Tadano TR-800XXL4 Service Manual
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Tadano TR-800XXL4 Service Manual

Tadano TR-800XXL4 Service Manual

Rough terrain crane
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◯ ｃ 2006
PRINTED IN JAPAN
0608
K
01
Rough Terrain Crane
TR-800XXL-
Model
Applicable Serial No. 545870, 545961--
GR-800XXL-1/S2(U)-1E
Publication No.
4

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Summary of Contents for Tadano TR-800XXL4

  • Page 1 GR-800XXL-1/S2(U)-1E Publication No. Rough Terrain Crane TR-800XXL- Model Applicable Serial No. 545870, 545961-- ◯ ｃ 2006 PRINTED IN JAPAN 0608...
  • Page 2 Safety Safety [NOTICE] [NOTICE] indicates an important operational or Most accidents that occur during machine operation maintenance procedure or condition, which, if not and maintenance are caused by failure to observe strictly observed, can result in damage to machine components or deteriorated machine performance. basic safety rules and precautions.
  • Page 3 Safety 1. Fundamental cautions fatal accidents, as there is a possibility that the vehicle loses its balance and falls down on a Servicemen inexperienced in the units of this machine worker in a dismounting process of certain units. should be cautious about safety operations. They 7.
  • Page 4 Safety 7. Put disassembled parts in order so that parts such In case that the position of the center of gravity is as bolts are not left behind in the machine. And not clear and there is a possibility of swing of load check that no parts run short at assembly.
  • Page 5 Safety 4.1 Gasoline 2. Battery fluid (dilute sulfuric acid) may cause loss of sight or burn injury. 1.Spill or leak: Review fire and explosion hazards If battery fluid stains an eye, skin, or clothes, before proceeding with clean up. Use appropriate immediately wash down them with a great deal personal protective equipment during clean up.
  • Page 6 Foreword Foreword This service manual describes the composition of the Model TR-800XXL-4 rough terrain crane, its repair, check 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.
  • Page 7 Foreword 3. Outline of specifications Spec. No. Item GR-800-1-00211 2M2D (North America) No. of boom sections No. of jib stages Single top Option Main winch Fitted Auxiliary winch Fitted Winch Winch brake Automatic brake (Neutral brake) Drum rotation indicator Touch-type (Option) Weight Counterweight Removable type...
  • Page 8 Foreword 4. Conversion table Length millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km 0.001 0.03937 0.00328 1.6093 0.01 0.3937 0.03281 0.6214 1000 39.37 3.281 25.4 2.54 0.0254 0.08333 304.8 30.48 0.3048 Area square millimeter, mm square centimeter, cm square meter, m...
  • Page 9 Foreword Work, energy inch-pound, N-cm kgf-cm kgf-m foot-pound, ft-lbf in-lbf 1X10 1.01972X10 1.01972X10 0.00737 0.0885 1X10 1.01972X10 1.01972X10 0.7376 8.851 9.80665 9.80665X10 1X10 0.0723 0.868 9.80665X10 9.80665 1X10 7.233 86.8 135.58 1.3558 13.83 0.1383 11.3 0.113 1.1525 0.01153 0.08333 Centigrade-Fahrenheit ゜F ℃...
  • Page 10 GROUP INDEX Hydraulic Power Generating System Outrigger System Swing System Boom Elevating System Winch System Boom Telescoping System Safety System Control System Steering System Brake System Suspension System Data, Adjustment and Checks System Diagrams WA04-2070E...
  • Page 11 Foreword 5. Contents Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) General General Cautions Refer to separate manual SA01-01-2E Hydraulic Power Generating System Hydraulic Power Generating System Hydraulic Pump (Double Variable Displacement Pump) Hydraulic Pump (Double Gear Pump) Hydraulic Pump (Gear Pump, Emergency Steering) (Option) Hydraulic Valve (Emergency Steering) (Option)
  • Page 12 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Hydraulic Power Generating System Jib Lock pin B-17 Jib Offset Cylinder B-18 Check valve (Gauge Isolator) B-19 Outrigger System Outrigger System Jack Cylinder Pilot Check Valve (Jack Cylinder Retracting Prevention) Extension Cylinder (UCHIDA) Solenoid Valve (Slide/Jack) (TOKIMEC)
  • Page 13 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Boom Elevating System Elevating System Elevating Cylinder Counterbalance Valve (Elevating) Winch system Winch System Winch Hydraulic Motor (Winch) Counterbalance Valve (Winch) Hydraulic Valve (Winch Brake Release) Boom T elescoping system Telescoping System Boom (Five-Section Boom) Telescoping Cylinder Counterbalance Valve (Telescoping)
  • Page 14 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Safety System Safety System Load Moment Indicator (AML) Refer to separate manual W301-0136E Boom Length and Angle Detector Outrigger Extension Length Detector Solenoid Valve (Auto Stop) Crane Cab Glass Air Conditioner (Option) Hydraulic Motor(Air conditioner, Option) Solenoid Valve(Air conditioner, Option) Control System...
  • Page 15 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Electrical System Multiplex Data Transmitter (MDT) Refer to separate manual W303-0257E Driving Power Transmission System Torque Converter and Transmission Refer to separate manual W561-0101E Driving Axle Refer to separate manual W563-0052E Steering System Steering System Priority Valve...
  • Page 16 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Suspension System Suspension System Suspension Lock Cylinder Pilot Check Valve (Suspension Lock Cylinder) Solenoid Valve (Suspension Lock Check Release) Data, Adjustment and Checks Hydraulic Pressure Setting Table Air Pressure Setting Table Air Bleeding Procedure Electric Switch Adjustment Adjustment and Checks...
  • Page 17 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) System Diagrams Hydraulic Circuit Torque Converter Circuit Brake Circuit (Pneumatic Circuit) Electric Circuit (AML, Crane) Electric Circuit (MDT, Carrier/Upper) Electric Circuit (MDT, Carrier/Lower) Location of Installation Location of Hydraulic Parts (Upper) Location of Hydraulic Parts (Lower) Location of Air Parts Location of Electric Parts (Inside Cab)
  • Page 18 Foreword Spec. No. Chapter GR-800-1-00211 Section 2M2D (North America) Harness (Swing Table, Right) Z-19 Harness (Boom) Z-20 Harness (AML, Upper) Z-21 Harness (Overwind) Z-22 Harness (Lower, Main) Z-23 Harness (Lower, Sub) Z-24 Harness (Lower, Electronic Governor) Z-25 WA04-2070E...

  • Page 19: Table Of Contents

    Hydraulic Power Generating System Contents B-1 Hydraulic Power Generating System B-6 Flow Control Valve......19 ..........1 Structure ..........19 General............. 1 B-7 Pressure Reducing Valve B-2 Hydraulic Pump (Double Variable (Pilot Pressure) ......20 Displacement Pump) ....4 Structure ..........20 Structure ...........
  • Page 20 B-11 Sequence Valve (Pilot Pressure) .. 46 Structure ..........46 B-12 Solenoid Valve (Pilot Pressure) ..49 Structure ..........49 B-13 Solenoid Control Valve (Jib Set)... 51 Structure ..........51 B-14 Pilot Check Valve (Jib Set).... 57 Structure ..........57 B-15 Solenoid Valve (Oil Cooler)...

  • Page 21: Hydraulic Power Generating System

    Hydraulic Power Generating System Hydraulic Power Generating System 1. General Hydraulic Circuit for Carrier winch, and auxiliary winch. This double variable NOTICE] displacement pump is driven only when the PTO If the machine is not equipped with the optional switch is turned on. emergency steering, two points “A”...
  • Page 22 Hydraulic Power Generating System △ ：545520 ~ Applicable serial No. Hydraulic Circuit for Crane auxiliary winch). When the PTO switch is turned [NOTICE] on, the solenoid valve for automatic stop is shifted, If the machine is not equipped with the optional air making the condition of this circuit onloaded.
  • Page 23 B-1 . B-1 . Hydraulic Power Generating System Circuit for pilot pressure, jibset, air conditioner(option), and oil cooler 1. The pressurized oil delivered through the P6 port of the rotary joint is supplied to these circuits. Pressurized oil reduced by the sequence valve is supplied to the circuit for the pilot pressure.

  • Page 24: Hydraulic Pump (Double Variable Displacement Pump)

    Hydraulic Pump (Double Variable Displacement Pump) Hydraulic Pump (Double Variable Displacement 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.
  • Page 25 Hydraulic Pump (Double Variable Displacement Pump) Main body Apply adhesive (No. 1305N of Threebond make) Apply (Sealub L101) to the oil seal surface circumferential 212 211 153 156 157 Valve plate for counter clockwise rotation Valve plate for clockwise rotation IW101-0270E01 111.Drive shaft (F) 212.Swash plate...
  • Page 26 Hydraulic Pump (Double Variable Displacement Pump) Enlarged view of the main body (the left side) Apply (Shealub L101) Apply adhesive (No. 1305N of Threebond make) to the oil seal surface circumferential 212 211 153 156 157 Valve plate for counter clockwise rotation IW101-0270E02 W101-0272E...
  • Page 27 Hydraulic Pump (Double Variable Displacement Pump) Enlarged view of the main body (the right side) Valve plate for clockwise rotation IW101-0270E03 W101-0272E...
  • Page 28 Hydraulic Pump (Double Variable Displacement Pump) Regulator IW101-012004 W101-0272E...
  • Page 29 Hydraulic Pump (Double Variable Displacement Pump) View Z IW101-012006 402.Hex. socket head bolt 614.Center plug 651.Sleeve 755.O-ring 412.Hex. socket head bolt 621.Compensator piston 652.Spool 801.Nut 413.Hex. socket head bolt 624.Spring seat 701.O-ring 887.Pin 496.Plug 625.Compensator spring 708.O-ring 897.Pin 601.Casing 627.Spring seat 724.O-ring 924.Hex.

  • Page 30: Theory Of Operating Of Regulator Section

    Hydraulic Pump (Double Variable Displacement Pump) 2. Theory of operating of regulator section W101-0272E...
  • Page 31 Hydraulic Pump (Double Variable Displacement Pump) Hydraulic oil (P) from the pump flows to areas A When the pump pressure is below a certain level, and B shown in Figs. 1 and 2 via the path in the the spool does not move because the leftward regulator casing.

  • Page 32: Air Bleeding Procedure

    B-2 . B-2 . Hydraulic Pump (Double Variable Displacement Pump) from the port D to the drain line via the spool. Then the servo piston’s large-diameter end G is pushed by the pressure exerted on the small-diameter end H, to stay in the maximum discharge rate position.

  • Page 33: (Double Gear Pump)

    Hydraulic Pump (Double Gear Pump) Hydraulic Pump (Double Gear 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.
  • Page 34 Hydraulic Pump (Double Gear Pump) Gear pump assy-1 18 19 17 16 6,10 IW101-013002 1.Body 7.Side plate 12.O-ring 16.Dowel pin 2.Bearing box 8.Backup ring 13.Drive gear 17.Oil seal 3.Bearing box 9.Rubber string 14.Driven gear 18.Oil seal 6.Front cover 10.Hex. socket head bolt 15.Rear cover 19.Retaining ring Connecting section-2...

  • Page 35: Air Bleeding Procedure

    B-3 . B-3 . Hydraulic Pump (Double Gear Pump) Gear pump assy-3 13 16 6,10 IW101-013003 1.Body 7.Side plate 12.O-ring 16.Dowel pin 2.Bearing box 8.Backup ring 13.Drive gear 3.Bearing box 9.Rubber string 14.Driven gear 6.Front cover 10.Hex. socket head bolt 15.Rear cover 2.

  • Page 36: Emergency Steering)

    Hydraulic Power Generating System Hydraulic Pump (Gear Pump, Emergency Steering) [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.

  • Page 37: Hydraulic Valve

    Hydraulic Valve (Emergency Steering) (Option) Hydraulic Valve (Emergency Steering) (Option) [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.
  • Page 38 B-5 . B-5 . Hydraulic Valve (Emergency Steering) (Option) Cross section along the line X-X, Y-Y IW123-0260E02 1.Body 5.Cover 9.O-ring 13.Spring washer 2.Check valve 6.Spring 10.Plug 14.Hexagon socket head bolt 3.Spool 7.Spring 11.Plug 4.Check valve 8.Spring 12.Plug △ 366-406-60000 W123-0261E...

  • Page 39: Flow Control Valve

    B-6 . B-6 . Flow Control Valve 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.

  • Page 40: Pressure Reducing Valve

    B-7 . B-7 . Pressure Reducing Valve (Pilot Pressure) Pressure Reducing Valve (Pilot Pressure) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 41: Solenoid Control Valve

    Solenoid Control Valve (Outrigger) Solenoid Control Valve (Outrigger) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 42 Solenoid Control Valve (Outrigger) P cover assy (illustrated as 10 on page 21) 1.Cover 2.O-ring 3.O-ring 4.Shim 5.Plug 6.Plug assy 7.Relief valve assy IW112-015003 W112-0152E...
  • Page 43 Solenoid Control Valve (Outrigger) P cover assy (2/2) Relief valve (illustrated as 7 on page 23) IW112-011004 1.Body 5.Adjuster screw 9.Shim 13.Backup ring 2.Plunger 6.Nut 10.O-ring 14.Cap 3.Body 7.Spring 11.O-ring 4.Poppet 8.Spring 12.O-ring W112-0152E...
  • Page 44 Solenoid Control Valve (Outrigger) Body assy (1/2) (illustrated as 1 on page 21) 1.Body 2.Spool 3.Plug Sol. a1 4.Plunger 5.Spring 6.O-ring 7.O-ring 8.O-ring 9.Shim 10.Pilot cover assy Sol. b1 IW112-015004 W112-0152E...
  • Page 45 B-8 . B-8 . Solenoid Control Valve (Outrigger) Body assy (2/2) Pilot cover assy (illustrated as 10 on page 21) 1.Cover 2.Plug 3.Spool 4.Spring 5.O-ring 6.Spring seat 7.Hexagon socket head bolt 8.Plug 9.Solenoid (DC24V) 10.Orifice 11.O-ring 12.O-ring 13.Hexagon socket head bolt 14.Hexagon socket head bolt 15.Spring IW112-015005...

