Page 1 TR-150XL-4/S1(U)-1E Publication No. Rough Terrain Crane TR-150XL- Model Applicable Serial No. FD0806 –– ◯ ｃ 2005 PRINTED IN JAPAN 0510...
Page 2 Safety Safety [NOTICE] Most accidents that occur during machine operation [NOTICE] indicates an important operational or and maintenance are caused by failure to observe maintenance procedure or condition, which, if not basic safety rules and precautions. Before operating strictly observed, can result in damage to machine your machine or performing maintenance, read and components or deteriorated machine performance.
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 In case that the position of the center of gravity is 7. Put disassembled parts in order so that parts such 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-150XL-4 rough terrain crane, its repair, checks and adjustment methods and other relevant matters. Note that this service manual does not provide the information in the separate service manuals given below.
Page 7 Foreword 3. Outline of specifications Spec. No. Item TR-150-4-00102 TR-150-4-00101 2M2D 1M1D (North America) (North America) No. of boom sections No. of jib stages Not Fitted Single top Fitted Main winch Fitted Auxiliary winch Fitted Not Fitted Winch Winch brake Automatic brake (Neutral brake) Main drum rotation indicator Visual-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 Torque, moment 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 WA04-1800E...
Page 11 Foreword 5. Contents Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (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)
Page 12 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Outrigger System Outrigger System Jack Cylinder Pilot Check Valve (Jack Cylinder Retracting Prevention) Extension Cylinder (UCHIDA) Solenoid Valve (Slide/Jack) (TOKIMEC) (NACHI) Check Valve (Outrigger Extending Prevention) Swing System Swing System Swing Assembly Hydraulic Motor (Swing)
Page 13 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Winch system Winch System Winch Hydraulic Motor (Winch) Counterbalance Valve (Winch) Hydraulic Valve (Winch Brake Release) Winch Brake Band Boom T elescoping system Telescoping System Boom (Six-Section Boom) Telescoping Cylinder Counterbalance Valve (Telescoping) Safety System...
Page 14 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Crane Cab Glass Air Conditioner Hydraulic Motor (Air conditioner) Solenoid Valve (Air conditioner) Control System Control System Remote Control Valve Solenoid Control Relief Valve (Swing and Elevating Slow Stop) Accelerator Sensor Solenoid Valve (Air) (2/4 Wheel Drive Shift) Electrical System...
Page 15 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Steering System Steering System Priority Valve Orbitrol Steering Cylinder Solenoid Valve (Steering Mode) Brake System Brake System Brake (Service Brake) Brake Valve Booster (Brake) Air Dryer Reducing Valve Brake Chamber Solenoid Valve (Air) Brake (Parking Brake)
Page 16 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Data, Adjustment and Checks Hydraulic Pressure Setting Table Air Pressure Setting Table Air Bleeding Procedure Electric Switch Adjustment Adjustment and Checks Mass Table Specifications Boom Connecting Pin and Thread Size Table System Diagrams Hydraulic Circuit...
Page 17 Foreword Spec. No. Chapter TR-150-4-00102 TR-150-4-00101 Section 2M2D 1M1D (North America) (North America) Location of Installation Location of Hydraulic Parts (Upper) Location of Hydraulic Parts (Lower) Location of Air Parts Location of Electric Parts (Inside cab) Z-10 Location of Electric Parts Z-11 (Swing Table, Boom) Location of Electric Parts...
Page 18: Table Of Contents
Hydraulic Power Generating System Contents B-1 Hydraulic Power Generating B-5 Hydraulic Valve (Emergency System........1 Steering) (Option) ....12 General............. 1 Structure ..........12 B-2 Hydraulic Pump (Double Variable B-6 Solenoid Control Valve Displacement Pump) ....4 (Outrigger, Suspension)..14 Structure ........... 4 Structure ..........
Page 19 B-8 Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, Winch) ........26 Structure ..........26 Hydraulic symbols ........27 Swing valve assy........28 Supply, drain section ........ 29 Elevating valve assy......... 30 Telescoping selection assy....... 31 Telescoping valve assy......32 Main winch valve assy......33 Auxiliary winch valve assy......
Page 20: Hydraulic Power Generating
Hydraulic Power Generating System Hydraulic Power Generating System 1. General Hydraulic Circuit for Carrier 3. The double gear pump supplies oil to the circuits [NOTICE] of outrigger, spring lock,steering, pilot pressure, If the machine is not equipped with the optional emergency steering, two points "A"...
Page 21 Hydraulic Power Generating System Hydraulic Circuit for Crane [NOTICE] For the crane “IMID” without the auxiliary winch, seven points “*2” are plugged. WB02-0340E...
Page 22 B-1 . B-1 . Hydraulic Power Generating System Circuits for swing, elevating, telescoping, main and auxiliary winches. 1. The hydraulic oil provided from the pumps is controlled (onloaded/unloaded) by the solenoid valve. This solenoid valve for automatic stop is switched by the AML output to control the vent ports of the relief valve (elevating, telescoping) and the relief valve (main winch, auxiliary winch).
Page 23: Structure
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 24: Hydraulic Pump (Double Variable Displacement Pump)
Hydraulic Pump (Double Variable Displacement Pump) 1.2 Section view X - X IW101-016003 1.Control section (LV, front) 7.Control piston section 14.Plate 21.Plug 2.Control section (LV, rear) 8.Hanger section (front) 15.O-ring 23.Coupling 3.Housing (front) 9.Hanger section (rear) 16.Hexagon socket head bolt 24.Hexagon socket head bolt 4.Housing (rear) 10.Shaft section (front)
Page 25: Control Section (Lv, Front)
Hydraulic Pump (Double Variable Displacement Pump) 1.3 Control section (LV, front) 1.Regulating cover 9.Guide 17.Parallel pin 25.Hexagon socket head bolt 2.Body 10.Adjusting screw 18.Parallel pin 26.Nut 3.Guide 11.Arm 19.O-ring 27.Plug 4.Barrel 12.Spring 20.O-ring 28.Hexagon socket head bolt 5.Spool 13.Spring 21.O-ring 29.Orifice 6.Spring seat 14.Spring...
