Tadano Faun Truck Crane TT-300XL-1 Service Manual SN 291030 - PDF DOWNLOAD

Service Manual

Publication No.

TT-300XL-1/S1(U)-1E

01

PRINTED IN JAPAN 0606

K

TT-300XL-1/S1(U)-1E

ｃ ◯2006

Truck Crane Model

TT-300XL-1 Applicable Serial No. 291030--

Safety Safety

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

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

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

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

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

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

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

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

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

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

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

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

1

WA01-0041E

Safety 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 This service manual describes the composition of the Model TT-300XL-1 truck crane, its repair, checks and adjustment methods and other relevant matters. Note that this service manual does not provide the information in the separate service manuals given below.

This service manual applies to the cranes with the specification numbers given below. Check the specification number on the nameplate of your crane.

Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales units in the parts catalog before replacing them.

1. Applicable spec. NO.

SPEC.

NO.

SERIAL.

NO.

MFG.DATE. KAGAWA, JAPAN

ISA04-001601

Spec. No.

Applicable serial No.

TT-300-1-90101

291030--

2. Separate service manual Separate Service Manual

Information No.

General Cautions

SA01-01-2E

AML (Load Moment Indicator)

W301-0311E

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

1

WA04-2000E

Foreword 3. Outline of specifications Spec. No. Item

TT-300-1-90101 1M1D (North America)

No. of boom sections

4

No. of jib stages

1

Single top

Not Fitted Main winch

Fitted

Auxiliary winch

Not Fitted

Winch brake

Automatic brake (Neutral brake)

Winch

Drum rotation indicator Weight

Pilot lamp type (Option)

Counterweight

Fitted

AML (Load moment indicator)

AML-L E

Front jack

Fitted

Outrigger

H type

Auto. stop solenoid valve energizing type

Normally energized

AML external indicator lamp

Option

Oil cooler

Fitted

Heater

Option

Carrier model

STERLING TRUCKS LT7501

Carrier type

Left hand steering, 6×4

Engine model

CAT C7

2

WA04-2000E

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 1

2

square centimeter, cm 0.01

2

square meter, m 0.000001

2

square inch, in 0.00155

2

2

square foot, ft

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

1

0.001

0.03527

0.0022

1000

1

35.27

28.349

0.02835

453.592

3

3

3

3

Mass metric ton, ton, t

short ton, s. t

2.205

0.001

0.001102

1

0.0625

0.00002835

0.00003125

0.4536

16

1

0.0004536

0.0005

1000000

1000

35274

2205

1

1.102

907185

907.2

32000

2000

0.9072

1

Pressure Pa 1

kPa -3 1X10

MPa -6 1X10

3

1

1X10

6

1X10

1X10

9.80665X10 6895

-3

3

1X10

4

2

kgf/cm -5 1.01972X10

1

9.80665X10

9.80665X10

6.895

0.006895

3

2

lbf/in , psi -5 14.5X10

1.01972X10

-2

14.5X10

1.01972X10

14.5X10

1

14.22

0.07031

1

-2

WA04-2000E

-2

Foreword

Work, energy 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-lbf

1.01972X10

1.01972X10 -2

9.80665 9.80665X10

-1

1.01972X10

1

-3

inch-pound, in-lbf 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

WA04-2000E

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

Control System

M N O P Q R S T U V W X Y Data, Adjustment and Checks Z System Diagrams 5

WA04-2000E

Foreword 5. Contents Chapter

Spec. No. TT-300-1-90101 1M1D (North America)

Section

General General Cautions

Refer to separate manual

SA01-01-2E

A

Hydraulic Power Generating System

B

Hydraulic Power Generating System

B-1

Hydraulic Pump

B-2

Manual Control Valve (lower)

B-3

Rotary Joint

B-4

Manual Control Valve (upper)

B-5

Unload Relief Valve

B-6

Flow Control Valve

B-7

Hydraulic Motor (Oil Cooler)

B-8

Check Valve (Gauge Isolator)

B-9 Outrigger System

C

Outrigger System

C-1

Jack Cylinder

C-2

Pilot Check Valve (Jack Cylinder Retracting Prevention)

C-3

Extension Cylinder

C-4

Front Jack Cylinder

C-5

Pilot Check Valve

C-6

6

WA04-2000E

Foreword

Chapter

Spec. No. TT-300-1-90101 1M1D (North America)

Section

Swing System

Swing System

D-1

Swing Assembly

D-2

Manual Control Valve (Swing)

D-3

Hydraulic Motor (Swing)

D-4

Swing Speed Reducer

D-5

Master Cylinder (Swing Brake)

D-6

D

Boom Elevation System

E

Elevating System

E-1

Elevating Cylinder

E-2

Counterbalance Valve (Elevating)

E-3

Winch system

F

Winch System

F-1

Winch

F-2

Hydraulic Motor and Counterbalance Valve (Winch)

F-3

Hydraulic Valve (Winch Brake Release)

F-4

Solenoid Valve (Winch Speed Select)

F-5

7

WA04-2000E

Foreword

Chapter

Spec. No. TT-300-1-90101 1M1D (North America)

Section

Boom Telescoping system

Telescoping System

G-1

Boom (Four-Section Boom)

G-2

Jib

G-3

Telescoping Cylinder

G-4

Counterbalance Valve (Telescoping)

G-5

Hose Reel

G-6

Hydraulic Valve

G-7

G

Safety System Safety System

H-1

AML (Load Moment Indicator)

Refer to separate manual

Boom Length and Angle Detector

H-2

Outrigger Extension Length Detector

H-3

Solenoid Valve (Auto Stop)

H-4

H

Control System Control System

L-1

Master Cylinder (Accelerator)

L-2

Control Cylinder (Accelerator)

L-3

L

8

WA04-2000E

W301-0311E

Foreword

Chapter

Spec. No. TT-300-1-90101 1M1D (North America)

Section

Data, Adjustment and Checks

Y

Hydraulic Pressure Setting Table

Y-1

Air Bleeding Procedure

Y-2

Electric Switch Adjustment

Y-3

Adjustment and Checks

Y-4

Oil and Grease Table

Y-5

Mass Table

Y-6

Boom Connecting Pin and Thread Size Table

Y-7

System Diagrams

Hydraulic Circuit

Z-1

Electric Circuit

Z-2 Location of Installation

Z

Location of Hydraulic Parts

Z-3

Location of Electrical Parts

Z-4

Hydraulic and Electric Parts Table

Z-5

Harness Diagrams Harness (Upper)

Z-6

Harness (Lower)

Z-7

9

WA04-2000E

B Hydraulic Power Generating System

Contents B-1 Hydraulic Power Generating System...................................... 1 1.

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

2.

1.2

Brush assy ................................................17

1.3

Wiring diagram ..........................................18

Potentiometer.......................................... 19

1.1

Hydraulic pump .......................................... 1

2.1

Adjustment of potentiometer resistance ...19

1.2

Manual control valve (lower) ...................... 1

2.2

Checking the “ON” range of limit switch

1.3

Rotary joint ................................................. 1

1.4

Manual control valve (upper)...................... 1

1.5

Unload relief valve...................................... 1

1.6

Flow control valve....................................... 1

1.7

Hydraulic motor (for oil cooler) ................... 1

(swing position limit switch) ................19

B-5 Manual Control Valve (Upper) .......20 1.

Structure ................................................. 20

B-2 Hydraulic Pump................................ 2 B-6 Unload Relief Valve........................31 1.

Structure ................................................... 2 1.1

General view............................................... 2

1.2

Inside view.................................................. 4

1.3

Pump Mounting .........................................11

1.

Structure ................................................. 31

B-7 Flow Control Valve.........................32 1.

B-3 Manual Control Valve (Lower)....... 12 1.

Structure ................................................. 12 1.1

Extension / retraction selector assy ......... 13

1.2

Supply / drain assy ................................... 13

1.3

Jack / slider selector assy ........................ 14

1.4

Relief valve assy ...................................... 14

1.5

Port relief valve assy ................................ 14

B-8 Hydraulic Motor (Oil Cooler) .........33 Structure ................................................. 33

2.

Air bleeding procedure ............................ 33

1.

Structure ................................................. 15 1.1

1.

B-9 Check Valve (Gauge lsolator)........34

B-4 Rotary Joint .................................... 15 1.

Structure ................................................. 32

General view............................................. 15

i

Structure ................................................. 34

B

B-1 .

B-1 .

Hydraulic Power Generating System B-1

1.5 Unload relief valve

Hydraulic Power Generating System

This valve is used to unload oil flow from an

1. Functions of units

accumulator circuit. When the pressure in the accumulator circuit rises to the specified unload

1.1 Hydraulic pump

pressure, the valve discharges the oil flowing into the valve through the IN port, to the OUT port.

This pump consists of double variable

When the accumulator circuit pressure drops to

displacement piston pump and double gear pump.

the specified onload pressure, the valve resumes

Pump A1 is used for the winch circuit, pump A2 for

feeding oil to the accumulator circuit.

the boom telescoping, boom elevation and winch circuits, pump A3 for the outrigger and swing

1.6 Flow control valve

circuits, and pump A4 for the winch accumulater and oil cooler circuits.

This valve serves to protect the cooler motor against over-speeding, by maintaining the pump

1.2 Manual control valve (lower)

oil flow rate to the cooler at a constant level regardless of the pump speed, and returning the

This manual valve controls the outriggers and the

excess flow to the tank.

front jack cylinder, and serves to control the circuit pressure by the built-in relief valve.

1.7 Hydraulic motor (for oil cooler)

A check valve is incorporated to prevent the jack from extending during vehicle travel.

1. If the crane is used under high load for a long time in summer, the hydraulic oil temperature will rise

1.3 Rotary joint

over 70°C (158°F), leading to oil deterioration such as oxidation and reduced oil viscosity that can

The rotary joint allows pressurized oil from the

cause leaks in the pump and motor and reduce

hydraulic pump and current from the battery to be

volume capacity.

sent to the swing table, and at the same time allows operation of the accelerator from the swing

2. To prevent such troubles, the returned oil is

table.

force-cooled (while the motor is driven by the oil delivered from the A4 pump).

1.4 Manual control valve (upper) This valve is an aggregate multi-element direction control valve unit consisting of the respective direction control valves for boom elevation, telescoping, main winch and auxiliary winch, all bolted together into one unit.

In addition to the above four valve blocks, the unit incorporates relief valves, port relief valves and flow control valves for circuit pressure control.

1

WB02-0350E

B-2

B-2

Hydraulic Pump B-2

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 1.1 General view

Symbol

Name

B1, B2

Delivery port

SAE1 1/4 (Standard type)

S1

Suction port

SAE2 1/2 (Standard type)

L1, L2

Drain port

G1/2

L3,L4

Drain port

7/8-14 UNF-2B (Plug)

X1, X2

Pilot port

7/16-20 UNF-2B (Plug)

B3,B4

Delivery port

SAE 1(Standard type)

S3,S4

Suction port

SAE 1 1/4(Standard type)

2

W101-0350E

Size

B-2

B-2

Hydraulic Pump

Thread size and tightening torque Sign / Port

Thread size

T1

Tightening torque N-m

ft-lbf

7/8-14 UNF

115

85

T2

7/16-20 UNF

15

11

T3

M10

69

51

1.Piston pump

5.Bushing

9 Gear pump

13.Piping

2.Control valve

6. ---

10. ---

14.Plug

3.Control valve

7.Flow limit ring

11.Power diagram

15.Bolt

4. ---

8. ---

12.Piping

16.Spring washer

3

W101-0350E

B-2

B-2

Hydraulic Pump 1.2 Inside view Variable displacement piston pump

4

W101-0350E

B-2

B-2

Hydraulic Pump 1.Rotary group

10.Drive shaft

19. ---

28. ---

2.Rotary group

11.Coupring

20.Shaft seal

29. ---

3.Control unit

12.Adjustment shim

21.O-ring

30.Plug

4.Pump housing

13. ---

22.O-ring

31.Plug

5.Pump housing

14. ---

23.O-ring

32. --33.Parallel pin

6.Port plate

15.Bearing

24. ---

7.Swash plate

16.Bearing

25.V-ring

8.Swash plate

17.Cradle shell

26. ---

9.Drive shaft

18. ---

27.Hexagon socket head bolt

Thread size and tightening torque Sign / Port

Thread size

T4 T5

Tightening torque N-m

ft-lbf

M14

165

122

7/8-14 UNF

127

94

5

W101-0350E

B-2

B-2

Hydraulic Pump Control valve (A)

1.Control valve

3.Bolt

2.O-ring

4.Plug

Thread size and tightening torque Sign / Port

Thread size

T6 T7

Tightening torque N-m

ft-lbf

M6

15.5

11.4

7/16-20 UNF

15

11

6

W101-0350E

B-2

B-2

Hydraulic Pump Control valve (B)

1.Control valve

4. ---

7.Hexagon socket head bolt

10.Spring pin

2.Control plate

5. ---

8.Hexagon socket head bolt

11.Cap

3. ---

6.O-ring

9.Spring pin

Thread size and tightening torque

Sign / Port

Thread size

T8 T9

Tightening torque N-m

ft-lbf

M6

15.5

11.4

M6

15.5

11.4

7

W101-0350E

B-2

B-2

Hydraulic Pump Rotary group

1.Piston

7.Spring

2.Cylinder block

8. ---

3. ---

9.Pressure pin

4.Retaining plate

10.V-ring

5. ---

11.Backup ring

6.Retainig ball

12.Control plate

8

W101-0350E

B-2

B-2

Hydraulic Pump Control unit

1.Control piston

5. -------6.Spring

2.Piston guide 3.Counter piston 4.Piston guide

Thread size and tightening torque

Sign / Port

Tightening torque

Thread size

N-m

ft-lbf

2*

1

–

130

96

1

–

130

96

4*

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.

9

W101-0350E

B-2

B-2

Hydraulic Pump Gear pump

1.Frame

9.Side plate

17. Oil seal

25.O-ring

2.Body

10.Side plate

18.O-ring

26.Bolt

3.Body

11.Seal ring

19.C-retaining ring

27.Spring washer

4.Case

12.Coupling

20.C-tetaining ring

28.Stud bolt

5.Gear

13.Bush

21.Plug

29.Stud bolt

6.Gear

14.Hexagon socket head bolt

22.Plain washer

7.Gear

15.Bearing

23.Nut

8.Gear

16.Square ring

24.Parallel pin

366-543-30000

10

W101-0350E

0 △

B-2 .

B-2 .

Hydraulic Pump 1.3 Pump Mounting

1. The drive power from P.T.O is transferred to the

[NOTICE]

hydraulic pump by the propeller shaft.

L: Installation dimension of propeller shaft Standard .......................1060 mm (41.7 in) Maximum allowance .....1080 mm (42.5 in) Minimum allowance ......1040 mm (40.9 in)

Thread size and tightening torque Sign / Port Bolt•1 Bolt•2 (*1)

Thread size

Tightening torque N-m

ft-lbf

M12

76 - 90

56 - 66

5/16-18UNC

12 - 14

8.9 - 10.3

Bolt•3

M16

177 - 206

131 - 152

Bolt•4

M14

116 - 133

86 - 98

Nut•1

M12

76 - 90

56 - 66

Nut•2

M14

57 - 67

42 - 49

Nut•3

M14

116 - 133

86 - 98

(*1): Apply the thread locking agent

11

W101-0350E

B-3

B-3

Manual Control Valve (Lower) B-3

Manual Control Valve (Lower)

[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

12

W113-0321E

B-3

B-3

Manual Control Valve (Lower) 1.Front cover assy

4.Control valve assy

7.Relief valve assy

10.Carry-over assy

2.Rear cover assy

5.Control valve assy

8.Check valve retainer

11. Control valve assy

3.Bolt

6.Nut

9.O-ring

12.Port relief valve assy

1.1 Extension / retraction selector assy

1.2 Supply / drain assy

13

W113-0321E

B-3 .

B-3 .