  • Page 46: Rotary Joint

    Rotary Joint 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.
  • Page 47 Rotary Joint Upper (view A) Lower (view B) W181-0440E...
  • Page 48 Rotary Joint 1.Slip ring assy 10.Support 19.Plug 28.Fitting 2.Plain bearing 11.Grease nipple 20.Support 29.Flare nut 3.Packing 12.Plain bearing 21.Flange bolt 30.Elbow fitting 4.Ring seal 13.Ring seal 22.Clamp 31.Support 5.Body 14.Packing 23.Nut 32.Grease nipple 6.Core 15.Ring seal 24.Plate 33.O-ring 7.Shaft 16.Bolt 25.Hexagon socket head bolt 8.Core 17.Flange bolt...
  • Page 49 Rotary Joint Pneumatic section Tightening torque Sign / port Thread size ft-lbf Upper Rc3/8 49 - 69 36 - 51 Air supply Lower G1/4 29.4 Upper Rc3/8 49 - 69 36 - 51 Service brake (primary) Lower G1/4 29.4 Upper Rc3/8 49 - 69 36 - 51...
  • Page 50 Rotary Joint Slip ring Assy IW181-0260E03 27 26 IW181-0260E04 16,17 IW181-0290E03 IW181-0260E05 W181-0440E...
  • Page 51 Rotary Joint IW181-0260E09 IW181-0260E07 32,33 IW181-0260E10 IW181-0260E08 1.Shaft 10.BH+CB 19.O-ring 28.Hose band 2.Ring set plate 11.Spacer 20.Potentiometer 29.Hexagon socket set screw 3.Bearing 12.Spacer 21.Cover 30.Machine screw 4.Ring 13.BH+CB 22.Packing 31.Bolt 5.Ring 14.Support 23.Lever 32.Bolt 6.Ring set plate 15.Base 24.Pin 33.Spring washer 7.U nut 16.Dry lock nut 25.Guide...
  • Page 52 Rotary Joint Wiring diagram LOWER (Slip ring) UPPER (Brush holder) Pot2 Pot1 626 1 26 26 1 626 3 2 23 23 2 27 12 627 627 12 27 28 11 628 628 11 28 29 10 629 629 10 29 630 9 30 20 8 20 8 20...

  • Page 53: Potentiometer

    B-9 . B-9 . Rotary Joint 2. Potentiometer 3. Turn the potentiometer shaft using a slotted screwdriver so that the resistance between the 2.1 Adjustment upper terminals 1 and 2 is minimum between 1 ohm and 15 ohm. Leave the terminals (6 pieces) 1.

  • Page 54: Hydraulic Pilot Control Valve

    B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) B-10 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 55 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Vent Vent (down) (down) (extending) (lowering) b3,b4 a3,a4 Aux. winch Main winch Telescoping Elevating (up) (up) (retracting) (raising) IW134-0270E02 W134-0271E...
  • Page 56 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 A3,B3,A4,B4 G3/4 P1,P2,A1,B1,A2,B2 W134-0271E...
  • Page 57 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Cross section of whole body Aux. winch Main winch Telescoping Elevating IW134-011012 W134-0271E...
  • Page 58 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) ・ Aux. winch Main winch ・ Telescoping Elevating IW134-0270E03 W134-0271E...
  • Page 59 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Aux. winch Main winch Telescoping Elevating IW134-011004 1.Winch selector valve 5.O-ring 9.Main relief valve 15.Plug 2.Telescoping selector valve 6.O-ring 12.Hex. socket head bolt 16.Eye bol 3.Elevating selector valve 7.Hex.
  • Page 60 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Winch selector valve Overload relief valve 25,24,23,13 9 8 12,23,24,25 16,17 C-C (Aux. winch) , D-D (Main winch) IW134-0270E04 Main relief valve 16,17 IW134-0110E07 W134-0271E...
  • Page 61 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) 1.Winch selector valve body 8.Return spring 16.Plug 23.Hex. socket head bolt 2.Spool (main,aux. winch) 9.Return spring 17.O-ring 24.Plain washer 3.-------------------------------- 10.Spring seat 18.Spring retainer 25.Spring washer 4.Flow control valve 11.Spool end (flow control valve) 26.Plug...
  • Page 62 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Telescoping selector valve Overload relief valve 27,26,25,13 12,25,26,27 19,20 19,20 F-F (Telescoping) IW134-0270E03 1.Telescoping selector valve 7.Spring seat 15.Plug (shuttle valve) 23.Plug (check valve) body 8.Return spring 16.O-ring 24.O-ring 2.Spool (telescoping) 9.Return spring...
  • Page 63 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Elevating selector valve Overload relief valve 22,21,20,13 12,20,21,22 16,17 16,17 G-G (Elevating) IW134-0110E09 1.Elevating selector valve body 7.Spring seat 13.Pilot cover 19.O-ring 2.Spool (elevating) 8.Return spring 14.Orifice 20.Hex. socket head bolt 3.Flow control valve (elevating) 9.Return spring 15.Spring (flow control valve)
  • Page 64 B-1 0 B-1 0 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Main relief valve (Main winch, Aux. winch), (Elevating, Telescoping) 20 19 14 13 12 11 10 9 IW134-011010 1.Socket 6.O-ring 11.Adjust screw 16.Valve 2.Valve 7.Packing 12.O-ring 17.Valve seat 3.Spring 8.Body 13.Nut...
  • Page 65 B-1 0 . B-1 0 . Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Overload relief valve (Main winch), (Aux. winch), (Elevating), (Telescoping) IW134-011011 1.Socket 5.Valve seat 9.Valve 13.Nut 2.Valve 6.O-ring 10.Spring 14.Cap nut 3.O-ring 7.O-ring 11.Adjust screw 15.Tie up wire 4.Spring 8.Body 12.O-ring...

  • Page 66: Sequence Valve (Pilot Pressure)

    B-1 1 B-1 1 Sequence Valve (Pilot Pressure) B-11 Sequence Valve (Pilot Pressure) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 67 B-1 1 B-1 1 Sequence Valve (Pilot Pressure) Cross section along the line A-A (back pressure regulating valve, pressure reducing valve) 1.Body 2.Filter 3.Filter retainer 4.Back pressure regulating valve 5.Pressure reducing valve 6.Hexagon socket head bolt 7.Plug 8.O-ring 9.Plug IW122-0112E01 Thread size and tightening torque Tightening torque Sign / port...
  • Page 68 B-1 1 . B-1 1 . Sequence Valve (Pilot Pressure) Pressure reducing valve (illustrated as 5 in the cross section along the line A-A) IW122-011005 1.Body 5.Spring seat 9.O-ring 13.O-ring 2.Spool 6.Spring 10.Nut 3.O-ring 7.Adjust screw 11.Cap nut 4.Plug 8.Body 12.O-ring △...

  • Page 69: Solenoid Valve (Pilot Pressure)

    B-1 2 B-1 2 Solenoid Valve (Pilot Pressure) B-12 Solenoid Valve (Pilot Pressure) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 70 B-1 2 . B-1 2 . Solenoid Valve (Pilot Pressure) Solenoid valve assy 31 1 312 361 IW121-067003 311.Spool 326.Retaining ring 363.O-ring 861. O-ring 312.Sleeve 361.O-ring 801.Solenoid valve 324.Spring 362.O-ring 802.Seal nut Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf 6.9 - 7.9...

  • Page 71: Solenoid Control Valve (Jib Set)

    B-1 3 B-1 3 Solenoid Control Valve (Jib Set) B-13 Solenoid Control Valve (Jib Set) [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.
  • Page 72 B-1 3 B-1 3 Solenoid Control Valve (Jib Set) C･O 27,38 IW112-0220E02 18.Name plate 27.Plug 31.Nut 33.Ball 21.Tigh rod 29.Hexagon socket head bolt 32.Ribbet screw 38.O-ring Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf P, T G1/2 A1, B1, A2, B2 G3/8...
  • Page 73 B-1 3 B-1 3 Solenoid Control Valve (Jib Set) 28 34 19 38 23 27 33 6.Collar 7.Spring folder 8.Plug 9.Spring 16.Solenoid 19.Body 20.Spring 22.Spring 23.Filter 25.Spool end 27.Plug 28.Hexagon socket head bolt 33.Ball 34.O-ring 35.O-ring 37.O-ring 38.O-ring 44.O-ring 34 19 38 27 23 20 IW112-0220E03 W112-0222E...
  • Page 74 B-1 3 B-1 3 Solenoid Control Valve (Jib Set) 14.Spol 15.Housing 17.Housing plunger 24.Housing 35.O-ring 43.O-ring IW112-0220E04 W112-0222E...
  • Page 75 B-1 3 B-1 3 Solenoid Control Valve (Jib Set) IW112-0220E05 IW112-0220E06 W112-0222E...
  • Page 76 B-1 3 . B-1 3 . Solenoid Control Valve (Jib Set) Relief valve 42 12 40 10 IW112-0220E07 1.Spring 5.Spring 13.Poppet 40.O-ring 2.Needle valve 10.Housing 30.Screw 41.O-ring 3.Nut 11.Sleeve 36.O-ring 42.O-ring 4.Gasket 12.Sleeve 39.O-ring △ 366-489-20000 W112-0222E...

  • Page 77: Pilot Check Valve (Jib Set)

    B-1 4 . B-1 4 . Pilot Check Valve (Jib Set) B-14 Pilot Check Valve (Jib Set) [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.

  • Page 78: Solenoid Valve (Oil Cooler)

    B-1 5 B-1 5 Solenoid Valve (Oil Cooler) B-15 Solenoid Valve (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.
  • Page 79 B-1 5 . B-1 5 . Solenoid Valve (Oil Cooler) Solenoid valve assy Connector (+): Red (-): Blue IW121-0542E01 IW121-025003 1.Body 7.Spring seat 11.Spring 2.Plug 8.Square ring 12.Solenoid (DC24V) 3.Spool 9.O-ring 15.Hexagon socket head bolt Thread size and tightening torque Tightening torque Sign / port Thread size...

  • Page 80: Hydraulic Motor (Oil Cooler)

    B-1 6 . B-1 6 . Solenoid Valve (Oil Cooler) B-16 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.

  • Page 81: Jib Lock Pin

    B-1 7 . B-1 7 . Jib Lock Pin B-17 Jib Lock Pin [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.

  • Page 82: Jib Offset Cylinder

    B-1 8 . B-1 8 . Jib Offset Cylinder B-18 Jib Offset 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.

  • Page 83: Check Valve (Gauge Lsolator)

    B-1 9 . B-1 9 . Check Valve (Gauge Isolator) B-19 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.
  • Page 84 Outrigger System Contents C-1 Outrigger System......1 C-7 Solenoid Valve (Slide/Jack) (NACHI) ........8 General............. 1 Structure ........... 8 C-2 Jack Cylinder........3 C-8 Check Valve (Outrigger Extending Structure ........... 3 Prevention) .......9 Structure ........... 9 C-3 Pilot check Valve (Jack Cylinder Retracting Prevention) ....

  • Page 85: Outrigger System

    Outrigger System Outrigger System 1. General Hydraulic Circuit for Outrigger 1. The outrigger controls use the solenoid control 4. During outrigger retraction, the pressure oil valve to select between extension or retraction for passes through the solenoid control valve and each cylinder.
  • Page 86 C-1 . C-1 . Outrigger System Electric Circuit (Relay RF3, Solenoid Valve) 1. The solenoid valve (extending/retracting) and the four solenoid valves (slide/jack) are switched according to the outputs from the multiplex data transmitter (lower). The outputs to the four solenoid valves (slide/jack) are transmitted via the relay RF3.

  • Page 87: Jack Cylinder

    C-2 . C-2 . Jack Cylinder 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.

  • Page 88: Pilot Check Valve

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

  • Page 89: Extension Cylinder

    C-4 . C-4 . Extension Cylinder 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.

  • Page 90: Solenoid Valve (Slide/Jack)

    C-5 . C-5 . Solenoid Valve (Slide/Jack) (UCHIDA) Solenoid Valve (Slide/Jack) (UCHIDA) [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.

  • Page 91: Solenoid Valve (Slide/Jack)

    C-6 . C-6 . Solenoid Valve (Slide/Jack) (TOKIMEC) Solenoid Valve (Slide/Jack) (TOKIMEC) [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.

  • Page 92: Solenoid Valve (Slide/Jack)

    C-7 . C-7 . Solenoid Valve (Slide/Jack) (NACHI) Solenoid Valve (Slide/Jack) (NACHI) [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.

  • Page 93: Check Valve (Outrigger Extending Prevention)

    C-8 . C-8 . Check Valve (Outrigger Extending Prevention) Check Valve (Outrigger Extending 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.
  • Page 94 Swing System Contents D-1 Swing System........1 General............. 1 D-2 Swing Assmbly ........ 3 Structure ........... 3 Swing bearing mounting bolt..... 4 Bearing Inner ring bolts ......4 Bearing outer ring bolts ......5 D-3 Hydraulic Pilot Control Valve (Swing) ........6 Structure ...........

  • Page 95: Swing System

    Swing System Swing System 1. General Hydraulic Circuit for Swing Remote Control Pressure Vent, Swing Free, Swing Brake Release [NOTICE] 1. The swing operation is controlled by the hydraulic The remote control valve and the hydraulic pilot pilot method. The pilot pressure from the remote control valve are connected at the two points having control valve controls the hydraulic pilot control the same symbols such as "a5"...
  • Page 96 D-1 . D-1 . Swing System 2. The maximum pressure in the swing circuit is 5. Circuit for swing brake release regulated by the relief valve. In case of sudden In this hydraulic circuit, the solenoid valve (swing stoppage of swing movement, the overload relief brake release) controls the pilot pressure to the valve (high pressure) in the circuit with unusually brake release port of the hydraulic motor for swing...