Page 26: Control Section (Lv, Rear)
B-2 . B-2 . Hydraulic Pump (Double Variable Displacement Pump) 1.4 Control section (LV, rear) 1.Regulating cover 9.Guide 17.Parallel pin 25.Hexagon socket head bolt 2.Body 10.Adjusting screw 18.Parallel pin 26.Nut 3.Guide 11.Arm 19.O-ring 27.Plug 4.Barrel 12.Spring 20.O-ring 28.Hexagon socket head bolt 5.Spool 13.Spring 21.O-ring...
Page 27: (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 28 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 29: 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 30: Emergency Steering) (Option)
B-4 . B-4 . Hydraulic Pump (Gear Pump, Emergency Steering)(Option) Hydraulic Pump (Gear Pump, 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 31: 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 32 B-5 . B-5 . Hydraulic Valve (Emergency Steering) (Option) Section X-X Check valve C IW123-0161E04 Section Y-Y Check valve B IW123-0161E03 Section Z-Z Check valve A IW123-0161E02 1.Body 4.Spring 7.O-ring 10.Plug 2.Poppet 5.Spring 8.Plug 11.O-ring 3.Spool 6.Spring 9.Plug 12.O-ring △ 366-470-30000 W123-0161E...
Page 33: Structure
Solenoid Control Valve (Outrigger, Suspension) Solenoid Control Valve (Outrigger, Suspension) [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: Cross Section View
Solenoid Control Valve (Outrigger, Suspension) 1.2 Cross section view 1. Cover assy (oil supply section) 3. Bolt 5. Valve assy (switching section) 2. Nut 4. Valve assy (switching section) 6. Cover assy (drain section) W112-0131E...
Page 35: Switching Section
Solenoid Control Valve (Outrigger, Suspension) 1.3 Switching section IW112-013003 1. Body 4. O-ring 7. Hexagon socket head bolt 10. Pilot assy 2. Spool 5. Oil seal 8. Check valve plug 3. O-ring 6. Retainer 9. O-ring 1.4 Cover (supply section) IW112-013006 1.
Page 36: Pilot Section
Solenoid Control Valve (Outrigger, Suspension) 1.5 Pilot section IW112-013004 1. Pilot piston 7. O-ring 13. Cover 19 O-ring 2. O-ring 8. Backup ring 14. Hexagon socket head bolt 20. O-ring 3. Body 9. Spring holder 15. Socket 21. Solenoid assy 4.
Page 37: Reducing Valve
B-6 . B-6 . Solenoid Control Valve (Outrigger, Suspension) 1.7 Reducing valve IW112-013008 1. Spool 4. Filter 7. Spring 2. Sleeve 5. O-ring 8. O-ring 3. O-ring 6. Washer 9. Cap Thread size and tightening torque Tightening torque Sign / port Thread size N•m ft•lbf...
Page 38: 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 39 Rotary Joint Swing platform side (Viewed from above) Chassis side (viewed from below) W181-0161E...
Page 40 Rotary Joint 1.Slip ring assy 9.Plain bearing 17.Flange bolt 25.Joint 2.Plain bearing 10.Support 18.Plate 26.Joint 3.Packing 11.Grease nipple 19.Support 27.Fitting 4.Ring seal 12.Plain bearing 20.Bolt 28.Joint 5.Body 13.Ring seal 21.Flange bolt 29.O-ring 6.Core 14.Packing 22.Clamp 30.Ring seal 7.Plug 15.Ring seal 23.Nut 8.Core 16.Hexagon socket head bolt...
Page 41: Slip Ring Assy
Rotary Joint 1.2 Slip ring assy IW181-016101 Apply the sealant IW181-0161E04 16,17 IW181-016104 IW181-016103 W181-0161E...
Page 42 Rotary Joint IW181-016107 IW181-016105 32,33 IW181-016108 IW181-016106 1.Shaft 10.Brush assy 19.O-ring 28.Hose band 2.Ring holder 11.Spacer 20.Potentiometer 29.Haxagon socket head set screw 3.Bearing 12.Spacer 21.Cover 30.Machine screw 4.Ring 13.Brush assy 22.Packing 31.Bolt 5.Ring 14.Support 23.Lever 32.Bolt 6.Ring holder 15.Base 24.Pin 33.Spring washer 7.U-nut 16.Dry locknut...
Page 43: Wiring Diagram
Rotary Joint 1.3 Wiring diagram W181-0161E...
Page 44: Potentiometer
B-7 . B-7 . Rotary Joint 2. Potentiometer 3. Attach the lever [23] to the potentiometer [20] temporarily. Upper terminal Lower terminal 4. Install the potentiometer-assy in the base [15]. At this time, orient the hole of the guide [25] to a direction which facilitates to install.
Page 45 Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, 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 46 Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.1 Hydraulic symbols Thread size and tightening torque Tightening torque Sign / Port Thread size N•m ft•lbf Pa, Pb, C1, C2 G 1/4 29.4 P1, P2, P3 and P1, P2 vent G 3/8 A3, A4, A5, A6, G 1/2...
Page 47: Swing Valve Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.2 Swing valve assy 14 13 11 10 IW134-013003 Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf – 39.2 - 49 29 - 36 Apply Spool end•11 –...
Page 48: Supply, Drain Section
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.3 Supply, drain section 12 11 10 IW134-013004 Thread size and tightening torque Tightening torque Sign / Port Thread size N•m ft•lbf – 58.8 - 68.6 43 - 50 – 39.2 - 49.0 29 - 36 Relief valve•15 –...
Page 49: Elevating Valve Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.4 Elevating valve assy 17 18 8 19 IW134-013006 11,12 10 9 13,12 Thread size and tightening torque Tightening torque Sign / port Thread size Remarks N•m ft•lbf 9.8 - 10.8 7.2 - 8 Apply 4.9 - 5.9...
