Tadano Faun Cargo Crane TM-ZR560-2 Service Manual SN EM5426 - PDF DOWNLOAD

Publication No.

Service Manual

01 Cargo Crane Model

PRINTED IN JAPAN 0603

K

TM-ZR560-2/S1-1E

ｃ2006 ◯

TM-ZR560-2 Applicable Serial No.

EM5426 ～

TM-ZR560-2/S1-1E

Safety Safety [NOTICE]

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

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

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

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

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

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

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

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

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

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

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

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

1

WA01-0041E

Safety 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.

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

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

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

The following are cautions to be observed all the time.

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

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

2. Cautions in working 2.1 General

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

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

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

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

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

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

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

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

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

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

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

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

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

2

WA01-0041E

Mark

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

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

8.Watch your step in the following cases:

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

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

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

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

2.3 Remounting 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.

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

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

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

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

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

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

4.3 Motor oil See HYDRAULIC OIL above.

4

WA01-0041E

Foreword Foreword

1.1 Unit No. of the TM-ZR560 series

This manual contains information on the systems

1 Standard

and components of TM-ZR560 series cranes.

It also contains repair, inspection, and adjustment

Model

procedures for those systems and components.

Boom nameplate Frame nameplate Unit No. Unit No.

ZR564S (TM-56Z-2-003) ZR565S (TM-56Z-2-004) ZR566S (TM-56Z-2-005) ZR566 (TM-56Z-2-007)

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

Whenever a part need to be replaced, check the part

310-940-20030 310-940-20040

411-202-10010

411-202-20050 411-202-30010

sales unit in the parts catalog.

2 Standard + Power slide ZR565S (TM-56Z-2-024) ZR566S (TM-56Z-2-025) ZR566 (TM-56Z-2-027)

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

（1）ユニット番号

NO.

LOT

411-202-20050

411-202-10030

411-202-30030

3 Hook-in

（2）ロット番号 UNIT

310-940-20040

ZR564S(H) (TM-56Z-2-303) ZR565S(H) (TM-56Z-2-304) ZR566S(H) (TM-56Z-2-305)

NO.

IWA04-062001

310-940-20130 310-940-20140

411-202-10020

310-940-20150

4 Hook-in + Power slide ZR565S(H) (TM-56Z-2-324) ZR566S(H) (TM-56Z-2-325)

Frame nameplate (1) Unit No. (2) Serial No.

310-940-20140 411-202-10040 310-940-20150

(3) Date of Mounting

5 Radio remote controls + AML (1) ZR564S(HE) (TM-56Z-2-813)

(2)

SPEC.

NO.

411-202-10090

2. Separate Service Manual

SERIAL. NO.

MFG. DATE.

KAGAWA,JAPAN

(3)

310-940-20830

IWA04-062002

Separate Service Manual

Publication No.

General Caution

SA01-01-2E

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

1

WA04-1990E

Foreword 3. Outline of specifications Item Spec.

Spec. No.

Standard

Model

No. of boom sections

TM-56Z-2-003 TM-ZR564S

4-section

TM-56Z-2-004 TM-ZR565S

5-section

Winch

Safety devices

TM-56Z-2-005 TM-ZR566S 6-section TM-56Z-2-007 TM-ZR566 TM-56Z-2-024 TM-ZR565S

Load meter Load indicator Hook safety latch Level gauge Hydraulic safety valves, check valves and holding valves Over-winding alarm Hoisting limiter P.T.O. indicator lamp

5-section

Standard +

TM-56Z-2-025 TM-ZR566S

Power slide

TM-56Z-2-027 TM-ZR566

Hook-in

Hook-in + Power slide

6-section

TM-56Z-2-303 TM-ZR564S(H)

4-section

TM-56Z-2-304 TM-ZR565S(H)

5-section

TM-56Z-2-305 TM-ZR566S(H)

6-section

TM-56Z-2-324 TM-ZR565S(H)

5-section

TM-56Z-2-325 TM-ZR566S(H)

6-section

Hydraulic motor driven spur gear speed reduction, providid with mechanical brake

Radio remote controls +

TM-56Z-2-813 TM-ZR564S(HE)

4-section

AML

2

WA04-1990E

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 alam Hoisting limiter P.T.O. indicator lamp

Foreword 4. Conversion table Length millimeter, mm

centimeter, cm

meter, m

inch, in, ”

foot, ft, ’

mile, mi

kilometer, km

1

0.1

0.001

0.03937

0.00328

1

1.6093

10

1

0.01

0.3937

0.03281

0.6214

1

1000

100

1

39.37

3.281

–

–

25.4

2.54

0.0254

1

0.08333

–

–

304.8

30.48

0.3048

12

1

–

–

Area square millimeter, mm

2

square centimeter, cm

2

square meter, m

2

square inch, in

2

2

square foot, ft

1

0.01

0.000001

0.00155

–

100

1

0.0001

0.155

0.001076

1000000

10000

1

1550

10.764

645.2

6.452

0.000645

1

0.006944

92903

929.03

0.0929

144

1

Volume cubic centimeter, 3 cm , cc 1

cubic meter, m

cubic inch, in

cubic foot, ft

gallon, gal

cubic inch, in

liter, lit, L

0.000001

0.0610

0.0000353

1

231

3.785

1000000

1

61024

35.31

0.004329

1

0.01639

16.39

0.0000164

1

0.000579

0.2642

61.02

1

28320

0.02832

1728

1

–

–

–

gram, g

kilogram, kg

ounce, oz

pound, lb

metric ton, ton, t

short ton, s. t

1

0.001

0.03527

0.0022

–

–

1000

1

35.27

2.205

0.001

0.001102

28.349

0.02835

1

0.0625

0.00002835

0.00003125

453.592

0.4536

16

1

0.0004536

0.0005

1000000

1000

35274

2205

1

1.102

907185

907.2

32000

2000

0.9072

1

3

3

3

3

Mass

Pressure Pa

kPa

MPa

1

1X10

1X10

3

1

1X10

6

1X10

-3

1X10

3

1X10

9.80665X10 6895

4

kgf/cm

2

lb/in , psi

-6

1.01972X10

-3

1

9.80665X10

9.80665X10

6.895

0.006895

3

2 -5

14.5X10

1.01972X10

-2

14.5X10

1.01972X10

14.5X10

1

14.22

0.07031

1

-2

WA04-1990E

-5 -2

Foreword

Torque N-cm

N-m

1

1X10

kgf-cm

-2

2

1X10

9.80665X10 2

0.00737

-1

0.7376

8.851

1X10

0.0723

0.868

foot-pound, ft-lb

1.01972X10

1.01972X10 -2

9.80665 9.80665X10

-1

1.01972X10

1

-3

inch-pound, in-lb 0.0885

kgf-m

1.01972X10 -2

1 2

9.80665

1X10

1

7.233

86.8

135.58

1.3558

13.83

0.1383

1

12

11.3

0.113

1.1525

0.01153

0.08333

1

Centigrade-Fahrenheit ゜F

℃

゜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

-1

1

1.01972X10

2.24809X10

9.80665

1

2.20461

4.44822

0.45359

1

4

WA04-1990E

GROUP INDEX A B

Hydraulic Power Generating System

C

Outrigger System

D

Swing System

E

Boom Elevation System

F

Winch System

G

Boom Telescoping System

H

Safety System

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

Radio-control System

W X Y

Data, Adjustment and Checks

Z

System Diagrams 5

WA04-1990E

Foreword 5. Contents ZR560 Series Chapter

Section

Standard Hook-in Radio remote Standard + Hook-in + controls TM-56Z-2-003, Power slide TM-56Z-2-303, Power slide + 004,005,007 TM-56Z-2-024, 304,305 TM-56Z-2-324, AML 025,027 325 TM-56Z-2-813 General

A

Refer to separate service manual SA01-01-2E

General Cautions

Hydraulic Pressure Generating System

Manual Control Valve Remote Control Valve B

B-1 –

–

B-2

Radio-control Valve

–

Rotary Joint

B-3

Hydraulic Pump

B-4

Jack Cylinder

C-1

Pilot Check Valve (Jack)

C-2

Power slide Cylinder (With the spec.)

C-3

Swing System

D

Hydraulic Motor (Swing) (-EM5496)

D-1

Hydraulic Motor (Swing) (EM5497-)

D-2

Swing Speed Reducer

D-3

Swing Bearing

D-4

6

– Refer to chapter V

–

Outrigger System

C

B-2

WA04-1990E

Foreword ZR560 Series Chapter

Standard Hook-in Radio remote Standard + Hook-in + controls TM-56Z-2-003, Power slide TM-56Z-2-303, Power slide + 004,005,007 TM-56Z-2-024, 304,305 TM-56Z-2-324, AML 025,027 325 TM-56Z-2-813

Section

Boom Elevation System

Elevating Cylinder

E-1

Counterbalance Valve

E-2

E

Winch System

Standard Specifications

F-1

Hook-in Specifications

F-2

Hydraulic Motor

F-3

Winch

F-4

F

Boom Telescoping System

Boom

G

Telescoping Cylinder

4-Section

G-1

5-Section

G-2

6-Section

G-3

4-Section Boom

G-4

5-Section Boom

G-5

6-Section Boom

G-6

Counterbalance Valve

G-7

-

–

-

–

7

WA04-1990E

Foreword ZR560 Series Chapter

Section

Standard Hook-in Radio remote Standard + Hook-in + controls TM-56Z-2-003, Power slide TM-56Z-2-303, Power slide + 004,005,007 TM-56Z-2-024, 304,305 TM-56Z-2-324, AML 025,027 325 TM-56Z-2-813 Safety Devices

AML

–

H-1

Length Detector

–

H-2

Angle Detector

–

H-3

Outrigger Extension Detector

–

H-4

H

Radio-control System Configurations of Radio-control System

–

V-1

Radio-control Valve

–

V-2

Accelerator Cylinder

–

V-3

Measures for Emergency Case

–

V-4

V

Data, Adjustment and Checks

Data

Y-1

Y

System Diagrams

Hydraulic Circuit

Without power slide

Z-1

–

Z-1

–

–

With power slide

–

Z-2

–

Z-2

Z-3

Without power slide

Z-4

–

Z-5

–

–

With power slide

–

Z-6

–

Z-7

Z-8

Z Electric Circuit

8

WA04-1990E

B Hydraulic Power Generating System

Contents B-1 Manual Control Valve (Hook-in Spec) ....................... 1 1.

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

B-2 Remote Control Valve.................... 6 1.

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

B-3 Rotary Joint .................................... 9 1.

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

2.

Reassembly .......................................... 10

B-4 Hydraulic Pump ............................ 11 1.

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

2.

Dismounting and remounting ................ 12

3.

Disassembly and reassembly ................ 12 3.1

Replacement of oil seal-2 ....................... 12

3.2

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

4.