  • Page 97: Swing Assmbly

    Swing Assembly 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.

  • Page 98: Swing Bearing Mounting Bolt

    Swing Assembly 2. Swing bearing mounting bolt 2.1 Bearing Inner ring bolts 6 7 8 9 7,10 View A "S" mark Front 1.Pain washer 2.Bolt (L=185mm) 3.Bolt (L=155mm) 4.Plain washer 5.Bolt 6.Support 7.Nut 8.Bolt 9.End 10.Spring washer 11.Pin IW514-0140E01 [NOTICE] Thread size and tightening torque Install the bearing inner ring with the "S"...

  • Page 99: Bearing Outer Ring Bolts

    D-2 . D-2 . Swing Assembly 2.2 Bearing outer ring bolts △ ：545543 -- Applicable serial No. △ 1.Bolt (L=160mm) 2.Bolt (L=190mm) 3.Plain washer (50points) 4.Nut (5points) 5.Reamer bolt (L=185mm) 6.Plain washer (2points) FRONT Swing table IW514-0140E02 [NOTICE] Thread size and tightening torque Apply torque control agent to the threaded sections of the bolts.

  • Page 100: Hydraulic Pilot Control Valve

    Hydraulic Pilot Control Valve (Swing) Hydraulic Pilot 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.
  • Page 101 Hydraulic Pilot Control Valve (Swing) Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf P, R 200 - 240 145 - 174 AM, BM G3/4 150 - 180 108 - 130 G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 25 - 28...
  • Page 102 Hydraulic Pilot Control Valve (Swing) Cross section Sol.3 Sol.2 Sol.1 Sol.4 152 701 IW134-012003 Enlarged view (Sol.1, Sol.4, RV) Sol.1 Sol.4 IW134-012007 W134-0123E...
  • Page 103 Hydraulic Pilot Control Valve (Swing) Cross section along the line A-A 414 413 401 450 412 411 415 IW134-012004 Cross section along the line B-B IW134-012005 W134-0123E...
  • Page 104 Hydraulic Pilot Control Valve (Swing) Cross section along the line C-C 561 511 521 152 201 243 242 222 261 Sol.3 Sol.2 231 211 212 234 235 IW134-012006 Enlarged view (Sol.2, Sol.3) Sol.3 Sol.2 IW134-012008 W134-0123E...
  • Page 105 D-3 . D-3 . Hydraulic Pilot Control Valve (Swing) 101.Casing 242.O-ring 401.Plug 552.Plug 151.Plug 243.O-ring 411.Plunger 561.O-ring 152.Plug 251.Orifice 412.Spring 562.O-ring 201.Spool 252.Plug 413.O-ring 641.Spring seat 211.Spacer bolt 253.Plug 414.Steel ball 642.Spring 212.Stopper 261.Solenoid 415.Stopper 643.Steel ball 221.Cover inverse-proportional 450.Air bleeder screw 644.Seat 222.Cover reducing valve...

  • Page 106: Hydraulic Motor (Swing)

    Hydraulic Motor (Swing) 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.
  • Page 107 D-4 . D-4 . Hydraulic Motor (Swing) 101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring 106.Spacer 123.Guide plate 437.Iocking ring 491.Oil seal 111.Cylinder 124.Shoe plate 438.Iocking ring 702.Brake piston 113.Spherical bush 131.Valve plate 443.Roller bearing 706.O-ring 114.Cylinder spring 301.Casing 444.Roller bearing 707.O-ring 116.Push rod 303.Valve cover 451.Spring pin...

  • Page 108: Swing Speed Reducer

    Swing Speed Reducer 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.
  • Page 109 D-5 . D-5 . Swing Speed Reducer [NOTICE] Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer bracket (19). Inject lithium based grease to the mating faces of the retainer (2) and the roller bearing (3). After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into casing(4).
  • Page 110 Boom Elevating System Contents E-1 Elevating System ......1 General............. 1 E-2 Elevating Cylinder......3 Structure ........... 3 E-3 Counterbalance Valve (Elevating) .. 5 Structure ........... 5 Function............ 7 When control valve is at the neutral position ..........7 While actuator is being pushed up ..... 7 While actuator descends ......

  • Page 111: Elevating System

    E -1 E -1 Elevating System Elevating System 1. General Hydraulic Circuit for Boom Elevating Remote Control Pressure Vent WE02-0200E...
  • Page 112 E -1 . E -1 . Elevating System 3. Circuit for boom elevating slow stop [NOTICE] The boom raising proportional control valve and The solenoid control relief valve and the hydraulic pilot control valve are connected at the two points the boom lowering proportional control valve having the same symbols such as "a1"...

  • Page 113: Elevating Cylinder

    E -2 E -2 Elevating Cylinder 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.
  • Page 114 E -2 . E -2 . Elevating Cylinder 4,5 4,6 7,40 38 12 13,14 15 16,17,18 11 39 IW155-0230E02 1.Cylinder 11.O-ring 21.O-ring 31.Spring washer 2.Spring pin 12.Damper ring 22.Fitting 32.Counter balance valve assy 3.Plain bearing 13.Packing 23.O-ring 33.Fitting 4.Packing 14.Backup ring 24.Pipe 34.O-ring 5.Backup ring...

  • Page 115: Counterbalance Valve (Elevating)

    E -3 E -3 Counterbalance Valve (Elevating) Counterbalance Valve (Elevating) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 116 E -3 E -3 Counterbalance Valve (Elevating) Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf G3/4 G3/8 177 - 196 130 - 145 2-15 127 - 147 94 - 108 108 - 127 80 - 94 59 - 78 43 - 58 Mounting bolt...

  • Page 117: Function

    E -3 . E -3 . Counterbalance Valve (Elevating) 2. Function IW119-021003 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.
  • Page 118 Winch System Contents F-1 Winch System ........1 F-5 Hydraulic Valve (Winch Brake Release) ..12 General............. 1 Structure ..........12 F-2 Winch ..........4 Structure ........... 4 F-3 Hydraulic Motor (Winch) ....6 Structure ........... 6 Air bleeding procedure......8 F-4 Counterbalance Valve (Winch) ..

  • Page 119: Winch System

    F - 1 Winch System Winch System 1. General Hydraulic Circuit for Winch WF02-0251E...
  • Page 120 F - 1 Winch System Boom Telescoping/Auxiliary Hoist (~#545522) Boom Telescoping / Auxiliary Hoist (#545523~) Remote Control Pressure Vent WF02-0251E...
  • Page 121 F - 1 . F - 1 . Winch System [NOTICE] 4. Circuit for boom telescoping/auxiliary hoist The remote control valve and the solenoid valve are In this hydraulic circuit, the two solenoid valves connected to the hydraulic pilot control valve at the (boom telescoping/auxiliary hoist) switch the pilot points having the same symbols such as "a2", "a3", "b2", and "b3".

  • Page 122: Structure

    F - 2 Winch 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.
  • Page 123 F - 2 . F - 2 . Winch Note: Apply THREE-BOND 1104 to the following 5 places: mating face of the gear case (18) and the gear case cover (37); mating face of the gear case (18) and the bracket (1); mating face of the gear case (18) and the bearing retainer (7);...

  • Page 124: Structure

    F - 3 Hydraulic Motor (Winch) Hydraulic Motor (Winch) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 125 F - 3 Hydraulic Motor (Winch) Cross section of the hydraulic motor IW102-013003 (720) IW102-013004 W102-0132E...

  • Page 126: Air Bleeding Procedure

    F - 3 . F - 3 . Hydraulic Motor (Winch) 121.Piston 301.Casing 471.O-ring 707.O-ring 122.Shoe 304.Front cover 472.O-ring 710.Brake shim 111.Cylinder 401.Hex. socket head bolt 473.O-ring 720.Brake casing 131.Valve plate 402.Hex. socket head bolt 476.O-ring 741.Separater plate 303.Valve cover 403.Bolt 485.O-ring 742.Friction plate...

  • Page 127: Counterbalance Valve (Winch)

    F - 4 Counterbalance Valve (W inch) Counterbalance Valve (W inch) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 128: Function

    F - 4 Counterbalance Valve (W inch) 101.Casing 201.Cover 272.Square spring washer 355.Orifice 151.Plug 202.Cover 273.Hex. socket head bolt 361.O-ring 152.Plug 203.Spacer 274.Square spring washer 362.O-ring 161.O-ring 204.Spacer 301.Spool 511.Plunger 162.O-ring 252.Air bleeder screw seat 302.Pilot piston 514.Seat 163.O-ring 253.Plug 312.Steel ball 521.Spring 164.O-ring...

  • Page 129: Principle Of Operation

    F - 4 . F - 4 . Counterbalance Valve (W inch) 3. Principle of operation Overload relief valve IW119-0500E03 3. This pressure flows through choke b in the spool, 3.1 When control valve is in neutral enters into chamber c, where it pushes the The holding pressure of the hydraulic motor is plunger to the right by overcoming the spring force, locked by the seat area a of the check valve, the...
  • Page 130 F - 5 . F - 5 . Hydraulic Valve (Winch Brake Release) 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.
  • Page 131 Boom Telescoping System Contents G-1 Telescoping System ......1 Installing slide plates onto sides of rear end..........18 General............. 1 Adjustment ..........18 Description of telescoping system (Refer to 5.1 Adjusting clearance for the boom....18 the circuit diagram in Chapter Z.)... 5 5.2 Adjusting boom telescoping wire rope ..18 Extension circuit .........
  • Page 132 G-5 Counterbalance Valve (Telescoping) ......28 Structure ..........28 Function..........29 When control valve is at the neutral position ........29 While actuator is being pushed up ... 29 While actuator descends ......29 G-6 Hose Reel ........30 Structure ..........30 Dismounting..........

  • Page 133: Telescoping System

    G - 1 G - 1 Telescoping System Telescoping System 1. General Hydraulic Circuit for Boom Telescoping (2M2D) Boom Telescoping/Auxiliary Hoist (~#545522) WG02-0321E...
  • Page 134 G -1 G -1 Telescoping System Boom Telescoping/Auxiliary Hoist (#545523~) Remote Control Pressure Vent WG02-0321E...
  • Page 135 G -1 G -1 Telescoping System Telescoping cylinder at select WG02-0321E...
  • Page 136 G -1 G -1 Telescoping System [NOTICE] The solenoid valve and the hydraulic pilot control valve are connected at the two points having the same symbols such as "a4" and "b4". 1. The telescoping operation is controlled by the hydraulic pilot method. The pilot pressure from the remote control valve (boom telescoping/auxiliary hoist control lever) or the remote control valve (boom telescoping control...

  • Page 137: Description Of Telescoping System (Refer To The Circuit Diagram In Chapter Z.)

    G -1 G -1 Telescoping System 2. Description of telescoping system (Refer to the circuit diagram in Chapter Z.) Fold at the rear end the 3rd boom section. Sheave at the rear end of Adjuster and sheave on the head of the 2nd boom section the 3rd boom section Sheave at the head of the 4th boom section Top boom section retraction wire...

  • Page 138: Retraction Circuit

    G -1 G -1 Telescoping System 3. The 4th and top boom sections are extended by Telescoping mode II the wire-rope mechanism linked to the No. 2 (The 3rd through top boom sections extend first.) telescoping cylinder. 1. Pressurized oil for boom retraction is delivered 4.

  • Page 139: Boom Telescoping Mechanism

    G -1 G -1 Telescoping System 3. Boom telescoping mechanism 4. Top boom section Extended by the wire rope mechanism that 3.1 Extension synchronizes with the extension of 4th boom 1. 2nd boom section section Extended by No.1 cylinder 4th boom : No.1 cylinder stroke) 2nd boom section travel (E 2.

  • Page 140: Retraction

    G -1 G -1 Telescoping System 3.2 Retraction Balance of force × 1. Top boom section Retracted by the wire rope mechanism that Equation of workload : W × R × R synchronizes with the retraction of 3rd boom ∴ ×...
  • Page 141 G -1 . G -1 . Telescoping System Balance of force × ∴ Equation of workload : W × R × R ∴ × × From equation (b) × = 2L 4th boom section travel (R ) = 2L 3. 3rd boom section Retracted by No.2 cylinder 3rd boom section travel (R ) = L...
  • Page 142 G -2 G -2 G -2 Boom (Five-Section Boom) Boom (Five-Section Boom) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 143 G -2 G -2 G -2 Boom (Five-Section Boom) W536-0761E...

  • Page 144: Boom (Five-Section Boom)

    G -2 G -2 Boom (Five-Section Boom) 1.Base boom section 47.Hexagon socket head bolt 93.Pin 139.Sheave assy 2.Second boom section 48.Slide plate 94.Sheave assy 140.Bolt 3.Third boom section 49.Bolt 95.Bolt 141.Split pin 4.Fourth boom section 50.Adjuster assy 96.Plate 142.Hexagon socket head bolt 5.Top boom section 51.Bolt 97.Spacer...

  • Page 145: Disassembly

    G -2 G -2 Boom (Five-Section Boom) Telescoping cylinder 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.

  • Page 146: Removing The 3Rd Boom Section

    G -2 G -2 Boom (Five-Section Boom) 2.2 Removing the 3rd boom section Top boom section 3rd boom section Bolt 1 Pin 1 1 Remove the wire rope for top boom section Support Sheave assy extension/4th boom section retraction located on the top of the 2nd boom head by loosening the nut.