Manual Control Valve (Lower) 1.3 Jack / slider selector assy

1.4 Relief valve assy

1.5 Port relief valve assy

0 366-341-80000 △

14

W113-0321E

B-4

B-4

Rotary Joint B-4

Rotary Joint

[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 General view

15

W181-0420E

B-4

B-4

Rotary Joint

1.Brush assy

7.Seal ring

13.Spring washer

19.Flange

2.Bolt

8.Body

14. ---

20.Hexagon socket head bolt

3.Spring washer

9.Core

15.O-ring

21.Spring washer

4.Seal ring

10.Plain bearing

16.O-ring

22.Pin

5.Plain bearing

11.Stopper

17.O-ring

6.Packing

12.Bolt

18.O-ring

Thread size and tightening torque Sign / Port

Thread size

P1,P2

Tightening torque N-m

ft-lbf

G1

196

145

P3

G 3/4

167

123

P4

G 1/2

98

72

49 - 69

36 - 51

P0

Swing platform side Rc 3/8 Chassis side G 3/8

49

36

16

W181-0420E

B-4

B-4

Rotary Joint 1.2 Brush assy

1.Case

13.Spring washer

25.Hexagon socket head bolt

37.Nut

2.Base

14.Brush base L

26.Bolt

38.Potentiometer

3.Lead wire

15.Brush base C

27.Washer

39.Flange

4.Plate

16.Brush base U

28.Spring washer

40.Stud

5.Axle base

17.Screw

29.Screw

41.Plate

6. ---

18.Screw

30.Brush

42.Screw

7.Coupling

19.O-ring

31.Plate

43.Plate

8.Bearing A

20.Slip ring

32.Band

44.Limit switch

9.Bearing B

21.Insulator

33.Cam

45.Screw

10.Cramp base

22.Insulator

34.Screw

46.Spring washer

11.Cramp

23.Terminal

35.Spring washer

12.Screw

24.Grommet

36.Set screw

17

W181-0420E

B-4

B-4

Rotary Joint 1.3 Wiring diagram

Fig. 3

18

W181-0420E

B-4 .

B-4 .

Rotary Joint 2. Potentiometer

2.2 Checking the “ON” range of limit switch (swing position limit switch)

2.1 Adjustment of potentiometer resistance

1. Make sure that the limit switch stays ON in the 170 - 190° over-left-side range circuit is closed

1. Place the rotary joint in position “I (0°…F,F

between terminals 1 and 2 of the connector F

converging point)” that corresponds to the

shown in Fig. 3.

over-front boom direction as shown in Fig. 4.

2. In this state, loosen the setscrew 36 and turn the shaft appearing on the top of potentiometer with a screwdriver so that potentiometer resistance will meet the level specified in Table. 1.

3. Tighten the setscrew 36 securely.

4. Place the rotary joint in position “II (270°)” that corresponds to the over-left-side boom direction, and measure the potentiometer resistance. Make sure that the measured resistance meets the level specified in Table. 1.

Fig. 4

Table.1 (Resistance between Pot Terminals Indicated in Fig. 3 (wiring diagram)

Swing direction (Boom direction) I (Over-front) II (Over-left- side)

Pot 2 Resistance between Pot B and D

Pot 1 Resistance between Pot C and D

454 - 494 Ω

204 - 244 Ω

362 - 402 Ω

1 - 15 Ω 1 336-308-90000 △

19

W181-0420E

B-5

B-5

Manual Control Valve (Upper) B-5

Manual Control Valve (Upper)

[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

20

W113-0450E

B-5

B-5

Manual Control Valve (Upper)

1.PT cover assy

4.Valve block assy

7.Cover (end)

10.Nut

2.Body assy (elevating)

5.Body assy (aux. winch)

8.Name plate

11.Spring washer

3.Body assy (telescoping)

6.Body assy (main winch)

9.Stud bolt

Thread size and tightening torque Sign / port

Thread size

G1,G2,S1,S2,V1,V2,t

Tightening torque N-m

ft-lbf

G1/4

29.4

22

L

G1/2

98

72

P1,P2,T1

G3/4

167

123

A1,A2,A3,A4,B1,B2,B3,B4,T2

G1

196

145

10

M10

59 - 69

43.5 - 51

21

W113-0450E

B-5

B-5

Manual Control Valve (Upper) PT cover assy

1.Cover

4.O-ring

7.Expander

2.PC valve

5.O-ring

8.Shim

3.Relief valve

6.Plug

9.Shim

10.Orifice

Thread size and tightening torque Sign / Port

Thread size

Tightening torque N-m

ft-lbf

2

–

69 - 78

51 - 57.5

3

–

69 - 78

51 - 57.5

M5

1.6 - 2.0

1.2 - 1.5

1

10*

*1 : Apply LOCTITE 242 (thread locking agent) to threaded sections.

22

W113-0450E

B-5

B-5

Manual Control Valve (Upper) Valve block assy

1.Valve block

7.Spring

13.Shim

19.PC valve

2.Plunger

8.Orifice

14.Expander

20.Plug

3.Plug

9.Orifice

15.O-ring

4.Plunger

10.Plug

16.O-ring

5.Plug

11.Plug

17.O-ring

6.Spring

12.Shim

18.O-ring

Thread size and tightening torque Sign / Port

Thread size

3 5

Tightening torque

–

N-m 216 - 265

ft-lbf 159 - 195

–

118 - 147

87 - 108

8*

1

M4

0.8 - 1.0

0.6 - 0.7

1

9*

M5

1.6 - 2.0

1.2 - 1.4

10

G 1/4

31 - 41

23 - 30

19

–

69 - 78

51 - 57

20

–

69 - 78

51 - 57

*1 : Apply LOCTITE 242 (Thread locking agent) to threaded sections.

23

W113-0450E

B-5

B-5

Manual Control Valve (Upper) Winch selector assy

0

24

W113-0450E

B-5

B-5

Manual Control Valve (Upper)

1.Winch selector valve body

12.Plunger

23.O-ring

34. ---

2.Spool (winch)

13.Spring

24.O-ring

35.O-ring

3.Spool end

14.Retainer

25. ---

36.Plug

4.Cover

15.Steel ball

26.O-ring

37. ---

5.Plate

16. ---

27.O-ring

38. ---

6.Spool end

17.Hexagon socket head bolt

28. ---

39.Valve seat

7.Spring seat

18.Hexagon socket head bolt

29.Packing

40.Spool end

8. ---

19.Plug

30.Parallel pin

41.Plate

9. ---

20.Expander

31.Split pin

42.O-ring

10.Spring

21.Orifice

32.Shim

43.Plug

11.Plug

22. ---

33.Shim

Thread size and tightening torque Sign / Port

Thread size

3

Tightening torque

–

N-m 19.6 - 24.5

ft-lbf 14.5 - 18

6

–

19.6 - 24.5

14.5 - 18

11

–

216 - 265

159 - 195

18

M8

28 - 35

21 - 26

21*

M4

0.8 - 1.0

0.6 - 0.7

36

G 1/4

31 - 41

23 - 30

1

*1 : Apply LOCTITE 242 (thread locking agent) to threaded sections.

25

W113-0450E

B-5

B-5

Manual Control Valve (Upper) Telescoping selector valve

1.Telescoping selector valve

9.Plug

18.Hexagon socket head bolt

27.O-ring

10.Plunger

19.Hexagon socket head bolt

28.Packing

2.Spool (telescoping)

11.Poppet

20.Plug

29.Parallel pin

3.Spool end

12.Distance piece

21.Expander

30.Split pin

4.Cover

13.Spring seat

22.Orifice

31.Plug

5.Plate

14.Spring

23.O-ring

32.Shim

6.Spool end

15.Spring

24.O-ring

33.Shim

7.Spring seat

16.Retainer

25.O-ring

34.Relief valve

8.Spring

17.Steel ball

26.O-ring

35.Valve seat

body

Thread size and tightening torque Tightening torque

Sign / port

Thread size

3

–

N-m 19.6 - 24.5

ft-lbf 14.5 - 18

6

–

19.6 - 24.5

14.5 - 18

9

–

216 - 265

159 - 195

19

M8

28 - 35

21 - 26

22*

M4

0.8 - 1.0

0.6 - 0.7

31

G 1/4

31 - 41

23 - 30

34

–

118 - 147

87 - 108

1

*1 : Apply LOCTITE 242 (thread locking agent) to threaded sections.

26

W113-0450E

B-5

B-5

Manual Control Valve (Upper) Elevating selector valve

1.Elevating selector valve body 9.Plug

17.Expander

25.Split pin

2.Spool (elevating)

10.Plunger

18.Orifice

26.Plug

3.Spool end

11.Spring

19.O-ring

27.Shim

4.Cover

12.Retainer

20.O-ring

28.Shim

5.Plate

13.Steel ball

21.O-ring

29.Relief valve

6.Spool end

14.Hexagon socket head bolt

22.O-ring

30.Relief valve

7.Spring seat

15.Hexagon socket head bolt

23.Packing

31.Valve seat

8.Spring

16.Plug

24.Parallel pin

Thread size and tightening torque Sign / port

Tightening torque

Thread size

3

–

N-m 19.6 - 24.5

6

–

19.6 - 24.5

14.5 - 18

9

–

216 - 265

159 - 195

M8

28 - 35

21 - 26

18*

M4

0.8 - 1.0

0.6 - 0.7

26

G 1/4

31 - 41

23 - 30

29

–

11 - 147

87 - 108

30

–

118 - 147

87 - 108

15 1

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.

27

W113-0450E

ft-lbf 14.5 - 18

B-5

B-5

Manual Control Valve (Upper) Main relief valve (Main winch, Aux. winch), (Elevating, Telescoping)

1.Body

5.Adjust screw

9.Shim

13.Buckup ring

2.Plunger

6.Nut

10.O-ring

14.O-ring

3.Valve seat

7.Spring

11.O-ring

15.Buckup ring

4.Poppet

8.Spring

12.O-ring

16.Cap nut

Overload relief valve (Elevating)

1.Cover

5.Spring seat

9.Nut

13.O-ring

2.Plunger

6.Spring

10.Steel ball

14.Backup ring

3.Valve seat

7.Adjust screw

11.O-ring

4.Piston

8.Cap

12.O-ring

28

W113-0450E

B-5

B-5

Manual Control Valve (Upper) Overload relief valve (Telescoping), (Elevating)

1.Cover

5.Spring seat

9.Nut

13.O-ring

2.Plunger

6.Spring

10.Steel ball

14.Backup ring

3.Valve seat

7.Adjust screw

11.O-ring

4.Piston

8.Cap

12.O-ring

Thread size and tightening torque Tightening torque

Sign / port

Thread size

2

M27×1.5

N-m 78.4 - 98

ft-lbf 58 - 72

9

M14×1

19.6 - 29.4

14.5 - 22

29

W113-0450E

B-5 .

B-5 .

Manual Control Valve (Upper) PC valve

1.Body

4.Spring

7.O-ring

10.Backup ring

2.Piston

5.O-ring

8.O-ring

11.Backup ring

3.Plug

6.O-ring

9.O-ring

Thread size and tightening torque Sign / port

Thread size

3

–

Tightening torque N-m 120 - 150

ft-lbf 88.5 - 110

3 366-324-60000 △

30

W113-0450E

B-6 .

B-6 .

Unload Relief Valve B-6

Unload Relief 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.Body

9.Filter

17.O-ring

25.Lock nut

2.Cover

10.Spring

18.Seat

26.Cap

3.Hexagon socket head bolt

11.Spacer

19.Nut

27.Plug

4.Sleeve

12.O-ring

20.Poppet

28.O-ring

5.O-ring

13.O-ring

21.O-ring

6.O-ring

14.Plug

22.Plug

7.Pressure-regulating valve

15.Spool

23.Spring

8.Retaining ring

16.Spacer

24.Adjusting screw

Thread size and tightening torque

Sign / Port

Thread size

P

Tightening torque N-m

ft-lbf

G1/4

29.4

22

IN,OUT

G1/2

98

72

A,Dr

Rc 1/4

24.5

18.1

27

G 1/4

29.4

22

Mounting bolt

M8

13 - 15

9.6 - 11.0 366-034-60000

31

W118-0010E

1 △

B-7 .

B-7 .

Flow Control Valve B-7

Flow 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) : Apply THREE-BOND 1104

1.Body

6.Guide

11.Set screw

16.Joint

2.Spool

7.O-ring

12.Spacer

17.Spring seal

3.Pin

8.Adjusting screw

13.Spring case

18.Adjusting nut

4.O-ring

9.Spring pin

14.O-ring

19.Lock nut

5.Backup ring

10.Cap

15.Spring

20.Dust seal

Thread size and tightening torque

Sign / Port

Thread size

P,B

Tightening torque N-m

ft-lbf

G1/2

98

72

A

G3/8

49

36

Mounting bolt

M8

13 - 15

9.6 - 11.0

3 366-100-00000 △

32

W114-0160E

B-8 .

B-8 .

Hydraulic Motor (Oil Cooler) B-8

Hydraulic Motor (Oil Cooler)

[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 25

14

2

4

7

5

32

8

10

1

33 34

13

D

A,B

27

12

21

17

19

20

16

22

23

3 IW102-012001

1.Front case

8.Spherical 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.Thrust plate

32.Piston assy

4.Cylinder block

13.Straight key

21.Hexagon socket head button bolt 33.Seal plate

5.Piston retainer

14.Plain washer

22.Ball bearing

7.Spherical retainer

16.Oil seal

23.Retaining ring

34.Flat head machine screw

Thread size and tightening torque Sign / Port

Thread size

A, B D 21 25 34

G3/8 G1/4 M5 M8 M5

Tightening torque N-m ft-lbf Max. 64 Max. 47 Max. 40 Max. 30 4-6 2.9 - 4.3 34 - 39 25 - 29 2-3 1.4 - 2.2

2. Air bleeding procedure 0 366-632-60000 △ 0 366-631-10000 △ 0 366-631-20000 △

Refer to “Air Bleeding Procedure” in chapter Y.

33

W102-0122E

B-9 .

B-9 .

Check Valve (Gauge Isolator) B-9

Check Valve (Gauge lsolator)

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

1. Structure Hydraulic symbols

P'

S

P1 7

8

1

P2 2

P3 5

4

IW116-012001

3

6

S

P1

P2

P3

IW116-012002

Thread size and tightening torque Sign / port P1, P2, P3, P’

Thread size

Tightening torque N-m

ft-lbf

G 1/4

29.4

22

G 3/8

49.0

36

M18×1.5

127 - 147

93 - 108

M8

13 - 15

9.6 - 11.0

Remark

S Mounting bolt

TT-300XL-1 only

1. Body

3. Poppet

5. O-ring

7. Plug

2. Plug

4. Spring

6. Screw

8. O-ring 1 366-244-50000 △ 0 366-251-20000 △

34

W116-0123E

C Outrigger System

Contents C-1 Outrigger System............................. 1

C-6 Pilot Check Valve .............................6

1.

1.

Description of the units ............................. 1

1.1 Jack cylinder .................................................. 1 1.2 Pilot check valve (for jack cylinder)................ 1 1.3 Extension cylinder .......................................... 1 1.4 Front jack cylinder .......................................... 1 1.5 Pilot check valve (for front jack cylinder) ....... 1

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

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

C-3 Pilot Check Valve (Jack Cylinder Retracting Prevention) ..................................... 3 1.

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

C-4 Extension Cylinder .......................... 4 1.

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

C-5 Front Jack Cylinder ......................... 5 1.

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

i

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

C

C-1 .

C-1 .

Outrigger System C-1

Outrigger System

1. Description of the units 1.1 Jack cylinder This cylinder is for setting up the crane for operation on the ground.

1. The retraction line is shared by the slide circuit and the jack circuit. Slide movement and jack movement are controlled by three ports.

1.2 Pilot check valve (for jack cylinder) 1. This valve prevents the retraction of the jack cylinder while the crane is set in crane operation configuration.

2. This valve is completely lock the jack pressure in the jack cylinder circuit in the setup condition to maintain the crane in a safe attitude in an accidental breakage of the piping.

1.3 Extension cylinder 1. These cylinders are for extending and retracting the outrigger inner cases.

1.4 Front jack cylinder 1. This cylinder is installed in the front area of the carrier, and serves to secure a uniform crane performance around the entire circumference.

1.5 Pilot check valve (for front jack cylinder) 1. This valve prevents the retraction of the front jack cylinder while the crane is set in crane operation configuration.

1

WC02-0170E

C-2 .

C-2 .

Jack Cylinder C-2

Jack Cylinder

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

1. Structure

1.Cylinder

6.O-ring

11.O-ring

16.Stopper

2.Spring pin

7.Backup ring

12.Damper ring

17.Bolt

3.Piston

8.Plain bearing

13.Packing

18.Spring washer

4.Packing

9.Rod

14.Backup ring

19.Bolt

5.Backup ring

10.Rod cover assy

15.Dust seal

20.Backup ring

*1:Face the notch or the lip toward the pressure side. *2:Apply Three-bond 1401 or equivalent. *3Apply Three-bond 1104 or equivalent.

Thread size and tightening torque

Sign / port

Thread size

Tightening torque N-m

ft-lbf

17,19

M10

22 - 25

16 - 18

Mounting bolt

M16

176-206

130-152 0 360-316-80000 △

2

W151-0310E

C-3 .

C-3 .

Pilot Check Valve (Jack Cylinder Retracting Prevention) C-3

Pilot check Valve (Jack Cylinder Retracting Prevention)

[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 A

B

C

D IW115-023001

1.Valve body

4.Valve

7.O-ring

2.Plug

5.Spring

8.Backup ring

10.Seat

3.O-ring

6.Piston

9.O-ring

Thread size and tightening torque Sign / port

Thread size

Tightening torque N-m

ft-lbf

A

G1/4

29.4

22

B

G1/4

29.4

22

Mounting bolt

M10

43 - 49

32 - 36

3

W115-0570E

1 366-220-40000 △

C-4 .