Page 50: Telescoping Selection Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.5 Telescoping selection assy Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf G 3/8 39.2 - 49.0 29 - 36 G 3/8 39.2 - 49.0 29 - 36 Apply –...
Page 51: Telescoping Valve Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.6 Telescoping valve assy Connector 23,22,21,20 (+) : Red (-) : Black IW121-0542E01 4,29 29,4 27,28 10,24 13,25 IW134-013008 Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf...
Page 52: Main Winch Valve Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.7 Main winch valve assy 7 12 9 11 10 14,18 17 13 22,21 IW134-013009 Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf G 3/8 39.2 - 49.0 29 - 36 9.8 - 10.8...
Page 53: Auxiliary Winch Valve Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.8 Auxiliary winch valve assy Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf G 3/8 39.2 - 49.0 29 - 36 9.8 - 10.8 7.2 - 8 16, 18 ―...
Page 54: Supply Section Assy
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.9 Supply section assy 1.Plug 2.O-ring Thread size and tightening torque Tightening torque Sign / Port Thread size N･m ft･lbf ― 58.8 – 68.6 43 – 50 1.10 Relief valve assy (RF2, RF3) 6,22 7,23 10,21 9 11 12 13...
Page 55: Relief Valve (For Winch) (Rf5)
Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.11 Relief valve (for winch) (RF5) 9 11 10 12 7 15 14 13 16 IW134-013014 1. Body 5. Backup ring 9. Backup ring 13. Screw 2. Socket 6. Spring 10. O-ring 14.
Page 56: Relief Valve Assy (Rf1)
B-8 . B-8 . Hydraulic Pilot Control Valve (Swing, Elevating, Telescoping, W inch) 1.13 Relief valve assy (RF1) IW111-012001 Thread size and tightening torque Tightening torque Sign /Port Thread size N•m ft•lbf ― 18.6 – 20.6 13.7 – 15.2 13, 14 M14×1.0 18.6 –...
Page 57: Hydraulic Valve (Pilot Pressure)
Hydraulic Valve (Pilot Pressure) Hydraulic 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 58: General View (Section View)
Hydraulic Valve (Pilot Pressure) Thread size and tightening torque Tightening torque Sign / Port Thread size N•m ft•lbf G 1/2 58.8 - 68.6 43 - 50 G 1/2 58.8 - 68.6 43 - 50 Pa, Pb G 1/4 25.5 - 29.4 19 - 22 G 1/4 25.5 - 29.4...
Page 59: Supply Section Assy
Hydraulic Valve (Pilot Pressure) 1.3 Supply section assy Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks N•m ft•lbf ― 9.8 - 10.8 7.2 - 8 Apply Loctite242 ― 3.92 - 4.90 29 - 36 Apply Loctite242 ―...
Page 60: Unload Valve Assy
Hydraulic Valve (Pilot Pressure) 1.4 Unload valve assy Thread size and tightening torque Tightening torque Sign / Port Thread size N•m ft•lbf G 1/8 7.85 - 9.8 5.8 – 7.2 ― 58.8 - 68.6 43 - 50 18, 19 18.6 – 20.6 13.7 –...
Page 61: Pilot Valve Assy
Hydraulic Valve (Pilot Pressure) 1.5 Pilot valve assy Connector IW121-0542E01 (+) : Red (-) : Black W123-0131E...
Page 62: Pressure Reducing Valve
B-9 . B-9 . Hydraulic Valve (Pilot Pressure) 1. Body 6. O-ring 11. Check valve•A 16. Rubber seal 2. Solenoid 7. O-ring 12. Check valve•B 17. Rear holder 3. Socket 8. Plug 13. Plug 4. Pilot valve 9. O-ring 14. Connector 5.
Page 63: Check Valve (Gauge Isolator)
B-1 0 . B-1 0 . Check Valve (Gauge Isolator) B-10 Check Valve (Gauge Isolator) [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 64 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 65: 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 66 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 67: 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 68: 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 69: 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 70: 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 71: 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 72: 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 73: 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 74 Swing System Contents D-1 Swing System........1 D-4 Swing Speed Reducer ....17 General............. 1 Structure ..........17 Removing of hydraulic motor....18 D-2 Swing Assembly ......3 Disassembly of reducer......18 Structure ........... 3 Assembly of reducer ....... 19 Swing bearing mounting bolt..... 4 Installation of hydraulic motor....
Page 75: Swing System
Swing System Swing System 1. General Hydraulic Circuit for Swing WD02-0290E...
Page 76 D-1 . D-1 . Swing System Remote Control Pressure Vent, Swing Brake Release 3. Circuit for swing automatic stop [NOTICE] The right swing proportional control valve and the The remote control valve and the solenoid control relief valve are connected to the hydraulic pilot left swing proportional control valve serve to control valve at the two points having the same automatically stop the swing movement.
Page 77: Swing Assembly
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 78: Swing Bearing Mounting Bolt
Swing Assembly 2. Swing bearing mounting bolt 2.1 Bearing lnner ring bolts 1.Bolt (L=90mm) 4.Plain washer 7.End 2.Pain washer 5.Nut 8.Spring washer 3.Bolt 6.Bolt 9.Pin [NOTICE] Thread size and tightening torque Install the bearing inner ring with the “S” mark facing the rear of the carrier.
Page 79: Bearing Outer Ring Bolts
D-2 . D-2 . Swing Assembly 2.2 Bearing outer ring bolts 1.Bolt (L=110mm) 2.Plain washer (28points) 3.Bolt (L=100mm) 4.Pin [NOTICE] Thread size and tightening torque Install the bearing inner ring with the “S” mark facing the rear of the carrier. Tightening torque Sign / port Thread size...
Page 80: 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 81 Hydraulic Motor (Swing) View from X Hydraulic symbols 1. Housing 9. Brake disc 17. Shaft 25. Dowel pin 2. Retaining ring 10. O-ring 18. Dowel pin 26. Cylinder block 3. Retaining ring 11. Hexagon socket head bolt 19. Rotary assembly 27.