  • Page 147: Removing The 4Th Boom Section

    G -2 G -2 Boom (Five-Section Boom) 2. Lift up the rear end of the telescoping cylinder [NOTICE] slightly using a crane and pull out the connecting Before loosening the nut, measure the length of the pin that connects the 3rd boom section and the wire rope protrusion (L3) as a guide for reassembly.
  • Page 148 G -2 G -2 Boom (Five-Section Boom) Guide Bolt 1 Support Bolt 2 Wire rope (for top boom section extension / 4th boom section retraction) IW536-0620E14 3. To prevent damage to the wire rope, secure it to the head of the top boom section using a jig. T op boom section Wire rope (for top boom section extension / 4th boom section retraction)

  • Page 149: Check

    G -2 G -2 Boom (Five-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...

  • Page 150: Installing Lower Slide Plates

    G -2 G -2 Boom (Five-Section Boom) 4.3 Installing lower slide plates 5. Adjustment 1. Apply thread locking agent to the bolt, tighten it 5.1 Adjusting clearance for the boom lightly and turn it in reverse for a quarter turn. 1.

  • Page 151: Operation Test

    G -2 . G -2 . Boom (Five-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.

  • Page 152: Jib

    G -3 G -3 G -3 △ △ ：545419,545457~,475330~ ：545419,545430~,475327~ Applicable serial No. △ △ ：545511~,475349~,437366~ ：545410~,475326~ △ ：545419,545430~,475330~ 1. Structure 1.1 Location of Jib W537-0102E...
  • Page 153 G -3 G -3 1.Support assy 13.Support 25.End 37.Stopper 2.Plate 14.Plate 26.Pin 38.Stopper 3.Pin assy 15.Bolt 27.Split pin 39.Bolt 4.Bolt 16.Nut 28.Plain washer 40.Spring washer 5.Spring washer 17.Plain washer 29.Clamp 41.---------------------- 6.Plain washer 18.Support 30.Flange nut 42.---------------------- 7.Bolt 19.Pin assy 31.Control cable 43.Plate 8.Plain washer...

  • Page 154: Jib Main Body

    G -3 G -3 G -3 △ △ ：545419,545457~,475330~ ：545410~,475326~ Applicable serial No. △ △ ：545511~,475349~,437353~ ：545410~,475326~ △ ：545410~,475326~ 1.2 Jib main body W537-0102E...
  • Page 155 G -3 G -3 1.Jib 2 15.Pin assy 29.Roller assy 43.Spacer 2.Jib1 16.Spacer 30.Spacer 44.Pin 3.Support 17.Sheave assy 31.Pin 45.Bolt 4.Snap pin 18.Plate 32.Bar 46.Spring washer 5.Pin 19.Pin 33.Pin 47.Roller assy 6.Pin 20.---------------------- 34.Split pin 48.Pin 7.Retaining ring 21.Link 35.Plate 49.Spacer 8.Sheave assy 22.Plate...

  • Page 156: Adjustment

    G -3 G -3 2. Adjustment 2.1 Adjusting jib 1-2 connecting spring pin 2.2 Adjusting jib inclination Make sure that the clearance (X) between the In order to facilitate inserting and removing the support and spring pin is 2 mm (0.08 in) while the elevating pin, adjust the jib inclination by using a jib 1 supports the jib 2.

  • Page 157: Adjusting Inclination Of Jib 2

    G -3 . G -3 . 2.3 Adjusting inclination of jib 2 Slide plate Shim (t 0.6) Adjust the inclination to facilitate inserting and removing the jib 1-2 connecting pin. 1) If the rear end of the jib 2 is too low for the pin to be inserted and removed easily, apply shims (t0.6 mm (t0.02 in)) to the slide plate on the support on the boom rear end.

  • Page 158: Telescoping Cylinder

    G -4 G -4 Telescoping Cylinder 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.
  • Page 159 G -4 . G -4 . Telescoping Cylinder 11 12 31 13 14 15 16 17 18 IW157-0390E03 1.Plug 6.Packing 11.O-ring 16.Backup ring 2.Spring pin 7.Plain bearing 12.Rod cover assy 17.Plain bearing 3.Nut 8.O-ring 13.Support 18.Dust seal 4.Piston 9.Cylinder 14.Damper ring 31.O-ring 5.Backup ring 10.Rod...

  • Page 160: Counterbalance Valve

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

  • Page 161: Function

    G -5 . G -5 . Counterbalance Valve (Telescoping) 2. Function IW119-022003 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.

  • Page 162: Hose Reel

    G -6 G -6 Hose Reel 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.

  • Page 163: Dismounting

    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 2) Tie one end of a wire of a sufficient length to dismounting the hose reel.
  • Page 164 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.

  • Page 165: Hydraulic Valve

    G -7 G -7 Hydraulic Valve 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.
  • Page 166 G -7 G -7 Hydraulic Valve 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 Tightening torque Sign / Port Thread size ft-lbf Mounting bolt (for solenoid valve.6) W123-0172E...
  • Page 167 G -7 . G -7 . Hydraulic Valve Solenoid valve assy Connector (+): Red (-): Blue IW121-0542E01 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 Tightening torque Sign / Port Thread size ft-lbf 44 - 49...
  • Page 168 Safety System Contents H-1 Safety System ........1 H-3 Outrigger Extension Length Detector ........8 General............. 1 Structure and function ....... 8 Pressure sensor ......... 1 Boom length and angle detector ....1 Disassembly..........9 Outrigger extension width detector..... 1 Other detectors and switches..... 1 Reassembly ..........

  • Page 169: Safety System

    H-1 . H-1 . Safety System Safety System 1.6 Overwind cutout (Anti-twoblock) device 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.

  • Page 170: Boom Length And Angle Detector

    Boom Length and Angle Detector 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.
  • Page 171 Boom Length and Angle Detector 1.Plate 16.Spring 31.Pin terminal 46.Cable 2.Case 17.Cover 32.Nut 47.Holder 3.Drum assy 18.Clip 33.Washer 48.Terminal 4.Slip ring assy 19.Support 34.Screw 49.Terminal 5.Contact assy 20.Clamp 35.Bolt 50.Angle detector 6.Contact assy 21.Cord guide 36.Bolt 51.Plug 7.Bearing case 22.Collar 37.Screw 52.Collar 8.Bearing...

  • Page 172: Disassembly And Reassembly

    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 Plate slowly until no tension of the spiral spring is applied on the cord.
  • Page 173 Boom Length and Angle Detector Core wire original position after it is rotated a quarter turn by Cord finger and released. If it is not returned, loosen the bolt and adjust the position of the bracket. Shield wire [NOTICE] Drum assy Vinyl tube If the potentiometer is faulty, replace it referring to the "Replacing the potentiometer (boom length...

  • Page 174: Replacing Spiral Spring

    Boom Length and Angle Detector 2.4 Disassembling the potentiometer 13. Draw out the cord slightly from the drum and (for boom length detector) make sure that the resistance between the red and white terminals increases smoothly. [NOTICE] If both the cord and spiral spring are faulty, remove 14.

  • Page 175: Reassembling Potentiometer

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

  • Page 176: Outrigger Extension Length

    Outrigger Extension Length Detector Outrigger Extension Length Detector [NOTICE] 3. The consequent rotation of the drum drives the There is a case that the appearance and so on potentiometer shaft through gears which reduce differ from the parts for this machine. Although there the speed to 5/6.

  • Page 177: Disassembly

    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.

  • Page 178: Reassembly

    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.
  • Page 179 H-3 . H-3 . Boom Length and Angle 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.

  • Page 180: Solenoid Valve (Auto Stop)

    Solenoid Valve (Auto Stop) 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.
  • Page 181 H-4 . H-4 . Solenoid Valve (Auto Stop) Solenoid valve assy 1.Body Connector 2.Plug 4.Spool 7.Spring seat (+): Red 8.Square ring (-): Blue 9.O-ring 11.Spring IW121-0542E01 12.Solenoid (DC24V) IW121-0540E04 Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf 44 - 49 32 - 36...
  • Page 182 Contents K-1 Crane Cab Glass ......1 Condenser Assy........18 Glass replacement procedure ....1 Electric ............ 19 Electric circuit ..........19 Bonding the joint between windshield glass Main harness A .........20 and roof glass........ 2 Main harness B .........21 Important points for assembly (Layout)..22 K-2 Air Conditioner.........
  • Page 183 12. Compressor ..........38 12.1 Compressor abnormal sound diagnosis chart ............38 12.2 Compressor diagnosis chart..... 39 13.Troubleshooting ........41 14.Control table ..........47 K-3 Hydraulic Motor (Air Conditioner) (Option) ........48 Structure ..........48 K-4 Solenoid Valve (Air Conditioner) (Option) ........

  • Page 184: Crane Cab Glass

    Crane Cab Glass Crane Cab Glass 6. Let the primer C coated surfaces dry for more than 15 minutes. 1. Glass replacement procedure 7. Clean and degrease the bonding surfaces of the Follow the procedure described below to replace new glass with a gauze soaked with white the fixed windshield window glass, roof glass, gasoline or acetone.

  • Page 185: Bonding The Joint Between Windshield Glass And Roof Glass

    K-1 . K-1 . Crane Cab Glass while aligning the marks (masking tape pieces put [NOTICE] in Step 3) on the glass with those on the cab body. Wipe away any excessive adhesive. 11. Fit the molding on the circumference of the new glass and bond its end joint with an instant aneous adhesive.

  • Page 186: Air Conditioner

    Air Conditioner Air Conditioner [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.

  • Page 187: Introduction To Air Conditioning

    Air Conditioner (Absorbing heat from surroundings.) 2. Introduction to air conditioning Vaporization [NOTICE] Liquid Vapor This section explains the fundamentals of the car air conditioner. Difficult concepts and special Condensation mechanisms have been omitted where possible, (Radiating heat of vapor outward.) and only contents which focus on the basic functions have been included.

  • Page 188: Basic Refrigeration Cycle

    Air Conditioner 3. Basic refrigeration cycle 2. Compressor This component absorbs the gaseous refrigerant 3.1 Structure that was vaporized in the evaporator, and An ordinary air conditioner circulates a volatile compresses it to higher pressure so that it can be liquid (called a refrigerant) that is contained in more easily liquefied in the condenser.

  • Page 189: Conditions For Air Conditioning Equipment

    Air Conditioner 3.2 Conditions for air conditioning equipment The conditions required for a high-performance air conditioner are the following. Refrigerant vaporizes at the lowest temperature possible. Refrigerant liquefies easily. The largest possible quantity of refrigerant vaporizes in the evaporator. 1. When we look at the conditions of the refrigerant 5.

  • Page 190: Refrigerant

    Air Conditioner 3.3 Refrigerant 2. As shown in the figure below, the refrigerant 1. The substance that circulates through the HFC134a remains in liquid form at relatively high refrigeration cycle, and functions to transmit heat, temperatures when it is strongly compressed. is known as the refrigerant.

  • Page 191: Refrigeration Cycle Of A Car Air Conditioner

    Air Conditioner 3.4 Refrigeration cycle of a car air conditioner 2. Compared with the basic refrigeration cycle described earlier, this cycle has an expansion 1. The refrigeration cycle of a car air conditioner valve with a different construction, and adds a comprises a compressor, condenser, receiver, receiver.

  • Page 192: Receiver Functions

    Air Conditioner 2. Large variations in compressor speed 3. There are two types of receivers – block joint type The compressor of a household air conditioner is and union type. The difference is the means of maintained at a constant motor speed. The connecting the pipes.

  • Page 193: Reheat Method

    Air Conditioner 3.7 Reheat method 1. The air which cools (or heats) the cab is taken in from outside (or inside) by a blower motor, and then passes through the cooler unit and heater unit before being blown out from each of the ducts. The temperature control type at this time is the reheat method.

  • Page 194: Components

    Air Conditioner 3.8 Components Air circulation inside cab LCD panel Outside-cab air supply COOL Min. Max. Cool Face Face and foot Foot The current volume The current temperature IW701-0160E14 Sign on the LCD panel Switches 8.Sign of air supply selection 1.Power switch 9.Sign of air conditioner operation (Snow-shaped sign) 2.Air conditioner switch...
  • Page 195 Air Conditioner Air outlet changeover switch WARNING This switch is used to select the air blowing While the engine and the air conditioner are direction. As it is pressed, the direction changes running, be sure not to touch the rotating objects (fan belt, condenser fan, etc).

  • Page 196: Layout

    Air Conditioner 4. Layout 4.1 Overall layout △ 345-107-61000 W701-0220E...

  • Page 197: Overall Layout

    Air Conditioner 4.2 Overall layout △ 345-110-73000 W701-0220E...

  • Page 198: Evaporator Section

    Air Conditioner 4.3 Evaporator section △ 345-107-02000 W701-0220E...

  • Page 199: Compressor Assy

    Air Conditioner 5. Compressor Assy W701-0220E...

  • Page 200: Evaporator Assy

    Air Conditioner 6. Evaporator Assy W701-0220E...

  • Page 201: Condenser Assy

    Air Conditioner 7. Condenser Assy W701-0220E...

  • Page 202: Electric

    Air Conditioner 8. Electric 8.1 Electric circuit △ 363-205-60030 W701-0220E...

  • Page 203: Main Harness A

    Air Conditioner 8.2 Main harness A W701-0220E...

  • Page 204: Main Harness B

    Air Conditioner 8.3 Main harness B W701-0220E...

  • Page 205: Important Points For Assembly (Layout)

    Air Conditioner 9. Important points for assembly (Layout) 9.1 Evacuation [NOTICE] If moisture and air are not fully eliminated from the cycle, they will cause problems such as cooling trouble and clogs in the cycle. 1. Evacuate by applying vacuum to the high- and low-pressure service valves.

  • Page 206: Check For Gas Leakage And Amount Of Refrigerant Charge

    Air Conditioner 9.3 Check for gas leakage and amount of 9.5 Run-in operation refrigerant charge Operate the A/C for 5 minutes or more under the [NOTICE] conditions below to perform the initial run-in Never check using a halide-torch type leak detector. operation.