C-4 .

Extension Cylinder C-4

Extension 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.Cylinder

4.Plain washer

7.Rod

10.Packing

2.Nut

5.Seal ring

8.Rod cover

11.Backup ring

3.Spring washer

6.Piston

9.O-ring

12.Dust seal

Thread size and tightening torque Sign / port

Thread size

Tightening torque N-m

ft-lbf

A, B, C

G3/8

49

36

D, E

G1/4

29.4

22

2

M20

196 - 245

145 - 180

8

-

343 - 392

253 - 289

0 360-425-80000 △

4

W153-0110E

C-5 .

C-5 .

Front Jack Cylinder C-5

Front Jack Cylinder

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

1. Structure

1.Cylinder

6.O-ring

11.O-ring

16.---

2.Spring pin

7.---

12.Damper ring

17.Bolt

3.Piston

8.Plain bearing

13.Packing

18.Spring washer

4.Packing

9.Rod

14.Backup ring

5.Backup ring

10.Rod cover assy

15.Dust seal

Thread size and tightening torque

Sign / port

Thread size

Tightening torque N-m

ft-lbf

17

M10

22 - 25

16 - 18

Mounting bolt

M12

69 - 82

51 – 60.5

4 360-303-40001 △

5

W151-0320E

C-6 .

C-6 .

Pilot Check Valve C-6

Pilot check 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.Pulg

4.Popet

7.O-ring

2.O-ring

5.O-ring

8.Body

3.Spring

6.Piston

9.Body

Thread size and tightening torque Sign / port

Thread size

Tightening torque N-m

ft-lbf

A

G1/4

29.4

22

B

G1/4

29.4

22

Mounting bolt

M10

43 - 49

32 - 36

1 366-258-40000 △

6

W115-0580E

D Swing System D

Contents D-1 Swing System................................... 1

4.

Assembly of reducer ............................... 13

1.

5.

Installation of hydraulic motor.................. 13

Description of the units ............................. 1

1.1 Swing drive unit.............................................. 1 1.2 Manual control valve (swing) ......................... 1

D-6 Master Cylinder (Swing Brake) .....14

1.3 Master cylinder (swing brake) ........................ 1

1.

D-2 Swing Assembly .............................. 2 1.

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

2.

Swing bearing mounting bolt..................... 3

2.1 Bearing Inner ring bolts .................................. 3 2.2 Bearing outer ring bolts .................................. 4

D-3 Manual Control Valve (Swing).................................... 5 1.

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

D-4 Hydraulic Motor (Swing).................. 9 1.

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

D-5 Swing Speed Reducer ................... 11 1.

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

2.

Removing of hydraulic motor .................. 12

3.

Disassembly of reducer .......................... 12

i

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

D-1 .

D-1 .

Swing System D-1

Swing System

1. Description of the units 1.1 Swing drive unit 1. A hydraulic motor with wet-type brake and the double reduction planetary gear is integrated in the unit. This unit converts the pressurized oil delivered from the pump into the low-speed high-torque turning force to employ it for driving the swing structure.

1.2 Manual control valve (swing) 1. This valve serves for boom swing operation.

The function of it is to change the flow direction of oil and to control the speed of the hydraulic motor of the swing driving unit.The unlod valve incorporated in this valve controls the pressure stored in the accumulator.

1.3 Master cylinder brake (swing brake) 1. The master cylinder sends pressurized oil to the brake of the swing driving unit to stop and lock swinging motion.

1

WD02-0300E

D-2

D-2

Swing Assembly D-2

Swing Assembly

[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.Bolt 2.Plain washer

[NOTICE] Apply torque control agent to the threaded sections of the bolts.

Place the high-strength plain washer orienting its chamfer to the underhead fillet as shown below.

Thread size and tightening torque

Sign / port

Thread size

1

2

W514-0280E

M18

Tightening torque N-m

ft-lbf

303 - 343

224 - 253

D-2

D-2

Swing Assembly 2. Swing bearing mounting bolt 2.1 Bearing Inner ring bolts

1.Pain washer

3.Bolt (L=125mm)

5.Spring washer

2.Plate

4.Bolt

6.Support

[NOTICE]

7.Support

Thread size and tightening torque

Install the bearing inner ring with the "S" mark facing the rear of the carrier.

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

Place the high-strength plain washer orienting its chamfer to the underhead fillet as shown below.

3

Tightening torque

Thread size

N-m

ft-lbf

3 (36 points)

M22

564 - 637

416 - 470

4

M10

22 - 25

16 - 18

Sign / port

W514-0280E

D-2 .

D-2 .

Swing Assembly 2.2 Bearing outer ring bolts

1.Bolt (L=115mm) 2.Plain washer (35points) 3.Nut (18points) 4.Reamer bolt (L=130mm)

[NOTICE]

Thread size and tightening torque

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

Sign / port

Place the high-strength plain washer orienting its chamfer to the underhead fillet as shown below.

Tightening torque

Thread size

N-m

ft-lbf

M22

627 - 671

463 - 495

1 (1 point) 4 (34 points)

1 333-004-90000 △ 1 338-501-70000 △ 0 332-306-40000 △

4

W514-0280E

D-3

D-3

Manual Control Valve (Swing) D-3

Manual Control Valve (Swing)

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

1. Structure

5

W113-0460E

D-3

D-3

Manual Control Valve (Swing) 1.Select valve assy

4.Name plate

7.Tube

2.Relief valve assy

5.Rivet

8.Tube

3.Manifold assy

6.Plug

9.Thread protector

Thread size and tightening torque

Sign / port

Thread size

Tightening torque N-m

ft-lbf

A, B, P, R

G3/4

167

123

D, G

Rc1/4

24.5

18.1

6

W113-0460E

D-3

D-3

Manual Control Valve (Swing) Cross section

1.Body

18.Spring

35.Spring

52.Cap

2.Spool

19.O-ring

36.Spool

53.Crimp contact

3.Sleeve

20.Plate

37.Stopper

54.Plug

4.Steel ball

21.Spring washer

38.Spring

55.Hexagon socket screw

5.Spring

22.Bolt

39.Push rod

56.Hexagon socket screw

6.Seal cap

23.Spring guide

40.O-ring

57.---

7.O-ring

24.Sheat

41.Solenoid

58.Sheat

8.---

25.Poppet

42.---

59.Spring washer

9.Plate

26.Spring

43.Screw

60.Bolt

10.Spring seat

27.Cap

44.Check valve

61.Bolt

11.Spring

28.O-ring

45.Spring

62.Cover

12.Collar

29.Adjust screw

46.Guide

63.O-ring

13.Sub spool

30.O-ring

47.Sheat

64.O-ring

14.Spring cap

31.Nut

48.O-ring

65.Dust seal

15.Back pressure valve

32.Sleeve

49.O-ring

16.Check valve

33.Plate

50.Plug

17.C-retaining ring

34.Sleeve

51.Plug

7

W113-0460E

D-3 .

D-3 .

Manual Control Valve (Swing) Thread size and tightening torque

Sign / port

Tightening torque

Thread size

N-m

ft-lbf

13

–

8.8 - 10.8

6.5 - 8.0

27

–

88 - 108

65 - 80

50

–

118 - 176

87 - 130

61

M6

6.9 - 8.3

5 -6

Overload relief valve (RA)

1.Nut

4.Spring

7.O-ring

10.Body

2.Adjust screw

5.O-ring

8.O-ring

11.Plug

3.Cap

6.Spring

9.O-ring

12.Plug

Thread size and tightening torque

Sign / port 3

Thread size -

Tightening torque N-m

ft-lbf

88 - 108

65 - 79.6

2 366-332-40000 △

8

W113-0460E

D-4

D-4

Hydraulic Motor (Swing) D-4

Hydraulic Motor (Swing)

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

1. Structure

9

W102-0600E

D-4 .

D-4 .

Hydraulic Motor (Swing) 1.Housing

6.Retaining ring

11.---

16.Spring

2.Rotary group

7.Plate (outer disc)

12.O-ring

17.Distance piece

3.Shaft

8.Parallel pin

13.O-ring

4.Cover assy

9.Retaining ring

14.---

5.Piston

10.Oil seal

15.---

Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

P1

Rc1/4

29

22

A, B

G3/4

167

123

U

G3/8

49

36

P2

G1/2

98

72

P3

M10

22 - 25

16 - 18

5 366-625-70000 △

10

W102-0600E

D-5

D-5

Swing Speed Reducer D-5

Swing Speed Reducer

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

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

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

Motor output shaft

Sun gear(1)

planetary gear(18)

Planetary gear(7)

carrier-B(30)

reducer output shaft(13)

11

carrier-A(20)

W511-0300E

Sun gear(24)

D-5

D-5

Swing Speed Reducer 1.Sun gear

9.King pin (B)

17.Needle bearing

25.Snap ring

2.Bolt

10.Ball bearing

18.Planetary gear

26.Retainer (B)

3.Spring washer

11.Retainer (A)

19.Plate

27.Hexagon socket plug

4.Plate

12.Roller bearing

20.Carrier (A)

28.Oil seal

5.Casing

13.Output shaft

21.King pin (A)

29.Plate

6.Needle bearing

14.Spacer

22.Name plate

30.Carrier (B)

7.Planetary gear

15.Plug

23.Rivet

8.Plate

16.Seal washer

24.Sun gear

Thread size and tightening torque

Sign / Port

Tightening torque

Thread size N-m

ft-lbf

2

M8

23.5 – 27.5

17.5 - 20

15

G1/2

245 - 274

181 - 202

2. Removing of hydraulic motor

3. Disassembly of reducer

[NOTICE]

[NOTICE]

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

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

Careful work is necessary.

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

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

1. Take out parts from sun gear(1) to carrierB(30).

3. After removing bolts(2) (eight places) securing the hydraulic motor, remove the motor by using

[NOTICE]

pulling-out screw (2-M8) on the motor flange.

King pins(9), (21) are fitted by shrinkage fitting, space(14) is fitted by caulking.

2. Remove snap ring(25), and remove output shaft(13) from casing (5) by using a press.

12

W511-0300E

D-5 .

D-5 .

Swing Speed Reducer 4. Assembly of reducer

5. Installation of hydraulic motor

1. Press-fit retainer(11) and roller bearing(12) to

1. Tighten hydraulic motor by bolt(2).

output shaft(13).

[NOTICE]

[NOTICE] Apply lithium type grease between retainer(11) and roller bearing (12).

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

2. Press-fit oil seal(28) into casing(5).

2. Supply gear oil into the reducer via plug(15).

3

(about 1.6L (97.6 in )) [NOTICE] Apply lithium type grease on the inner of oil seal(28).

3. Install output shaft(13) in casing(5).

4. Press-fit ball bearing(10)

into output shaft(13),

install retainer (B)(26) and fix it with snap ring(25).

5. Hereafter, assemble carrier B(30) to sun gear(1) in reverse order of

"Disassemly of reducer."

[NOTICE] Confirm sun gear(1) turns lightly by your hand.

Secure clearance X=0.2 to 2.1mm (0.008 to 0.083 in) and Y=0.1 to 2.45 mm (0.004 to 0.096 in) shown in figure of previous page when mounting the hydraulic motor.

1 363-402-90000 △

13

W511-0300E

D-6 .

D-6 .

master Cylinder (Swing Brake) D-6

Master Cylinder (Swing Brake)

1. Structure

1.Cylinder body

8.Gasket

15.Gasket

22.Push rod

2.Boot

9.Piston cup

16.Gasket

23.Breather

3.Stop wire

10.Retainer

17.Union bolt

24.Rubber cap

4.Stop plate

11.Valve cup

18.Cap

25.Pipe nut

5.Secondary cup

12.Valve rod

19.Gasket

26.Union

6.Piston

13.Valve spring

20.Yoke

7.Guide pin

14.Spring

21.Nut

0 164-151-34000 △

14

W401-0300E

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

Description of the units ............................. 1

1.1 Elevating cylinder .............................................. 1 1.2 Counterbalance valve ....................................... 1

E-2 Elevating Cylinder............................ 2 1.

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

E-3 Counterbalance Valve(Elevating) ... 4 1.

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

2.

Function.................................................... 5

2.1 When control valve is at the neutral position ..................................... 5 2.2 While actuator is being pushed up................. 5 2.3 While actuator descends................................ 5

i

E -1 .

E -1 .

Elevating System E-1

Elevating System

1. Description of the units 1.1 Elevating cylinder 1. The elavating cylinder serve to elevate the boom.

2. A pressure sensor is installed to input the value to the AML for calculating load moment.

1.2 Counterbalance valve 1. This valve serves to prevent the cylinder piston rod from pushed in by the load during boom lowering to maintain the lowering speed at a level determined by the oil entry flow rate to the cylinder.

2. It also prevent the retraction of the piston rod when the piping between it and the manual control valve is broken.

1

WE02-0181E

E-2

E- 2

Elevating Cylinder E-2

Elevating Cylinder

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

1. Structure

1.Spring pin 2.Packing 3.Backup ring 4.O-ring 5.Piston 6.O-ring 7.Rod cover assy 8.---

9.Packing 10.Backup ring 11.Head cover 12.O-ring 13.Dust seal 14.Retaing ring 15.--16.---

17.Counter balance valve assy 18.Cover 19.Hexagon socket head bolt 20.Spring washer 21.--22.--23.Plain bearing 24.Rod assy

2

W155-0291E

25.Cylinder 26.Damper ring 27.Plate 28.Plug 29.Grease nipple 30.Orifice

E-2.

E-2.

Elevating Cylinder *1:Face the notch or the lip toward the pressurized side. *2:Apply Three-bond 1401 or equivalent. *3:Apply Three-bond 1104 or equivalent. *4:Apply KONISHI car body sealer or equivalent (waterproof), however it is not possible to paint on the rubber side of dust seal.

Thread size and tightening torque Sign / port

Thread size

A

Tightening torque N-m

ft-lbf

G3/4

108 - 123

80 - 90

B

G1/2

54 - 64

40 - 47

C, D

G3/8

25 - 30

18.5 - 22

0 360-273-20000 △

3

W155-0291E

E -3

E -3

Counterbalance Valve (Elevating) E-3

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 B C A IW119-022001

1.Body

6.Orifice (φ0.7)

11.Plug

16.Backup ring

2.Main spool

7.O-ring

12.Backap ring

17.O-ring

3.Check valve

8.Orifice (φ0.5)

13.O-ring

18.O-ring

4.Spring

9.Spring

14.O-ring

19.O-ring

5.Pilot spool

10.Spring

15.Plug

20.Backup ring

Thread size and tightening torque Sign / Port

Thread size

6 8 11 15

-

Tightening torque N-m ft-lbf 9 - 10 6.5 - 7 1 - 1.2 0.7 - 0.9 78 - 98 58 - 72 29 - 49 22 - 36

4

WE119-0510E

E -3 .

E -3 .

Counterbalance Valve (Elevating) 2. Function

This counterbalance valve prevents the actuator

2.3 While actuator descends

from being driven by the load and its own weight 1. The hydraulic oil directly flowing from the control

faster than the speed corresponding to the oil

valve to the actuator also enters through port PP

supply rate.

to exert force to the main spool to move the main

2.1 When control valve is at the neutral position

spool.

2. Consequently, the holding hydraulic pressure in

The actuator holding pressure is sealed by seat

port B is vented to port A.

“a” of the main spool and seat “b” of the check valve.

3. At this time, the main spool motion is smoothened by orifices.

2.2 While actuator is being pushed up 1. The pressurized oil entering through port A of the control valve enters chamber C, flows out through port B by opening the check valve, and enters the holding side of the actuator.

2. At this time, since port PP is connected to the tank circuit, the main spool is kept forced to the valve body by the spring, and remains inactive.

4 162-651-53000 △

5

WE119-0510E

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

Description of the units ............................. 1 1.1

Hydraulic motor .......................................... 1

1.2

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

1.3

Hydraulic valve (winch brake release) ....... 1

F-2 Winch ................................................ 2 1.

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

2.

Assembly .................................................. 3

F-3 Hydraulic Motor and Counterbalance Valve ............. 4 1.

Structure ................................................... 4 1.1

General view............................................... 4

1.2

Hydraulic motor .......................................... 5

1.3

Counterbalance valve assy ........................ 6

F-4 Hydraulic Valve (Winch Brake Release)............ 7 1.

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

F-5 Solenoid Valve (Winch Speed Select) .............. 8 1.

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

i

F-1.

F-1.

Winch System F-1

Winch System

1. Description of the units 1.1 Hydraulic motor 1. A hydraulic motor provided with multiple wet brake, which converts the pressurized oil delivered from the motor into the turning force.

2. When a winch lever is operated, this motor releases the brake by the pressurized oil delivered from the hydraulic valve, as well as transmits the turning force.