Page 82: Functions
Hydraulic Motor (Swing) 2. Functions Piston chamber Ａ Piston shoe Three pins Piston Tilt angle Port A Port B IW102-0230E04 Plate Retainer Spherical guide Spring Cylinder block 1. The hydraulic motor is rotated by supplying a high 4. The piston then moves from the position pressure fluid from port A and discharging a low represented by the lower half of the figure to the pressure fluid from port B, or vice versa.
Page 83 Hydraulic Motor (Swing) 6. There are a total of 9 pistons, the four or five of which are involved in performing the function described in 5. above at the port A side. 7. Figure shows a state where the brake is released. The spring in the brake piston always presses the brake piston to the right, keeping the piston pressed against the brake disc.
Page 84: Disassembly
Hydraulic Motor (Swing) 3.2 Disassembly 3. Disassembly 1. Put a mark across housing•1 and cover•13. [NOTICE] Avoid using a copper hammer. Copper particles could enter the motor. Be extremely careful when handling the inner parts of the motor. Most of them are quite sensitive to damage such as dents and scratches.
Page 85 Hydraulic Motor (Swing) 4. Insert a blade screwdriver into the slot formed in 7. Insert screwdriver blades into the internal the cover and lever up control plate•15 to remove. circumferential groove of the brake piston•7. Lever the piston up using the drive shaft end as a fulcrum.
Page 86 Hydraulic Motor (Swing) 11. Remove retaining ring•2. IW102-023021 15. Remove the retaining ring•3 so that the oil seal•4 IW102-023018 can be removed. 12. Lightly tap the rear end of the drive shaft with a plastic hammer, and remove the shaft•17. IW102-023022 16.
Page 87: Reassembly
Hydraulic Motor (Swing) 4. Reassembly 4.1 Installation of oil seal 1. Fit the oil seal•4 on the oil seal installation jig. Fill the space between lips of the oil seal with grease. Inject grease IW102-023027 2. Fit retaining ring•30. Oil seal Installing Direction IW102-0230E25 3.
Page 88: Reassembly Of Rotary Assembly
Hydraulic Motor (Swing) 6. Apply grease to O-ring•5 and fit the O-ring in the [NOTICE] brake portion of housing•1. Exercise care to prevent the three pins from falling off. 3. Install the combination of guide•22, retainer•21 and piston assemblies•24 in cylinder block•26. Before installation, apply grease to the spherical surface of the guide and the cylindrical surfaces of the piston assemblies.
Page 89: Installation Of Brake Piston
Hydraulic Motor (Swing) 4.4 Installation of brake piston [NOTICE] Exercise care to prevent the springs from falling off. 1. Put a mark at the position that is in line with dowel pin•18. 5. Align the alignment marks on the brake piston and housing, and insert the piston.
Page 90: Installation Of Brake Cover
D-3 . D-3 . Hydraulic Motor (Swing) 4.5 Installation of brake cover 4. Install O-ring•10 on the housing at the surface that joins with the cover. 1. Install the brake disc so that its portions with omitted internal teeth with the notches (3 places) 5.
Page 91: 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 92: Removing Of Hydraulic Motor
Swing Speed Reducer 1.Bolt 9.Needle bearing 17.Ball bearing 25.Planetary gear 2.----- 10.Plate 18.Ball bearing 26.King pin (A) 3.Spacer 11.king pin (B) 19.Hexagon socket plug 27. Hexagon socket plug 4.Plate 12.Spacer 20.Snap ring 28.Sun gear 5.Carrier (A) 13.Oil seal 21.Carrier (B) 29.Hydraulic motor assy 6.Name plate 14.Sun gear...
Page 93: Assembly Of Reducer
D-4 . D-4 . Swing Speed Reducer 4. Assembly of reducer 5. Installation of hydraulic motor 1. Press-fit ball bearing(17) on output shaft(16). 1. Tighten hydraulic motor by bolt(1). 2. Press-fit oil seal(13) into casing(22). [NOTICE] Apply THREE BOND 1215 on the mating surface [NOTICE] between the hydraulic motor casing and the swing lithium type grease on the inner of oil seal(13).
Page 94 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 95: Elevating System
E -1 E -1 Elevating System Elevating System 1. General Hydraulic Circuit for Boom Elevating Remote Control Pressure Vent WE02-0290E...
Page 96 E -1 . E -1 . Elevating System 3. Circuit for boom elevating slow stop [NOTICE] The boom raising proportional control valve and The remote control valve and the solenoid control relief valve are connected to the hydraulic pilot the boom lowering proportional control valve control valve at the two points having the same make the boom elevating movement stop slowly.
Page 97: 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 98 E -2 . E -2 . Elevating Cylinder 1.Grease nipple 8.O-ring 15.Packing 22.Spring washer 2.Spring pin 9.Backup ring 16.Backup ring 23.O-ring 3.Plain bearing 10.Cylinder 17.O-ring 24.Fitting 4.Packing 11.Rod assy 18.Dust seal 25.Pipe 5.Backup ring 12.Rod cover assy 19.Retaining ring 26.T-fitting 6.Piston 13.O-ring 20.Counter balance valve assy...
Page 99: 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 100 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 101: 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 102 Winch System Contents F-1 Winch System ........1 F-4 Counterbalance Valve (Winch)..14 General (2M2D) ........1 Structure ..........14 General (1M1D) ........3 F-5 Hydraulic Valve (Winch Brake Release) ..17 F-2 Winch ..........5 Structure ..........17 Structure ........... 5 Reassembly..........
Page 103: Winch System
F - 1 Winch System Winch System 1. General (2M2D) Hydraulic Circuit for Winch (2M2D) WF02-0340E...
Page 104 F - 1 Winch System Remote Control Pressure Vent [NOTICE] The remote control valve are connected to the hydraulic pilot control valve at the points having the same symbols such as "a1", "a2", "b1", and "b2". 1. The main winch is controlled by the hydraulic pilot method.
Page 105: General (1M1D)
F - 1 Winch System 2. General (1M1D) Hydraulic Circuit for Winch (1M1D) WF02-0340E...
