When the dimension A is larger than the reference value, move the swing right side switch in direction C.

3. Re-check whether the dimensions A and B are in the allowable range after adjustment.

2 313-607-43010 △

5

WY04-1070E

Z System Diagrams

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

Z-2 Electric Circuit.................................. 2 1.

Applicable serial No.: -- EP9035 ................ 2

2.

Applicable serial No.: EP9036-- ................. 3

Z i

Z-1.

Z-1.

Z-1.

Hydraulic Circuit Z-1

Hydraulic Circuit

1 314-009-20200 △

1

WZ01-1980E

1

Z-2

Z-2

Z-2

Electric Circuit Z-2 Electric Circuit 1. Applicable serial No.: -- EP9035

0 368-053-50100 △

2

WZ03-3410E

2

Z-2.

Z-2.

Z-2.

Electric Circuit 2. Applicable serial No.: EP9036 --

0 368-058-40100 △

3

WZ03-3410E

3

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