  • Page 207: How To Charge Air Conditioner Gas

    Air Conditioner 10. How to charge air conditioner gas 10.1 Charging gas in automatic operation Gas charging unit (Reference) W701-0220E...
  • Page 208 Air Conditioner Jigs Flow Procedure Safety point tools Plug the power supply cord of the main unit. Connect the coupler of the high-pressure side (red hose) and the Be careful to the low-pressure side with the compressor main body sequentially. scaffold Purge residual pressure before connecting because the connection of coupler becomes firm if there is residual pressure in...

  • Page 209: How To Charge Air Conditioner Gas

    Air Conditioner 10.2 How to charge air conditioner gas Flow Jigs and Procedure Safety point tools Plug the power supply cord of the main unit. Connect the coupler of the high-pressure side (red hose) and the Be careful to the low-pressure side with the compressor main body sequentially.
  • Page 210 Air Conditioner Flow Jigs and Procedure Safety point tools Detach the empty gas can, and purge pressure in the hose. 1) Set the timer knob to the vacuum side. 2) Set the power switch to the automatic or manual. 3) Turn OFF the power switch when the high/low-pressure gauge indicates approx.

  • Page 211: How To Check Air Conditioner

    Air Conditioner 10.3 How to check air conditioner Jigs Flow Procedure Safety point tools Illumination lamp check (for control panel) 1) The lamp lights with the working lamp switch ON. (Two lamps Lights both 2 lamps. on upper and lower of center in the panel.) 2) The lamp turns off with the working lamp switch OFF.

  • Page 212: Diagnosis Table

    Air Conditioner 11 Diagnosis table 11.1 Car air conditioner system diagnosis table I (Refrigeration circuit) A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure...
  • Page 213 Air Conditioner A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure repair method) Remove blocked foreign object, or ------------------------------ TXV failure (blocking) replace TXV and R/D.
  • Page 214 Air Conditioner A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure repair method) Check that thermo Evaporator is frosting. Thermistor Installation position failure of therms sensor is in is not cold.
  • Page 215 Air Conditioner 11.2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure) Trouble Diagnosis result phenomena Phenomenon explanation to Measures (specific part name Disorder section (phenomenon of principal Possible cause other than A/C consider other factors and repair method) cause)
  • Page 216 Air Conditioner Trouble Diagnosis result phenomena Phenomenon explanation to Measures (specific part name Disorder section (phenomenon of principal Possible cause other than A/C consider other factors and repair method) cause) system Noise sounds. Engine room side Sound is generated when -------------------------------- Vibration or slip by belt Tension belt, replace, or...
  • Page 217 Air Conditioner 11.3 Car air conditioner system diagnosis table III (Electrical system) Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part phenomenon of check and and confirmation (phenomenon of name and repair method) functional parts confirmation principal cause) 1) Neither...
  • Page 218 Air Conditioner Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part phenomenon of check and and confirmation (phenomenon of name and repair method) functional parts confirmation principal cause) 6) Compressor Measure clutch -------------------------------- ---------------------------- Clutch suction voltage is low (7V Repair or replace parts.
  • Page 219 Air Conditioner 11.4 Car air conditioner system diagnosis table IV (Electronic thermo system) Operation Measures Guessing of Diagnosis result trouble Check and confirmation of (Thermistor amplifier trouble functional (Refer to temperature Possible cause phenomenon of operational parts replacement, and connector parts characteristic for thermistor.) functional parts...

  • Page 220: (Electronic Thermo System)

    Air Conditioner Operation Measures Guessing of Diagnosis result trouble Check and confirmation of (Thermistor amplifier trouble functional (Refer to temperature Possible cause phenomenon of operational parts replacement, and connector parts characteristic for thermistor.) functional parts repair.) Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp.

  • Page 221: Compressor

    Air Conditioner 12. Compressor 12.1 Compressor abnormal sound diagnosis chart W701-0220E...
  • Page 222 Air Conditioner 12.2 Compressor diagnosis chart (1/2) W701-0220E...

  • Page 223: Compressor Diagnosis Chart

    Air Conditioner Compressor diagnosis chart (2/2) W701-0220E...

  • Page 224: Troubleshooting

    Air Conditioner 13.Troubleshooting W701-0220E...
  • Page 225 Air Conditioner W701-0220E...
  • Page 226 Air Conditioner W701-0220E...
  • Page 227 Air Conditioner W701-0220E...
  • Page 228 Air Conditioner W701-0220E...
  • Page 229 Air Conditioner W701-0220E...

  • Page 230: Control Table

    K-2 . K-2 . K-2 . Air Conditioner 14.Control table Input Output Input from Panel LCD display on panel Blowout mode In/outside air ON/OFF In/outside A/C switch Blowout mode Air blow mode Relay change switch mode Switch air switch INPUT/OUTPUT CONTROL ＣＯＯＬ...

  • Page 231: Structure

    Hydraulic Motor (Air Conditioner) (Option) Hydraulic Motor (Air Conditioner) (Option) [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.
  • Page 232 K-3 . K-3 . Hydraulic Motor (Air Conditioner) (Option) 25 20 IW102-037003 IW102-037002 1.Casing 8.Tapered roller bearing 15.Spring washer 22.Steel ball 5/16 2.Drive shaft 9.Tapered roller bearing 16.Key (7×7×30) 23.Spring retainer 3.Pintle 10.Timing pin 17…. 24.O-ring 4.Cylinder block 11.Timing ring 18….

  • Page 233: Structure

    Solenoid Valve (Air Conditioner) (Option) Solenoid Valve (Air Conditioner) (Option) [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.
  • Page 234 K-4 . K-4 . Solenoid Valve (Air Conditioner) (Option) Solenoid valve assy Connector (+): Red (-): Blue IW121-0542E01 157 156 IW121-076003 1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V) 4.Plug 21.Spool 113.Square ring 159.O-ring 9.O-ring 60.Spring seat 156.O-ring Thread size and tightening torque Tightening torque Sign / Port Thread size...
  • Page 235 Control System Contents L-1 Control System ........ 1 L-7 Solenoid Valve (Air) .......14 General of hydraulic pilot system ....1 Structure ..........14 General of pneumatic control devices ..2 L-2 Remote Control Valve (Lever)..3 Structure ........... 3 L-3 Remote Control Valve (Pedal)..6 Structure ...........

  • Page 236: Control System

    L - 1 Control System Control System 1. General of hydraulic pilot system Hydraulic Pilot Circuit WL02-0090E...

  • Page 237: General Of Pneumatic Control Devices

    L - 1 . L - 1 . Control System 2. General of pneumatic control devices Pneumatic Circuit WL02-0090E...

  • Page 238: Remote Control Valve (Lever)

    L - 2 Remote Control Valve (Lever) Remote Control Valve (Lever) [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.
  • Page 239 L - 2 Remote Control Valve (Lever) Cross section along the line A-A PORTS 1•3 PORTS 2•4 IW135-0130E03 101.Casing 171.Bolt 216.Spring seat 445.Hexagon socket head bolt 103.Casing 172.Nut 217.Washer 452.Disc 111.Port plate 201.Spool 221.Spring 453.Cam shaft 122.O-ring 211.Plug 241.Spring 454.Set screw 123.O-ring 212.Push rod 247.Spring pin...
  • Page 240 L - 2 . L - 2 . Remote Control Valve (Lever) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf P, T G1/4 34 - 38 25 - 28 PORTS 1, 2, 3, 4 G1/4 34 - 38 25 - 28 27 - 31...

  • Page 241: Remote Control Valve (Pedal)

    L - 3 Remote Control Valve (Pedal) Remote Control Valve (Pedal) [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.
  • Page 242 L - 3 Remote Control Valve (Pedal) Section A-A 2,4,6 1,3,5 IW135-015003 273.Nut 413.Cam shaft 101.Casing 214.Push rod 301.Spool 414.Bush 102.Casing 217.Shim 311.Spring seat 420.Cam 103.Casing 251.RO plug 313.Washer 431.Block 115.Plate 261.O-ring 315.Iock nut 471.Ball 201.Cover 262.O-ring 323.Iever 472.Set screw 202.Plug 263.O-ring 324.Spring...
  • Page 243 L - 3 . L - 3 . Remote Control Valve (Pedal) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf 19.1 - 22.1 14.1 - 16.3 8.7 - 8.9 6.4 - 6.6 G1/4 27.4 - 31.4 20.2 - 23.2 56.3 - 61.3 41.5 - 45.2...

  • Page 244: Shuttle Valve (Lever / Pedal)

    L - 4 . L - 4 . Shuttle Valve (Lever/Pedal) Shuttle Valve (Lever / Pedal) [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.

  • Page 245: Solenoid Valve (Boom Telescoping / Aux. Hoist)

    L - 5 Solenoid Valve (Boom Telescoping/Aux. W inch) Solenoid Valve (Boom Telescoping / Aux. W inch) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 246 L - 5 . L - 5 . Solenoid Valve (Boom Telescoping/Aux. W inch) Cross section along the line X-X B (F) D (H) C (G) A (E) IW121-031003 Note: Apply LOCTITE 262 (thread locking agent) to the threaded section of the seat (1). 1.Seat 5.Solenoid (DC24V) 11.Plain washer...

  • Page 247: Structure

    L - 6 Solenoid Control Relief Valve (Elevating Slow Stop) Solenoid Control Relief Valve (Elevating Slow 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.
  • Page 248 L - 6 . L - 6 . Solenoid Control Relief Valve (Elevating Slow Stop) Proportional Reducing Valve 326 324 312 361 IW136-0250E02 311.Spool 326.Retaining ring 362.O-ring 861.O-ring 312.Sleeve 331.Spring seat 363.O-ring 324.Spring 351.Orifice 801.Proportional reducing valve 325.C-ring 361.O-ring 802.Seal nut Thread size and tightening torque Tightening torque Sign / Port...

  • Page 249: Solenoid Valve (Air)

    L - 7 Solenoid Valve (Air) Solenoid Valve (Air) [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.
  • Page 250 L - 7 . L - 7 . Solenoid Valve (Air) IW210-0170E03 IW210-0170E04 1.Packing holder 8.Plunger 15.Valve 22.Valve seat 2.Packing 9.Rod 16.Spring 23.Bolt 3.Coil assy (DC24V) 10.O-ring 17.O-ring 24.Bolt 4.Core 11.Coil cover 18.Body 25.Spring washer 5.Spring 12.O-ring 19.Body 26.Filter 6.O-ring 13.Valve seat 20.Housing 27.Spring...
  • Page 251 Steering System Contents S-1 Steering System....... 1 S-6 Pilot Check Valve (Rear Steering Cylinder Lock)......12 General............. 1 Structure ..........12 S-2 Priority Valve ........2 Structure ........... 2 Function............ 2 Principle of operation ........ 3 Neutral state ..........3 Right steering ..........3 Right steering to the end ......

  • Page 252: Steering System

    S -1 . S -1 . Steering System Steering System 1. General Hydraulic Circuit for Steering Layout of Steering Cylinders 1. The steering wheel is coupled with the orbitrol. (Right steering) 2. The orbitrol, together with the priority valve, supplies the steering cylinders with oil at the rate corresponding to the rotational speed of the steering wheel.

  • Page 253: Priority Valve

    S -2 S -2 Priority Valve Priority 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.

  • Page 254: Principle Of Operation

    S -2 . S -2 . Priority Valve 3. Principle of operation NEUTRAL RIGHT STEERING The above figure is for illustrating the principle. The construction of the actual machine may differ from the figure. 3.1 Neutral state 3.2 Right steering While the engine is standing still, spool 2 in the When the steering wheel is turned clockwise, the priority valve is pushed to the left end by spring 3,...

  • Page 255: Orbitrol

    S -3 S -3 Orbitrol Orbitrol [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.
  • Page 256 S -3 S -3 Orbitrol Cross section Star IW184-0010E05 IW184-001003 IW184-001006 16 17 13 10 11 12 8 24 7 23 3 1 A- A IW184-001004 W184-0012E...
  • Page 257 S -3 S -3 Orbitrol [NOTICE] Orient the star of the rotor set (4), drive (8) and pin (13) as shown in the "OK" figure. 1.Screw 8.Drive 16.Race bearing 22.Seal gland bushing 2.Retainer screw assy 10.Housing 17.Thrust needle 23.O-ring 3.End cap 11.Sleeve 18.O-ring 24.O-ring...

  • Page 258: Function

    S -3 . S -3 . Orbitrol 2. Function Spool The machine is equipped with a load-sensing type Housing Sleeve Drive orbitrol consisting of the following main components: 1. Housing The housing has five piping ports: P, T, R, L and 2.

  • Page 259: Steering Cylinder

    S -4 . S -4 . Steering Cylinder Steering 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.

  • Page 260: Solenoid Valve (Steering Mode)

    S -5 S -5 Solenoid Valve (Steering Mode) Solenoid Valve (Steering Mode) [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.
  • Page 261 S -5 S -5 Solenoid Valve (Steering Mode) Section A-A 402 403 101 401 201 IW121-039003 Section B-B 101.Casing 102.Cover 103.Spool 105.Spring seat 201.Spring 302.Hexagon socket head bolt 401.O-ring 402.O-ring 403.O-ring 601.Solenoid valve assy IW121-039004 W121-0392E...
  • Page 262 S -5 . S -5 . Solenoid Valve (Steering Mode) Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf d(mounting bolt) 29.5 ± 3 22 ± 2.2 2 or less 1.5 or less 5.4 ± 0.5 4 ±...

  • Page 263: Pilot Check Valve (Rear Steering Cylinder Lock)

    S -6 . S -6 . Pilot Check Valve (Rear Steering Cylinder Lock) Pilot Check Valve (Rear Steering Cylinder Lock) [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.
  • Page 264 Brake System Contents T-1 Brake System ........1 Operation under piping rupture ....11 General............. 1 Dismouting and remounting ....11 Disassembly..........11 T-2 Brake (Service Brake)...... 2 Disassembly of the mount plate....12 Disassembly of the body......12 Structure and function ....... 2 Cleaning and checking ......
  • Page 265 T-7 Brake Chamber.......44 Principles of operation ......22 Relay valve ..........22 Structure ..........44 Cylinder ............ 24 Function ..........45 T-5 Air Dryer ......... 25 Disassembly..........45 Structure ..........25 Cleaning and checking ......46 Cleaning ............46 Function..........29 Checking ...........46 Dehumidification ........