Cautions for starting the pump .............. 12

i

B

B-1

B-1

Manual Control Valve (Standard Spec. and Hook-in Spec) B-1

Manual Control Valve (Hook-in Spec)

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

1. Structure General View Pressure gauge

P

T

Pressure tapping hole

T

SOL-1

Pressure tapping hole Pressure gauge

Unload valve

Boom telescoping

A1 B1

SOL-2

Winch

A2 B2

LRV

Boom elevation

A3 B3

Swing

A4 B4

Jack 2

A5 B5

Jack 1

A6 B6

SOL-1

P

Unload valve

A1

B1

SOL-2

Boom telescoping

A2

B2

LRV

Winch

A3

B3

Boom elevation

A4

B4

Swing

A5

B5

Jack 2

A6

B6

Jack 1

T = 21.6 - 23.5 N-m (15.9 - 17.3 ft-lbf)

Hydraulic circuit

IW113-003001E

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

A-B port

G 3/8

44.3 - 53.9

33 - 40

P port

G 1/2

53.9 - 63.7

40 - 47

T port

G 1/2

53.9 - 63.7

40 - 47

Pressure gauge

G 1/4

24.5 - 29.4

18 - 22

1

W113-0031E

B-1

B-1

Manual Control Valve (Standard Spec. and Hook-in Spec)

Cross section

Unloading valve

A

A

Hook stowing

Boom elevation

Winch

Boom telescoping

Swing

Jack 2

Jack 1

SOL-1

P T

A-A

2

IW113-0370E02

W113-0031E

B-1

B-1

Manual Control Valve (Standard Spec. and Hook-in Spec)

Unloading valve

Tightening toque 1.08 N-m (0.8 ft-lbf)

SOL-1

Tightening toque 2.94 - 3.54 N-m (2.2 - 2.6 ft-lbf) (Loctite 242)

Tightening toque 14.7 - 19.6 N-m (10.8 - 14.5 ft-lbf)

Burrs

Install the snap ring in the direction shown in the figure so that it should not be coming off the place.

IW113-029002

3

W113-0031E

B-1

B-1

Manual Control Valve (Standard Spec. and Hook-in Spec) Boom telescoping

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

A1

B1

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

Tightening toque 18 - 20 N-m (13.3 - 14.8 ft-lbs) (Loctite 242) IW113-003103E

Winch

A2

B2

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

LRV

IW113-003104E

Boom elevation

A3

B3

IW113-003006

4

W113-0031E

B-1 .

B-1 .

Manual Control Valve (Standard Spec. and Hook-in Spec)

Swing

A4

B4

IW113-003007

Jack 2

A5

B5

IW113-003008

Jack 1

A6

B6

IW113-003009

5

W113-0031E

B-2

B-2

Remote Control Valve B-2

Remote Control Valve

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

1. Structure General View

Back pressure regulating solenoid valve SV4 2

Front cover Power slide (left) Power slide (left) SL winch (option)

Main relief valve Back pressure regulating solenoid valve

SV4

Back pressure regulating solenoid valve Stop valve

Main relief valve T A ↓

↓A ← P

A－A

6

W135-0050E

IW135-005002E

B-2

B-2

Remote Control Valve

Front cover

For reducing valve

Solenoid valve (SA/SB) (Supply side)

Relief valve

Filter Relief valve (For overload)

Solenoid valve (SB) (Supply side)

Solenoid valve (SA/SB) (Return side)

Reducing valve

Main relief valve Back pressure regulating valve

Relief valve (For overload)

From relief valve (For overload)

7

W135-0050E

Solenoid valve (SA) (Supply side)

IW135-005003E

B-2 .

B-2 .

Remote Control Valve Power slide (right) Solenoid valve SB8

A8

SA8

B8

IW135-005004E

Power slide (left), winch Solenoid valve SB7

A7

SA7

B7

IW135-005005 E 0 366-376-60000 △

8

W135-0050E

B-3

B-3

Rotary Joint B-3

Rotary Joint

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

1. Structure General View

9

W181-0200E

B-3 .

B-3 .

Rotary Joint 1. Body

6. Bolt

11. Connector

16. Bolt

2. Core

7. Spring washer

12. Plate

17. Cap

3. Packing

8. Bolt

13. Connector

4. Ring seal

9. Plain washer

14. Plate

5. Slip ring assembly

10. Spring washer

15. Support

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

Thread size and tightening torque

Sign / Port

The Union part of the pipe

Thread size

Tightening torque N-m

ft-lbf

R 1/8

8.8 - 11.8

6.5 - 8.7

G 1/4

24.5 - 29.4

18.1 - 21.7

G 3/8

44.1 - 53.9

32.5 - 39.8

1 316-313-20000 △

10

W181-0200E

B-4

B-4

Hydraulic Pump B-4

Hydraulic Pump

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

1. Structure

1.Retaining ring

5.Body

9.Front cover

13.Backup strip

2.Oil seal

6.Spring washer

10.Bush

14.Rear cover

3.Gasket

7.Hexagon socket head bolt

11.Driven gear

4.Side plate

8.Drive gear

12.Gasket

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

Suction port

G1

107.9±10.8

79.6±8.0

Delivery port

G1/2

32.4±2.9

23.9±2.1

11

W101-0190E

B-4 .

B-4 .

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

2. Dismounting and remounting [NOTE]

1. Front cover side

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

Unscrew bolts-7 and remove front cover-9.

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

3. Disassembly and reassembly

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

CAUTION

disassembly.

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

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

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

4. Cautions for starting the pump

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

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

3.1 Replacement of oil seal-2

direction, the suction and delivery sides are

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

reversed,possibly resulting in the protrusion of the oil seal and other damage to the pump.

2. Remove retaining ring-1 from front cover-9; 2. Before starting the pump, fill the suction line with

remove oil seal-2.

hydraulic oil. First inch the pump, and then run it 3. Install new oil seal-2, and install retaining ring-1.

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

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

the pump at high speeds and/or under heavy load

the lips of oil seal-2.

from the beginning.

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

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

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

leakage, vibration, excentricity of the shaft,

front cover-9, and tighten bolts-7.

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

1 366-522-90000 △

12

W101-0190E

C Outrigger System

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

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

2.

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

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

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

C-3 Power Slide Cylinder ....................... 3 1.

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

i

C

C-1 .

C-1 .

Jack Cylinder C-1

Jack Cylinder

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

1. Structure General View

1. Cylinder

4. Plain bearing (＊)

7. Packing

2. Piston

5. Rod cover

8. Backup ring

3. O-ring

6. O-ring

9. Dust seal

10. Rod

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

2. Check Valve Mounting Bolt Check Valve

0 360-347-80000 △

1

W151-0210E

C-2 .

C-2 .

Pilot Check Valve (Jack) C-2

Pilot Check Valve (Jack)

[NOTE] There is a case that the appearance and so on differ from the parts for this 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. Plug

3. Spring

5. Piston

2. O-ring

4. Poppet

6. O-ring

7. Body

Thread size and tightening torque Sign / Port

Thread size

Tightening torque N-m

ft-lbf

A-B port

G 1/4

24.5 - 29.4

18.1 - 21.7

Plug-1

G 3/8

44.1 - 53.9

32.5 - 39.8

Mounting bolt

M 10

43 - 49

31.7 - 36.1 1 366-239-30000 △

2

W115-0351E

C-3 .

C-3 .

Power Slide Cylinder C-3

Power Slide Cylinder

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

1. Structure General View

1. Dust seal

4. Packing

7. Rod

10. Nut

2. Rod cover

5. O-ring

8. Piston

11. Plug

3. Backup ring

6. Cylinder

9. Seal ring

0 360-430-20000 △

3

W153-0030E

D Swing System D

Contents D-1 Hydraulic Motor (Swing): - EM5496 ................................. 1 1.

D-4 Swing Bearing ..................................8 1.

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

2.

Notes for Installation ................................. 9

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

2.

Disassembly and Reassembly .................. 2

3.

Operation Test .......................................... 2

D-2 Hydraulic Motor (Swing) : EM5497-.................................... 3 1.

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

2.

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

3.

Reassembly.............................................. 4

4.

Operation Test .......................................... 4

D-3 Swing Speed Reducer ..................... 5 1.

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

2.

Dismounting And Remounting .................. 6

3.

Disassembly ............................................. 6

i

D-1

D-1

Hydraulic Motor (Swing) D-1

Hydraulic Motor (Swing): - EM5496

1. Structure Pilot port

71 65 67 48 46

Drain port

33 12 21

5

14 22 47 45

8

13 32 11 43 23

61

70

60

66

72

2

50

42

9

31

4

7

6

49

34

10

41

1

44

3

IW102-015001E

Drain

Pliot

A

B Lock Pin (Spool 60)

Hydraulic symbol IW102-015002E

1. Front case

11. Oil seal coolar

34. Back-up ring

50. O-ring

2. Rear case

12. Spring retainer

41. Bearing

60. Spool

3. Shaft

13. Shim plate

42. Bearing

61. Cover

4. Piston

14. Spring collar

43. C-type stop collar

65. Piston ring

5. Cylinder block

21. Spring

44. C-type stop collar

66. Piston ring

6. Torque plate

22. C-type stop collar

45. Socket head bolt

67. O-ring

7. Piston retainer

23. Parallel key

46. Washer

70. Spring

8. Plate

31. Piston ring

47. Washer

71. Socket head bolt

9. Piston ring retainer

32. Oil seal

48. Socket head bolt

72. Hexagon socket

10. Piston shoe

33. R-type stop collar

49. O-ring

plug

1

W102-0290E

D-1 .

D-1 .

Hydraulic Motor (Swing) Thread size and tightening torque Sign / Port

Tightening torque

Thread size

N･m

ft･lbf

A

G3/8

39.2 – 49.0

28.9 – 36.1

B

G3/8

39.2 – 49.0

28.9 – 36.1

Pilot and Drain

G1/4

19.6 – 29.4

14.5 – 21.7

Hydraulic motor mounting bolt

M12×35

68.6 – 82.4

50.6 – 60.8

[NOTICE] When dismounting and remounting the motor ass'y, always keep it in its horizontal position.

After remounting, fill the motor housing with hydraulic oil through the drain port.

2. Disassembly and Reassembly [NOTICE] Refer to the separate REPAIR MANUAL, GENERAL CAUTIONS ("Hydraulic units" and "Sealing parts" sections).

3. Operation Test 1. Run the motor at idling speed under no load for 15 to 20 minutes, and check for the following.

Excessive rise in oil temperature Unusual noise Vibration Leakage 2. If the test above reveals no fault, gradually increase the load up to the maximum operating pressure. During this process, check for the above listed four points again.

3. At the maximum pressure, run the motor for 1 to 2 minutes and check for abnormality. If there is no abnormality, reduce the pressure to the normal level.

3 366-623-80000 △

2

W102-0290E

D-2

D-2

Hydraulic Motor (Swing) D-2

Hydraulic Motor (Swing) : EM5497-

[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

16

1

19 3 5

2 15

11 20

12 13 6

7

4

8

21

9 10

14 IW102-0510E01 IW102-0510E01

Drain

Pliot

A B Lock cylinder a'ssy Hydraulic symbol IW102-015002E

1. Shaft

6. Oil seal

11. Bottom cover

16. Lock cylinder a’ssy

2. Bearing

7. Retaining ring

12. Bearing

17. ------

3. Housing

8. Thrust plate

13. Pin

18. ------

4. O-ring

9. Cylinder block

14. O-ring

19. Parallel key

5. Oil seal cover

10. Valve plate

15. Bolt

20. Plug 21. Thrust plate

3

W102-0511E

D-2 .

D-2 .

Hydraulic Motor (Swing) Thread size and tightening torque Sign / Port

Tightening torque

Thread size

N･m

ft･lbf

A

G3/8

39.2 – 49.0

28.9 – 36.1

B

G3/8

39.2 – 49.0

28.9 – 36.1

Pilot and Drain

G1/4

19.6 – 29.4

14.5 – 21.7

Hydraulic motor mounting bolt

M12×35

68.6 – 82.4

50.6 – 60.8

2. Disassembly

When dismounting and remounting the motor ass'y, always keep it in its horizontal position.