3. The motor power is transmitted to the winch drum.

While the rotating speed is reduced and torque is increased with by the planetary gear reduction device.

1.2 Counterbalance valve 1. This valve gives back pressure to the return circuit in order to prevent abrupt load falling or motor rotation and ensure the hoist-down speed corresponding to the oil rate delivered from the hydraulic motor.

2. When high hold pressure is generated between the winch motor and the counterbalance valve due to quick switching of the winch operation selector valve, the overload relief valve opens to let the pressure escape to the tank in order to prevent damage.

1.3 Hydraulic valve (winch brake release) The hydraulic valve is actuated by the winch operating hydraulic pressure and the accumulator pressure. When the winch is operated the valve routes the accumulator pressure to the automatic brake cylinder to release the brake.

1

WF02-0360E

F-2

F-2

Winch F-2

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

2

W526-0360E

F-2.

F-2.

Winch 1.Hexagon socket head bolt

13.Snap ring

25.Spring pin

37.Collar

2.Plate

14.Needle bearing

26.---

38.Nut

3.Pin(B)

15.Hexagon socket head bolt

27.---

39.Washer

4.Planetary gear

16.Planetary gear

28.Sleeve

40.Ball bearing

5.Needle bearing

17.Pin(A)

29.Oil seal

41.Spacer

6.Carrier(A)

18.Spacer

30.Ball bearing

42.Snap ring

7.Snap ring

19.Ball bearing

31.Ball bearing

43.Plug

8.Bracket

20.Plug

32.Drum shaft

44.Name plate

9.Plug

21.Internal gear

33.Drum

45.Rivet

10.Sun gear

22.Carrier(B)

34.Bolt

46.Plug

11.Sun gear

23.Flange

35.Spring washer

12.Plate

24.Spring pin

36.Drum boss

Thread size and tightening torque Sign / Port

Thread size

Tightening torque N-m

ft-lbf

1, 15

M12

7 - 8.4

5-6

34

M16

18 - 21

13.3 - 15.5

2. Assembly [NOTICE] Apply THREE BOND 1215 on the mating surface between bracket(8) and internal gear(21).

Apply THREE BOND 1215 on the mating surface between flange(23) and internal gear(21).

Apply THREE BOND 1215 on the outer of oil seal(29), and press-fit oil seal(29) into flange(23).

Apply lithium type grease on the inner of oil seal(29).

Supply gear oil into the reducer about 2L(0.528gal).

2 360-717-70000 △

3

W526-0360E

F-3

F-3

Hydraulic Motor and Counterbalance Valve F-3

Hydraulic Motor and Counterbalance 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 General view

Dr

A

B IW102-042001

Thread size and tightening torque

Sign / Port

Tightening torque

Thread size

N-m

ft-lbf

A, B

G1

196

145

Dr

G3/8

49

36

Air bleeding port

Rc1/4

10.6-30.9

8-23

Mounting bolt

M16

132-157

97-116

4

W526-0420E

F-3

F-3

Hydraulic Motor and Counterbalance Valve 1.2 Hydraulic motor assy

3

9

26,26-1 26-2

13

28

19

23

21

22 16 15 27,27-6

6 20

1 12 27-2 27-3

8

11

5

2

10

7

27-5

27-4 27-1 14

18

17 IW102-042003

1.Shaft

11.Spring washer

20.Housing

27-2.Sheet

2.Bearing

12.S-bolt

21.Spring washer

27-3.C-retaining ring

3.Oil seal cover

13.Spring

22.Bolt

27-4.Plunger

5.Oil seal

14.Parallel pin

23.Bottom cover

27-5.Plunger bearing

6.O-ring

15.Plate

26.Plunger holder assy

27-6.Cylinder barrel

7.O-ring

16.Valve plate

26-1.Plunger holder

28.Plug

8.O-ring

17.Ball bearing

26-2.Spherical ring

9.Cam plate

18.Spring pin

27.Cylinder barrel assy

10.Spring pin

19.O-ring

27-1.Center spring

5

W526-0420E

F-3.

F-3.

Hydraulic Motor and Counterbalance Valve 1.3 Counterbalance valve assy 19

24

23 17 8 18 10

1-4

2

1-3

1-2

A

1,1-1

16

B

15

9

14

6

13

7

12

26

11

5 4

25-10

3

25-1, 25 25-9

20 25-16 25-17

1-5

25-14 25-15

19

25-13 21

22

25-2

25-3 25-12 25-11 25-4 25-5 25-6 25-7 25-8 IW102-042004

1.Body assy

8.Spring cover

20.Spring

25-7.O-ring

1-1.Body

9.O-ring

21.Cover

25-8.Backup ring

1-2.Spool

10.C-bolt

22.C-bolt

25-9.O-ring

1-3.Plug

11.Orifice plate

23.Plug

25-10.O-ring

1-4.Piston

12.Spring

24.C-bolt

25-11.Backup ring

15.Check

13.Check

25.Overload relief valve assy

25-12.O-ring

2.Orifice plug

14.Plug

25-1.Body

25-13.Cap

3.Steel ball

15.O-ring

25-2.Orifice plate

25-14.Nut

4.Spring

16.O-ring

25-3.Needle valve

25-15.Set screw

5.Plug

17.Cover

25-4.Spring

25-16.Cap nut

6.Spring

18.C-bolt

25-5.Spring seat

25-17.Tube

7.Spring

19.O-ring

25-6.Push rod

26.Spring

1 366-616-80000 △

6

W526-0420E

F-4.

F-4.

Hydraulic Valve (Winch Brake Release) F-4

Hydraulic Valve (Winch Brake Release)

[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 B1 P1 B2 P2

T Dr

AC IW123-0200E01

1. Valve body

4. Side cover

7. Plug

10.Spring seat

2. O-ring

5. Spool

8. Hexagon socket head bolt

3. Side cover

6. Spring

9. Hexagon socket head bolt

Thread size and tightening torque

Sign / port

Tightening torque

Thread size

N-m

ft-lbf

P1,P2,B1,B2,Ac

G 1/4

29.4

22

T, Dr

G 1/4

29.4

22

Bolt •8, 9

M8

23 - 27

17 - 20

Mounting screw (2 places)

M8

23 -27

17 - 20

7

W123-0201E

0 366-452-90000 △

F-5

F-5

Solenoid Valve (Winch Speed Select) F-5

Solenoid Valve (Winch Speed Select)

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

1. Structure 1.Body

A B

2.Plunger

P

T

3.Spring 4.Plug

T

5.Plug 6.O-ring

P IW121-0460E02

7.Solenoid valve assy 8.Orifice 9.O-ring

7 8 9 4 T

B

P

P T

1

2

3

5

6

IW121-0460E01

Thread size and tightening torque Sign / Port

Thread size

P, T 5

G3/4 G3/4

Tightening torque N-m ft-lbf 108 - 122.5 80 - 90 108 - 122.5 80 - 90

8

W121-0461E

F-5.

F-5.

Solenoid Valve (Winch Speed Select)

Solenoid valve assy 1.Body 2.Plug 4.Spool 7.Spring seat 8.Square ring 9.O-ring 11.Spring 12.Solenoid (DC24V) 15.Hexagon socket head bolt

Thread size and tightening torque Sign / Port

Thread size

2 15 T1 T2

M5 -

Tightening torque N-m ft-lbf 44 - 49 32 - 36 7 5 39 - 49 29 - 36 4.4 – 5.4 3-4

3 366-420-10000 △

9

W121-0461E

G Telescoping System Contents G-1 Telescoping System ........................ 1 1.

2.

3.

4.

General..................................................... 1

G Reassembly ............................................ 10

4.1

Greasing....................................................10

4.2

Install anti-buckling bolts for telescoping

1.1

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

1.2

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

4.3

Installing lower slide plates .......................10

1.3

Hydraulic valve ........................................... 1

4.4

Installing slide plates onto sides of

1.4

Hose reel .................................................... 1

cylinder................................................10

rear end...............................................10

Description of telescoping system (Refer to the circuit diagram in Chapter Z.)... 2 2.1

Extension circuit ......................................... 2

2.2

Retraction circuit......................................... 2

5.

5.1

6.

Boom telescoping mechanism .................. 3 3.1

Extension.................................................... 3

3.2

Retraction ................................................... 4

Adjustment .............................................. 11 Adjusting clearance for the boom ............. 11

Test

.................................................... 12

6.1

Operation test ...........................................12

6.2

Boom lateral warp test ..............................12

6.3

Other functional test..................................12

G-3 Jib .................................................13 G-2 Boom (Four-Section Boom) ............ 5 1.

1.

2.

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

1.1

Location of Jib...........................................13

1.2

Jib main body............................................15

Disassembly ............................................. 7 2.1

Removing the 2nd boom section................ 7

2.2

Removing the 3rd boom section................. 8

2.3

Removing the top boom section................. 9

G-4 Telescoping Cylinder .....................17 1.

3.

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

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

Check .................................................... 10 3.1

Boom ........................................................ 10

3.2

Slide plate................................................. 10

3.3

Sheave ..................................................... 10

3.4

Boom telescoping wire rope ..................... 10

G-5 Counterbalance Valve (Telescoping) .........................19

i

1.

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

2.

Function .................................................. 20

2.1

When control valve is at the

2.2

While actuator is being pushed up ........... 20

2.3

While actuator descends .......................... 20

neutral position ................................... 20

G-6 Hose Reel ....................................... 21 1.

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

2.

Dismounting............................................ 22

3.

Mounting................................................. 22

4.

Disassembly ........................................... 22

5.

Reassembly............................................ 22

G-7 Hydraulic Valve .............................. 24 1.

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

ii

G -1

G -1

Telescoping System G-1

Telescoping System

1. General 1.1 Telescoping cylinder 1. The telescoping cylinders are incorporated in the boom, and serve to telescope the boom to witch they are connected by pins.

2. It telescopes the 2nd boom section, and telescopes the 3rd and top boom sections simultaneously using two double-acting hydraulic cylinders and wire ropes.

1.2 Counterbalance valve 1. The counterbalance valve is directly connected to the telescoping cylinder, and serves to prevent the cylinder from retracting while the control lever is in NEUTRAL, to prevent the cylinder from being driven by the load during retraction, and to prevent its violent retraction, when the hoses and other parts of the extension circuit are damaged.

1.3 Hydraulic valve This valve is electrically controlled to selectively deliver the pressurized oil from the manual control valve into the No. 1 cylinder circuit or the No.2 cylinder circuit.

1.4 Hose reel The hose reel serves to let out and take in the hose as the boom telescopes to maintain the hydraulic circuit to the No.2 cylinder all the time.

1

WG02-0460E

G -1

G -1

Telescoping System 2. Description of telescoping system (Refer to the circuit diagram in Chapter Z.) Top boom section retraction wire rope

Sheave at the head of the 3rd boom section Top boom section extension wire rope

Fix at the head of the 2nd boom section

Fix at the rear end of the top boom section

Adjuster and sheave on the head of the 2nd boom section

Sheave at the rear end of the 3rd boom section

Top boom

3rd boom

2nd boom

Base boom

Fold at the rear end of the 3rd boom section IWG02-0440E02

5. The 3rd and top boom sections are extended by

2.1 Extension circuit

the wire-rope mechanism linked to the No. 2 1. When the boom telescoping lever is operated to

telescoping cylinder.

the extension side, shifting the telescoping control valve to extension side and delivering the

2.2 Retraction circuit

pressurized oil from the hydraulic pump to the

1. Pressurized oil for boom retraction is delivered

selector valve.

from the manual control valve to the No. 1 and No.

2. The pressurized oil is sent to the No. 1

2 telescoping cylinder directly.

telescoping cylinder, making the 2nd boom

2. While the No. 2 telescoping cylinder is extended,

section extend.

the solenoid of the selector valve is energized due

3. After the 2nd boom section is fully extended,

to the boom full retraction detector switch.

press the next section extension switch while

Consequently the return circuit of the No. 1

keeping the boom telescoping lever operated. The

telescoping cylinder is closed and only the No. 2

hydraulic valve will be energized, the pressurized

telescoping cylinder retracts, resulting in retraction

oil will be sent to the No. 2 telescoping cylinder

of the 3rd boom section.

and the 3rd boom section will extend.

3. At the same time, the 3rd and top boom sections retract by the wire-rope mechanism.

4. In this case, you need not keep pressing the next section extension switch when the No. 2

4. When the No. 2 telescoping cylinder is almost fully

telescoping cylinder extends slightly because the

retracted, the boom full retraction detector switch

boom full retraction switch is shifted and the

is activated and disestablishes the solenoid

solenoid self-holding circuit for the hydraulic valve

self-holding circuit for the hydraulic valve.

is established.

Consequently the selector valve automatically shifts, the No. 1 telescoping cylinder retracts and the 2nd boom section retracts.

2

WG02-0460E

G -1

G -1

Telescoping System 3. Boom telescoping mechanism

Balance of force

3.1 Extension

: F3 = 4 ×

WT = 2WT 2

Equation of workload : W T × E4 = F3 ×E3

1. 2nd boom section Extended by No.1 cylinder

∴E4 = F3 ×

(L1: No.1 cylinder stroke) 2nd boom section travel (E2)=L1

E3 WT

= 2WT ×

2. 3rd boom section

E3 WT

= 2E3

Extended by No.2 cylinder (L2: No.2 cylinder stroke)

Top boom section travel (E4) = 2L2

3rd boom section travel (E3)=L2 3. Top boom section Extended by the wire rope mechanism that synchronizes with the extension of 3rd boom section F3 3rd boom WT 2

WT WT 2 2

WT 2

Top boom

E4

Top boom WT

2nd boom

2nd boom 3rd boom

2nd boom

.

IWG02-0440E03

E4 : top boom section travel E3 : 3rd boom section travel F3 : 3rd boom section force W T : Top boom section weight

3

WG02-0460E

G -1 .

G -1 .

Telescoping System 3.2 Retraction

2. 3rd boom section Retracted by No.2 cylinder 3rd boom section travel (R3) = L2

1. Top boom section Retracted by the wire rope mechanism that synchronizes with the retraction of 3rd boom

3. 2nd boom section Retraction by No.1 cylinder 2nd boom section travel (R2) = L1

section.

2nd boom F3

WT 2

R3=L2 3rd boom

3rd boom WT 2

WT 2

WT 2

2nd boom

R4

WT 2

WT 2 Top boom

Top boom IWG02-0440E04

R4 : Top boom section travel R3 : 3rd boom section travel (=L2: No.2 cylinder stroke) F3 : 3rd boom section force (=No.2 cylinder force) W T : Top boom section weight : F3 = 4 ×

Balance of force

WT = 2WT 2

Equation of workload : W T × R4 = F3 × R3

∴R 4 = F3 ×

R3 WT

= 2WT × = 2R3

R3 WT

= 2L2

Top boom section travel (R4) = 2L2

4

WG02-0460E

G -2

G -2

G -2

Boom (Four-Section Boom) G-2

Boom (Four-Section Boom)

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

1. Structure

5

W536-1010E

5

G -2

G -2

Boom (Four-Section Boom) 1.Top boom section

22.Snap pin

43.Retainer assy (R)

64.Thoothed look washer

2.Third boom section

23.Pin

44.Retainer assy (L)

65.Sheave assy

3.Second boom section

24.Spacer

45.Slide plate

66.Retaining ring

4.Base boom section

25.Sheave assy

46.Retainer assy (R)

67.Pin

5.Slide plate assy

26.Shim

47.Plate

68.Bolt

6.Slide plate assy

27.Guide

48.Bolt

69.Slide plate

7.Slide plate assy

28.Wire rope

49.Plate

70.Pin

8.Slide plate assy

29.Adjust assy

50.Pin

71.Pin

9.Slide plate assy

30.Nut

51.Hexagon socket head bolt

72.Set screw

10.Shim

31.Nut

52.Slide plate

73.Plain bearing

11.Spacer

32.Wire rope

53.Shim

74.Slide plate

12.Pin

33.Guide

54.Shim

75.Shim

13.Plate

34.Bolt

55.Pin

76.Shim

14.Bolt

35.Spring washer

56.Bolt

77.Bolt

15.Spring washer

36.Support

57.Slide plate

78.Nut

16.Pin

37.Hexagon socket head bolt

58.Shim

79.Grease nipple

17.Sheave assy

38.Slide plate

59.Shim

80.Retainer assy (L)

18.Spacer

39.Guide

60.Hexagon socket head bolt

81.Plain washer

19.Nut

40.Bolt

61.Guide

82.Grease nipple

20.Toothed lock washer

41.Bolt

62.Slide plate

83.Pin

21.Pin

42.Spring washer

63.Nut

84.Snap pin

0 322-012-50000 △

6

W536-1010E

G -2

G -2

Boom (Four-Section Boom) 2. Disassembly The procedure to remove the 2nd boom section and further sections as an assembly is described below.