Page 106 F - 1 . F - 1 . Winch System Remote Control Pressure Vent 3. The overload relief valve (down) regulates the [NOTICE] maximum pressure in the hoist-down circuit for The remote control valve is connected to the hydraulic pilot control valve at the two points having the main winch.
Page 107: 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 108: Winch
F - 2 Winch Section G Rotation sensor mounting section Section G Rotation Sensor Mounting Section IW526-0160E02 Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf 68.6 - 82.4 50.6 – 60.8 23.5 - 27.5 17.3 – 20.2 32.3 - 36.7 23.8 –...
Page 109 F - 2 . F - 2 . Winch 2. Reassembly [NOTICE] Apply ThreeBond 1104 to the mating surfaces of the gear case•1 and seat packing•19, and the mating surfaces of the case cover•2 and seat packing•19. Apply ThreeBond 1104 to the mating surfaces of the gear case•1 and covers•10,•11,•12,•13, and•14.
Page 110: 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 111: Hydraulic Moter Section
F - 3 Hydraulic Motor (Winch) Thread size and tightening torque Tightening torque Sign / port Thread size Remarks ft-lbf A, B G 3/4 108 - 123 80- 91 G 1/2 53.9 - 63.7 40 - 47 Instruction by G 1/2 106 - 141 78 - 104 manufacturer...
Page 112: Control Section Assy
F - 3 Hydraulic Motor (Winch) 1.2 Control section assy 1. Cover 8. O-ring 15. Hexagon. socket head set screw 22.----- 2. ----- 9. O-ring 16. ----- 23.----- 3. Control assy 10. O-ring 17. Plug 24. Plug 4. Piston 11. Nut 18.
Page 113: Functions
F - 3 Hydraulic Motor (Winch) 2. Functions [NOTICE] The construction shown below may differ from the parts of the actual equipment, however there are no major differences in function or disassembly procedure. Use the contents below for reference. cylinder block is pressed against the control plate 1.
Page 114: Disassembly
F - 3 Hydraulic Motor (Winch) 3.3 Removing the control section assy 3. Disassembly 1. Remove the hexagon socket head bolt. [NOTICE] These are precision parts. Be sure to perform 2. Remove the HA control section assy. disassembly and assembly in a clean environment, and use sufficient care in handling the parts.
Page 115: Reassembly
F - 3 . F - 3 . Hydraulic Motor (Winch) 4. Reassembly 5. Install the packing and control section assy. Tighten with the hexagon socket head bolt. (Be [NOTICE] careful not to allow the control plate to fall.) Be sure to thoroughly clean all parts. 4.2 Installing the oil seal case Check carefully that there are no dropped parts or parts with scratches on them.
Page 116: Counterbalance Valve (Winch)
F - 4 Counterbalance Motor (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 117 F - 4 Counterbalance Motor (W inch) 1. Body 7. Body 13. Plug 19. O-ring 2. Spool 8. Spring seat 14. Bushing 20. O-ring 3. Cover 9. Steel ball 15. Hexagon socket head bolt 21. O-ring 4. Cover 10. Spring 16.
Page 118 F - 4 . F - 4 . Counterbalance Motor (W inch) Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf 7 *1 28 - 35 20.7 – 25.8 ― 6.9 - 8.3 5.1 – 6.1 R 1/4 11 - 14 8.1 –...
Page 119: Structure
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 120: Structure
F - 6 Winch Brake Band Winch Brake Band [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 121: Principle Of Operation
F - 6 Winch Brake Band Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf M 10 43.2 - 49.0 32 - 36 23.5 - 27.5 17.3 – 20.3 23.5 - 27.5 17.3 – 20.3 2. Principle of operation 2.2 Automatic braking cancellation during hoisting or free-fall operation 2.1 Automatic braking when the control lever is...
Page 122: Braking By Foot Brake During Free-Fall Operation
F - 6 Winch Brake Band 2.3 Braking by foot brake during free-fall 3. Disassembly and reassembly operation [NOTICE] Braking Compress the cylinder spring before performing disassembly / reassembly work. To compress the spring, screw a hex. socket head bolt (fully threaded M8×45 bolt) into section.
Page 123: Adjustment
F - 6 . F - 6 . Winch Brake Band 4. Adjustment 4.1 Adjustment of shim 4.2 Adjustment of stroke 1. Screw a hex. socket head bolt (fully threaded [NOTICE] M8×45 bolt) into section A until dimension X Adjust the stroke after adjusting by shims. becomes zero.
Page 124 Boom Telescoping System Contents G-1 Telescoping System ......1 Installing upper slide plates.......18 Installing slide plates onto sides of General............. 1 rear end..........18 Description of telescoping system (Refer to Adjustment ..........18 the circuit diagram in Chapter Z.)... 3 Adjusting clearance for the boom .....18 Extention circuit ..........
Page 125: Telescoping System
G -1 G -1 Telescoping System Telescoping System 1. General Hydraulic Circuit for Boom Telescoping (2M2D) WG02-0450E...
Page 126 G -1 G -1 Telescoping System Remote Control Pressure Vent Top Cylinder Select [NOTICE] 4. Circuit for top cylinder select Remote control valve is connected to the hydraulic In this hydraulic circuit, the solenoid valve (top pilot control valve at the two points having the same cylinder select) controls the hydraulic valve which symbols such as "a4"...
Page 127: 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.) 2.1 Extention circuit 5. In this case, you need not keep pressing the 4th 1. When the telescoping lever (linked to the remote /top boom full retraction detection switch when the control valve) is operated to the extention side, No.2 telescoping cylinder is slightly extended, the...
Page 128: Boom Telescoping Mechanism
G -1 G -1 Telescoping System 4. When the No. 2 telescoping cylinder is almost fully retracted, the 4th/top boom full retraction detector switch is operated to open the self holding circuit of the selector valve’s solenoid. The selector valve then automatically opens the oil passage to allow the No.1 telescoping cylinder to retract.