  • Page 266: Brake System

    T - 1 . T - 1 . Brake System Brake System 1. General Brake Circuit (air over hydraulic brake) WT02-0120E...

  • Page 267: Brake (Service Brake)

    T - 2 Brake (Service Brake) Brake (Service Brake) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 268: Principle Of Operation

    T - 2 Brake (Service Brake) 1.1 Principle of operation The simple check method of pad assy is shown as follows: 1. When hydraulic pressure is applied Check the pad thickness by inserting a check gauge as shown below in the check holes in the torque The pistons exert force to the pad assy by plate.

  • Page 269: Replacing The Pad Assy

    T - 2 Brake (Service Brake) 4. Replacing the pad assy 7. Push in torque pin 4 in its hole after applying grease to both. At this time, adjust the clearance When the thickness of the brake lining has between the disc plate and torque pin 4 to 1.5 - 3 reduced to 4 mm (0.16 in) , replace the pad assy.

  • Page 270: Disassembly

    T - 2 Brake (Service Brake) 5. Disassembly 6. Washing and checking 6.1 Washing CAUTION Never use mineral oil. Wash the metal parts in trichloroethylene or brake fluid. After washing, blow air into the holes and grooves in the torque plate and wipe off all residual liquid with clean cloth.

  • Page 271: Reassembly

    T - 2 . T - 2 . Brake (Service Brake) 7. Reassembly [NOTICE] For the installing procedure, see 1. Apply the rust preventive lubricant found in the “ Replacing the pad assy ” . seal kit to piston seal 15, backup rings 16, pistons 13 and to the cylinder bores.

  • Page 272: Brake Valve

    T - 3 Brake Valve Brake 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.
  • Page 273 T - 3 Brake Valve 1. Upper body 13.O-ring 25.Spring washer 37.Exhaust cover 2. Upper valve 14.O-ring 26.Nut 38.Screw and washer 3. Valve retainer 15.Return spring 27.O-ring 39.Exhaust check 4. Valve spring 16.Stem 28.Lower body 40.O-ring 5. Retainer 17.Inner spring 29.Lower valve 41.Bolt and washer 6.

  • Page 274: Description Of Operation

    T - 3 Brake Valve 2. Description of operation 7. The lower valve moves further down, opening the air inlet valve seat on the lower body. This allows 2.1 Generation of air pressure pressurized air from the secondary supply port to flow through the delivery port into the brake 1.

  • Page 275: Release Of Air Pressure

    T - 3 Brake Valve Rubber spring Piston Discharge valve sheet Relay piston Inlet valve sheet Upper body Discharge valve sheet Upper valve Inlet valve sheet Lower body Lower valve IW202-0010E05 IW202-0010E04 2.3 Release of air pressure 7. In the secondary air system, relay piston lowers in proportion to the air pressure in the primary 1.

  • Page 276: Operation Under Piping Rupture

    T - 3 Brake Valve Return spring Plunger 2. Operation with only secondary system Spring seat When the primary brake system is damaged, no Rubber spring air pressure is generated in the primary system, Piston so that no primary air pressure is available to work on the relay piston for actuation of the secondary system.

  • Page 277: Disassembly Of The Mount Plate

    T - 3 Brake Valve Place the disassembled parts in neat order to Upper body Stem facilitate reassembly. 4.1 Disassembly of the mount plate 1. Remove three bolts and washers, and remove mount plate, plunger, and plunger boot. Plunger Plunger boot Bolt and washer Mount plate Relay piston...

  • Page 278: Cleaning And Checking

    T - 3 Brake Valve 4. Remove the O-ring from between the upper body and lower body. Clamp the lower body in a vise, Retaining ring with the exhaust check facing up. Special washer 5. Unscrew the 4 screws, and remove the exhaust O-ring cover and lower valve assy.

  • Page 279: Checking

    T - 3 Brake Valve 3. The mount plate incorporates an oilless alloy bush. 2. Build the lower valve assy into lower body. Wash it with kerosene and dry it with compressed 3. Install exhaust cover, and secure with screw and air.
  • Page 280 T - 3 Brake Valve 3. Insert the upper valve assy in upper body, and secure with retaining ring. Stem assy Upper body Retaining ring Relay piston Upper valve assy O-ring Spring IW202-0010E19 IW202-0010E20 4. Put the springs, stem washer, and sleeve onto the stem, and tighten the sleeve.

  • Page 281: Reassembly Of The Mount Plate

    T - 3 Brake Valve 7.1 Air leakage through supply valve and exhaust valve Spring washer In the fully released state, the air leakage to the Special washer delivery port and the exhaust port combined Spring seat should be less than 100 cm /min {6.1in /min}.

  • Page 282: Maintenance Standards

    T - 3 . T - 3 . Brake Valve 8. Maintenance standards 8.1 600-hour check Disassemble the parts above the mount plate, wash and check them. Replace defective parts, and apply grease to the sliding surfaces. 8.2 2000-hour or 1-year check Disassemble the valve, and clean all the parts.

  • Page 283: Booster (Brake)

    T - 4 Booster (Brake) Booster (Brake) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 284 T - 4 Booster (Brake) Enlarged view of relay valve 11 8 33-16 Signal (from brake valve) 33-17 33-13 33-12 33-15 33-14 Supply Delivery 33-2 33-3 33-11 33-6 33-4 33-10 Exhaust 33-5 33-9 33-19 33-7 33-1 33-8 IW404-0010E05 Enlarged view of oil cylinder 37 13 From oil reservoir Output...
  • Page 285 T - 4 Booster (Brake) [NOTICE] When assembling the relay valve, apply appropriate amount of the silicon grease to the following places: sliding surfaces of the air piston (33-14) and valve (33-19); O-rings; O-ring grooves. When assembling the air cylinder, apply appropriate amount of silicon grease to the inner surface of the air cylinder (7), the outer surface of the air piston assy (8), air piston ring (9), and the air piston ring (10).

  • Page 286: Function

    T - 4 Booster (Brake) 2. Function This booster receives pressurized air from the relay valve into the air cylinder, and outputs hydraulic pressure in proportion to the pneumatic pressure to the wheel cylinders and other members of the brake system. It comprises the following three major components.

  • Page 287: Principles Of Operation

    T - 4 Booster (Brake) 3. Principles of operation 3.1 Relay valve 1. Booster not in operation 2. Booster in operation for assisting braking The above figure shows the state of the relay When the brake pedal is depressed, the signal valve when the booster is not in operation.
  • Page 288 T - 4 Booster (Brake) When the inside pressure in chamber B reaches 3. Booster in operation when releasing brakes the signal pressure level (same level as pressure When the brake pedal is released slightly, the in chamber A), the body seat comes in contact pressure in chamber A becomes lower than that in with valve assy 33s, shutting off the passage chamber B, causing piston 33n to be moved up.

  • Page 289: Cylinder

    T - 4 . T - 4 . Booster (Brake) 3.2 Cylinder 3. Brakes are released When the compressed air in the air cylinder becomes open to the atmosphere through the relay valve, air piston assy 8, valve 15 and oil 1.

  • Page 290: Air Dryer

    T - 5 Air Dryer Air Dryer [NOTICE] Air circuit diagram There is a case that the appearance and so on differ from the parts for this machine. Although there Purge chamber is not so much difference in functions and Drying tube disassembly procedures, make sure of the serial number of this machine and the part sales unit...
  • Page 291 T - 5 Air Dryer View A Heater IW232-0030E03 W232-0032E...
  • Page 292 T - 5 Air Dryer Section B-B IW232-0030E04 View C Thermostat IW232-0030E05 W232-0032E...
  • Page 293 T - 5 Air Dryer 1. Body 17. Piston 33. Cap nut 49. Screw and washer 2. Steel ball 18. O-ring 34. Check valve 50. Cover 3. Valve body 19. Special washer 35. Check valve spring 51. Oil separator filter 4.

  • Page 294: Function

    T - 5 Air Dryer 2. Function 2. The air flows through a filter which includes an oil mist separator, which removes minute oil droplets 1. When the air pressure at the air dryer outlet port and dust before the air enters the drying tube. (air tank air pressure) reaches the specified release pressure, this governor sends that 3.

  • Page 295: Regeneration

    T - 5 Air Dryer 2.2 Regeneration 4. In addition, because there is no feedback 1. When the air pressure in the system reaches the command to the compressor, the compressor upper limit pressure of the governor, the governor continues to supply pressure. For this reason, this control pressure passes through the control line pressure is also ejected from the dryer into the and opens the drain valve...

  • Page 296: Intake Position

    T - 5 Air Dryer 2.3 Intake position 2.4 Release position 1. The pressurized air from the air dryer outlet port 1. When the outlet port air pressure (air tank air (air tank pressurized air) travels through the pressure) increases, and the force acting on the passage and acts on the bottom of the governor bottom of the governor piston becomes stronger piston.

  • Page 297: Precautions For Handling

    T - 5 Air Dryer 3. Precautions for handling 4. Maintenance and inspections WARNING WARNING When performing inspections, use caution to Never touch the desiccant with wet hands, or prevent dirt from entering the eyes. put the desiccant in your mouth. Doing so will cause heating of the desiccant, and can result in burns.

  • Page 298: Disassembly

    T - 5 Air Dryer 5. Disassembly 6. Use the on-board air pressure gauge to check that the pressure governor is operating at the specified 5.1 Removing DU-3 pressure. Also check that there is no decrease in pressure when the brakes are not in use. 1.
  • Page 299 T - 5 Air Dryer Case cover CAUTION Purge chamber Set spring Keep pressing on the case cover with your Screw hand until all screws and washers have been Washer removed. The case cover can be extremely dangerous if the set spring inside causes the cover to jump Purge chamber up and strike a person in the face or other body Desiccant...

  • Page 300: Reassembly

    T - 5 Air Dryer 6. Reassembly 3. Insert filter plate A and the filter into the case. Insert the filter so that the soft surface is on top. [NOTICE] With the exception of rubber parts and the Purge chamber desiccant, wash all disassembled parts well with clean oil and wipe off all adhering substances.

  • Page 301: Tapping

    T - 5 Air Dryer 6.2 Tapping 6.3 Cartridge (upper) [NOTICE] DANGER Applying grease to the raised part of the check valve will allow it to be inserted more easily. When tapping is not performed, the desiccant Use NABCO grease (grease pack 45499030090, may deteriorate and be lost, with pieces blocking grease weight: approximately 10 g (0.022lb).

  • Page 302: Troubleshooting

    T - 5 Air Dryer 7. Troubleshooting [NOTICE] Be sure to perform daily inspections and periodic maintenance, as described in 4. Maintenance and Inspections. If any of the below symptoms or malfunctions occur, follow the remedy procedures listed below to inspect and correct the problem Symptom Probable cause...
  • Page 303 T - 5 Air Dryer Symptom Probable cause Remedy Condensate If the purge time is too short, the Inspect the check valve and O-ring. flows out from desiccant regeneration capability will be (Purge time should be approximately 35 seconds the air tank. reduced.
  • Page 304 T - 5 . T - 5 . Air Dryer Symptom Probable cause Remedy Main tank If the air dryer outlet check valve fails to Disassemble and inspect the air dryer outlet pressure drops function, the air in the main tank flows check valve.

  • Page 305: Brake (Parking Brake)

    T - 6 Brake (Parking Brake) Brake (Parking Brake) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 306: Replacing Pad

    T - 6 Brake (Parking Brake) 2. Replacing pad [NOTICE] At this time, if the clearance between the pad and the disc plate is too narrow to adjust, loosen the WARNING hand brake bolt. Be sure to immobilize the vehicle before starting to work.

  • Page 307: Remounting

    T - 6 Brake (Parking Brake) 3. Remounting 3.1 Connecting parking brake to spring chamber 3.2 Adjusting parking brake clearance 1. Adjust the clearance between the pad and the 1. Move the parking brake lever to the release disc plate to approximately 0.15 mm (0.006 in) per position to bring the brake chamber into the side with the hand brake bolt.

  • Page 308: Check

    T - 6 . T - 6 . Brake (Parking Brake) 4. Check WARNING When the brake has been used as emergency brake, adjust the pad clearance as soon as the use is terminated. When the clearance between the pad and the disk plate is set to 0.15 mm (0.006 in) per side before starting to use, the brake can be used without adjusting the hand brake...

  • Page 309: Brake Chamber

    T - 7 Brake Chamber Brake Chamber [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.

  • Page 310: Function

    T - 7 Brake Chamber DANGER 2. Function Never attempt to disassemble without using the 1. When compressed air is introduced behind the special jig. Doing so is extremely dangerous. diaphragm, it pushed the diaphragm, and the The spring is powerful. Be sure to use the push rod to release the brake.

  • Page 311: Cleaning And Checking

    T - 7 Brake Chamber Clamp ring Pressure plate Spring Push rod Adapter Special jig IW576-0020E03 4. Cleaning and checking 1. The diaphragm and clamp ring are pressed against the pressure plate by a spring. 4.1 Cleaning 2. In order to neutralize this force, use the special jig 1.

  • Page 312: Reassembly

    T - 7 . T - 7 . Brake Chamber 5. Reassembly 5. Align diaphragm and pressure plate to non-pressure plate, hook clamp ring on the edge 1. Set push rod vertically on a flat bench, with its end of the pressure plate by expanding the ring, and align the marks.