2.1 Removing the 2nd boom section 1. Retract the boom fully and set the crane level.

2. Remove the hook block and the rope socket.

Wind up the wire rope on the drum.

3. Swing the boom to place where there is enough clearance, then lower the boom to 0° and stop the engine.

4. Remove the wiring connector, loosen the wiring clip and secure the cable end using a tape at the 6. Pull out the connecting pin that connects the base

cable guide (a) located closest to the cord reel.

boom section and the No. 1 telescoping cylinder by removing the retaining ring. Then loosen the nut and remove the bolt.

5. Remove the high-pressure hoses (2 pieces) and the hose leading to the hose reel from the telescoping cylinder.

[NOTICE] To prevent the hose reel from spinning, attach a wire to the hose to the pipe sleeve of the hose and secure the wire to the swing frame.

7. After removing the slide plate assy on the top of the base boom section head, pull out the 2nd boom section by approx. 1 m (3.281 ft).

8. While lifting up the 2nd boom section slightly, remove the retainer and slide plate from the bottom of the base boom section head.

9. Lift up and pull out the 2nd boom section using a crane, and place it on a level platform.

7

W536-1010E

G -2

G -2

Boom (Four-Section Boom) 2.2 Removing the 3rd boom section

5. Lift up and pull out the No.1 telescoping cylinder using a crane.

1. Remove the high-pressure hose (1 piece) that connects the No.1 telescoping cylinder and No.2

6. Remove the connecting pin that connects the

telescoping cylinder.

No.2 telescoping cylinder and the 2nd boom section.

Then loosen the nut and remove the bolt.

2. Remove the support assy of the No.1 telescoping cylinder located at the rear end of the 3rd boom section by loosening the bolt.

7. Remove the end of wire rope for the top boom section extension located on the top of the 2nd boom section head by loosening the nut.

[NOTICE] Before loosening the nut, measure the length of the wire rope protrusion (L1) as a guide for reassembly.

8. Remove the sheave assy from the 3rd boom

3. Lift up and retain the No.1 telescoping cylinder

section head.

using a crane.

4. After removing the retaining ring, remove the connecting pin that connects the 2nd boom section and the No.1 telescoping cylinder.

9. Fix the end of wire rope to the top boom section with the string etc.

10. Remove the adjuster assy from the 2nd boom section by loosening the bolt, fix to the 3rd boom section with the string etc.

8

W536-1010E

G -2

G -2

Boom (Four-Section Boom) 2.3 Removing the top boom section

[NOTICE] Before loosening the nut, measure the length of the wire rope protrusion (L2) as a guide for reassembly.

1. Remove the sheave located on both side of the rear end of the 3rd boom.

11. Lift up and retain the No.2 telescoping cylinder using a crane.

Next, remove the connecting pin that connects the 3rd boom section and the No.2 telescoping cylinder.

12. Lift up and pull out the No.2 telescoping cylinder

2. Remove bolt, pin and the wire ropes for top boom

using a crane.

section retraction.

13. After removing the slide plate assy on the top of

3. After removing the slide plate assy on the top of

the 2nd boom section head, pull out the 3rd boom

the 3rd boom section head, pull out the top boom

section by approx. 1m (3.281ft).

section by approx. 1m (3.281ft).

14. While lifting up the 3rd boom section slightly,

4. While lifting up the top boom section slightly,

remove the retainer and slide plate from the

remove the retainer and slide plate from the

bottom of the 2nd boom section head.

bottom of the 3rd boom section head.

15. Lift up and pull out the 3rd boom section using a

5. Lift up and pull out the top boom section using a

crane, and place it on a level platform.

crane, and place it on a level platform.

[NOTICE]

[NOTICE]

When pulling out the 3rd boom, take care not to damage wire rope located on the upper surface.

Pull out the extending and retracting wire rope on the top boom section together.

9

W536-1010E

G -2

G -2

Boom (Four-Section Boom) 3. Check

4. Reassembly

3.1 Boom

4.1 Greasing

Check the boom for twist, deformation, wrap, and

• When installing unplated pins, apply grease

cracks.

beforehand.

• Apply TNR-2 Grease sufficienty to the sliding

3.2 Slide plate

surfaces of the slide plates, the booms and Check the slide plates for cracks and wear, and

telescoping cylinders.

replace when these conditions are excessive.

4.2 Install anti-buckling bolts for telescoping cylinder

3.3 Sheave Check the sheaves for damage, deformation and

A

wear, and replace them when these conditions are

Boom side

B

E D

Cylinder side

excessive.

3.4 Boom telescoping wire rope S

Wire rope in the condition described below must not

C

be used.

IW536-0680E12

• Deformation or corrosion 1. Connect the boom and telescoping cylinder using

• Kinking

the pins A and B. 2. Adjust the bolt C locked with nuts D and E so that

• 10% or more broken wire (filler wires excluded) in

it can be turned by hand and the clearance (S) is

one lay of the wire rope

0.5mm (0.02in) or less.(Apply thread locking • diameter reduction exceeding 7% of the nominal

agent.)

diameter.

[NOTICE] • Evidence of any heat damage from any cause.

Refer to normal insert directions of bolt•C shown on [2.Disassembly]

4.3 Installing lower slide plates 1. Apply thread locking agent to the bolt, tighten it lightly and turn it in reverse for a quarter turn.

2. If the tip of the bolt protrudes beyond the bottom of the retainer, scrape it off with a grinder.

4.4 Installing slide plates onto sides of rear end Apply thread locking agent to the bolt, tighten it lightly and turn it in reverse for a quarter turn.

10

W536-1010E

G -2

G -2

Boom (Four-Section Boom) 5. Adjustment 5.1 Adjusting clearance for the boom 1. Lateral clearance at the bottom of the boom rear end Place shims so that the total clearance (distributed to right and left) is 0.5 mm (0.02 in).

2. Upper clearance on boom rear end Place shims that the lateral deviation of center is ±1.5 mm (0.06 in), and vertical deviation is 3-5 mm (0.12-0.2 in).

3. Lateral clearance at boom head Place shims so that the total clearance is 0.5 mm (0.02 in) when the boom is 1 m (3.281 ft) longer than that of full retraction.

11

W536-1010E

G -2 .

G -2 .

Boom (Four-Section Boom) 6. Test [NOTICE] ◆Bleed the telescoping cylinders completely and apply grease to the boom sliding surfaces before starting the tests.

6.1 Operation test Telescope the boom several times, and make sure that the telescoping operation is in order.

6.2 Boom lateral warp test [Conditions] ･Crane levelness : ± 6' max. ･Boom length

: Full extension

･Boom elevation : Maximum ･Boom direction : Over-front, Over-rear, Over-right, Over-left

6.3 Other functional test

･Other conditions: Free from solar heat and wind

Check all the electric and electric parts (boom

1. The hook displacement (A in sketch) under the

length and angle detector, etc.) that are influenced

above test conditions under no load must be

by boom dismounting, for function and accuracy.

brought within 150mm (5.9 in) in all boom directions by shim adjustment.

2. After shim adjustment, the hook displacement (A in sketch) under the above test conditions under the total rated load must be within the specified of 450mm (17.7 in).

When the displacement is more than the specified limit, readjust the shim.

12

W536-1010E

G -3

G -3

Jib

3 ：291042 - △ 2 ：291036 - △ Applicable serial No. △ 1 ：291032 - -

G -3

G-3 Jib 1. Structure 1.1 Location of Jib

13

W537-0180E

13

G -3

G -3

Jib 1.Jib assy

7.Support

13.Pin assy

19.Support

2.Pin assy

8.Support assy

14.Support

20.Support

3.Grease nipple

9.Plate

15.Support

21.Stopper 2

4.Nut

10.Plate

16.Pin

5.Bolt

11.Plate

17.Plate

6.Plate

12.Stopper

18.Plate

2 332-216-10000 △

14

W537-0180E

G -3

G -3

G -3

Jib 1.2 Jib main body

15

W537-0180E

15

G -3 .

G -3 .

Jib 1.Jib

8.Guide assy

15.Link

22.Retaining ring

2.Support

9.Pin

16.Pin

23.Pin

3.Sheave assy

10.Plain washer

17.Snap pin

24.Snap pin

4.Spacer

11.Split pin

18.Stopper

25.Support

5.Pin

12.Pin

19.Sheave assy

26.Support

6.Bolt

13.Plain washer

20.Pin

27.Pipe

7.Spring washer

14.Plate

21.Grease nipple

28.Support assy

1 332-216-11000 △

16

W537-0180E

G -4

G -4

Telescoping Cylinder G-4

Telescoping Cylinder

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

1. Structure

IW157-0390E01

1. No.1 cylinder 2. No.2 cylinder 3. Hose 4. Bolt Thread size and tightening torque

Sign / Port

Thread size

Tightening torque N-m

ft-lbf

A, B

G4/3

108 - 123

80 - 90

C

G1/2

54 - 64

40 - 47

4

M10

43 - 49

32 - 36

17

W157-0450E

G -4 .

G -4 .

Telescoping Cylinder

1.Plug

7.Plain bearing

13.Support

2.Spring pin

8.O-ring

14.Damper ring

3.Nut

9.Cylinder

15.Packing

4.Piston

10.Rod

16.Backup ring

5.Packing

11.O-ring

17.Plain bearing

6.Backup ring

12.Rod cover assy

18.Dust seal

19.Backup ring

*1: Face the notch or lip toward the pressurized side.

4 360-118-70001 △ 3 360-118-60000 △

18

W157-0450E

G -5

G -5

Counterbalance Valve (Telescoping) G-5

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 B C A IW119-022001

1.Body

6.Orifice (φ0.7)

11.Plug

16.Backup ring

2.Main spool

7.O-ring

12.Backap ring

17.O-ring

3.Check valve

8.Orifice (φ0.5)

13.O-ring

18.O-ring

4.Spring

9.Spring

14.O-ring

19.O-ring

5.Pilot spool

10.Spring

15.Plug

20.Backup ring

Thread size and tightening torque Sign / Port

Thread size

6 8 11 15

-

Tightening torque N-m ft-lbf 9 - 10 6.5 - 7 1 - 1.2 0.7 - 0.9 78 - 98 58 - 72 29 - 49 22 - 36

19

W119-0510E

G -5 .

G -5 .

Counterbalance Valve (Telescoping) 2. Function

This counterbalance valve prevents the actuator

2.3 While actuator descends

from being driven by the load and its own weight 1. The hydraulic oil directly flowing from the control

faster than the speed corresponding to the oil

valve to the actuator also enters through port PP

supply rate.

to exert force to the main spool to move the main

2.1 When control valve is at the neutral position

spool.

2. Consequently, the holding hydraulic pressure in

The actuator holding pressure is sealed by seat

port B is vented to port A.

“a” of the main spool and seat “b” of the check valve.

3. At this time, the main spool motion is smoothened by orifices.

2.2 While actuator is being pushed up 1. The pressurized oil entering through port A of the control valve enters chamber C, flows out through port B by opening the check valve, and enters the holding side of the actuator.

2. At this time, since port PP is connected to the tank circuit, the main spool is kept forced to the valve body by the spring, and remains inactive.

4 162-651-53000 △

20

W119-0510E

G -6

G -6

Hose Reel G-6

Hose Reel

[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.Drum plate

8.Aux. spring

15.Retaining ring

22.Special bolt

2.Drum plate

9.Spring case

16.Oil seal

23.Spring washer

3.Seat packing

10.Bearing

17.Spacer

24.Nut

4.Special bolt

11.Bush

18.Pin

25.Bolt

5.Spring washer

12.Seal ring

19.Set screw

26.Plate

6.Nut

13.Backup ring

20.O-ring

27.Bolt

7.Spring

14.Bearing

21.Support

28.Spring washer 29.Stop plate

21

W183-0240E

G -6

G -6

Hose Reel 2. Dismounting

1) Remove the protection plate from the case 4 and secure the case 4 in a sufficiently wide

[NOTICE]

space.

When the circuit is suspected to retain high pressure oil, be sure to vent pressure before dismounting the hose reel.

2) Tie one end of a wire of a sufficient length to the inner end of the spring 5 and pull the other

Since the spring force for extra winding turns is applied to the hose, hold the drum when disconnecting the hose.

end of the wire by hand to take out the spring 5.

5. Reassembly 3. Mounting

1. Install seal rings and backup rlngs on pin, apply grease thinly on these rings and their surrounding

[NOTICE]

areas,and install the pin in spring case.

After installation and bleeding the circuit and the device, test the operation check and check any abnormality.

2. To reinstall spring in case proceed as follows:

1. After making sure that the whole hose is reeled in,

[NOTICE] If the spring recoils, it may hurt personnel. Be sure to clamp it securely with vice pliers.

turn the reel further (for 4.5 - 5.5 turns).

2. Draw out the hose and install it.

Clamp with vice pliers, paying attention to the installation orientation of the spring.

4. Disassembly

1) With spring clamped by vice pliers, remove the spring holder constricting the spring.

[NOTICE] This process is very dangerous. Take extreme caution in executing it to secure safety.

1. Unscrew hexagon socket set screws, and remove support from spring case .

2. Unscrew nuts, and remove drum plates from spring case.

3. After attaching protection plates as shown, utilizing the case mounting holes, to prevent spring from hurtling out, unscrew special bolt on the pin side, and extract pin.

4. To replace spring, remove it from spring case as follows:

22

W183-0240E

G -6 .

G -6 .

Hose Reel

2) With the lower side coated with grease, place spring in case clamped in a vise, and install the protection plates.

3) Fasten spring and pin with special bolt coated with screw locking compound.

4) Remove the vise pliers on the outer end side of spring and attach auxiliary spring.

5) Fasten the spring to spring case with special bolt coated with screw locking compound.

6) After installation, apply water repllant compound to nut.

7) Remove the remaining vice pliers.

3. Temporarily install drum plate, to spring case, install support to pin, and fasten with set screws.

4. Remove the protection plates, install seat packing, coated with adhesive on both sides, aligning with the bolt holes to spring case.

5. Install drum plates to the spring case with nuts.

6. Apply water replellant compound to the mating surfaces of drum plates.

366-714-10000

23

W183-0240E

0 △

G -7

G -7

Hydraulic Valve G-7

Hydraulic 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

PP

P

C

T

Dr IW123-017001

PP

Dr C

P

T

IW123-017002

Thread size and tightening torque Sign / Port

Thread size

Tightening torque N-m

ft-lbf

P, C, T

G3/4

167

123

PP, Dr

G1/4

29.4

22

24

W123-0172E

G -7

G -7

Hydraulic Valve

19

6

17

3 15 C

15

3

P

10

1

T

Dr

2

7

10 IW123-017003

1.Body

3.Cover

7.Spring

15.Hex. socket head bolt

2.Spool

6.Solenoid valve

10.O-ring

17.Plug 19.Orifice

Thread size and tightening torque Sign / Port Mounting bolt (for solenoid valve.6)

Thread size

M5

Tightening torque N-m

ft-lbf

7

5

25

W123-0172E

G -7 .

G -7 .

Hydraulic Valve Solenoid valve assy Connector (+): Red (-): Blue

+IW121-0542E01

T1

3

T

T2

12

9

1

A

15

P

B

8

7

T

11

2

IW121-025003

1.Body

7.Spring seat

11.Spring

2.Plug

8.Square ring

12.Solenoid

3.Spool

9.O-ring

15.Hexagon socket head bolt

Thread size and tightening torque Sign / Port

Thread size

2 15 T1 T2

M5 -

Tightening torque N-m 44 - 49 6.9 - 8.9 39 - 49 4.4 - 5.4

ft-lbf 32.5 - 36 5 - 6.5 28.8 - 36 3.3 - 4

1 366-497-50000 △

1 366-463-10000 △

26

W123-0172E

H Safety System

Contents H-1 Safety System .................................. 1 1.

H-3 Outrigger Extension Length Detector ....................................8

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

Pressure sensor ......................................... 1

1.2

Boom length and angle detector ................ 1

1.3

Outrigger extension width detector............. 1

1.4

Other detectors and switches..................... 1

1.5

AML (Load moment indicator) main body .. 1

1.6

Overwind cutout (Anti-twoblock) device ..... 1

1.7

Solenoid valve ............................................ 1

1.

Structure and function ............................... 8

2.

Disassembly.............................................. 9

3.

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

H-4 Solenoid Valve (Auto Stop) ...........12 2.

Description of system................................ 1 1.

H-2 Boom Length and Angle Detector .. 2 1.Structure and function................................... 2 2.

Disassembly and reassembly ................... 4 2.1

Removing the cord ..................................... 4

2.2

Installing the cord ....................................... 4

2.3

Replacing spiral spring ............................... 6

2.4

Disassembling the potentiometer (for boom length detector).................... 6

3.

2.5

Reassembling potentiometer...................... 7

2.6

Replacing the boom angle detector ........... 7

Adjustment................................................ 7

i

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

H

H-1 .