Page 129 G -1 G -1 Telescoping System 4. 5th boom section 5. Top boom section Extended by the wire rope mechanism that Extended by the wire rope mechanism that synchronizes with the extension of 4th boom synchronizes with the extension of 5th boom section section.
Page 130: Retraction
G -1 G -1 Telescoping System 3.2 Retraction 2. 5th boom section Retracted by the wire rope mechanism that 1. Top boom section synchronizes with the retraction of top boom Retracted by the wire rope mechanism that section. synchronizes with the retraction of 4th boom section.
Page 131 G -1 . G -1 . Telescoping System 3. 4th boom section Retracted by No.2 cylinder 4th boom section travel (R ) = L 4. 3rd boom section Retracted by the wire rope mechanism that synchronizes with the retraction of 2nd boom section.
Page 132 G -2 G -2 G -2 Boom (Six-Section Boom) △ ：FD0534-- Applicable serial No. Boom (Six-Section Boom) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 133 G -2 G -2 G -2 Boom (Six-Section Boom) W536-0970E...
Page 134: Boom (Six-Section Boom)
G -2 G -2 Boom (Six-Section Boom) 1.Top boom section 38.Bolt 75.Bolt 112.Pin 2.5th boom section 39.Plain washer 76.Spacer 113.Roller assy 3.4th boom section 40.Retainer 77.Support 114.Slide plate 4.3rd boom section 41.Guide 78.Sheave assy 115.Shim 5.2nd boom section 42.Retaining ring 79.Spacer 116.Shim 6.base boom section...
Page 135: Disassembly
G -2 G -2 Boom (Six-Section Boom) 2. Disassembly [NOTICE] Before loosening the nut, measure the length of the The procedure to remove the 2nd boom section and wire rope protrusion(L1) as a guide for reassembly. further sections as an assembly is described below. When the wire rope cannot be removed from the support, loosen the two bolts to remove the support 2.1 Removing the 2nd boom section...
Page 136: Removing The 3Rd Boom Section
G -2 G -2 Boom (Six-Section Boom) 2.2 Removing the 3rd boom section 9. Pull out the connecting pin that connects the base boom section and the No.1 telescoping cylinder 1. Loosen the hose fitting (No. 2 cylinder side) to by removing the retaining ring.
Page 137 G -2 G -2 Boom (Six-Section Boom) 3. Remove the support assy of the No. 1 telescoping cylinder located at the rear end of the 3rd boom section by loosening the hexagon socket head bolts. Also remove the roller assy by loosening the Support bolt.
Page 138: Removing The Of 4Th Boom Section
G -2 G -2 Boom (Six-Section Boom) 2. Remove the pin and remove sheave•A. [NOTICE] Prevent the wire rope on the bottom surface of the [NOTICE] 3rd boom section from being crushed by the 2nd Before loosening the nut, measure the length of the boom section.
Page 139: Removing The 5Th Boom Section
G -2 G -2 Boom (Six-Section Boom) 7. Loosen the two bolts to remove the support. 10. Pull out the 4th boom section by approx. 1m(3.281 lft). While lifting up the 4th boom section slightly, remove the retainer from the bottom of the 3rd boom section head.
Page 140 G -2 G -2 Boom (Six-Section Boom) 3. Pull out the support (for 5th boom section extension wire rope) from the top of the 5th boom section rear end rearward. 8. Loosen the bolts to remove the slide plates from both sides of the 4th boom section head.
Page 141: Removing The Top Boom Section
G -2 G -2 Boom (Six-Section Boom) 2.5 Removing the top boom section 4. Pull out the top boom section by approx. 1. Loosen the three hexagon socket head bolts on 1m(3.281 ft). While lifting up the top boom section both upper sides of the 5th boom section head to slightly, remove the retainer from the bottom of the remove the support (guide for top boom section...
Page 142: Reassembly
G -2 G -2 Boom (Six-Section Boom) 4. Reassembly 5. Adjustment 4.1 Greasing 5.1 Adjusting clearance for the boom • When installing unplated pins, apply grease 1. Vertical clearance at 2nd boom section head beforehand. Place shims to adjust the clearance to the 3rd •...
Page 143: Operation Test
G -2 . G -2 . Boom (Six-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 144: Jib
G -3 G -3 G -3 1. Structure 1.1 Location of jib 1.Jib assy 1 2.Support assy 3.Support 4.Support 5.Plate 6.Support 7.Pin 8.Snap pin 9.Bolt 10.Spring washer △ 342-214-30000 W157-0430E...
Page 145: Jib Main Body
G -3 . G -3 . G -3 . 1.2 Jib main body 1.Jib•1 7.Roller assy 13.Snap pin 19.Plate 25.Spacer 2.Jib•2 8.Retaining ring 14.Slide plate 20.Bolt 26.Pin 3.Pin 9.----- 15.Slide plate 21.Sheave assy 27.Bolt 4.Snap pin 10.Split pin 16.Plate 22.Retaining ring 5.Rod 11.Spring washer 17.Plate...
Page 146 G -4 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 147: Telescoping Cylinder
G -4 . G -4 . Telescoping Cylinder 1.Plug 5.Backup ring 9.Cylinder 13.Rod cover 2.Spring pin 6.Piston 10.O-ring 14.Dust seal 3.Nut 7.O-ring 11.Packing 15.Plain bearing 4.Packing 8.Rod 12.Backup ring 16.O-ring △ 360-163-00000 △ 360-163-10000 W157-0430E...
Page 148: Structure
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 149 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 150: 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 151: 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 152 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 153: 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 154 Boom Length and Angle Detector original position after it is rotated a quarter turn by Core wire finger and released. If it is not returned, loosen the Cord bolt and adjust the position of the bracket. Shield wire [NOTICE] If the potentiometer is faulty, replace it referring to Drum assy Vinyl tube the "Replacing the potentiometer (boom length...
Page 155: 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 156: 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 157: 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 158: 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 159: 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 160 H-3 . H-3 . Outrigger Extension Length Detector When replacing the potentiometer with a new one, mount it onto the bracket, then solder the cable to the potentiometer terminal. [NOTICE] Finish soldering the wire to the potentiometer terminal as quick as possible (max. 5 seconds) to minimize undesirable heat transmission to the potentiometer.