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

After remounting, fill the motor housing with hydraulic oil through the drain port.

cover (15) about 10 mm. This is necessary to prevent the shaft (1) from popping out by the force of the center spring (14-5).

4. Operation Test

2. Remove the retaining ring (7).

1. Run the motor at idling speed under no load for 15 to 20 minutes, and check for the following.

3. Insert the flat blade of a screwdriver into the slot of the oil seal cover (5) to remove the oil seal (6).

Excessive rise in oil temperature Unusual noise

[NOTICE]

Vibration

Do not pull out the shaft (1).

As it is difficult to engage the male spline teeth of the shaft (1) with the female ones of the cylinder block (9), reassembly will be troublesome.

Leakage 2. If the test above reveals no fault, gradually increase the load up to the maximum operating pressure. During this process, check for the above

3. Reassembly

listed four points again.

1. Make sure that the O-rings (4) and (14) are placed

3. At the maximum pressure, run the motor for 1 to 2

in position.

minutes and check for abnormality. If there is no abnormality, reduce the pressure to the normal

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

level.

Install the oil seal (6), together with the oil seal cover (5), into the housing (3).

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

4. Install the bottom cover (11) as before.

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

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

1 366-626-00000 △

4

W102-0511E

D-3

D-3

Swing Speed Reducer D-3

Swing Speed Reducer

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

1. Structure General View Hydraulic Motor (Swing)

Apply THREE BOND 1215 when shrink-fitting Fill lithium grease between the lips

(Oil supply opening)

Take care of the installing order (The seal of the upper bearing is different from the one of the lower bearing )

・ Apply THREE BOND 1104

Apply THREE BOND 1305 (Oil exhaust opening) IW511-014001E

1. Snap ring

8. Seal washer

15. Bearing

22. Pin

2. Spacer

9. Plug

16. Bolt

23. Air breather

3. Shim set

10. Spur gear

17. Key

24. Nameplate

4. Bearing

11. Sleeve

18. Worm wheel

25. Rivet

5. Worm

12. Oil seal

19. Gear case

26. Washer

6. Bearing

13. Gear case

20. Bearing

7. Oil gauge

14. Bearing

21. Nut

5

W511-0171E

D-3

D-3

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

Fill the reducer with gear oil (Mobil 632) to the middle point on the oil gauge. (To check the oil level, just place the gauge on the gauge hole) Quantity: 0.6 lit.

3. Disassembly 1. Remove plug-9 , and drain the oil.

2. Remove oil gauge-7.

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

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

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

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

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

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

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

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

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

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

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

Maintenance Standards Item Bearing damage/wear

Maintenance standards No vibration/shakiness caused by damage/wear

Backlash between worm and worm wheel

Standard value

0.11 – 0.19 mm (0.004 – 0.007 in.)

6

W511-0171E

Correction Replace Replace

D-3 .

D-3 .

Swing Speed Reducer

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

Note

7

Oil gauge M16

88.3-147

65.1-108.4

9

R 3/8

32.4-35.3

23.9-26

16

M 10

57

42

–

21

M55×2

167-216

123.2-159.3

Apply adhesive (Threebond 1305)

– The thing of the tape seal.

2 360-813-80000 △

7

W511-0171E

D-4

D-4

Swing Bearing D-4

Swing Bearing

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

1. Structure General View

1. Swing bearing

4. Bolt

7. O-ring

10. Hydraulic motor

2. Bolt

5. Spring washer

8. Hexagon socket head bolt

11. Plain washer

3. Bolt

6. Swing speed reducer

9. Spring washer

8

W512-0150E

D-4 .

D-4 .

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

Install the rotary joint so that the B3 hose (G 1/4) is positioned as shown in the figure on the previous page.

Tighten the bolts-2 to secure the rotary joint as well as the swing bearing.

To tighten the bolts-2, follow the procedures below.

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

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

Do not let oils or greased contact threaded sections of the bolts-3. Remove any oil or grease on the threaded section before installing the bolts-3, otherwise the thread-locking agent will not adhere on the threaded sections.

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

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

Apply screw locking compound (LOCTITE 262T) to the thread of bolts.

2

M20

436–485

321.6–357.7

3

M20

436–485

321.6–357.7

4

M16

171–200

126.1–147.5

–

8

M12

68.6–82.3

50.6–60.7

–

0 313-011-70000 △

9

W512-0150E

E Boom Elevation System E Contents E-1 Boom Elevating Cylinder ................ 1 1.

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

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

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

2.

Pressure detector for AML (AMA) ............. 3

i

E -1 .

E -1 .

Boom Elevating Cylinder E-1

Boom Elevating Cylinder

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

1. Structure General View

1. Grease nipple

5. O-ring

9. O-ring

13. Dust seal

2. Plain bearing

6. Cylinder

10. Rod cover

14. Retaining ring

3. Piston

7. Rod

11. Packing

15. Retaining ring

4. Plain bearing

8. Plain bearing

12. Backup ring

Sign / Port

Thread size

Tightening torque N-m

Piston-3

Rod cover-10

M109

M166

72

Before installing Piston-3, apply Loctite 638 from 1st crest to 2nd crest of thread on Rod-7. Application area is shown by ※※ marks in drawing.

506

Before installing Rod cover-10, apply Threebond 1104 to thread portion shown by ※ mark. After installation, bend edge of Cylinder-6 at notch (one place) to prevent rotation.

98

686

Note

ft-lbf

0 312-410-60000 △

1

W155-0180

E -2

E -2

Counterbalance Valve (elevating) E-2

Counterbalance Valve (elevating)

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

1. Structure General View

13. O-ring

1. Body

5. Spring

9. Plug

2. Spool

6. O-ring

10. Poppet

3. Plug

7. Plug

11. Spring

4. Backup ring

8. Plug

12. O-ring

2

W119-0322E

E -2 .

E -2 .

Counterbalance Valve (elevating) Thread size and tightening torque

Sign / Port

Tightening torque

Thread size

N-m

ft-lbf

M10

34.3 - 39.2

25.3 - 28.9

A-B port

G 3/8

44.1 - 53.9

32.5 - 39.8

Plug-3.9

G 3/8

44.1 - 53.9

32.5 - 39.8

Plug - 7

G 1/2

53.9 - 63.7

39.8 - 47

Mounting bolt

2. Pressure detector for AML (AMA)

Pressure detector

[NOTE] The adjustment of pressure detector is unnecessary.

2 366-051-80001 △

3

W119-0322E

F Winch System F Contents F-1 Explanation of Winch System (Standard Specifications) ..... １ 1.

2.

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

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

1.2

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

Principle of Operation ............................... 2 2.1

Overwinding warning device ...................... 2

F-2 Explanation of winch system (Hook-in Specifications) ......... 3

F-3 Hydraulic motor (Winch) ............... 11 1.

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

2.

Thread size and tightening torque........... 12

F-4 Winch .............................................. 13 1.

2.

Structure ................................................. 13 Principle of Operation ............................. 14 2.1

Hoisting up................................................ 14

2.2

Hoisting down ........................................... 14

i

F-1

F-1

Explanation of W inch System (Standard Specifications) F-1

1.2 Hydraulic Circuit

Explanation of W inch System (Standard Specifications)

1. The circuit pressure of the winch system is

1. General

regulated by the relief valve in the manual control valve.

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

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

1.1 Electrical Circuit 1. When the hook is hoisted up too high and touches the weight of the overwinding warning device, the buzzer will be activated. If the buzzer switch is set to the off position, the buzzer will not be activated.

Winch System [NOTE] These circuit diagrams are for the ZR300 series (standard specifications). As some portions may differ from your machine, please refer to the circuit diagrams in Chapter Z at the same time.

These circuit diagrams show the de-energized condition.

1

WF02-0040

F-1.

F-1.

Explanation of W inch System (Standard Specifications) 2. Principle of Operation 2.1 Overwinding warning device 1. When the PTO is turned on: First, the contact of the power supply relay is closed. Second, DC 24V is outputted to the No. 2 & 4 terminals of the overwinding detection relay from the No. 3 terminal of the power supply relay.

2. When the hook does not touch the weight of the overwinding warning device: As the contact of the overwinding detection switch is closed, the contact of the overwinding detection relay becomes open, which does not activate the buzzer.

3. When the hook is hoisted up too high and touches the weight of the overwinding warning device: First, the contact of the overwinding detection switch is opened.

Second, the contact of the overwinding detection relay is closed.

Third, the buzzer is activated.

2

WF02-0040

F-2

F-2

Explanation of winch system (Hook-in Specifications) F-2

Explanation of winch system (Hook-in Specifications)

3

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

4

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

5

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

6

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

7

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

8

WF02-0030

F-2

F-2

Explanation of winch system (Hook-in Specifications)

9

WF02-0030

F-2.

F-2.

Explanation of winch system (Hook-in Specifications)

10

WF02-0030

F-3

F-3

Hydraulic motor (Winch) F-3

Hydraulic motor (Winch)

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

1. Structure General View

1. Front case

8. Spherical socket pin

17. Needle bearing

25. Hexagon socket head bolt

2. Rear case

10. Collar

19. Thrust roller bearing

27. O-ring

3. Shaft

12. Spring

20. Plate

32. Piston assembly

4. Cylinder block

13. Key

21. Hexagon socket head bolt

5. Piston retainer

14. Washer

22. Bearing

7. Spherical head retainer

16. Oil seal

23. C-ring

11

W102-0300

F-3.

F-3.

Hydraulic motor (Winch)

2. Thread size and tightening torque Sign / Port

Tightening torque

Thread size

Oil entrance port

G 3/8 (PF3/8)

Drain port

Rc 1/8

Hydraulic motor mounting bolt

M8

N-m

ft-lbf

39.2±4.9

1.54±0.19

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

11.8 - 16.7

0.46 - 0.66

0 366-631-00000 △

12

W102-0300

F-4

F-4

Winch F-4

Winch

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

1. Structure General View 17 4 9

7

8 6 23 28 27

12 10 11 24

18

35, 34 13 14

A－A

B－B

15

7

26 8

25

B

2 10

5 20

A

A

B

21 19

32

33

16 31

3 1 29

IW526-013001

1. Gear case

10. Ratchet

19. Ball bearing

28. Spring washer

2. Gear case

11. Shaft

20. Oil seal

29. Plug

3. Spur gear

12. Spring

21. Retaining ring

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

4. Spur gear

13. Cap

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

31. Nameplate

5. Spur gear

14. Pin

23. O-ring

32. Pin

6. Break disk

15. Nut

24. O-ring

33. Oil gauge

7. Ratchet wheel

16. Ball bearing

25. Split pin

34. Round head screw

8. Link

17. Ball bearing

26. Key

35. Spring washer

9. Disk ass'y

18. Ball bearing

27. Bolt

Thread size and tightening torque

Sign / Port 27

Thread size M10×28

Tightening torque N-m

Ft-lbf

43.1 - 49.0

1.7 – 1.93

13

W526-0200

F-4.

F-4.

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

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

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

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

when hoi st i ng up

when hoi st i ng down

hoi st i ng up hoi st i ng down

IW526-013002

14

W526-0200

F-4.

F-4.

Winch

15

W526-0200

G Boom Telescoping System G

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

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

2.

Notes for Reassembly............................... 2

3.

3.