H-1 .

Safety System H-1

1.6 Overwind cutout (Anti-twoblock) device

Safety System

1. General

The anti-twoblock device prevents damage to the crane that would be caused by pulling the hook

1.1 Pressure sensor

block into the boom head. When the hook block approaches the boom head, single top or jib, the

1. A retraction pressure sensor and an extension pressure sensor are incorporated in the elevating

overwind cutout device sends a signal to AML,

cylinders.

which then stops any further crane action toward the critical condition.

2. They convert the elevation pressure into the electric signal and transmit it to AML (Load

1.7 Solenoid valve

moment indicator) main body, making the limiter

1. If AML malfunctions or if the actual moment

calculate the total moment created by the lifted load and the mass of the boom.

reaches 100% of the rated moment or the hook

1.2 Boom length and angle detector

stop) is sent from AML main body to this valve.

block is over-hoisted, an electric signal (auto.

The Boom length and angle detector is installed

2. When the solenoid valve is deenergizied, this

on the boom side, and uses the potentiometer

solenoid valve contents the vent line of the relief

inside the detector to convert the extended boom

valve mounted on the hydraulic pilot control valve

length and the angle of the boom relative to the

to the tank. The solenoid valve by allowing the

ground into an electric signal that is transmitted to

pressurized oil from the pump to escape through

AML main body.

the relief valve to the tank, therefore the crane operation stops.

1.3 Outrigger extension width detector It is installed on the rear end of the outrigger outer

2. Description of system

case. The potentiometer in the detector converts

Refer to the repair manual of AML-L.

the outrigger extension width into the electric signal and transmits it to AML main body.

1.4 Other detectors and switches The outer detectors and switches convert the crane operation modes and working conditions into an electric signal that is transmitted to AML main body.

1.5 AML (Load moment indicator) main body 1. AML main body calculates the moment being generated on the crane based on signals from the pressure sensor and the Boom length and angle detector.

2. The calculation result is compared with the rated moment and,when it reaches 90% and 100% of the rating, AML sends alarm and auto. stop signals, respectively, to prevent the crane from being overloaded.

1

WH02-0080E

H-2

H-2

Boom Length and Angle Detector H-2

Boom Length and Angle Detector

[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 and function rotation is reduced by the reduction gear,which in turn rotates the shaft of the potentiometer.

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

3. The electric resistance of the potentiometer shaft varies proportional to the reduction of the shaft rotation,and the change in electric resistance is transmitted to the AML main body to detect the boom length.

2. The cord wound on the drum is unwound and rewound by the recoil spring after the extension and retraction of the boom.The resultant drum

2

W305-0461E

H-2

H-2

Boom Length and Angle Detector 1.Plate 2.Case 3.Drum assy 4.Slip ring assy 5.Contact assy 6.Contact assy 7.Bearing case 8.Bearing 9.Retaining ring 10.Retaining ring 11.Speed reducer 12.Gear 13.Gear

14.Bracket 15.Poteitiometer 16.Spring 17.Cover 18.Clip 19.Clip 20.Clamp 21.Cord guide 22.--23.Packing 24.Packing 25.Packing 26.Connector

27.Connector 28.Cord lock 29.--30.Pin terminal 31.Pin terminal 32.Nut 33.Washer 34.Screw 35.Bolt 36.Bolt 37.Screw 38.Screw 39.Screw

Potentiometer Resistance : 5000 ± 750Ω (for boom length detection) Electric turning angle : 347-352° Mechanical turning angle : 360°, continuous rotation Potentiometer (for boom angle detection)

Resistance : 1000±200Ω Electric angle : 120 ± 1.8°

Electric Symbol

3

W305-0461E

40.Screw 41.Screw 42.Screw 43.Set screw 44.Nut 45.Cable assy 46.--47.Holder 48.Terminal 49.Terminal 50.Angle detector 51.Plug 52.Collar

H-2

H-2

Boom Length and Angle Detector Drum assy

2. Disassembly and reassembly 2.1 Removing the cord 1. Remove the connector and the cord lock from the end of the cord. Wind up the cord on the drum slowly until no tension of the spiral spring is applied on the cord.

Plate

2. Loosen the clamp and remove the cover (2 place).

3. Disconnect the cable, potentiometer and angle detector from the terminal, and remove the cover and the cable together.

Nut

IW305-0230E04

7. Remove the slip ring assy from the drum assy.

Then remove the solder that bonds the slip ring and the cord.

4. Loosen the set screw and remove the gear. Then remove the screw and detach the speed reducer.

[NOTICE]

Slip ring assy

Remove the speed reducer straight upward. Do not twist it while removing.

Slip ring assy

5. Remove the retaining ring and bolt, and separate the case from the drum assembly.

Core wire Cord

[NOTICE]

Shield wire

Put match marks on the case and the plate to identify the direction for removing the sub-cord.

IW305-0230E05

Retaining ring

8. Detach the whole old cord from the drum assy.

Case

2.2 Installing the cord 1. Wind a yellow tape around the new cord as a 0-marker.

Bolt

Sub-cord

Plate Match marks IW305-0230E03

2. Pass the new cord through the hole of the drum 6. Remove the nut and separate the drum assy from

assy. Solder it on the slip ring assy.

the plate.

[NOTICE] Attach the cord core wire to the inner slip ring.

Attach the shield wire to the outer slip ring.

Completely insulate the soldered section.

4

W305-0461E

H-2

H-2

Boom Length and Angle Detector original position after it is rotated a quarter turn by finger and released. If it is not returned, loosen the bolt and adjust the position of the bracket.

Core wire Cord Shield wire

Vinyl tube

[NOTICE]

Drum assy

If the potentiometer is faulty, replace it referring to the "Replacing the potentiometer (boom length detector)" described later.

IW305-0230E07

3. Install the slip ring assy so that the cord is not

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

slackened.

reducer shaft using a set screw. Apply thread locking agent to the set screw.

4. Wind the new cord around the drum assy while taking up slack in the cord. When the 0-marker on the 7.33 m (24.0ft) point of the cord shows on the drum, wind the cord 7 turns more and fix it with gummed tape to prevent slackening.

Tightening torque : 1.18 N-m {0.87ft-lbf} 11.Take out the new cord from the guide hole of the cord reel and draw it out completely. Then wind it again the drum. When the 0-marker comes to the edge of the cord guide, fix the cord there as shown in the figure.

[NOTICE] Wind the cord around the drum assy clockwise as seen from the slip ring.

0-marker Slip ring

Gummed tape IW305-0230E09

Gummed tape IW305-0230E08

12. Applied voltage DC 5V to the potentiometer (for boom length detector) as shown in the figure and turn the gear using a screwdriver until the output voltage between the red and white terminals is 0.5 ± 0.06 V. Then fix the gear using a set screw.

Apply thread-locking agent to the set screw.

5. Insert the shaft of the drum assy into the boss hole of the plate and fix it with a nut.

6. Put the case over the drum assy, leading the sub-cord outside through the hole of the case and the cord end outside through the opening of the cord guide.

Tightening torque : 1.18N-m {0.87ft-lbf } Screwdriver Gear B

7. Secure the case and the plate with a bolt and

Gear A

attach the retaining ring.

Set screw Bracket Spring

8. Apply sealant agent thinly on the bottom of the speed reducer. Then install the speed reducer on the case.

White Red

9. Inset the gear on the shaft of the speed reducer.

Black

Loosen the set screw on the potentiometer side to allow both gears to idle.

Check that the gear is spring-returned to the

+ -

Tester

+

Applied voltage IW305-0230E10

5

W305-0461E

H-2

H-2

Boom Length and Angle Detector 2.4 Disassembling the potentiometer (for boom length detector)

13. Draw out the cord slightly from the drum and make sure that the resistance between the red and white terminals increases smoothly.

[NOTICE]

15. Attach the cover.

If both the cord and spiral spring are faulty, remove the detector assy from the boom.

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

16. Pull the cable to eliminate slack, and tighten the clamp. (2 places)

1. Loosen the 2 clamps and remove the bolt and cover.

17. Install the cord lock on the cord end and install

2. Disconnect the lead wire terminals (3 pieces) and

14. Connect the cable to the terminals for the potentiometer and angle detector.

cable terminal from the potentiometer, and remove the potentiometer together with the bracket.

the lead wires and the connector close to the cord end. Completely insulate the soldered connections.

[NOTICE] Before replacement, disconnect the wiring to the boom angle detector from the pin terminal section to disconnect the lead wires (red and black) from the boom angle detector.

Gear

Spring Bracket Lead wire

18. Check for conduction and shortcircuit between

Potentiometer

the terminals of the sub-cord connector and the cord connector.

To boom angle detector

Black Red Pin terminal IW305-0230E13

Sub-cord

Cord

3. Remove the gear and the spring, and detach the potentiometer from the bracket.

IW305-0230E12

4. Remove the connector and the cord lock from the

2.3 Replacing spiral spring

end of the cord. Wind up the cord on the drum slowly until no tension of the spring is applied on the cord.

[NOTICE] If the spiral spring is broken, replace the whole drum assy. For removing and installing the spring, refer to the "Removing the cord" and "Installing the cord" above mentioned.

6

W305-0461E

H-2.

H-2.

Boom Length and Angle Detector 2.5 Reassembling potentiometer

2.6 Replacing the boom angle detector

1. Install a new potentiometer.

Disconnect the lead wires to the boom angle

[NOTICE]

detector from the pin terminal section, and replace the boom angle detector assy.

To avoid exposing the potentiometer to high temperature for a long time, solder the potentiometer terminal and the lead wires quickly.

Fix the potentiometer terminal including the lead wires to the bracket using insulating sealant.

3. Adjustment 1. Adjust the cord lock so that the 0-marker on the cord is on the edge of the cord guide when the boom is fully retracted.

Recommended sealant: Shin-Etsu Silicone KE45RTV (Shin-Etsu Chemicals Industry)

Bracket 0-marker

Potentiometer

Insulating sealant

Cord lock IW305-0230E16

IW305-0230E14

2. Adjust the boom length display of the AML. (Refer to the repair manual of the AML.)

2. Loosen the set screws on the reducer side and potentiometer side to allow both gears to idle.

Check that the gear on the potentiometer side is spring-returned to the original position after it is rotated a quarter turn by finger and released. If it is not returned, loosen the bolt and adjust the position of the bracket.

Gear B Gear A

Bracket Spring

Bolt

IW305-0230E15

3. Fix the gear in the notched section of the speed reducer shaft using a set screw. Apply thread locking agent to the set screw.

Tightening torque : 1.18N-m {0.87ft-lbf} 4. Follow the same procedure as described in the step 12. and below of the "Installing the cord" section.

0 361-312-40001 △

7

W305-0461E

H-3

H-3

Outrigger Extension Length Detector H-3

Outrigger Extension Length Detector

[NOTICE]

3. The consequent rotation of the drum drives the

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.

potentiometer shaft through gears which reduce the speed to 5/6.

4. The rotation of the shaft causes a proportional change in the electrical resistance of the potentiometer. This change is supplied by the multiplex data transmission (MDT) system to the

1. Structure and function

AML (Load Moment Indicator) unit for detection of the outrigger extension length.

1. The detector consists of the following major components: a spiral spring, wire, and

5. When the wire is reeled out, the gears,

potentiometer.

potentiometer, and potentiometer brush either rotate or move.

2. The wire wound around the drum is unwound or rewound by the action of the spiral spring as the cylinder extends or retracts.

Electric symbols

Potentiometer B R W

1 3 2

Black Red White

0V +5V (Power supply) Out put IW305-0250E01

Use silicon sealant to seal the part that is shaded.

1

2

3

4

5

6

7

8

15

16

9 10

17

11

12

13

18

14

19

0V (Black) Power supply (Red)

IW305-0251E02 Output (White)

8

W305-0251E

H-3

H-3

Outrigger Extension Length Detector 1. Base plate

6. Nut

11. Screw

16. Screw

2. Drum assy

7. Potentiometer

12. Set screw

17. Clamp

3. Case

8. Cover

13. Screw

18. Connector

4. Packing

9. Shaft

14. Gear•B

19. Cable

5. Gear•A

10. Bolt

15. Bracket

4. Remove screw to remove case .

Specification Item Gear ratio

Case

Specifications 6/5 Resistance: 2kΩ ± 5%

Potentiometer

Screw

Mechanical rotating angle: 360°

IW305-0250E05

2. Disassembly 5. Remove bolt and separate drum assy and base

1. Get the wire slowly rewound round the drum until

plate.

the power spring loses its power.

2. Remove screw and loosen clamp to remove cover.

Cover Screw

Clamp

Cable

IW305-0250E03

3. Remove screw and remove potentiometer and gear together with bracket.

6. Remove the wire from the drum assy.

Potentiometer Gear Bracket Screw

IW305-0250E04

9

W305-0251E

H-3

H-3

Outrigger Extension Length Detector 3. Reassembly

4. Apply grease (Molyspeed Grease No.0) to the bearing of case and put the case over drum assy.

1. Put a zero marker on a new wire by winding a

In this time, lead the end of the auxiliary string out

yellow tape on it. Then tie an auxiliary string of

through the opening of the cord guide.

about 1.0 m (3.3 ft) in length to the terminal of the

Case

wire.

Zero marker (yellow tape) Drum side L4 L3

Aux. string

Scrwe

Approx.

1m (3.3ft)

IW305-0250E05

IW305-0251E10

5. Secure case on base plate with screw.

L3 : 2.72 m (8.9ft) L4 : 0.08m (0.26ft)

6. Draw out the wire from the guide window of the reel. After the wire has been extended to the

2. Wind the wire round drum assy until the yellow tape position. Then wind it three additional turns

0-point mark (yellow tape), secure the wire to the

an secure the wire with a packing tape to prevent

case with gummed tape.

it from getting loose.

7. Rotate gear•A of the potentiometer by hand. At the position where the resistance between B and W is

[NOTICE]

200 ± 30Ω, mesh gears•A and B, and install the

The wire winding direction should be clockwise as viewed from the shaft end.

potentiometer.

Gear B Gear A

Gear side

Gummed tape IW305-0251E11

3. Mount base plate on drum assy with bolt.

IW305-0250E09

Potentiometer 1 3 2

B R W

Black Red White

0V +5V (Power supply) Out put IW305-0250E01

10

W305-0251E

H-3 .

H-3 .

Outrigger Extension Length Detector

When replacing the potentiometer with a new one, mount it onto the bracket, then solder the cable to the potentiometer terminal.

[NOTICE] Finish soldering the wire to the potentiometer terminal as quick as possible (max. 5 seconds) to minimize undesirable heat transmission to the potentiometer.

Apply insulation sealant to the terminal of the potentiometer.

Recommended sealant: Shin-Etsu Chemical’s Shin-Etsu Silicon KE45TRV 8. Slightly draw out the wire from the drum. Check to verify that the resistance between B and W decreases smoothly.

9. Mount cover, while positioning clamp on the opposite side of the potentiometer.

Cover Screw

Clamp

Cable

IW305-0250E03

10. Pull cable to take up the slack and then tighten clamp.

0 361-318-00000 △

11

W305-0251E

H-4

H-4

Solenoid Valve (Auto Stop) H-4

Solenoid Valve (Auto Stop)

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

1. Structure 1.Body 2.Distance piece 3.Filter element 4.Plug 5.Plug 6.O-ring 7.O-ring 8.Solenoid valve assy

T1

8

1

5

6

3

2

7

Thread size and tightening torque Sign / Port

Thread size

A, B, T 4 T1

G1/4 G3/8 M5

Tightening torque N-m ft-lbf 29.4 22 30 - 37 22.1 - 27.3 7–9 5 – 6.5

12

W121-0543E

4

IW121-0540E03

H-4 .

H-4 .

Solenoid Valve (Auto Stop)

Solenoid valve assy 1.Body

Connector

2.Plug 4.Spool

+-

7.Spring seat 8.Square ring

(+): Red (-): Blue

9.O-ring 11.Spring IW121-0542E01

12.Solenoid (DC24V)

T2

2

T1

A

T

12

11

9

7

P

4

B

T

8

1 IW121-0540E04

Thread size and tightening torque Sign / Port

Thread size

2 T1 T2

-

Tightening torque N-m ft-lbf 44 - 49 32 - 36 39 - 49 29 - 36 4.4 – 5.4 3-4

1 366-460-80000 △

13

W121-0543E

L Control System

Contents L-1 Control System ................................ 1 1.

Crane control devices ............................... 1

L-2 Master Cylinder (Accelerator)......... 3 1.

L

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

L-3 Control Cylinder (Accelerator)........ 4 1.

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

i

L-1

L-1

Control System L-1

Control System

1. Crane control devices

1

WL01-0120E

L-1.

L-1.

Control System

2

WL01-0120E

L-2.

L-2.