Page 161: Solenoid Valve
Solenoid Valve (AML Vent, Hook-in) Solenoid Valve (AML Vent, Hook-in) [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 162 Solenoid Valve (AML Vent, Hook-in) IW121-034003 1.Body 5.Distance piece 9.Nut 13.O-ring 2.Valve seat 6.Filter element 10.Shim 14.O-ring 3.Adjust screw 7.Cap 11.Spring 15.O-ring 4.Poppet 8.Solenoid valve assy 12.Plug 16.O-ring Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf A, B, T G1/4...
Page 163 H-4 . H-4 . Solenoid Valve (AML Vent, Hook-in) Solenoid valve assy Connector (+): Red (-): Blue IW121-0542E01 SOL.a SOL.b IW121-034004 1.Body 7.Spring seat 9.O-ring 12.Solenoid (DC24V) 3.Spool 8.Square ring 11.Spring 15.Hexagon socket head bolt Thread size and tightening torque Tightening torque Sign / port Thread size...
Page 164 Contents K-1 Crane Cab Glass ......1 Charging with refrigerant......14 Check for gas leakage and amount of Glass replacement procedure ....1 refrigerant charge .......15 Heated water circuit ........15 Bonding the joint between windshield glass Run-in operation ........15 and roof glass........ 2 Bolt size and tightening torque ....15 Erectric............
Page 165: 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 166: 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 167: 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 168: 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 169: 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 170: 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 171: 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 172: 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 173: 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 174: Reheat Method
Air Conditioner 3.7 Reheat method (flow control valve) 2. With this method, the temperature is controlled by 1. The air which cools (or heats) the cab is taken in changing the opening of a water valve that is from outside (or inside) by a blower motor, and attached to the heater unit.
Page 175: Layout
Air Conditioner 4. Layout 4.1 Overall layout W701-0200E...
Page 176: Overall Layout
Air Conditioner 4.2 Overall Layout W701-0200E...
Page 177: Evaporator Section
Air Conditioner 4.3 Evaporator section W701-0200E...
Page 178: Important Points For Assembly (Layout)
Air Conditioner 5. Important points for assembly (Layout) 5. Bending radius in refrigerant hose When routing the refrigerant hose, the bending 5.1 Seal during part installation work radius for hose bends must be 120mm (4.7in) or 1. Do not remove seal before the parts are to be more.
Page 179: Check For Gas Leakage And Amount Of Refrigerant Charge
Air Conditioner 5.5 Check for gas leakage and amount of 5.7 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 180: Erectric Circuit
Air Conditioner 6. Electric 6.1 Electric circuit W701-0200E...
Page 181: Wiring System Diagram
Air Conditioner 6.2 Wiring system diagram W701-0200E...
Page 182: Harness (Inside Cab)
Air Conditioner 6.3 Harness (inside cab) W701-0200E...
Page 183: Harness (Outside Cab)
Air Conditioner 6.4 Harness (outside cab) W701-0200E...
Page 184: Control Table
Air Conditioner 6.5 Control table IW701-0110E22 W701-0200E...
Page 185: Control
K-2 . K-2 . Air Conditioner 7. Control 7.1 Oil 1. ND-OIL8 will harm (corrode and deteriorate) the acrylic resin and ABS resin. For this reason, be careful that none adheres. 2. ND-OIL8 absorbs water easily. Quickly seal the oil can after use.
Page 186: Hydraulic Motor (Air Conditioner)
Hydraulic Motor (Air Conditioner) Hydraulic Motor (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 K-3 . K-3 . Hydraulic Motor (Air Conditioner) 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…. 25.O-ring 5.Piston 12.Oil seal...
Page 188: Structure
Solenoid Valve (Air Conditioner) Solenoid Valve (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 189 K-4 . K-4 . Solenoid Valve (Air Conditioner) Solenoid valve assy Connector (+): Red (-): Blue IW121-0542E01 157 156 IW121-076003 1.Body 15.Hexagon 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 190 Control System Contents L-1 Control System ........ 1 General of hydraulic pilot system ....1 General of pneumatic control devices ..2 L-2 Remote Control Valve...... 3 Structure ........... 3 L-3 Solenoid Control Relief Valve (Swing and Elevating Slow Stop) ....6 Structure ...........
Page 191: Control System
L - 1 Control System Control System 1. General of hydraulic pilot system Hydraulic Pilot Circuit WL02-0080E...
Page 192: General Of Pneumatic Control Devices
L - 1 . L - 1 . Control System 2. General of pneumatic control devices Pneumatic Circuit WL02-0080E...
Page 193: Remote Control Valve
L - 2 Remote Control Valve Remote 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 194 L - 2 Remote Control Valve Section A-A 2,4,6 1,3,5 IW135-015003 101.Casing 214.Push rod 273.Nut 413.Cam shaft 102.Casing 217.Shim 301.Spool 414.Bush 103.Casing 251.RO plug 311.Spring seat 420.Cam 115.Plate 261.O-ring 313.Washer 431.Block 201.Cover 262.O-ring 315.Iock nut 471.Ball 202.Plug 263.O-ring 323.Iever 472.Set screw 210.Seal 271.Hexagon Socket head bolt 324.Spring...
Page 195 L - 2 . L - 2 . Remote Control Valve Thread size and tightening torque Tightening torque Sign / Port Thread size Remarks 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 196: Structure
L - 3 Solenoid Control Relief Valve (Swing and Elevating Slow Stop) Solenoid Control Relief Valve (Swing and 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 197 L - 3 . L - 3 . Solenoid Control Relief Valve (Swing and Elevating Slow Stop) Proportional Reducing Valve 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...