Boom Adjustment Procedures ................. 12 3.1

Grease Application Procedure ..................12

3.2

Top Slide Plate Installation Procedure ......12

3.3

Telescoping wire rope

3.4

Adjustment of Clearance between

adjustment procedure .........................13

Boom Adjustment Procedures................... 3 3.1

Top Slide Plate Installation Procedure........ 3

3.2

Adjustment of Clearance between

Boom Sections....................................14

Boom Sections ..................................... 3

G-4 Telescoping Cylinder (Four-Section Boom) .............16

G-2 Boom (Five-Section Boom) ............. 5

1.

1.

2.

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

2.

Notes for Reassembly............................... 6

3.

Boom Adjustment Procedures................... 7

Structure ................................................. 16 Description of Operation.......................... 19 2.1

Control of Telescoping Sequence .............19

2.2

Shock-Absorbing Mechanism of No. 2 Cylinder .....................................20

3.1

Top Slide Plate Installation Procedure........ 7

3.2

Adjustment of Clearance between

3.

Notes for Reassembly of Cylinder Assembly ....................... 21

4.

Notes for Reassembly of Telescoping Cylinder.................... 22

5.

Cautions about Telescoping Wire Rope Adjustment ................. 24

6.

Telescoping Wire Rope Adjustment Procedure .................................... 24

Boom Sections ..................................... 8

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

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

2.

Notes for Reassembly............................. 10

6.1

Wire rope adjustment with the telescoping cylinder out of the boom .....................24

i

6.2

G-7 Counterbalance Valve (Telescoping) .........................52

Wire rope adjustment with the telescoping cylinder installed in the boom............. 26

1.Structure ..........................................................52

G-5 Telescoping Cylinder (Five-Section Boom).............. 27 1.

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

2.

Description of Operation ......................... 30 2.1

Control of Telescoping Sequence............. 30

2.2

Shock-Absorbing Mechanism of No. 3 Cylinder..................................... 33

3.

Notes for Reassembly of Cylinder Assembly....................... 34

4.

Notes for Reassembly of Telescoping Cylinder ................... 36

5.

Telescoping Wire Rope Adjustment Procedure.................................... 38 5.1

Wire rope adjustment with the telescping cylinder out of the boom..................... 38

5.2

Wire rope adjustment with the telescoping cylinder installed in the boom............. 39

G-6 Telescoping Cylinder (Six-Section Boom) ............... 41 1.

Structure ................................................. 41

2.

Description of Operation ......................... 44 2.1

Control of Telescoping Sequence............. 44

2.2

Shock-Absorbing Mechanism of No. 3 Cylinder................................... 47

3.

Notes for Reassembly of Cylinder Assembly....................... 48

4.

Notes for Reassembly of Telescoping Cylinder ................... 50

ii

G -1

G -1

G -1

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

1 312-033-90100 △

1

W536-0271E

1

G -1

G -1

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

1. Base boom section

15. Slide plate

29. Shim

43. Nut

2. Second boom section

16. Cover

30. Slide plate

44. Bolt

3. Third boom section

17. Cover

31. Shim (for the fixation)

45. Nut

4. Top boom section

18. Plate

32. Shim (for the adjustment)

46. Button bolt

5. Grease nipple

19. Pin

33. Shim (for the adjustment)

47. Spring washer

6. Cap

20. Bolt

34. Slide plate

48. Set screw

7. Cover

21. Grease nipple

35. Sheave

49. Slide plate

8. Flange bolt

22. Pin

36. Pin

50. Pin

9. Flange bolt

23. Retaining ring

37. Pin

51. Roller assembly

10. Pin

24. Roller assembly

38. Roller assembly

52. Nameplate

11. Retaining ring

25. Pin

39. Hexagon socket head bolt

53. Nameplate

12. Plain bearing

26. Bolt

40. Spring washer

54. ----------------------

13. Button bolt

27. Spring washer

41. Slide plate

55. Nameplate

14. Slide plate

28. Plate

42. Set screw

56. Tapping screw

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

(see Fig. 3).

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).

2

W536-0271E

G -1

G -1

Boom (Four-Section Boom)

4. Install the wire rope 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 wire rope support.

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

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

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

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

And locks it with the nut.

If the gate retainer is a plate, use a shim to adjust demension "a" to max 2mm (0.08in.) (see Fig. 7 on next page).

2. Adjust dimension "b" (see Fig. 6 on next page) using shims-1, -2, and 3 such that the boom's degree of lateral bending and the boom's degree of lateral play comply with the following values:

3. Boom Adjustment Procedures

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

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

Boom lateral play: max.80mm (3.15in.) (see Fig. 9 on next page)

3.1 Top Slide Plate Installation Procedure Apply thread locking compound (Threebond 1305 [NOTE]

or equivalent) to the button bolts before using

Install the slide plates before assembling the boom.

them to secure the slide plate. After tightening the

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

button bolts, loosen each of them by half a turn

be installed last.

and make sure the slide plate can move longitudinally (see Fig. 5).

3

W536-0271E

G -1 .

G -1 .

Boom (Four-Section Boom)

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

10kgf (22.1 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0990E03

Fig. 9

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

Boom fullyextended

Adjustment of boom lateral bending IW536-043002E

Fig. 8

1 312-033-90100 △

4

W536-0271E

G -2

G -2

G -2

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

1 312-029-40100 △

5

W536-0440E

5

G -2

G -2

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

1. Base boom section

16. Grease nipple

31. Shim (for the fixation)

46. Button bolt

2. Second boom section

17. Cover

32. Shim (for the adjustment)

47. Spring washer

3. Third boom section

18. Plate

33. Shim (for the adjustment)

48. Cover

4. Fourth boom section

19. Pin

34. Slide plate

49. Slide plate

5. Top boom section

20. Bolt

35. Sheave

50. Pin

6. Cap

21. Grease nipple

36. Pin

51. Roller assembly

7. Cover

22. Pin

37. Pin

52. Slide plate

8. Flange bolt

23. Retaining ring

38. Pin

53. Plate

9. Flange bolt

24. Roller assembly

39. Hexagon socket head bolt

54. Spacer

10. Pin

25. Pin

40. Spring washer

55. Spacer

11. Retaining ring

26. Bolt

41. Roller assembly

56. Nameplate

12. Plain bearing

27. Spring washer

42. Set screw

57. Nameplate

13. Button bolt

28. Plate

43. Nut

58. ----------------------

14. Slide plate

29. Shim

44. Slide plate

59. Nameplate

15. Slide plate

30. Slide plate

45. Bolt

60. Tapping screw

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

(see Fig. 3).

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).

6

W536-0440E

G -2

G -2

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

4. Install the wire rope 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

3.1 Top Slide Plate Installation Procedure

loosely fit the wire rope support.

Apply thread locking compound (Threebond 1305

Tighten the bolts until the wire rope support's

or equivalent) to the button bolts before using

longitudinal play is eliminated, then lock them in

them to secure the slide plate. After tightening the

position with the nuts.

button bolts, loosen each of them by half a turn

Verify through the inspection holes that the wire

and make sure the slide plate can move

rope support is pressed firmly against the

longitudinally (see Fig.5).

stopper.

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

7

W536-0440E

G -2 .

G -2 .

Boom (Five-Section Boom) 3.2 Adjustment of Clearance between Boom Sections 1. Adjust dimension "a" (see Fig.6) to the following values: With boom fully extended: a = 2mm (0.08in.).

And locks it with the nut.

If the gate retainer is a plate, use a shim to adjust demension "a" to max 2mm (0.08in.) (see Fig.7) 2. Adjust dimension "b" (see Fig.6) using shims-1,-2, and 3 such that the boom's degree of lateral

Boom fully retracted

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

Max. 35mm (1.38 in.)

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

Boom fullyextended

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

Adjustment of boom lateral bending

(see Fig. 9)

IW536-043002E

[NOTE]

Fig. 8

Install the slide plates before assembling the boom.

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

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

10kgf (22.1 lbf)

Boom fully extended

Adjustment of boom lateral play IW536-0990E03

Fig. 9

1 312-029-40100 △

8

W536-0440E

G -3

G -3

G -3

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

1 312-029-60100 △

9

W536-0450E

9

G -3

G -3

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

25. Pin

49. Pin

73. Pin

2. Second boom section

26. Bolt

50. Retaining ring

74. Roller assembly

3. Third boom section

27. Spring washer

51. Slide plate

75. Slide plate

4. Fourth boom section

28. Plate

52. Roller assembly

76. Spacer

5. Fifth boom section

29. Shim

53. Pin

77. Slide plate

6. Top boom section

30. Slide plate

54. Plate

78. Cover assembly

7. Cover

31. Shim (for the fixation)

55. Sheave assembly

79. Nameplate

8. Flange bolt

32. Shim (for the adjustment)

56. Pin

80. Nameplate

9. Flange bolt

33. Shim (for the adjustment)

57. Spacer

81. Wire rope

10. Pin

34. Slide plate

58. Set screw

82. Nut

11. Retaining ring

35. Sheave

59. Bolt

83. Nut

12. Plain bearing

36. Pin

60. Spring washer

84. Wire rope

13. Button bolt

37. Pin

61. Bolt

85. Nut

14. Slide plate

38. Pin

62. Spring washer

86. Nut

15. Cap

39. Hexagon socket head bolt

63. Retainer

87. Wire rope

16. Grease nipple

40. Spring washer

64. Plate

88. Nut

17. Cover

41. Roller assembly

65. Slide plate

89. Support

18. Plate

42. Slide plate

66. Plate

90. Shim

19. Pin

43. Spacer

67. Sheave assembly

91. Wire rope

20. Bolt

44. Spacer

68. Pin

92. -----------

21. Grease nipple

45. Set screw

69. Spacer

93. Nameplate

22. Pin

46. Nut

70. Spacer

94. Tapping screw.

23. Retaining ring

47. Slide plate

71. Slide plate

24. Roller assembly

48. Sheave assembly

72. Plate

2. Notes for Reassembly

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

1. Apply grease to the boom inside surfaces that rub

(see Fig.2).

against slide plates.

Fig. 2

10

W536-0450E

G -3

G -3

Boom (Six-Section Boom)

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

5th boom section

Slide plate mounting bolt

IW536-040005E

Fig. 5 5. When installing the sheave assemblies at the rear end of the 5th boom section, play attention to the following instructions: Install each sheave assembly with the clinched

Fig. 3

part on the inside.

4. Apply thread locking compound (Threebond 1305 or equivalent) to the bolts provided for

Apply thread locking compound(Threebond 1305

mounting of the slide plates at the bottom of the

or equivalent) to the hexagon socket head bolt

４th and fifth boom sections (see Figs. 4 and 5).

used to install the sheave assemblies (see Fig.6).

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 – 2mm (0.04 - 0.08 in.).

(see Fig 7).

Sheave assembly (with clinched part on inside)

4th boom section

5th boom section Slide plate mounting bolt

IW536-040006E

IW536-040004E

Fig . 6

Fig. 4

11

W536-0450E

G -3

G -3

Boom (Six-Section Boom) 7. Install the sheave assembly at the top of the 5th boom section with the clinched part on the inside

5th boom section retracting wire rope

(see Fig. 10).

Bend after include a wire Mounting surface

Plate

detail

Sheave assembly (with clinched part on in side)

View 5th boom section IW536-040007E

Fig. 7 IW536-040010E

6. Bend the plates on the wire rope supports on the Fig. 10

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

Plate

3. Boom Adjustment Procedures 3.1 Grease Application Procedure Before performing this work, supply grease (TNR) to each slide plate and to each grease cup.