Master Cylinder (Accelerator) L-2

Master Cylinder (Accelerator)

1. Structure

1. Lock nut

7-1. Piston

7-8. Retainer

13. Gasket

2. Push rod

7-2. Cup

7-9. Spring

14. Plug

3. Boot

7-3. Cup

8. Spacer

15. Band

4. Stop ring

7-4. Backup ring

9. Gasket

16. Nipple

5. Cylinder body

7-5. Valve rod

10. Stopper bolt

6. Stopper

7-6. Valve cup

11. Spring

7. Piston assy

7-7. Valve spring

12. Check valve

3

W401-0040E

L-3.

L-3.

Control Cylinder (Accelerator) L-3

Control Cylinder (Accelerator)

1. Structure

1. Cylinder

5. Push rod

2. Piston

6. Bleeder valve

3. Cup

7. Cup

4. Boots

4

W402-0010E

Y Data, Adjusting and Checks

Contents 5.

Y-1 Hydraulic Pressure Setting Table... 1 1.

2.

Manual control valve (upper)..................... 1 1.1

Winch.......................................................... 1

1.2

Elevating..................................................... 2

1.3

Telescoping................................................. 3

1.

Crane operation detection switch ............ 12

Manual control valve (lower) ..................... 4

2.

3rd/top boom full retraction detection switch (S18).................. 12

3.

Jib stowed detection proximity switch (S9)................................... 12

4.

Outrigger operation detection switch ..... 13

5.

F/J overload detection switch .................. 13

6.

Drum rotation detection switch (main) ..... 13

2.1

3.

Y-3 Electric Switch Adjustment ...........12

Outrigger..................................................... 4

Unload relief valve .................................... 5 3.1

4.

Oil cooler................................................. 11

Accumulator circuit ..................................... 5

Others ...................................................... 6 4.1

Manual control valve (swing)...................... 6

4.2

Counterbalance valve................................. 6

4.3

Pressure switch .......................................... 7

4.4

Flow control valve (oil cooler)..................... 7

4.5

Relief valve (RV4)....................................... 7

Y-4 Adjustment and Checks ................14 Y-2 Air Bleeding Procedure ................... 8 1.

1.

Pump 4 circuit ........................................... 8 2.

2.

3.

4.

Swing brake ............................................ 14

Accelerator circuit ..................................... 8

Winch brake ............................................ 14 2.1

Adjustment of shim ...................................14

2.2

Adjustment of stroke .................................14

Swing circuit ............................................. 9 3.1

Swing motor................................................ 9

3.2

Swing brake................................................ 9

3.

Accelerator.............................................. 15 3.1

Accelerator pedal ......................................15

3.2

Speed control ............................................16

Winch circuit ........................................... 10 4.1

Winch motor ............................................. 10

4.2

Winch counterbalance valve .................... 10

4.3

Winch brake cylinder .................................11

4.

i

Adjusting boom telescoping wire ropes ... 17

Y

Y-5 Oils and Grease Table ................... 19

Y-6 Mass Table ..................................... 20

Y-7 Boom Connecting Pin and Thread Size Table .................. 21

ii

Y-1

Y-1

Hydraulic Pressure Setting Table Y-1

Hydraulic Pressure Setting Table

1. Manual control valve (upper) 1.1 Winch [NOTICE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator) moment display Item

Main winch hoisting up (RV1)

Set pressure MPa

23 - 24

psi

3343 - 3485

Engine speed -1 (min )

2055 (MAX.)

Check procedure

1. Block the main winch hoisting up side port.

2. Turn the PTO switch ON. 3. Set the winch speed select switch to Low. 4. Move the main winch control lever fully to the hoisting up position. In this state, set the engine -1 speed to 2055 min and check the pressure.

1

WY02-0580E

Y-1

Y-1

Hydraulic Pressure Setting Table 1.2 Elevating [NOTICE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator) moment display Item

Set pressure MPa

psi

Engine speed -1 (min )

Boom raising (RV2)

20.1 - 21.1

2916-3058

2055 (MAX.)

Boom lowering (PR1)

3.6 - 3.9

526.4-569

(IDL.) 700

Boom raising (PR2)

-

-

-

Check procedure 1. Turn the PTO switch ON 2. Tighten the adjusting screw of port relief valve(PR2) 3. Fully extend the boom elevating cylinder.

4. Move the boom elevating control lever fully to the boom raising position.

-1 In this state, set the engine speed to 2055 min and check the pressure.

1. Turn the PTO switch ON. 2. Fully retract the boom elevating cylinder.

3. Move the boom elevating control lever fully to the boom lowering position. In this state, check the pressure.

1. Tighten the adjusting screw of port relief valve(PR2)

2

WY02-0580E

Y-1

Y-1

Hydraulic Pressure Setting Table 1.3 Telescoping [NOTICE] o

o

Oil temperature: 45 - 55 C (113 - 131 F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator) moment display Item

Set pressure MPa

psi

Engine speed -1 (min )

Check procedure

Boom extending (PR3)

14.2 - 15.2

2063-2205

2055 (MAX.)

1. Turn the PTO switch ON. 2. Fully extend the 2nd boom.

3. Move the boom telescoping control lever fully to the boom extension position. ( Do not push the 3rd/top boom extending switch ) -1 In this state, set the engine speed to 2055 min and check the pressure.

Boom retracting (PR4)

–

–

–

1. Tighten the adjusting screw of port relief valve (PR4).

3

WY02-0580E

Y-1

Y-1

Hydraulic Pressure Setting Table 2. Manual control valve (lower) 2.1 Outrigger [NOTICE] °

°

Oil temperature: 45 – 55 C (113 – 131 F) (Hydraulic oil: TADANO Hydraulic oil LL) Set pressure

Item

MPa

*1 (RV3)

20.1 - 21.1

psi

2916 - 3058

Engine speed -1 (min )

Check procedure

1614

1. Connect a pressure gauge to the pressure check port.

2. Turn the PTO switch ON. 3. Set the jack/slide select lever to neutral position.

4. Move the extending/retracting select lever fully to the EXT or RET position.

-1 In this state, set the engine speed to 1614 min and check the pressure by the pressure gauge.

1614

1. Connect a pressure gauge to the pressure check port.

2. Turn the PTO switch ON. 3. Extend all the jack cylinders fully.

4. Move the front jack extension lever to extension position.

After the front jack has set on the ground, set -1 the engine speed to 1614 min and check the pressure by the pressure gauge.

Outrigger

*2 (PR5)

3.4 - 3.9

498 - 569

*1: Relief valve *2: Port relief valve

4

WY02-0580E

Y-1

Y-1

Hydraulic Pressure Setting Table 3. Unload relief valve 3.1 Accumulator circuit [NOTICE] °

°

Oil temperature: 45 – 55 C (113 – 131 F) (Hydraulic oil: TADANO Hydraulic oil LL) Item

Set pressure MPa

psi

Engine speed -1 (min )

Check procedure 1. Rotate the handle of oil coder counterclock wise.

2. Turn the PTO switch ON.

On-load

11.3-12.3

1636-1778

(IDL.) 700

Unload

15.2-16.2

2205-2347

(IDL.) 700

3. Move the winch control lever to the hoisting up and hoisting down positions alternately, and mesure the pressure at which the accumulator pressure changes from lowering to rising (on-load pressure).

Then stop winch lever manipulation, and measure the pressure at winch the accumulator pressure stops rising (unload pressure).

5

WY02-0580E

Y-1

Y-1

Hydraulic Pressure Setting Table 4. Others [NOTICE] (*1) : Does not require adjustment because it is set up by the maker.

4.1 Manual control valve (swing) Set pressure

Item

Remark

MPa

psi

Overload relief valve (RA)

19.6-20.1

2845-2916

(*1)

Relief valve (RB)

1.17-1.37

171-199

(*1)

4.2 Counterbalance valve Item

Set pressure MPa

psi

Elevating

1.69

245

Telescoping

1.69

245

27.4

3983

1.76

256

Remark

(*1) No-load valve opening pressure (*1) No-load valve opening pressure (*1) Overload relief pressure

Winch (*1) Pilot pressure (Valve opening pressure)

6

WY02-0580E

Y-1 .

Y-1 .

Hydraulic Pressure Setting Table 4.3 Pressure switch Item Front jack overload detection pressure

Set pressure

Remark

MPa

psi

17.2

2489

(*1) Pressure switch (psc1)

10.3

1494

Set up the pressure by AML data

(PSC1) Pressure gauge (for accumulator) (SPS2)

4.4 Flow control valve (oil cooler) Item

Pilot pressure

Set pressure MPa

psi

2.9

427

Remark

(*1)

4.5 Relief valve (RV4) Item

P4 pump main circuit (RV4)

Set pressure MPa

psi

20.1-21.1

2916-3058

Remark

(*1)

7

WY02-0580E

Y-2

Y-2

Air Bleeding Procedure Y-2

Air Bleeding Procedure

2. Accelerator circuit

1. Pump 4 circuit

[NOTICE] When air is being bled, the level of oil in the oil reservoir will drop as the oil is discharged from the circuit. Bleed the air, while at the same time supplying the reservoir with new hydraulic oil in order to prevent air from entering the circuit.

[NOTICE] After replacing hydraulic pump or hydraulic oil, be sure to bleed the circuit as follows. Without bleeding the circuit, the hydraulic pump will be broken.

1. Bleed the accelerator circuit, using the bleeder screw on the inside of the swing talble, as follows: (1)Connect one end of a vinyl hose to the bleeder screw and place the other end in an oil pan.

1. Fill the hydraulic oil tank with hydraulic oil.

2. Unplug the vent port of the unload valve to bring the unload valve into the continuous unload state,

(2)Pump the accelerator pedal twice or three times,

and in this state, run the engine at the idling

then keep it depressed. Loosen the bleeder screw

speed for approx. One minute to bleed the circuit.

and release the air from the circuit.

As oil starts to frow out of the vent port, stop the engine, and plug the vent port.

(3)When the flow of oil weakens, tighten the bleeder screw and release the accelerator pedal.

3. With the engine operation, check that the accumulator pressure builds. If not, repeat

(4)Repeat steps (2) and (3) until oil flows out free of

process 2 above.

air from the bleeder screw.

2. After bleeding the circuit, repeat the above steps to bleed the accelerator cylinder, using the bleeder screw located forward of the front outrigger.

8

WY05-1260E

Y-2

Y-2

Air Bleeding Procedure 3. Swing circuit 3.1 Swing motor [NOTICE] Do not apply any load to the motor before performing air bleeding.

Bleed the swing motor by following either (1), (2) or (3).

(1) Pour the hydraulic oil through the drain port into the casing until the oil flows out.

(2) Perform the right or left swing operation slowly for

3. Check the oil level in the reservoir. Add if low.

approx. one minute.

(3) Set the swing brake switch to ON. Perform the right or left swing operation and keep the swing circuit hydraulic pressure at approx. 4.9MPa (710 psi) for approx. 30 seconds.

3.2 Swing brake [NOTICE] The swing brake will be sluggish if air is present in the circuit. When trapped air is suspected, bleed the circuit following the steps given below.

1. Start the engine and engage the PTO. Keep the engine running at idling speed.

2. Bleed the brake circuit as follows: (1)Connect one end of a vinyl hose to the bleeder screw on the swing brake master cylinder, and place the other end in an oil pan.

9

WY05-1260E

Y-2

Y-2

Air Bleeding Procedure 4. Winch circuit

[NOTICE] The master cylinder is located on the left side of the upperstructure.

4.1 Winch motor [NOTICE]

(2)Pull up the swing brake lever. Loosen the bleeder

Do not apply any load to the motor before performing air bleeding.

screw on the master cylinder to let out the air together with the oil.

Bleed the winch motor by following either (1) or (2).

(1) Pour the hydraulic oil through the drain port into the casing until the oil flows out.

(2) Perform the slow hoist-up or hoist-down operation for approx. One minute.

4.2 Winch counterbalance valve For winch, use the operations below to bleed the air from the counterbalance valve.

1. Engine speed: Max., with PTO ON (Start at idle and gradually increase the speed.)

(3)When the flow of the hydraulic oil weakens, tighten the bleeder screw and return the swing

2. Lever operation: Repeat hoist-up and hoist down.

brake lever to its original position.

3. When there are no more bubbles in the oil that

(4)Repeat steps (2) and (3) until there is no longer

flows out, close the plug while the oil continues to

any air in the oil coming out of the bleeder screw.

flow.

3. After the air in the master cylinder has been let out, repeat the above steps to bleed the air from the bleeder screw of the swing motor.

4. Place the PTO switch in the OFF position and shut off the engine.

10

WY05-1260E

Y-2 .

Y-2 .

Air Bleeding Procedure 4.3 Winch brake cylinder

5. Oil cooler motor

WARNING

Pour the hydraulic oil through the drain port into

The winch brake circuit is always under high pressure. If the bleeder screw is carelessly loosened, you may be injured by a spurting high-pressure oil. Be extremely careful when bleeding the air, and face away from the bleeder screw.

Hydraulic oil on the winch brake linings is dangerous because it significantly impairs the functioning of the brake. Use special care to prevent any oil from coming in contact with the linings when bleeding the air from a hydraulic circuit.

the casing until the oil frows out.

The winch brake will drag if air is present in the brake cylinder circuit. When trapped air is suspected, bleed the circuit following the steps given below.

1. Start the engine and engage the PTO (PTO switch is ON). Keep the engine running at idling speed.

2. Connect one end of a vinyl hose to the bleeder screw on brake cylinder and place the other end in an oil pan.

3. Bleed the circuit as follows: (1) Operate the winch (hoist up/down).

(2) Loosen the bleeder screw to discharge the air in the circuit.

(3) When no air is found in the hydraulic oil coming out, tighen the bleeder screw.

(4) Stop operating the winch.

4. Disengage the PTO (PTO switch is OFF), and stop the engine.

11

WY05-1260E

Y-3

Y-3

Electric Switch Adjustment Y-3

Electric Switch Adjustment

(*1): Apply the screw locking agent (Three-Bond 1401 or the aquivalent).

1. Crane operation detection switch

Dimension A : 1mm (0.04in)

S1 : Main winch hoisting-up detection switch

Dimension B : 2.5m (0.1in)

S6 : Boom extending detection switch S7 : Boom raising detection switch

2. 3rd/top boom full retraction detection switch (S18)

S8 : Boom lowering detection switch Adjust all these switches so that when the spools

Adjust the switch position so that its contact is

are shifted 1-2mm (0.04-0.08in) from the neutral

shifted (opened/closed) when the top boom

position, they are turned OFF.

section is extended/retracted beyond the position

(Check that “LED” of the switch is not lit.)

where it is 5-8 mm (0.2-0.31 in) longer than its fully retracted length.

3. Jib stowed detection switch (S9) Adjust the switch position so that the dimension A becomes 7-8 mm (0.28-0.32 in) with the jib stowed. (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent).

12

WY04-0820E

Y-3 .

Y-3 .

Electric Switch Adjustment 4. Outrigger operation detection switch

5. F/J overload detection switch (PSC1)

CS21 : F/J and outrigger extension operation

Adjust the switch so that when the cylinder

detection switch

internal pressure rises to 17.2 MPa (2494psi), it is actuated.

CS22 : F/J and outrigger retraction operation

(Dimension A : 18.4mm (0.72in))

detection switch 1. Adjust these switches so that when the spool is shifted 2mm (0.08in) from the neutral position, they are turned ON. (Check that “LED” of the switch is lit.)

2. Check these switches so that when the lever is shaked right and left on the neutral position, they are not turned ON. (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent).

Dimension A1 : 1.5 mm (0.06in) Dimension A2 : 3.5 mm (0.14in)

6. Drum rotation detection switch (main)(SD1)

Dimension B : 2.5 mm (0.1in) Dimension C : 30 mm (1.2in)

Adjust the switch position so that the dimension A becomes 3-5mm (0.12-0.2in).

13

WY04-0820E

Y-4

Y-4

Adjustment and checks Y-4

2.1 Adjustment of shim

Adjustment and checks

1. Swing brake

1. Screw the hexagon socket head bolt (fully threaded M10×50 bolt) into section A until

Adjust the control cable so that there exists no

dimension X becomes zero.

play in the cable when the swing brake lever is released. (Check that the master cylinder push

2. Push support (b) to the right until dimension C

rod is not being pushed.)

becomes zero.

3. Measure dimension B. Determine the shim stock thickness using the following formula and select and install shim (s) corresponding to the obtained thickness. Shim thickness = (B-10) ± 0.3mm [(B-0.4) ± 0.01in] 4. Remove the hexagon. socket head bolt.

2.2 Adjustment of stroke [NOTICE] Adjust the stroke after adjusting by shims.

1. Adjust the synchronization adjusting bolt so that distanse L is 18mm. (0.7in)

2. Winch brake

2. Supply hydraulic pressure to the cylinder (a) to move it until dimension X becomes zero.

Make sure that the hydraulic pressure is 20.6 MPa (2987psi) or less.