  • Page 313: Solenoid Valve (Air)

    T - 8 Solenoid Valve (Air) Solenoid Valve (Air) [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.
  • Page 314 T - 8 . T - 8 . Solenoid Valve (Air) 1.Core 6.Coil assy (DC24V) 12.Valve seat 17.Filter 2.O-ring 8.Rod 13.Valve 18.Packing 3.Case 9.Coil cover 14.Body 19.Packing holder 4.Spring 10.O-ring 15.Spring 5.Plunger 11.O-ring 16.Cover Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf...
  • Page 315 Suspension System Contents U-1 Suspension System......1 General............. 1 U-2 Suspension Lock Cylinder ....2 Structure ........... 2 U-3 Pilot Check Valve (Suspension Lock Cylinder)........3 Structure ........... 3 U-4 Solenoid Valve (Suspension Lock Check Release)......4 Structure ........... 4...

  • Page 316: Suspension System

    U-1 . U-1 . Suspension System Suspension System 1. General Hydraulic Circuit for Suspension Lock 1. The suspension lock function is either activated or 2. There are two kinds of pressure controlling valves released by the two suspension lock cylinders in the suspension lock hydraulic circuit, namely a installed between the carrier frame and rear axles.

  • Page 317: Suspension Lock Cylinder

    U-2 . U-2 . Suspension Lock Cylinder Suspension Lock 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.

  • Page 318: Pilot Check Valve (Suspension Lock Cylinder)

    U-3 . U-3 . Pilot Check Valve (Suspension Lock Cylinder) Pilot Check Valve (Suspension Lock 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.

  • Page 319: Solenoid Valve (Suspension Lock Check Release)

    Solenoid Valve (Spring Lock Check Release) Solenoid Valve (Spring Lock Check 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.
  • Page 320 U-4 . U-4 . Solenoid Valve (Spring Lock Check Release) Solenoid valve assy Connector (+): White (-): Black IW121-0542E01 IW121-044002 8 14 9 10 14 2 1.Body 6.Spring 10.Solenoid guide 14.O-ring 2.Spool 7.Detent spring 11.Solenoid coil 15.O-ring 3.Retainer 8.Nut 12.Name plate 16.O-ring 4.Retainer 9.Rod...
  • Page 321 Data, Adjusting and Checks Contents Y-1 Hydraulic Pressure Setting Table... 1 5. Jib lock pin and jib offset cylinder ....14 1. Winch ............. 1 6. Suspension lock cylinder .........15 2. Telescoping and Elevating ........ 2 7. Hydraulic pilot circuit........16 3. Steering ............. 3 Swing ............16 4.
  • Page 322 Y-5 Adjustment and Checks ....20 Y-8 Oil and Grease Table .....36 1. Service brake adjustment ....... 20 Adjusting the brake pedal......20 Tightening the cap of reserve tank of service Y-9 Mass Table........37 brake fluid........... 20 2. Accelerator adjustment ........20 Accelerator pedal ........

  • Page 323: Hydraulic Pressure Setting Table

    Hydraulic Pressure Setting Table 1. Winch [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator) moment display Shift the elevation slow stop cancel switch to OFF side...

  • Page 324: Telescoping And Elevating

    Hydraulic Pressure Setting Table 2. Telescoping and Elevating [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator) moment display Engine Set pressure Item Check procedure speed (min 1.

  • Page 325: Steering

    Hydraulic Pressure Setting Table 3. Steering [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1. Connect a pressure gauge to the pressure check port. 2. Turn the PTO switch OFF.

  • Page 326: Swing

    Hydraulic Pressure Setting Table 4. Swing [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Confirm set pressure on AML (load moment indicator ) moment display Engine Set pressure Item Check procedure speed (min (21.1)

  • Page 327: Outrigger

    Hydraulic Pressure Setting Table 5. Outrigger [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1. Connect a pressure gauge to the pressure check port. 2. Turn the PTO switch OFF.

  • Page 328: Lower Pilot Pressure

    Hydraulic Pressure Setting Table 6. Lower pilot pressure [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1. Connect a pressure gauge to the pressure check port.

  • Page 329: Pilot Pressure

    Hydraulic Pressure Setting Table 7. Pilot pressure [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1. Connect a pressure gauge to the pressure check port.

  • Page 330: Flow Control Valve

    Hydraulic Pressure Setting Table 8. Flow control valve [NOTICE] Oil temperature: 45 – 55°C (113 – 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1. Connect a pressure gauge to the pressure Flow control 2150 check port (U).

  • Page 331: Pressure Reducing Valve

    Y-1 . Y-1 . Hydraulic Pressure Setting Table 10. Pressure reducing valve [for Europe and Canada (option)] [NOTICE] Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL) Engine Set pressure Item Check procedure speed (min 1.

  • Page 332: Air Pressure Setting Table

    Y-2 . Y-2 . Air Pressure Setting Table Air Pressure Setting Table 1. Air pressure setting table Pressure Item Turning on pressure 725 - 765 105 - 111 Pressure regulator Turning off pressure 813 - 853 118 - 124 Cracking pressure Safety valve Full opening pressure 931 - 971...

  • Page 333: Air Bleeding Procedure

    Air Bleeding Procedure Air Bleeding Procedure 3) Others • After the shakedown of the pump, do not let the engine speed exceed the middle range (1000 1. Starting pump ) if you bleed the cylinders. When you try to raise the oil temperatuer in 1.1 Before starting the engine order to adjust the hydraulic pressure, make Make sure that...

  • Page 334: Service Brake Circuit

    Air Bleeding Procedure 2. Service brake circuit 3. Swing circuit [NOTICE] 3.1 Swing motor The vehicle has two boosters; one for the front Bleed the swing motor by following either (1), (2) or (3). wheel brakes and the other for the rear wheel brakes.

  • Page 335: Winch Circuit (Main And Aux.)

    Air Bleeding Procedure 4. Winch circuit (main and aux.) [NOTICE] Bleed the main and auxiliary winch circuits by following the procedures below. The procedures are common to the both circuits. 4.1 Winch motor 4.3 Winch brake release circuit Bleed the winch motor by following either (1) or (2). Repeat the slow hoist-up and slow hoist-down operations with the engine idling until no more air (1) Pour the hydraulic oil through the drain port into...

  • Page 336: Jib Lock Pin And Jib Offset Cylinder

    Air Bleeding Procedure 5. Jib lock pin and jib offset cylinder [NOTICE] Bleed the jib lock pin, jib offset cylinder by following either (1), (2), or (3). (1) Start the engine, turn the PTO switch ON, and raise the engine speed to approx. 2,150 rpm. (2) Attach a hose to the bleeder screw (A).and loosen the bleeder screw.

  • Page 337: Suspension Lock Cylinder

    Air Bleeding Procedure 6. Suspension lock cylinder (6) Turn off the starter switch and connect the on/off connector in the inside-cab relay box. [NOTICE] Bleed the suspension lock cylinder by following either (1), (2), (3), (4), (5), (6) or (7). (1) Set the crane in the traveling configuration on level ground.

  • Page 338: Hydraulic Pilot Circuit

    Y-3 . Y-3 . Air Bleeding Procedure 7. Hydraulic pilot circuit 8. Oil cooler motor Pour the hydraulic oil through the drain port into the 7.1 Swing casing until the oil flows out. Set the hydraulic oil temperature to 50 C (122 F) or higher, set the PTO switch and the swing brake...

  • Page 339: Electric Switch Adjustment

    Electric Switch Adjustment Tightening torque : Electric Switch Adjustment 3.7N-m (33in-lbf) 1. 3rd / top boom full retraction detection (*1) switch (CN859) Adjust the switch position so that its contact is shifted (opened/closed) when the top boom section is extended/retracted beyond the position where it is 5-8 mm (0.2-0.31 in) longer than its fully retracted length.

  • Page 340: (Cn573)

    Electric Switch Adjustment 4. Jib lock pin retraction detection switch (CN573) Adjust the switch position so that the dimension A becomes 30.5 –31.5mm (1.2 –1.24 in) with the switch in free position. (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent). Tightening torque : 4-6N-m (35-53in-lbf) (*1)

  • Page 341: Control Lever Stand Position Detection Switch

    Y-4 . Y-4 . Electric Switch Adjustment 8. Control lever stand position detection 9. Straight ahead detection proximity switch (Swing control and boom switch (CN408) telescoping/aux. hoist) (CN529) Set the rear wheels in a straight-forward position, and adjust the switch position so that the dimension Before the adjustments below, tilt the lever stand by A becomes 2.5-3 mm (0.1-0.12 in).
  • Page 342 Adjustment and Checks Adjustment and Checks 2. Accelerator adjustment 1. Service brake adjustment 2.1 Accelerator pedal 1.1 Adjusting the brake pedal With the pedal weight causing the roller to contact the plunger, adjust the bolt until it contacts the Switch (Idle volume) stopper, then use the nut to lock it in place.
  • Page 343 Adjustment and Checks 3. Parking brake adjustment 4. Tire steering angle adjustment 4.1 Tire air pressure 3.1 Adjusting the parking brake clearance (between pad and disc plate) unit: kPa {psi} Tire size Traveling On-tire operation Adjust so that the clearance between pad and 29.5 - 25 - 22PR 350 - 450 (50.75 - 65.25) 400 - 440 (58 - 63.8)
  • Page 344 Adjustment and Checks 5. Engine speed (and governer setting) 6. Torque converter and transmission 6.1 Maximum allowable speed [NOTICE] Units: MPH (km/h) Before checking the engine speed, run the engine to warm it up. (Light weight grease should reach Shift position Hi position Lo position approximately 50°C (122°F).)
  • Page 345 Adjustment and Checks 7. Braking force 8. Adjusting the headlight light axes (1) Turn the switch to the high beam side. 7.1 Parking brake force (2) Use a tester and adjust as following. 1. Must be 20% or more of the vehicle weight. Check Left-right direction: 0°...
  • Page 346 Adjustment and Checks 9. Adjusting boom telescoping wire ropes 1. With the boom fully retracted, tighten the nut-A until a tension is placed on the top boom section retraction wire rope (to keep the boom fully retracted). [NOTICE] Loosen the sway stopper bolt on the bottom of each boom section until it is out of contact with the support.
  • Page 347 Adjustment and Checks 4. Tighten the nut-A until the top and 4th boom sections are fully retracted. 5. Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control lever and then retract it fully. Check the boom is fully retracted. 6.
  • Page 348 Adjustment and Checks 8. When the wire rope is tense: 8.1 Tighten nut-A by approx. a third turn. 8.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control lever and then retract it fully. Check the boom is fully retracted. 9.
  • Page 349 Y-5 . Y-5 . Adjustment and Checks 10. Adjust the sway stopper bolt for the each boom section. [NOTICE] Refer to “Adjusting the bolt on the bottom of each boom section head” in chapter G. △ 345-803-33000 △ 345-800-62500 WY05-1390E...
  • Page 350 Check (Crane Operation) Check (Crane Operation) 1. Outrigger status indicator Main switch : ON Shift lever : Not in N position Operate the outrigger extension/retraction switch. Lamp lights. O/R SW IWY05-014019 Press all operation push-buttons. Outriggers do not operate. Main switch : ON Shift lever : N position Operate the outrigger extension/retraction switch.
  • Page 351 Check (Crane Operation) 2. Hoisting 5. Jib 1. Make sure that the two-blocking function does not [Condition] work while the jib set status is registered. • Load :None 2. Check the jib lock indicator lamp. • Engine speed :Approx.670 min to medium speed •...
  • Page 352 Check (Crane Operation) 6. Boom Telescoping Control Retraction [Boom length: 11.5 - 44.0 m (37.7 - 144.4 ft)] Appox. 27.75m (91.0ft) boom (3rd) : Emergency telescoping switch for 3rd to top boom sections : Emergency telescoping switch for 2nd boom 3rd to top boom sections retract.
  • Page 353 Check (Crane Operation) 6.2 Telescoping mode II Retraction Extension Appox. 39.93m (131.0ft) boom (4th and 5th) 11.5m (37.7ft) boom (base) 2nd boom section retract. 3rd to top boom sections extend. Switch L : ON Boom length: 35.72m (117.2ft) Switch S : OFF 3rd to top boom sections retract.
  • Page 354 Y-6 . Y-6 . Check (Crane Operation) 7. Alarms Type of Item Sound Checking procedure alarm • 280Hz Occurs at 100% when main switch is ON and PTO switch Electronic is ( | ) ON. (Intermittent low tone sound occurs at 90% and AML limit •...
  • Page 355 Check (Driving Devices) Check (Driving Devices) Manual shift 1 Exhaust brake (EXB) 1. Turn the EXB switch ON. Engine speed is idling. (The pilot lamp illuminates.) 2. Check pattern [Low position] [NOTICE] Check whether or not EXB is operating from the [NOTICE] engine noise and from the movement of the air No automatic shift in Low position.
  • Page 356 Check (Driving Devices) 3. Steering mode change 2-wheel 4-wheel Crab Rear Change the steering mode switch to 4-wheel, crab, or rear steering. IWY05-0141E16 Turn the steering wheel, and check the steering. Check that the lamp is ON, except when it is straight advancement of the state of the rear tire.
  • Page 357 Y-7 . Y-7 . Check (Driving Devices) 5. Overshift prevention 4. Maintain a speed of 10 km/h. Move the shift lever [NOTICE] to “1.” Check that transmission does not downshift Jack up the vehicle and shift to 4WD Hi position. (display: 2).
  • Page 358 Y-8 . Oil and Grease Table Oil and Grease Table Item Quantity :L (gaL) Remarks Hydraulic oil 995 (263) TADANO Hydraulic oil LL (*2): #22 Swing assy 3.8 (1.0) Mobil Gear 632 ISO VG 320 Winch assy Main 4.0 (1.06) API Service Class GL-3 Aux.
  • Page 359 Y-9 . Y-9 . Mass Table Mass Table Spec. No. Part Name GR-800-1-00211 2M2D (North America) Boom assy (including telescoping 11470kg (25290lbf) cylinder, jib-1 and jib-2) Telescoping cylinder (No.1) 790kg (1740lbf) Boom Telescoping cylinder (No.2) 880kg (1940lbf) Jib-1 560kg (1230lbf) Jib-2 280kg (620lbf) Elevating cylinder...
  • Page 360 Y-1 0 . Y-1 0 . Specifications Y-10 Specifications Idling speed: 605 - 652min 1. Engine speed Max. speed: 1645 - 2720min 3.2 Pump displacement • Engine model : MITSUBISHI 6M60-TLA3B • T/C model : RF80C-76F4 52.2 + 31.1cm /rev (3.18 + 1.9in /rev) 1.1 Idling speed 4.
  • Page 361 Y-1 1 . Y-1 1 . Boom Connecting Pin and Thread Size Table Y-11 Boom Connecting Pin and Thread Size Table (mm) Applicable model TR-450XL-4, TR-500XL-4 GT-350C-1 Part Name Diameter Thread size Diameter Thread size Rod end pin Φ100 M30×3.5 Φ100 M30×3.5 Elevating cylinder...
  • Page 362 System Diagrams Contents Z-1 Hydraulic Circuit ......1 Z-11 Location of Electric Parts (Swing Table, Boom) .....23 Z-2 Torque Converter Circuit ....3 Z-12 Location of Electric Parts (Relay Assembly / Upper) ..24 Z-3 Brake Circuit (Pneumatic Circuit)... 4 Z-13 Location of Air Parts (AML)...25 Z-4 Electric Circuit (AML, Crane) ..