5th boom section

3.2 Top Slide Plate Installation Procedure

IW536-040008E

Fig. 8 Apply thread locking compound (Threebond 1305 or equivalent) to the button bolts before using them to secure the slide plate. After tightening the

Plate

button bolts, loosen each of them by half a turn and make sure the slide plate can move longitudinally (see Fig. 11).

Button bolt Top boom section IW536-040009E

fig. 9

Slide Plate

Top slide plate installation procedure IW536-040011E

Fig. 11

12

W536-0450E

G -3

G -3

Boom (Six-Section Boom) 3.3 Telescoping wire rope adjustment procedure

3. Tighten the retracting wire rope’s adjusting nut until the stopper of the fifth boom section touches

1. Loosen the respective lock nuts of the extending

the end of the fourth boom section and the

wire rope and retracting wire rope (see Fig. 12).

stopper of the top boom section touches the end Extending wire rope

of the fifth boom section (see Fig. 14).

Retracting wire rope

5th boom section stopper

Adjusting nut Lock nut

Lock nut Adjusting nut

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

Support and shim retaining nut

IW536-040014E

Fig. 14 4. Fasten the retraction wire rope nut till each stopper for the 5th and top boom sections comes Extending wire rope thread (detail)

Retracting wire rope thread (detail)

to contact with the fourth and fifth boom sections respectively.

IW536-040012E

Fig. 12 5. Fasten the extension wire rope nut till each 2. Position the boom horizontally, then extend the

stopper for the 5th and top boom sections comes

fourth, fifth, and top boom sections by 500mm

1 to 2mm (0.04 to 0.08 in.) distant from the 4th

(19.69 in.) each.

and 5th boom sections respectivery.

With the hydraulic motor idling (with a flow rate of 6. Additionally tighten each retraction wire rope

approximately 15 l/min.), fully retract the boom and lock the third boom section and fourth boom

adjustment nut 6 turns and each extension wire

section in position. (It is not necessary to lock

rope adjustment nut 1 turns.

them in position if pressure remains on the

7. Position the boom horizontally, then extend the

retraction side of the telescoping cylinder.)

fourth, fifth, and top boom sections by 500mm

Measure dimension “B” shown in Fig. 13.

(19.69 in.) each.

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

With the hydraulic motor idling (with a flow rate of

(for reference)

approximately 15 l/mim.), fully retract the boom.

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

The stopper of the fifth boom section is touching the end of the fourth boom section, and the stopper of the top boom section is touching the end of the fifth boom section. (The boom is fully retracted.)

Fig. 13

IW536-040013E

13

W536-0450E

G -3

G -3

Boom (Six-Section Boom)

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

A Slide Plate

31 Shim (For the fixation) 32 Shim (For the adjustment) 5th boom section stopper Top boom section stopper (located on rear surface of top boom section)

33 Shim (For the adjustment)

View from A IW536-040016E

IW536-040015E

Fig. 16

Fig. 15

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

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

demension "a" to 2 –3mm (0.08-0.12 in.).

satisfied, make adjustments again.

(see Fig. 17) If 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 but dimension “B” is not the

28

same as when measured in step 2, perform these

Slide Plate

steps: IW536-040017E

Slightly loosen the retracting wire rope’s adjusting Fig. 17

nut.

3. Adjust dimension "b" (see Fig. 16) using

Slightly tighten the extending wire rope’s adjusting nut until dimension “B” is the same as

shims-31,-32, and 33 such that the boom's

when measured in step 2.

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

9. The tightening nut of the wire rope for each Boom lateral bending: max. 45mm (1.77 in.)

telescoping is locked with the lock nut.

(see Fig. 18) Boom lateral play: max. 100mm (3.94 in.)

3.4 Adjustment of Clearance between Boom Sections

(see Fig. 19) [NOTE]

1. Adjust dimension "a" (see Fig. 16) to the following

Install the slide plates before assembling the boom.

values:

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

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

And locks it with the nut.

14

W536-0450E

G -3 .

G -3 .

Boom (Six-Section Boom)

Boom fully retracted Max. 45 mm (1.77 in.)

Boom fullyextended

Adjustment of boom lateral bending IW536-045001

89 90

Fig. 18

Top boom section 10kgf (22.1 lbf) Max. 100mm (3.94 in.)

D detail

10kgf (22.1 lbf)

IW536-040020E

Boom fully extended

Fig. 20 Adjustment of boom lateral play IW536-045002

Fig. 19 4. Adjust dimension ”C” (see Fig. 20) to 0 – 0.5mm (0 – 0.02 in.) using the support-89 and shim-90.

1 312-029-40100 △

15

W536-0450E

G -4

G -4

Telescoping Cylinder (Four-Section Boom) G-4

Telescoping Cylinder (Four-Section Boom)

1. Structure General View

1 312-115-70000 △

16

W157-0290E

G -4

G -4

G -4

Telescoping Cylinder (Four-Section Boom) Cylinder assembly

0 360-163-60000 △

17

W157-0290E

17

G -4

G -4

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

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

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

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

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

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

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

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

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

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

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

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

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

18

W157-0290E

G -4

G -4

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.

19

W157-0290E

G -4

G -4

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

Oil flows at maximum rate.……

Oil flows through four chokes.……

Oil flows through three chokes.……

Oil flows through two chokes.……

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

20

W157-0290E

G -4

G -4

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

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

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

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

Perform this step with each rod cover.

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

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

below before tightening those items.

cylinder down onto the rod cover in one place.

Perform this step with each cylinder.

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

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

21

W157-0290E

G -4

G -4

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

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

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

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

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

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

22

W157-0290E

G -4

G -4

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

6. Tighten each of the support mounting bolts shown

the extending wire rope end loop support, be sure

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

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

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

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

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

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

8. Apply grease to the surface that rubs against the

and use the machine screws to install the wire

slide plate (the bottom surface of the No.2

rope guides.

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

23

W157-0290E

G -4

G -4

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

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

Then attach the two wire guide supports-26 after

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

applying screw locking agent to the threaded

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

portion of the machine screw-27.

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

3. With the heads of the extending wire rope adjusting bolts pressing firmly against the adjusting bolt mounting surface, adjust dimension

6. Telescoping Wire Rope Adjustment Procedure

"E" (see Fig.18) to 120-121mm (4.72-4.76 inch.)

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

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

Dimension D: 152.5mm (6 in.)

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

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

24

W157-0290E

G -4

G -4

Telescoping Cylinder (Four-Section Boom)

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

9. After adjustment is completed, thrust the adjusting bolt locking support against the horizontal face of the extending wire rope adjusting bolt and secure the support using the hexagon head bolts-13 and the spring washers-14. (see the Fig.21) 5. Use the specified jig to retain the top boom 10. After adjustment is completed, thrust the

stretch support in the position at which dimension

adjusting bolt locking support against the

"C" (see Fig.20) is 294mm (11.57 inch.)

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

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

Adjusting nut tightening torque： 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 on the right and left close to the boom head equally.)

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

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

25

W157-0290E

G -4 .

G -4 .

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

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

Perform the "6.1 Wire rope adjustment with the telescoping cylinder out of the boom" again.

1. Telescope the boom for several strokes and check the dimension of F (clearance between the top boom section and 3rd boom section). If F is 2mm (0.08in.) or shorter re-adjustment is not necessary.

2. When F is longer than 0.08in. and does not exceed 4mm (0.16in.)

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

Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and loosen the extending wire rope adjusting bolts-16 on the right and left fot one turn.(see the Fig.21) Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and tighten the retracting wire rope adjusting bolts until F is 2mm (0.08in.) or shorter. (see the Fig.22) Attach the adjusting bolt locking support-15, hexagon head bolt 13-and spring washers-14 (both for the retracting wire rope and for the extending wire rope).Then attach the top cover.

26

W157-0290E

G -5

G -5

Telescoping Cylinder (Five-Section Boom) G-5

Telescoping Cylinder (Five-Section Boom)

1. Structure General View

2 312-115-80000 △

27

W157-0300

G -5

G -5

G -5

Telescoping Cylinder (Five-Section Boom) Cylinder assembly

0 360-163-70000 △

28

W157-0300

28

G -5

G -5

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

General View 1. Cylinder assembly

8. Spring washer

14. Spring washer

21. Plate

2. Wire rope

9. Support

15. Support

22. Bolt

3. Support

10. Spring washer

16. Bolt

23. Support

4. Nut

11. Bolt

17. Support

24. Plate

5. Wire rope

12. Counterbalance valve

18. Sheave assembly

25. Support

19. Retaining ring

26. Machine screw

20. Pin

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

6. Sheave assembly 7. Hexagon socket head bolt

assembly(※) 13. Hexagon socket head bolt

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

15. Packing

29. O-ring

43. Backup ring

2. Retaining ring

16. Backup ring

30. Piston

44. Dust seal

3. Plunger

17. Dust seal

31. Plain bearing

45. Support

4. Backup ring

18. Check valve assembly

32. Packing

46. Hexagon socket head bolt

5. O-ring

19. O-ring

33. Backup ring

47. Spring washer

6. Retaining ring

20. O-ring

34. Piston

48. O-ring

7. Seal

21. Rod cover

35. Rod

49. Hexagon socket head bolt

8. Piston

22. Roller assembly

36. Cylinder

50. Slide plate

9. O-ring

23. Roller assembly

37. Rod

51. Machine screw

10. Plain bearing

24. Check valve assembly

38. Cylinder

52. Slide plate

11. Cylinder

25. Stopper

39. O-ring

53. Button bolt

12. Rod

26. Pipe

40. Rod cover

54. Slide plate

13. Rod cover

27. Plain bearing

41. Plain bearing

55. Machine screw

14. O-ring

28. Plain bearing

42. Packing

29

W157-0300E

G -5

G -5

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

9. O-ring

3. Check valve

10. O-ring

4. Rod

11. Hexagon socket head bolt

5. O-ring

12. Plug

6. Backup ring

13. Spacer

7. Cap

Check Valve Assembly (Cylinder Assembly Part24) Detail

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

30

8. Body

W157-0300E

G -5

G -5

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

31

W157-0300E

G -5

G -5

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.

32

W157-0300E

G -5

G -5

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

Oil flows at maximum rate.……

Oil flows through four chokes.……

Oil flows through three chokes.……

Oil flows through two chokes.……

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

33

W157-0300E

G -5

G -5

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

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

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

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

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

chapter in the separate repair manual, "General

cylinders, apply adhesive (Loctite 638) to the

Cautions".

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

Check valve mounting bolts (N) (eight)

areas marked with "※" in Fig. 3).

Machine screws (M4x2) and button bolts (M6x2) Tightening torque: 98.1 N-m (72.4 ft-lbf)

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

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

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

34

W157-0300E

G -5

G -5

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

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

at rear end of No.2 cylinder

cylinder's front end

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

Perform this step with each rod cover.

Tightening torque: 343-392 N-m (253-289.1 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 (M12x8) at rear end of cylinder assembly

35

W157-0300E

G -5

G -5

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.

36

W157-0300E

G -5

G -5

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

4. When passing the extending and retracting wire

boom, align as shown in Fig.15 the groove

ropes through their respective wire rope end loop

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

support, be sure to follow these instructions:

the rear end of the No.3 cylinder.

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

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

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

7. Apply grease to the surface that rubs against the

thread locking compound to the machine screws

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

and use the machine screws to install the wire

apply grease to the top surface of the No.3

rope guides.

cylinder.

Retracting wire rope: six wire rope guides.