[NOTICE] Be careful not to screw the bolt in too far. A gap will be produced at portion Z. 3. Screw in the synchronization adjusting bolt until dimension Y becomes zero and lock it with lock nut (c).

4. Measure distance L. Check that it is within the range 15 ± 2 mm. (0.6 ± 0.08in) 5. Loosen the stroke adjustment nut.

6. Adjust the stroke adjustment nut so that X = 2.5 to 3mm (X=0.1 to 0.12in) 7. Supply hydraulic pressure to the cylinder (a) (the brake is release.)

8. Adjust bolt A so that the clearance at part (A) is 0.5 mm (0.02in).

14

WY05-1270E

Y-4

Y-4

Adjustment and checks 3. Accelerator

9. Adjust bolt B so that the clearance at part (B) is 0.5 mm (0.02in).

3.1 Accelerator pedal

[NOTICE]

Adjust the push rod so that angle θ of the

There must be no clearance at Z when the brake is release.

accelerator pedal becomes 55°-60°, and lock the push rod with nut (a).

10.After setting the bolts A and B, check that the drum is free. Adjust C, D, E, and F to make the clearance between the drum and shoe as even as possible around the entire circumference.

11.After completion of adjustment, activate the winch brake, and install the sticker so that the edge of the pointer is in line with the black line of the sticker.

15

WY05-1270E

Y-4

Y-4

Adjustment and checks 3.2 Speed control

1. Apply grease to the rotating part and the sliding

3. Adjusting maximum engine speed

area.

(1)While the accelerator pedal (in the crane cab is

2. Adjusting idling speed with the PTO engaged (Set

depressed, adjust the stopper bolt N so that the -1

the high/low select swith to “HIGH” before

pump speed becomes 2100-2150 min (i, e,

adjustment.)

engine speed becomes 2055-2105 min ).

-1

Fix the stopper bolt of the accelerator pedal in the

(1)Set the length of cylinder F at 107mm (4.2in) and

crane cab in this condition.

shift the lever H so that gap G becoms 2-3mm (0.08-0.12in). Then adjust the stopper bolt I.

4. Adjusting speed during outrigger operation

(2)Turn on the PTO switch. Adjust the adjuster bolt

(1)Perform outrigger operation and adjust the gap Q

-1

using the turnbuckle P so that the maximum pump

so that the pump speed becomes 715-765min -1

speed with the rod O operated becomes

(i, e, engine speed becomes 700-750 min ).

-1

1650-1750 min (i, e, engine speed becomes -1

1614-1714 min ).

(Do not close the gap Q.)

16

WY05-1270E

Y-4

Y-4

Adjustment and checks 4. Adjusting boom telescoping wire ropes 1. After assembling each boom section and adjusting the slide plate by adding or removing shims, retract the boom fully. (Keep the wire rope free.)

[NOTICE] Loosen the sway stopper bolt on the bottom of each boom section until it is out of contact with the support.

2. Tighten the rigth and left adjustment nuts for the top boom section extension wire rope alternately. Pull out the top boom section for 5-10mm (0.2-0.4in).

Adjusting nut for top boom section extension wire rope

0.2-0.4inch (5-10mm)

17

IWY05-0590E04

WY05-1270E

Y-4 .

Y-4 .

Adjustment and checks

3. Tighten the adjustment nut for top boom section retraction wire rope until the top boom section stopper seats

Adjusting nut for top boom section retraction wire rope

Contact IWY05-0590E05

4. After checking the contacting condition of stopper for each boom section, fix adjuster section for each extension and retraction wire rope with two nuts.

18

WY05-1270E

Y-5 .

Y-5 .

Oils and Greases Table Y-5

Oils and Grease Table

The oils and greases listed below are used in new cranes at shipment.

Oil or grease

Grease

Gear oil

Hydraulic oil

No

Component

1

Side and bottom surfaces of boom

2

Slide plates (bottom surface of boom)

3

Slide plates (top surface of boom)

4

Boom pivot pin

Daphne Eponex SR No.2 (ldemitsu)

5

Wire rope (for winch)

Mobilarma 798 (Mobil)

6

Wire rope (for telescoping)

7

Swing bearing

8

Swing gear

9

Outrigger floats

10

Front jack float

11

Pin (for winch guide sheave)

12

Winch guide sheave

13

Jib head sheave

14

Jib connecting pin boss

15

Elevating cylinder lower pivot pin

16

Main hook block (Option)

17

Auxiliary hook block (Option)

18

Propeller shaft

1

Winch speed reducer

Pegasus Gear Oil 90 (Mobil)

0.53 gal. (2.0L)

2

Swing speed reducer

Mobil Gear 632 (Mobil)

0.42 gal. (1.6L)

1

Hydraulic oil tank

TADANO Hydraulic Oil LL

83 gal. (314L)(*1)

(TADANO Genuine Hydraulic Oil)

124gal. (470L)(*2)

Daphne Super Hydro 22WR (ldemitsu)

0.05 gal. (0.17L)(*1)

2

Brand (manufacturer)

Capacity / Quantity

TNR (TADANO Genuine Grease)

As required

Daphne Eponex SR No.2 (ldemitsu)

Oil reservoir (for accelerator)

(*1) : Tank capacity (*2) : Total capacity

19

WY01-1080E

0.24gal. (0.9L)(*2)

Y-6 .

Y-6 .

Mass Table Y-6

Mass Table Spec. No. Part Name

Boom

TT-300-1-90101 1M1D (North America)

Boom assy (including telescoping cylinder and Jib)

4900kg (10780 lb)

Telescoping cylinder

720 kg (1590 lb)

Jib

390 kg (860 lb)

Elevating cylinder

490kg (1080 lb)

Swing table assy (excluding boom, elevating cylinder, swing bearing and counterweight )

3500kg (7700 lb)

Swing bearing

280kg (600 lb)

Swing speed reducer and swing motor

90kg (200 lb)

Rotary joint

110kg (240 lb)

Winch

Weight

Outrigger

Main winch assy (including winch motor)

440kg (970 lb)

Winch motor

50 kg (110 lb)

Counterweight

1800 kg (3960 lb)

Sub counter weight (for aux. winch)

530 kg (1170 lb)

Outrigger inner case assy (including jack cylinder and extension cylinder)

450kg (990 lb)

Jack cylinder

100kg (220 lb)

Extension cylinder

40kg (90 lb)

Front jack cylinder

40kg (90 lb)

[NOTICE] The values given above do not include the weight of hydraulic oil.

20

WY01-1060E

Y-7 .

Y-7 .

Boom Connecting Pin and Thread Side Table Y-7

Boom Connecting Pin and Thread Size Table (mm) Applicable model Part Name Elevating cylinder

TR-450XL-4, TR-500XL-4

GT-350C-1

Diameter

Thread size

Diameter

Thread size

Rod end pin

Φ100

M30×3.5

Φ100

M30×3.5

Base pin

Φ90

M30×3.5

Φ90

M30×3.5

Φ90

M16×2.0 (Qty:4)

Φ100

M18×2.5 (Qty:4)

Boom base pin

(mm)

Applicable model

Part Name Elevating cylinder

GT-550E-1, TR-600XL-4, TR-600XXL-4, TR-800XXL-4, TT-600XL-1, TT-800XXL-1, GR-700EXL-1,GT-700E-1 Diameter

Thread size

Rod end pin

Φ120

M33×3.5

Base pin

Φ110

M30×3.5

Φ100

M18×2.5 (Qty:4)

Boom base pin

(mm) Applicable model Part Name Elevating cylinder

TR-300XL-4, GR-300EX-1 Diameter

Thread size

Diameter

Thread size

Rod end pin

Φ100

M30×3.5

Φ90

M30×3.5

Base pin

Φ110

M30×3.5

Φ90

M30×3.5

Φ100

M30×3.5

Φ90

M30×3.5

Boom base pin

(mm) Applicable model Part Name Elevating cylinder Boom base pin

TT-300XL-1

TR-150XL-4 Diameter

Thread size

Rod end pin

Φ60

-

Base pin

Φ70

M24×3.0

Φ60

M10×1.5

21

WY01-0624E

Z System Diagrams

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

4.

Harness (AML) ........................................ 12

5.

Harness (heater) (option) ........................ 13

Z-2 Electric Curcuit ................................ 2 1.

Upper ......................................................... 2

Z-7 Harness (Lower) .............................14

2.

Lower ....................................................... 3

1.

Haness (main) ......................................... 14

2.

Sub Harness (front jack).......................... 15

3.

Harness (inside cab) (#291030--#291032)..................... 16

4.

Harness (inside cab) (#291033--)................................... 17

Z-3 Location of Hydraulic Parts ............ 4 1.

Upper ......................................................... 4

2.

Lower ....................................................... 5

Z-4 Location of Electric Parts................ 6 1.

Upper ......................................................... 6

2.

Lower ....................................................... 7

Z-5 Hydraulic and Electric Parts Table ................. 8

Z-6 Harness (Upper) ............................... 9 1.

Harness (main) .......................................... 9

2.

Harness (drum indicator) ......................... 10

3.

Switch assy.............................................. 11

Z i

Z-1.

Z-1.

Z-1.

Hydraulic Circuit Z-1

Hydraulic Circuit

1 334-013-90000 △

1

WZ01-1820E

1

Z-2

Z-2

Z-2

Electric Circuit Z-2 Electric Circuit 1. Upper

0 334-113-80000 △

2

WZ03-3181E

2

Z-2.

Z-2.

Electric Circuit

3 ：291040 - △ 2 ：291045 - △ Applicable serial No. △ 1 ：291033 - -

Z-2.

2. Lower

334-113-80500

3

WZ03-3181E

3 △

3

Z-3

Z-3

Z-3

Location of Hydraulic Parts Z-3 Location of Hydraulic Parts 1. Upper

4

WZ07-1590E

4

Z-3.

Z-3.

Z-3.

Location of Hydraulic Parts 2. Lower

5

WZ07-1590E

5

Z-4

Z-4

Z-4

Location of Electric Parts Z-4 Location of Electric Parts 1. Upper

6

WZ02-2811E

6

Z-4.

Z-4.

Location of Electric Parts

Z-4.

Applicable serial No. △ 1 ：291040 - -

2. Lower

7

WZ02-2811E

7

Z-5.

Z-5.

Hydraulic and Electric Parts Table Z-5 No. 1 2 3 4 5 6 7 8-1 8-2 8-3 8-4 9-1 9-2 9-3 9-4 10-1 10-2 10-3 10-4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25-1 25-2 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42-1

Z-5.

Applicable serial No. △ 1 ：291040 - -

Hydraulic and Electric Parts Table Parts Name Engine PTO Double variable piston and tandem gear pump Drain filter Return filter Relief valve (RV4) Manual control valve (lower) Jack cylinder (FL) Jack cylinder (FR) Jack cylinder (RL) Jack cylinder (RR) Pilot check valve (FL) Pilot check valve (FR) Pilot check valve (RL) Pilot check valve (RR) Extension cylinder 8FL) Extension cylinder (FR) Extension cylinder (RL) Extension cylinder (RR) Control cylinder (accelerator) --------------------------------Rotary joint Master cylinder (Accelerator) Oil reservoir Unload relief valve (UV) Check valve Pressure sensor (SPS1) (main pressure) Pressure sensor (SPS2) (accumulator) Accumulator Flow control valve Check valve Oil cooler Check valve Check valve Manual control valve (upper) Solenoid valve (AML vent) (SL100) Solenoid valve (winch speed select) (SL288) Check valve (gauge isolator) Manual control valve (swing) (SL161) Swing drive unit Master cylinder (swing brake) Elevating cylinder Pressure sensor (SPS4) Pressure sensor (SPS3) Counterbalance valve

No. 42-2 42-3 43 44 45 46 47-1 47-2 48-A 48-B 49 50 51 52 53 54 55 56

8

Parts Name Counterbalance valve Counterbalance valve Telescoping cylinder (No.1) Telescoping cylinder (No.2) Hose real Hydraulic valve (top cylinder select) (SL230) Orifice Orifice Hydraulic motor (winch) Counterbalance valve Check valve Hydraulic valve (winch brake release) Filter Filter Pilot check valve F/J extending detection switch (PSC2) F/J overload detection switch (PSC1) Front jack cylinder

WZ09-0171E

No. 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 SN2 SN7 SN8 SN9 SN10 SN11 SN12 SN13 SN14 SN15 SN16 SN17 SN23 SN30 SN50 SN51 S1 S3 S6 S7 S8 S9 S16 S17 S18 S20 SL100 SL161 SL230

Parts Name Heater (option) Upper-structure power switch Fuse box Front wiper motor Roof wiper motor Boom lamp Flood lamp (right) Flood lamp (left) Cab lamp Cigarette lighter Horn ID lamp End outline marker lamp AML-L2E (load moment indicator) Boom length detector Boom angle detector Swing angle detector 1,2 Cord reel Buzzer 2 (Two-blocking alarm) Buzzer 1 (AML alarm, accumulator low-pressure alarm) Drum indicator External warning lamps (option) Terminal assy (D6, D7) Swing free/lock select switch Anti-twoblock disable switch 3rd / top boom emergency telescoping switch 2nd boom emergency telescoping switch Override key switch Fan switch (option) Front wiper switch Flood lamp switch Winch high-speed switch (main) Winch high-speed switch (aux.)

3rd / top boom section extending switch Horn switch Winch speed select switch Roof wiper switch Winch select switch Outrigger state emergency register switch Main winch hoisting-up detection switch Aux. winch hoisting-up detection switch Boom extending detection switch Boom raising detection switch Boom lowering detection switch Jib stowed detection switch Boom two-blocking detection switch Jib two-blocking detection switch 3rd / top boom full-retraction detection switch Swing position check switch Solenoid valve (AML vent) Solenoid valve (swing free / lock select) Solenoid valve (3rd / top boom full-extension)

No. SL288 SPS1 SPS2 SPS3 SPS4 SD1 SD2 LP1 LP2 RL0 RL11 RL12 RL13 RL14 RL h C1

Parts Name Solenoid valve (winch speed select) Pressure sensor (main) Pressure sensor (accumulator) Pressure sensor (elevating cylinder, boom raising) Pressure sensor (elevating cylinder, boom lowing) Drum rotation detection switch (main) Drum rotation detection switch (aux.)

Aux. winch select indicator lamp Outrigger state emergency register indicator lamp AML power supply AML warning indicator (90--100%) AML limit indicator (100%--) Two-blocking circuit 3rd / top boom full-retraction circuit Horn Condenser (horn)

130 131 132 133 134 135 136 137 138 139 1 140 141 142 PSC1 PSC2 CS21 CS22 RL50 RL51 RL52 1 RL53 BR12 BR24

Transmitter type 2 O/R length detector (FR) O/R length detector (FL) O/R length detector (RR) O/R length detector (RL) Battery PTO switch DC/DC converter Side marker lamp Clearance lamp Remote throttle switch Upper accelerator Lower accelerator F/J overload detection switch F/J extending detection switch F/J and O/R extending operation detection switch F/J and O/R retracting operation detection switch PTO power supply relay Battery power supply relay DIM power supply relay Upper / lower accelerator select relay Converter power supply relay Battery power supply relay

8

Z-6

Z-6

Z-6

Harness (Upper) Z-6 Harness (Upper) 1. Harness (main)

9

WZ04-2151E

2 333-513-40000 △

9

Z-6

Z-6

Harness (Upper) 2. Harness (Drum indicator)

0 334-764-31000 △ 0 334-764-30010 △

10

WZ04-2151E

Z-6

Z-6

Z-6

Harness (Upper) 3. Switch assy

1 334-327-81000 △

11

WZ04-2151E

11

Z-6

Z-6

Z-6

Harness (Upper) 4. Harness (AML)

3 333-613-90100 △

12

WZ04-2151E

12

Z-6.

Z-6.

Z-6.

Harness (Upper) 5. Harness (heater) (option)

0 362-906-61020 △

13

WZ04-2151E

13

Z-7

Z-7

Harness (Lower)

5 ：291045 - △ 4 ：291033 - △ Applicable serial No. △ 3 ：291033 - -

Z-7

Z-7 Harness (Lower) 1. Harness (main)

5 326-521-70201 △

14

WZ04-2161E

14

Z-7

Z-7

Harness (Lower) 2. Sub harness (Front jack)

1 326-521-70500 △

15

WZ04-2161E

Z-7

Z-7

Harness (Lower)

Z-7 Applicable serial No. △ 2 ：291031 - -

3. Harness (Inside Cab) (#29130--#29103)

2 326-521-74100 △

16

WZ04-2161E

16

Z-7.

Z-7.

Harness (Lower)

Z-7.

Applicable serial No. △ 1 ：291040 - -

4. Harness (Inside Cab) (#291033--)

0 326-521-70800 △ 1 326-521-74101 △

17

WZ04-2161E

17

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