  • Page 363: Hydraulic Circuit

    Z - 1 Hydraulic Circuit △ Hydraulic Circuit Applicable serial No. ：545520 ~ 1.Engine 43…. 2.Torque converter 44…. 3.Double variable displacement pump 45…. 4.Double gear pump 46.Solenoid control valve (jib set) 5.Gear pump (emergency steering, option) 47.Sequence valve (pilot pressure) 6.Drain filter 48.Priority valve 7.Hydraulic oil tank...
  • Page 364 Z - 1 . Z - 1 . Z - 1 . Hydraulic Circuit [NOTICE] When the optional emergency steering is not installed, two points "A" are directly joined and four portions "*1" are plugged. When the optional air conditioner is not installed, two points "B" are directly joined. △...

  • Page 365: Torque Converter Circuit

    Z - 2 . Z - 2 . Z - 2 . Torque Converter Circuit Torque Converter Circuit △ 347-411-60000 WZ05-0330E...

  • Page 366: Brake Circuit (Pneumatic Circuit)

    Z - 3 . Z - 3 . Z - 3 . Brake Circuit (Pneumatic Circuit) Brake Circuit (Pneumatic Circuit) △ 347-411-50000 WZ06-0410E...

  • Page 367: Electric Circuit (Aml, Crane)

    Z - 4 Electric Circuit (AML, Crane) Electric Circuit (AML, Crane) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page Air solenoid valve （air horn） Boom length and angle detector B-18 Touch-type winch drum indicator controller (option) N-19 AML (Load moment indicator) vent solenoid valve Swing angle detector...
  • Page 368 Z-4. Z-4. Z-4. Electric Circuit (AML, Crane) 〔Notice〕 (1) This program includes options ; is based on the following conditions : (2) Wire specification codes are based on JIS D607. (4) The wiring numbers 900∼999 show 12-voltage system, the other show 24-voltage system. (6) Applicable model list Mark (-) is not applied.
  • Page 369 Z - 5 Electric Circuit (MDT, Carrier/Upper) Electric Circuit (MDT, Carrier/Upper) CN No. Usage Coordinates Page CN No. Usage Coordinates Page Power window switch (outside cab) Door junction Power window switch Flasher unit Roof wiper switch Buzzer 1 (air low pressure alarm) Working lamp switch Buzzer 1 (air low pressure alarm) Engine speed output...
  • Page 370 Z - 5 . Z - 5 . Z - 5 . Electric Circuit (MDT, Carrier/Upper) IWZ03-3300E01 WZ03-3300E...
  • Page 371 Z - 6 Electric Circuit (MDT, Carrier/Lower) Electric Circuit (MDT, Carrier/Lower) CN No. CN No. CN No. Usage Coordinates Page Usage Coordinates Page Usage Coordinates Page Suspension lock selector solenoid valve MDT (lower) CN7 Fuse box (R) J-22 Suspension lock MDT (lower) CN8 Fuse box (R) I-21...
  • Page 372 Z - 6 Electric Circuit (MDT, Carrier/Lower) IWZ03-3310E01 WZ03-3310E...

  • Page 373: Cab And Swing Table

    Z - 7 Location of Hydraulic Parts (Upper) Location of Hydraulic Parts (Upper) 1. Cab and swing table (*1) : For the A section in the figure below, see the enlarged view on the following page. WZ07-0691E...
  • Page 374 Z - 7 Location of Hydraulic Parts (Upper) List of components illustrated in the “Cab and swing table” figure (in alphabetical order) Compressor (air conditioner, option) Condenser (air conditioner, option) 78.Hose real 38.Hydraulic motor (air conditioner, option) 34.Hydraulic motor (oil cooler) 79-2.Hydraulic valve (Protection of No.2 cylinder retraction while mode II select) (SL238) 33.Oil cooler 52.Orbitrol...
  • Page 375 Z - 7 Location of Hydraulic Parts (Upper) A section (behind cab) List of components illustrated in the “A section” figure (in alphabetical order) 60.Accumulator 30.Check valve (gauge isolator) 68.Hydraulic pilot control valve (elevating, telescoping, winch) 53.Hydraulic pilot control valve (swing) (SL120, SL121, SL161, SL162) 70.Hydraulic valve (winch brake release) 79-1.Hydraulic valve (top cyl.

  • Page 376: Boom

    Z - 7 . Z - 7 . Location of Hydraulic Parts (Upper) 2. Boom List of components illustrated in the “Boom” figure (in alpha betical ovder) 42.Jib lock pin 39.Jib offset cylinder 40.Pilot check valve (jib set) WZ07-0691E...

  • Page 377: Carrier

    Z - 8 Location of Hydraulic Parts (Lower) Location of Hydraulic Parts (Lower) 1. Carrier [NOTICE] The parts on the carrier are divided in to Front, Center and Rear and magnified of each is shown on the following pages. WZ07-0592E...

  • Page 378: Front

    Z - 8 Location of Hydraulic Parts (Lower) 1.1 Front List of components illustrated in the “Front” figure (in alphabetical order) 17.Pilot check valve (jack cylinder retracting prevention) 14.Solenoid valve (slide/jack) (for FL) (SL22,SL23) 14.Solenoid valve (slide/jack) (for FR) (SL24,SL25) WZ07-0592E...

  • Page 379: Center

    Z - 8 Location of Hydraulic Parts (Lower) 1.2 Center (*1): Application Canada Option North America ― List of components illustrated in the “Center” figure (in alphabetical order) 13.Check valve (outrigger extending prevention) 20.Pilot check valve (suspension lock cylinder) 6.Drain filter 18-1.Pressure reducing valve (pilot pressure) 10.Flow control valve 18-2.Pressure reducing valve (emergency steering)(*1)

  • Page 380: Rear

    Z - 8 . Z - 8 . Location of Hydraulic Parts (Lower) 1.3 Rear List of components illustrated in the “Rear” figure (in alphabetical order) 4.Double gear pump 14.Solenoid valve (slide/jack) (for RL) (SL26, SL27) 3.Double variable displacement pump 14.Solenoid valve (slide/jack) (for RR) (SL28, SL29) 17.Pilot check valve (jack cylinder retracting prevention)

  • Page 381: Location Of Air Parts

    Z - 9 Location of Air Parts Location of Air Parts 1. Cab and swing table List of components illustrated in the “Cab and swing table” figure (in alphabetical order) Air pressure sender Air solenoid valve (air horn) (SL60) Air tank (10L) Brake valve △...

  • Page 382: Carrier

    Z - 9 Location of Air Parts 2. Carrier Enlarge view of A (center of the carrier’s right hand) WZ08-0300E...
  • Page 383 Z - 9 . Z - 9 . Location of Air Parts (inside cab) List of components illustrated in the “Carrier” figure (in alphabetical order) Air brake chamber (parking) Air cylinder (parking) Air dryer Air low-pressure switch (low air pressure warning) Air Low-pressure switch (parking brake) Air pressure switch (stop lamp) Air solenoid valve (2/4 wheel drive shift) (SL51)

  • Page 384: Location Of Electric Parts

    Z -1 0 . Z - 1 0 . Z -1 0 . Location of Electric Parts (Inside cab) Z-10 Location of Electric Parts (Inside cab) △ 343-536-21000 WZ02-2970E...

  • Page 385: Location Of Electric Parts

    Z -1 1 . Z - 1 1 . Z -1 1 . Location of Electric Parts (Swing Table, Boom) [NOTICE] The connection in frame ( ) in figure is applied only for Europe: CN546,547,595,596,CN518,CN949 (*1): CN238 is applied only for GR-800XXL-1. Z-11 Location of Electric Parts (Swing Table, Boom) (*2): CN994 is not applied only for GR-600XXL-1.

  • Page 386: Location Of Electric Parts

    Z -1 2 . Z - 1 2 . Z -1 2 . Location of Electric Parts (Relay Assembly / Upper) Z-12 Location of Electric Parts (Relay Assembly / Upper) △ 343-536-21500 △ 343-632-33000 WZ02-2990E...

  • Page 387: Location Of Air Parts (Aml)

    Z -1 3 . Z - 1 3 . Z -1 3 . Location of Air Parts (AML) Z-13 Location of Air Parts (AML) △ 343-632-81000 △ 343-632-31000 WZ02-3000E...

  • Page 388: Location Of Electric Parts

    Z -1 4 . Z - 1 4 . Z -1 4 . Location of Electric Parts (Lower) [NOTICE] The connection in frame ( ) in figure is applied only for Europe. Z-14 Location of Electric Parts (Lower) △ 349-310-00000 WZ02-3010E...

  • Page 389: Location Of Electric Parts

    Z -1 5 . Z - 1 5 . Z -1 5 . Location of Electrical Parts (Box Assembly / Lower) Z-15 Location of Electrical Parts (Box Assembly / Lower) △ △ 349-310-02000 349-310-01000 △ △ 349-310-02300 349-310-01300 WZ02-3020E...

  • Page 390: Harness (Connector No. Table)

    Z -1 6 Z - 1 6 Z - 1 6 Harness (Connector No. Table) Z-16 Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page Suspension lock selector solenoid valve Straight ahead detection proximity switch B-11 Steering mode select switch...
  • Page 391 Z -1 6 Z - 1 6 Z - 1 6 Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page MDT (lower) CN7 ECU DIAG lamp-2 (umber) Door junction MDT (lower) CN8 Air drier heater Flasher unit D-16...
  • Page 392 Z -1 6 . Z - 1 6 . Z -1 6 . Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page Harness (AML) Harness (AML) Transmission power supply cut relay To inside cab harness To inside cab harness RB11...

  • Page 393: Harness (Inside Cab)

    Z -1 7 . Z - 1 7 . Z -1 7 . Harness (Inside Cab) Z-17 Harness オイルクーラ 作業灯 ワイヤ捨巻解除 ルーフウォッシャ ルーフワイパ ジブ有り無し ル−ムランプ (Inside Cab) 非常用 非常用O/R ジブ有り無し 切り替え 作業灯 J3５ O/R状態設定 状態設定ランプ 切り替えランプ ル−フワイパモ−タ 1.25L 1.25LO 1.25RY （...

  • Page 394: Harness (Swing Table, Left)

    Z -1 8 . Z - 1 8 . Z -1 8 . Harness (Swing Table, Left) Z-18 Harness (Swing Table, Left) △ 343-536-22020 WZ04-2280E...

  • Page 395: Harness (Swing Table Right)

    Z -1 9 . Z - 1 9 . Z -1 9 . Harness (Swing Table Right) Z-19 Harness (Swing Table Right) △ 343-536-22010 WZ04-2290E...

  • Page 396: Harness (Boom)

    Z -2 0 . Z - 2 0 . Z -2 0 . Harness (Boom) Z-20 Harness (Boom) Boom, base Boom, top △ 343-536-22030 △ 343-536-22040 WZ04-2300E...

  • Page 397: Harness (Aml, Upper)

    Z -2 1 . Z - 2 1 . Z -2 1 . Harness (AML, Upper) Z-21 Harness (AML, Upper) △ 343-632-31300 △ 343-632-31200 △ 343-632-31100 WZ04-2310E...

  • Page 398: Harness (Overwind)

    Z -2 2 . Z - 2 2 . Z -2 2 . Harness (Overwind) Z-22 Harness (Overwind) △ 343-724-40000 △ 343-724-40010 △ 343-721-83000 △ 343-723-61000 WZ04-2320E...

  • Page 399: Harness (Lower, Main)

    Z -2 3 . Z - 2 3 . Z -2 3 . Harness (Lower, Main) Z-23 Harness (Lower, Main) ダイオードASSY 236B オペASSY,アウトリガ 249A 249B 236A 236B （オプション） 141A 0.85BrW DIAG LAMP オペASSY,アウトリガ (黄褐） （オプション） バックアップ ランプ RA11 RA11 236A DIAG LAMP エンジン付属部品...

  • Page 400: Harness (Lower, Sub)

    Z -2 4 . Z - 2 4 . Z -2 4 . Harness (Lower, Sub) Z-24 Harness (Lower, Sub) △ 349-310-00200 WZ04-2450E...

  • Page 401: Harness

    System Diagrams Contents Z-1 Hydraulic Circuit ......1 Z-11 Location of Electric Parts (Swing Table, Boom) .....23 Z-2 Torque Converter Circuit ....3 Z-12 Location of Electric Parts (Relay Assembly / Upper) ..24 Z-3 Brake Circuit (Pneumatic Circuit)... 4 Z-13 Location of Air Parts (AML)...25 Z-4 Electric Circuit (AML, Crane) ..
  • Page 402 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...

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