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

37

W157-0300E

G -5

G -5

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

Dimension D: 5.75 in.

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

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

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

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

5. Use the specified jig to retain the top boom stretch in the position at which dimension "C" (see Fig.20) is 338mm (13.31 inch.).

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

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

38

W157-0300E

G -5

G -5

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

10.After adjustment is completed, thrust the

rope adjusting nut and lock it in position using the

adjusting bolt locking support againt the horizontal

lock nut (see Fig.20).

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

Adjusting nut tightening torque:

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

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 on the right and left close to the boom head equally.)

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

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

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

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

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

1. Telescope the boom for several strokes and check the dimension of F (clearance between the top boom section and 3rd boom section). If F is 2mm (0.08in.) or shorter re-adjustment is not necessary.

2. When F is longer than 2mm (0.08 in.) and does not exceed 4mm (0.16 in.).

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

39

W157-0300E

G -5 .

G -5 .

Telescoping Cylinder (Five-Section Boom) Remove the adjusting bolt locking support-15, hexagon head bolt-13, and the spring washer-14, and loosen the extending wire rope adjusting bolts-16 on the right and left for one turn. (see the Fig.21) Remove the adjusting bolt locking support-15, hexagon head bolt-13 and the spring washer-14, and tighten the retracting wire rope adjusting bolts until F is 2mm (0.08 in.) or shorter. (see the Fig.22) Attach the adjusting bolt locking support-15, hexagon head bolt-13 and spring washers-14 (both for the retracting wire rope and for the extending wire rope). Then attach the top cover.

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

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

2 312-115-80000 △

40

W157-0300E

G -6

G -6

Telescoping Cylinder (Six-Section Boom) G-6

Telescoping Cylinder (Six-Section Boom)

1. Structure General View

1 312-115-90000 △ 0 312-116-90000 △

41

W157-0310E

G -6

G -6

G -6

Telescoping Cylinder (Six-Section Boom)

Cylinder assembly

0 360-163-80001 △ 0 360-166-50000 △

42

W157-0310E

42

G -6

G -6

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

General View 1. Cylinder assembly

3. Hexagon socket head bolt

5. Support

7. Bolt

2. Sheave assembly

4. Spring washer

6. Spring washer

8. Counterbalance valve assembly(※)

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

15. Piston

29. Rod cover

43. Plain bearing

2. Retaining ring

16. Cylinder

30. Roller assembly

44. Hexagon socket head bolt

3. Support

17. Rod

31. Check valve assembly

45. Spring washer

4. Plunger

18. Rod cover

32. Stopper

46. Roller assembly

5. Backup ring

19. O-ring

33. Pipe

47. O-ring

6. O-ring

20. Packing

34. Plain bearing

48. Hexagon socket head bolt

7. Retaining ring

21. Backup ring

35. Packing

49. Slide plate

8. Seal

22. Dust seal

36. Backup ring

50. Machine screw

9. Piston

23. Check valve assembly

37. Piston

51. Button bolt

10. O-ring

24. O-ring

38. Rod

52. Slide plate

11. Plain bearing

25. O-ring

39. Cylinder

53. Slide plate

12. Plain bearing

26. Packing

40. Rod

54. Machine screw

13. Plain bearing

27. Backup ring

41. Cylinder

14. O-ring

28. Dust seal

42. Rod cover

Check Valve Assembly (Cylinder Assembly Parts・23) detail 1. O-ring

6. O-ring

2. Backup ring

7. Spring

3.Check valve

8. Plug

4. O-ring

9. O-ring

5. Valve seat

10. Plug

43

W157-0310E

G -6

G -6

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

9. O-ring

3. Check valve

10. O-ring

4. Rod

11. Hexagon socket head bolt

5. O-ring

12. Plug

6. Backup ring

13. Spacer

7. Cap

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.

44

8. Body

W157-0310E

G -6

G -6

Telescoping Cylinder (Six-Section Boom)

2. When the No.2 cylinder has been fully extended, the No.3 cylinder is extended.

45

W157-0310E

G -6

G -6

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.

46

W157-0310E

G -6

G -6

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 0.04 inch. 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).

47

W157-0310E

G -6

G -6

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

5. Apply thread locking compound (Threebond 1305) to the items listed below before installing the items (see Figs. 4 - 6).

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

For any tightening torque not shown in the

correctly aligned.

drawings, refer to the "Mechanical Elements"

2. Before installing the pistons of the No.1 cylinders,

chapter in the separate repair manual, "General

apply adhesive (Loctite 638) to the three

Cautions".

consecutive crests of each rod's external thread,

Check valve mounting bolts (N) (eight)

starting with the second crest (see the areas marked with "※" in Fig. 3).

Machine screws (M4x2) and button bolts (M6x2) used to mount slide plates at front ends of No.1

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

and No.2 cylinders

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

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

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

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

48

W157-0310E

G -6

G -6

Telescoping Cylinder (Six-Section Boom)

Machine screws (M4x4) used to mount slide plate at rear end of No.2 and No.3 cylinder

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 (253-289.1 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.

Hexagon socket head bolts (M8x4) on top of No.3 cylinder’s front end

49

W157-0310E

G -6

G -6

Telescoping Cylinder (Six-Section Boom) 4. Notes for Reassembly of Telescoping Cylinder 1. Install the sheave assembly at the rear end of the No. 3 cylinder with the clinched part on the inside.

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

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

When passing the retracting wire 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. (6 place)

50

W157-0310E

G -6 .

G -6 .

Telescoping Cylinder (Six-Section Boom)

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

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

5. When installing the telescoping cylinders in the 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.

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

51

W157-0310E

G -7

G -7

Counterbalance Valve (Telescoping) G-7

Counterbalance Valve (Telescoping)

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

1. Structure General View

13. O-ring

1. Body

5. Spring

9. Plug

2. Spool

6. O-ring

10. Poppet

3. Plug

7. Plug

11. Spring

4. Backup ring

8. Plug

12. O-ring

52

W119-0281E

G -7 .

G -7 .

Counterbalance Valve (Telescoping)

Thread size and tightening torque Sign / Port Mounting bolt

Thread size

Tightening torque N-m

ft-lbf

M10

34.3 - 39.2

25.3 - 28.9

G 3/8

44.1 - 53.9

32.5 - 39.8

G 1/2

53.9 - 63.7

39.8 - 47

A-B port Plug-3.9 Plug - 7

2 366-051-80000 △

2 366-055-20000 △

53

W119-0281E

H Safety System

Contents 4.

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

Assembly ................................................ 12

5. Replacing the Potentiometer ...................... 14 1.

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

2.

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

H-3 Angle Detector (Boom) ..................15

3.

Caution About Installing Length Detector .. 3

1.

Structure ................................................. 15

4.

AML Adjustment........................................ 4

2.

Specifications (Potentiometer)................. 15

4.1

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

4.2

AML components........................................ 4

4.3

Selecting the crane model and

H-4 Outrigger Extension Detector .......16

capacity data............................................. 5 4.4

1.

Zero-and span-adjustment of length detector . ........................................ 6

4.5

Zero-and span-adjustment of angle detector. .......................................... 7

4.6

Procedure to adjust outrigger extension detector switch and uninstalled outrigger warning switch .............. 16 1.1

Adjusting outrigger extension

1.2

Adjusting uninstalled outrigger warning

Confirming Accuracy .................................. 7

5.

List of Error Nos. Related to AML.............. 8

6.

Adjustment items when parts are

detector switch ........................................16 switch ..................................................16

2.

exchanged................................................ 9

Checking outrigger extension detector switch and uninstalled outrigger warning switch ............................. 16 2.1

Checking outrigger extension detector switch ....................................16

H-2 Length Detector (Boom)................ 10

2.2

Checking uninstalled outrigger warning switch ..................................................16

1.

Structure and Function............................ 10

2.

Specifications...........................................11

3.

Disassembly ............................................11

i

H

H-1

H-1

AML H-1

Overload Prevention Device (AML)

1. Structure

1

W301-0300E

H-1

H-1

AML 2. Function of Components

4. Display alteration

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

Only the display on the AML main body can be

extension width of right and left outriggers.

altered.

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

Usually the real load is shown on the display

When both outriggers are extended to minimum,

window. As the display alteration switch is pressed,

the MIN indicator lamp (red) is lit.

the real load display alternates with the moment display.

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

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

2

W301-0300E

H-1

H-1

AML 3. Caution About Installing Length Detector

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

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

reeled in all the way, leading to damage to the

yellow tape on the cord is located as shown in the

potentiometer.

drawing when the boom is fully retracted.

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

Warning light

Length detector

Boon angle detector

Yellow tape

Less than 0.98" 9.8"

Length detection vessel terminal treatment details

IW301-017003

3

W301-0300E

H-1

H-1

AML 4. AML Adjustment

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

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

4. Shift the dip switches and the rotary switch using

you must select the capacity data that

an extra thin screwdriver.

corresponds to the actual model and confirm

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

accuracy of the data.

adjustment.

4.1 Attention for adjustment work

6. Keep off the buttons other than the specified

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

switches.

the outriggers extended as specified.

(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.

4.2 AML components Over-front indication lamp Display window

OPERATI ON SWI TCH OPERATI ON SWI TCH

1

ON

1

C

4 5

13

6

14

7

15

8

16

8

3

12

0

2

11

F

A

2 3 4 5 6 7 8

6

ZERO

MOOD

2 4

CODE

1

8

1

ON

9 10

Dip switch (DS1)

SPAN

ON

ZERO

7

8

8

6

7

7

5

6

6

4

5

5

3

4

4

2

3

3

1

2

2

SELECT

ON

1

9

4

12

5

13

6

14

7

15

8

16

MOOD

Select button

6

2

4

CODE

AMA main unit with the cover removed

Rotary switch

C A

8

3

11

0

10

F

2

Dip switch (DS2)

SPAN

SELECT

IW301-017004

4

W301-0300E

H-1

H-1

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 "1".

NO

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

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

NO

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

Shift the rotary switch to "5".

NO

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

Yes Completed

IW301-017005

Table 1 Crane model

ZR564S ZR565S ZR566S ZR564S ZR565S ZR566S ZR564S ZR565S ZR566S

Over Capa -front city capaci type ty A D A D A D A D A D A D A D A D A D

Dip switch setting

DS1

DS2

100 %

00101000

00010000

11101000

00010000

100 %

00100100

00010000

11100100

00010000

100 %

00101100

00010000

11101100

00010000

00101010

00010000

11101010

00010000

00100110

00010000

11100110

00010000

00101110

00010000

11101110

00010000

60% 60% 60% 25% 25% 25%

00101001

00010000

11101001

00010000

00100101

00010000

11100101

00010000

00101101

00010000

11101101

00010000

Indication Indication Indication Indication 1 2 3 290 291 292 294 295 296 298 299 300

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

005

009

008

009

5

Outrigger extension

Condition for accuracy confirmation Boom Angle

Minimum

10o

Minimum

10o

Minimum

10o

Minimum

o

Minimum

10

10o

Minimum

10o

Minimum

10o

Minimum Minimum

W301-0300E

10o 10o

Load to be lifted (t)

R1(m)

R2(m)

0.5

5.81

6.24

0.5

8.74

9.79

0.5

5.37

5.74

1.0

5.18

5.57

0.5

5.28

5.48

1.0

5.16

5.49

0.5

5.81

6.24

0.5

8.74

9.79

0.5

5.37

5.74

1.0

5.18

5.57

0.5

5.28

5.48

1.0

5.16

5.49

0.5

5.81

6.24

0.5

8.74

9.79

0.5

5.37

5.74

1.0

5.18

5.57

0.5

5.28

5.48

1.0

5.16

5.49

H-1

H-1

AML Table 2 Zero-point adjustment range

Crane model

Boom length detector

Boom angle detector

ZR564S

3.45 – 3.65

0.8 - 1.2

ZR565S

3.68 - 3.88

0.8 - 1.2

ZR566S

3.76 - 3.96

0.8 - 1.2

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

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

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

Capacity type Loading capacity of applicable vehicle

Capacity ; A

Capacity ; D

about 6ton

About 10ton

4.4 Zero-and span-adjustment of length detector .

Swing the boom to over-front before adjustment.

START

Turn the rotary switch to the "2" position.

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

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

Retract the boom fully again.

No

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

Yes Completed

IW301-017007

6

W301-0300E

H-1

H-1

AML 4.5 Zero-and span-adjustment of angle detector.

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

START

Turn the rotary switch to the "3" position.

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

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

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

No

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

Yes Completed

IW301-017008

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

START Shift the rotary switch to "0".

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

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

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

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

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

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

NO

Yes

Contact TAC

Completed

7

W301-0300E

IW301-017006

H-1

H-1

AML 5. List of Error Nos. Related to AML No. E14 E15

Description

Improper setting of model selection dipswitch

E16 E17 E18

E20

E21 E29 E22 E23

E24

Improper setting of function selection dipswitch

Cause

Measures

Boom length value or boom angle value left unadjusted

Adjust

Improper setting of dipswitch

Set property

Improper setting of dipswitch

Set property

Maladjusted boom length value

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

Faulty AML itself

Replace the AML main body if check result is normal.

Faulty AML itself

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

Faulty AML itself

Replace the AML main body if check result is normal.

Abnormal display of load

Faulty CPU Faulty hardware

Faulty length detector

8

W301-0300E

H-1 .

H-1 .

AML

No.

E25

E26 E27

Description

――

Measures

Connector (CN4) disconnected

Connect.

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

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

Adjust the boom angle value and check precision.

Faulty boom angle adjuster.

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

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

Faulty AML itself.

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 itself.

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)

Broken wiring E65

Cause

Abnormality “‐‐‐” is displayed

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

Executed adjustment item ・”4.4 Boom length adjustment” ・”4.6 Confirming accuracy” ・”4.5 Boom angle adjustment” ・”4.6 Confirming accuracy” ・Nothing ・”4.3 Selecting the crame model and capacity data”

AML itselt

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

9

W301-0300E

H-2

H-2

Length Detector (Boom) H-2

Length Detector (Boom)

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

[NOTE]

and potentiometer.

There is a case that the appearance and so on differ from the parts for this 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.

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

Connection diagram Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W

Connector 1 2 3

Shield

(Length detector portion)

4

Knob-type terminal IW305-017001

Overall plan 15 16 15 16 77 11

22 3

19 19

66 10 4 12 12 9 9 10

21 21

20 20

Water cutout hole

8 8

55

11 11 18 18

Yellow tape

GND(B)

Power supply(R)

Water cutout hole

Shield(G)

Output(W)

14 14 13 13

Air vent

17 17 IW305-017002

1.Plate

6. Case

11.Seal

16.Sleeve

2.Case

7.Packing

12.Gear A

17.Cord guide

3.Drum ass’y

8.O-ring

13. Knob-type terminal

18.Connector

4.Contact point circle

9.Bracket

14.Sleeve

19.Super lock

5.Contact ass’y

10.Potentiometer

15. Knob-type terminal

20.Cord lock

10

W305-0171E

H-2

H-2

Length Detector (Boom) Potentiometer

2. Specifications

Bracket

Speed reducer

Reduction ratio : 1/35

Potentiometer

Resistance : 5000 ± 1000Ω

(for boom length detection)

Electrical turning angle : 340

Gear B

o

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

IW305-011004E

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

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

Setscrew

Gear A

1. Loosen the cord clamp and remove the cover.

Cable Cord clamp Cover Potentiometer IW305-011005E

Knob-type terminal

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

IW305-011003E

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

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

Remove the cover and table from the main body.

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

11

W305-0171E

H-2

H-2

Length Detector (Boom) 4. Assembly

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

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

the opening.

yellow tape.

Then remove the gummed tape that fixes the wire.

7. Align the alignment marks that have been put on

Yellow tape To drum

the base plate and the case during disassembly.

Attach the case.

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

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

IW305-0171E02

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

to the opening and fix the wire with gummed tape.

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

Yellow tape

tape comes onto the drum.

Gummed tape IW305-011009E

Wire ass'y Drum ass'y

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

IW305-011007E

Setscrew

Gear A

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

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

IW305-011005E

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

Gummed tape

Potentiometer Drum assy

Bracket IW305-011008E

Gear B

4. Attach the base plate to the drum assy.

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

IW305-011004E

12

W305-0171E

H-2

H-2

Length Detector (Boom)

15. Attach the length detector to the original position.

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

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

the potentiometer by hand so that the output

necessary.

voltage between the terminals 2 and 3 is 0.3 ±

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

0.05 V. When the output voltage is within the

[NOTE]

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

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

B and secure the bracket.

Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W Shield

(Length detector portion)

Connector 1 2 3 4

Knob-type terminal IW305-017001

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

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

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

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

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

Cable Cord clamp Cover Potentiometer

Knob-type terminal

IW305-011003E

13

W305-0171E

H-2 .

H-2 .

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

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

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

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

Insulating sealant

IW305-011010E

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

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

Potentiometer

Cable

3

0.5B(black)

B

1

0.5R(red)

R

2

0.5W(white)

W

(Length detector portion)

Shield

Connector 1 2 3 4

Knob-type terminal IW305-017001

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

0 361-317-40000 △

14

W305-0171E

H-3 .

H-3 .

Angle Detector (Boom) H-3

Angle Detector (Boom)

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

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

1. Case

4. Weight

7. O-ring

10. Binding band

2. Cover

5. Arm

8. Oil

11. -

3. Potentiometer

6. Terminal

9. -

12. Connector

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

0 361-404-70000 △

15

W305-0180E

H-4

H-4

Outrigger Extension Detector H-4

Outrigger Extension Detector

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

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

Check the switches in the following procedure.

1.1 Adjusting outrigger extension detector switch

2.1 Checking outrigger extension detector switch

1. Measure the clearance C shown in the right figure

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

when it becomes smallest due to lateral play of

the frame does not affect outrigger extension

the outrigger in the frame.

detection.

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

O/R extension

Indicator lamp

Max

Lit

Min

Unlit

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

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

1. Check the switch when the outriggers are fully

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

extended and when they are extended to

(In the usual service condition, the clearance is

minimum.

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

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

Outrigger

Indicator lamp

Extended

Lit

No extended

Unlit

2. Make sure that the uninstall outrigger warning

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

alarm does not sound when the crane is in a

each outrigger inner case.

configuration given in the Table 1.

(Check both cases when the boom is in the

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

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

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

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

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

16

W313-0200E

H-4

H-4

Outrigger Extension Detector

2.5mm

Side of outrigger

(0.1")

C

Outrigger inner case

E D

Confir mation lamp Confirmation Side of frame View A

Section B

17

W313-0200E

IW313-0150E02

H-4 .

H-4 .

Outrigger Extension Detector

Harness

0 316-539-31000 △ 0 316-539-31100 △

18

W313-0200E

V Radio Control System

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

1.

When Radio-control Mode Operation is Not Available ...................................... 13

2.

When Neither Radio Nor Manual Control Mode Operations are Available .... 15

3.

Troubleshooting Guide ............................ 16

Structure ................................................... 1 1.1

2.

V-4 Measures for Emergency Case .....13

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

Crane control by Radio-control System..... 3 2.1

Preparation ................................................. 3

2.2

Inching Mode Switch Operation ................. 4

2.3

Alarm function ............................................ 6

V-2 Radio-control Valve ......................... 7 1.

Structure ................................................... 7 1.1

Hydraulic circuit .......................................... 7

1.2

Electric circuit ............................................. 8

1.3

General View .............................................. 9

1.4

Cross section............................................ 10

V-3 Acclerator Cylinder........................ 12 1.

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

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

WV02-0040E

V -1

V -1

Configurations of Radio-control System

1.1 Names and functions of each part

1. ─

7. Power switch

13. ─

2. Inching mode lamp

8. Boom telescoping switch

14. ─

3. Inching mode switch

9. Hoisting switch

15. Grip

4. Hook-in switch (*1)

10. Boom elevation switch

16. Speed control lever

5. Horn switch

11. Swing switch

17. Remote control connector

6. Power lamp

12. Cable

18. Mode display lamp

: Used for Hook-in specification crane. Not functionable for standard specification crane.

2

WV02-0040E

V -1

V -1

Configurations of Radio-control System 2. Crane control by Radio-control System When connecting the remote-control transmitter with the receiver, set the power switch off. With power switch on, radio-control is inoperable.

2.1

Preparation

Before engine start, make sure each control lever is located at: (1) Boom telescoping, winch, boom elevation, swing and jack lever : neutral (2) Accelerator lever : LOCK (3) PTO lever : off 1. Start the engine.

2. Set on the PTO. 3. Make sure the mode display lamp on the receiver display "00", meaning manual operation mode. ◆If the figure shown is other than "00", see the "Emergency Procedures" section.

4. Stand the transmitter antenna.

5. Press the power switch on and the power lamp will flash and then light on. ◆Power does not come on when any of the control switches or the speed control lever is set on, even though the power switch is pressed. Do not touch any other than the power switch.

6. Make sure the mode display lamp on the receiver displays “01”, or “02”, meaning radio-control operation mode. ”01” : Frequency 1used. ”02” : Frequency 2used. ◆If the figure shown are other than “01” or “02”, see the “Emergency Procedures” section. ◆For details of frequency, see “Frequency Selection” in the “Other Devices” section.

3

WV02-0040E

V -1

V -1

Configurations of Radio-control System

2.2 Inching Mode Switch Operation Operating the inching mode switch will control the engine speed and provide the following two functions: (1) Setting the inching mode In the inching mode, a larger amount of speed control lever pull does not affect the engine rpm.

Nor does full pulling of the speed control lever make the control valve full open. And the crane keeps slow speed operation.

(2) Setting the engine speed limit While the engine speed limit is set, the engine speed does not exceed the set limit level even if the speed control lever is pulled fully.

Use this mode when you want to operate the crane slowly or where nuisance at night time is a problem. ◆Inching operation and setting the engine speed limit are not available at the same time. Choose either of them. ◆The above functions are effective only for the radio-control operation. They are not available during manual-control operation.

(1) Setting Inching Operation Mode Press the inching mode switch. The inching mode operation will be possible. ◆If any control switch is in operation, the inching mode is not available even though the inching mode switch is pushed in. Release the control switch. ◆To set the inching operation mode after cancelling the engine speed limit, perform some radio-control operation after canceling the limit; otherwise the inching operation mode cannot be set.

4

WV02-0040E

V -1

V -1

Configurations of Radio-control System

(2) Setting the Engine Speed Limit 1. Retract the boom fully.

2. While keeping the boom telescoping switch to the "Ret." side, pull the speed control lever slowly until the engine speed reaches the desired limit level.

3. Press the inching mode switch while keeping the switches described in 2. as they are.

Inching mode lamp will light up and the beeping alarm "Ding-dong." will be output from the speaker. ◆While the engine speed limit is set, the engine speed does not exceed the set limit level even if the speed control lever is pulled fully.

(3) Canceling Inching Operation Mode Press the inching mode switch again.

The inching mode indicator lamp will go off and inching operation mode or the engine speed limit will be canceled. ◆These functions will not be canceled even though the transmitter power is shut off. Push the inching mode switch to cancel them.

5

WV02-0040E

V -1 .

V -1 .

Configurations of Radio-control System

2.3 Alarm function The following alarms sound when the system has a problem, when a wrong operation is made, or to call attention for proper operations.

(1) At the time of abnormal stop of the radio-control system: Warning sound Beep (Three times) Warning timing When the computer judges that serious trouble has occurred to the system Crane operation The radio-control operation is disabled.

Measures

Refer to the chapter of “Measures for Emergency Case”

(2) At the time of a problem occurring when the operation lever is at the neutral position Warning sound Beep (Three times) Warning timing When the operation lever of the crane does not return to the neutral position even after the motion selection switch of the transmitter is returned to the neutral position.

Crane operation The radio-control operation is disabled.

Measures Refer to the chapter of “Measures for Emergency Case” (3) Battery exhaustion warning Warning sound Two-tone alarm (once) Warning timing When the motion selection switch of the transmitter is operated under the low battery-voltage condition of the transmitter.

Measures

Refer to the chapter of “Battery Replacement for Transmitter”

(4) At the set of emergency stop state Warning sound Beep (Once) Warning timing When the operation to set the emergency stop state is made.

(5) At the release of emergency sop state Warning sound Two-tone alarm (once) Warning timing When the operation to release the emergency stop state is made.

6

WV02-0040E

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

7

W135-0020E

V -2

V -2

Radio-control Valve

1.2 Electric circuit

8

W135-0020E

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

–

G 1/4

24.5 - 29.4

18 - 22

P, T port

G 1/2

53.9 - 63.7

40 - 47

A, B port

G 3/8

44.3 - 53.9

33 - 40

9

W135-0020E

V -2

V -2

Radio-control Valve

1.4 Cross section Section (Elevating, Winch, Telescoping, Swing)

Section (Jack)

[NOTICE] Do not rotate the jack 1 and jack 2 spools unless they are placed in the neutral position, or the switches may be damaged.

10

W135-0020E

V -2 .

V -2 .

Radio-control Valve

11

W135-0020E

V -3 .

V -3 .

Acclerator Cylinder V-3

Acclerator Cylinder

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

1. Structure

1. Flange

7. O-ring

13. Body

19. Solenoid assy

2. Differential transformer assy

8. O-ring

14.O-ring

20. Machine screw

3. Shim

9. Seal cover

15. Rod assy

21.O-ring

4.Shim

10. Steel ball

16. Scraper

22. Solenoid valve assy

5.Shim

11.O-ring

17. Spring B

23. Steel ball

6. Machine screw

12.O-ring

18. Spring A

12

W165-0040E

V -4

V -4

Measures for Emergency Case V-4

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. ◆If dispositions as shown in the table below cannot bring the crane to normal operation, stow the crane and have it checked and repaired at a TADANO's authorized distributor or dealer. ◆When two or more failure codes are registered, the display repeatedly displays these codes in sequence.

13

W307-0050E

V -4

V -4

Measures for Emergency Case

Error number 11

12 86 87 13

30-33

Trouble and measures 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.

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 operation “32”: Hoisting operation “31”: Elevation operation “33”: Swing operation 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 operation "41", "46": Hoisting operation "42", "47": Elevation operation "43", "48": Swing operation "44", "49": Acceleration operation

14

W307-0050E

V -4

V -4

Measures for Emergency Case 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 operation “52” “57”: Hoisting operation “51” “56”: Elevation operation “53” “58”: Swing operation “54” “59”: Accelerating operation

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 “62”: Hoisting operation “61”: Elevation operation “63”: Swing operation 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.

70-85 88

2. When Neither Radio Nor Manual Control Mode Operations are Available [NOTICE] The procedure described in this section is used to stow the crane in an emergency. Do not perform crane operation in this situation.

2.1 The unloading solenoid of the radio-control valve should be fastened so that the crane can be manually stowed.

(1) Remove the cap nut.

(2) Loosen the lock nut and lightly tighten the screw inside until it cannot be turned any longer.

15

W307-0050E

V -4

V -4

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

Trouble Power 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.

Checkpoints • 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.

Measures • 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 used for 10 minutes or longer, the automatic power off function cuts off the power supply.

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

• Inching mode selected.

• Press the power switch again.

• 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.

• Replace the batteries with new ones.

16

• Press the power switch again.

• Cancel the mode.

• Reconnect the antenna correctly.

• Repair the defective antenna and/or cable.

• Set the antenna correctly.

• See subsequent pages.

W307-0050E

V -4 .

V -4 .

Measures for Emergency Case Radio wave transmission is hindered under the following conditions, which may stop the crane operation.

Take an appropriate measure according to the operational condition.

If the appropriate measure does not improve the situation, use the manual operation.

Operation example

Appropriate measures

Distance between the transmitter and reception unit is too far.

•Too large a distance between the transmitter and reception unit may not only hinder the radio wave transmission but also increase noise influences.

Normally, make the operations within the operating radius of the crane.

•When a noise generating device such as a revolving light, electric fan or vehicle’s air conditioner is used nearby, the radio-control operation is influenced by the source.

Turn off the noise-generating device when it is possible to refrain from using it.

Since a motorcycle also generates a noise, pay attention to motorcycles passing through.

Operation is made near the noise-generating source.

Operation is made in a place with an intensive radio wave interference causing noise to the radios and to television screens.

•Approach the transmitter to the reception unit and operate the transmitter.

A large metal cargo is lifted with the crane.

Or, there are obstacles between the transmitter and reception unit such as wire netting or metal doors.

•Metal products between the transmitter and reception unit hinder the radio wave transmission.

Move yourself to the location where the reception unit can be seen and then operate the transmitter.

17

W307-0050E

Y Data, Adjustment and Checks

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

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

2.

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

3.

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

Y i

Y-1

Y-1

Service data

Y-1

Service data

[NOTE] There is a case that the appearance and so on differ from the parts for this 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. Set pressure 1-1 Standard Set pressure

Item Main relief valve

Check procedure

MPa

psi

19.6 – 20.1

2843 – 2914

at 60L/min (16gal/min)

1-2 Hook - in Set pressure

Item

Check procedure

MPa

psi

Main relief valve

19.6 – 20.1

2843 – 2914

at 60L/min (16gal/min)

Low - pressure relief valve

2.94 – 4.9

426 – 710

at 20L/min (5gal/min)

1-3 Radio control Set pressure

Item

Check procedure

MPa

psi

Main relief valve

19.6 – 20.1

2843 – 2914

at 60L/min (16gal/min)

Low - pressure relief valve

2.94 – 4.9

426 – 710

at 20L/min (5gal/min)

Relif valve :F

1.67 – 2.26

242 – 328

at 1.5L/min (0.4gal/min)

Back pressure valve :D

1.57 – 1.97

199 – 286

at 5L/min (1.3gal/min)

Reducing valve :E

1.37 – 1.57

199 – 228

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

2. Hydraulic units 1. Swing motor 3

3

3

3

Displacement : 40.1 cm / rev (2.46 in /rev) -------- – EM5496 : 39.3 cm / rev (2.40 in /rev) -------- EM5497 – 2. Winch motor 3

3

Displacement : 1.49 in /rev (24.5 cm / rev) 3. Swing speed reducer Reduction ratio : 34 : 1 4. Winch speed reducer Reduction ratio : 3.3 : 1

1

WY01-1040E

Y-1

Y-1

Service data 3. Hydraulic circuit 3-1 Standard and Hook - in Pressure setting Set Pressure

Part Control valve Main circuit (Flow rate)

Note

MPa

psi

19.6-20.1 (60L/min)

2843-2914 (16gal/min)

Relief valve RV1

Pressure adjustment o

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

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

RV1 PG(G1/4)

Hook stowing

Boom elevation

Winch

Boom telescoping

Swing

Jack 2

Jack 1

IWY01-0750E01

2

WY01-1040E

Y-1 .

Y-1 .

Service data 3-2 Radio-control Pressure setting Set Pressure

Part Control valve Main circuit (Flow rate)

Note

MPa

psi

19.6-20.1 (60L/min)

2843-2914 (16gal/min)

Relief valve RV1

Pressure adjustment o

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

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

Flow rate : 60L / min (16gal/min)

3

WY01-1040E

Z System Diagrams

Contents Z-1 Hydraulic Circuit : Standard, Hook-in................ １

Z-7 Electrical Circuit : Spec. TM-56Z-2-324, 325 Hook-in (with power slide) ......8

Z-2 Hydraulic Circuit : with power slide..................... 2

Z-8 Electrical Circuit : Spec. TM-56Z-2-813 Radio remote controls.............9

Z-3 Hydraulic Circuit : Spec. TM-56Z-2-813 (Radio remote controls) .......... 3

Z-4 Electrical Circuit : Spec. TM-56Z-2-003,004,005,007 (Standard) ................................ 4

Z-5 Electrical Circuit : Spec. TM-56Z-2-303,304,305 (Hook-in)................................... 5 1.

-EM5539 ................................................... 5

2.

EM5540- ................................................... 6

Z-6 Electrical Circuit : Spec.

TM-56Z-2-024, 025, 027 Standard (with power slide).... 7

Z i

Z-1.

Z-1.

Z-1.

Hydraulic Circuit Z-1

Hydraulic Circuit : Standard, Hook-in

0 314-009-10200 △

1

WZ01-0500E

1

Z-2.

Z-2.

Z-2.

Hydraulic Circuit Z-2

Hydraulic Circuit : with power slide

0 314-014-10200 △

2

WZ01-0510E

2

Z-3.

Z-3.

Z-3.

Hydraulic Circuit Z-3

Hydraulic Circuit : Spec. TM-56Z-2-813 (Radio remote controls)

0 314-013-30200 △

3

WZ01-1850E

3

Z-4.

Z-4.

Z-4.

Electrical Circuit 1. This diagram shows the circuit with the power supply off and winch overwound.

Z-4

Electrical Circuit : Spec. TM-56Z-2-003,004,005,007 (Standard)

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

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

1 314-014-00100 △

4

WZ03-0670E

4

Z-5

Z-5

Z-5

Electrical Circuit Z-5

Electrical Circuit : Spec. TM-56Z-2-303,304,305 (Hook-in)

1. -EM5539

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

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

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

1 314-009-10100 △

5

WZ03-0111E

5

Z-5.

Z-5.

Z-5.

Electrical Circuit 2. EM5540-

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

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

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

0 314-009-10101 △

6

WZ03-0111E

6

Z-6.

Z-6.

Z-6.

Electrical Circuit Z-6

Electrical Circuit : Spec. TM-56Z-2-024, 025, 027 Standard (with power slide)

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

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

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

0 314-014-10100 △

7

WZ03-0680E

7

Z-7.

Z-7.

Z-7.

Electrical Circuit Z-7

Electrical Circuit : Spec. TM-56Z-2-324, 325 Hook-in (with power slide)

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

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

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

0 314-014-20100 △

8

WZ03-0690E

8

Z-8.

Z-8.

Z-8.

Electrical Circuit Z-8

Electrical Circuit : Spec. TM-56Z-2-813 Radio remote controls

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

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

0 314-021-20101 △

9

WZ03-3240E

9

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