Page 198: Accelerator Sensor
L - 4 . L - 4 . Accelerator Sensor Accelerator Sensor [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 199: Solenoid Valve (Air)
L - 5 Solenoid Valve(Air)(2/4 W heel Drive Shift) Solenoid Valve(Air)(2/4 W heel Drive Shift) 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 200 L - 5 . L - 5 . Solenoid Valve(Air)(2/4 W heel Drive Shift) 1.Core 6.Coil assy (DC24V) 11.O-ring 16.Cover 2.O-ring 7.----------- 12.Valve seat 17.Filter 3.Case 8.Rod 13.Valve 18.Packing 4.Spring 9.Coil cover 14.Bady 19.Packing holder 5.Plunger 10.O-ring 15.Spring 20.Plug Thread size and tightening torque Tightening torque Sign / Port Thread size...
Page 201 Steering System Contents S-1 Steering System....... 1 Disassemlby..........16 Rotor section ..........16 General............. 1 Control section ..........17 Check ............ 18 S-2 Priority Valve ........2 Reassembly ..........18 Structure ........... 2 Control section ..........18 Rotor section ..........20 Principle of operation ........ 4 Neutral state ..........
Page 202: 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 203: 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 204 S -2 S -2 Priority Valve 1. Housing 6. Spool 11. Body 16. Damper collar 2. Plug 7. Set screw 12. Ring 17. Spring 3. O-ring 8. Set screw 13. Screen 18. Poppet 4. Spring 9. Plug 14. Valve seat 19.
Page 205: Principle Of Operation
S -2 S -2 Priority Valve 2. Principle of operation 2.1 Neutral state 1. The oil from the pump enters the priority valve 2. The pressure difference produced when the oil through port P and, passing through the external passes through orifice Cdy (called “dynamic passage of spool, it reaches port CF.
Page 206: Right Steering
S -2 S -2 Priority Valve 2.2 Right steering flowrate corresponding to the opening area is 1. Turning the steering wheel right changes the oil ensured. passages in the orbitrol as shown in the figure. In this case, the oil used for steering assistance 4.
Page 207: Right Steering To The End
S -2 S -2 Priority Valve 2.3 Right steering to the end 1. When the steering wheel is turned right until the 2. Under this condition, the pressure loss as the oil steering cylinder reaches the end of its stroke, a passes through orifice Cdy result in a pressure further attempt to rotate the steering wheel causes difference between chambers A and B, causing...
Page 208: Troubleshooting
S -2 S -2 Priority Valve 3. Troubleshooting The problems which can generally be experienced with the priority valve are listed below with their possible causes and recommended measures to be taken. These problems, however, may result from causes not shown here and require other measures to be taken.
Page 209: Disassembly
S -2 S -2 Priority Valve 4. Disassembly 2. Remove plug(2) for port LS and remove spring(4) and spool assy(5). Then remove plug(9). CAUTION Set screw(7)(orifice Cdy) and set screw(8)(orifice Remove the dirt, dust, water, etc. from the Cpp) cannot be disassembled, as they are fixed in valve surfaces prior to disassembly, taking care spool assy(5).
Page 210: Cleaning
S -2 . S -2 . Priority Valve 5. Cleaning 3. Install spool assy(5) in port LS of housing(1). 1. Clean all the metallic parts in a clean kerosine and [NOTICE] blow compressed air to dry them. Make sure that the direction of the spool is correct. Check that the spool moves smoothly when 2.
Page 211: Orbitrol
S -3 S -3 Orbitrol Orbitrol [NOTICE] There is a case that the appearance and so on 1. Structure and functions differ from the parts for this machine. Although there is not so much difference in functions and The orbitrol is a load sensing, dynamic signalling disassembly procedures, make sure of the serial type oil passage switching device.
Page 212 S -3 S -3 Orbitrol IW184-001003 16 17 13 10 11 12 7 23 IW184-001004 1.Screw 8.Drive 15.--- 22.Bushing 2.Retaining screw assy 9.--- 16.Bearing race 23.O-ring 3.End cap 10.Housing 17.Thrust needle 24.O-ring 4.Rotor set 11.Sleeve 18.O-ring 25.Adapter screw 5.Spacer 12.Spool 19.Oil seal 26.Ball 6.---...
Page 213: Spool And Sleeve
S -3 S -3 Orbitrol 1.2 Spool and sleeve 4. In the section corresponding to View D-D, spool, 1. Spool is splined to the steering wheel. When the sleeve and drive are connected together by pin spool turns as the steering wheel is roted, its without clearance, whereas spool has slots that position relative to sleeve changes, and the oil allow it to move on pin within a certain angle.
Page 214: Operation
S -3 S -3 Orbitrol 2. Operation The orbitrol operates interacting with the priority valve. This section describes the operation of the orbitrol itself. For information on the interaction between the orbitrol and the priority valve, refer to the “Priority Valve” section. 2.1 Neutral state High pressure oil The pressure oil that has entered port LS flows...
Page 215: Right Steering
S -3 S -3 Orbitrol 2.2 Right steering flowrate), and the pressure reflecting the orifice area change is guided from port LS to the priority 1. When the steering wheel is turned clockwise the valve for use as a signal pressure to control the oil spool shifts clockwise with respect to the sleeve to distribution by the priority valve.
Page 216 S -3 S -3 Orbitrol 2.3 Steering wheel turned left IW184-002009 Left turn IW184-0020E08 High pressure oil from pump Delivery oil Return oil Neutral or trapped IW184-0020E03 W184-0021E...
Page 217: Rotor Section
S -3 S -3 Orbitrol 3. Disassembly 5. Remove O-ring from end cap. 3.1 Rotor section 6. Remove rotor set taking care not to allow the star in the rotor set to fall. 1. Lightly hold the mounting flange of the unit in a O-ring vise, the rotor side up.
Page 218: Control Section
S -3 S -3 Orbitrol 3.2 Control section 6. Remove the spool and sleeve assembly from 1. Remove housing from the vise, and place it on a housing by pulling it in the opposite direction to clean cloth, while taking care not to give damage the flange.
Page 219: Check
S -3 S -3 Orbitrol 4. Check 5. Reassembly 1. Check all the parts for matching surface condition. 5.1 Control section Scratched or burred parts should be replaced, as 1. Slide spool into sleeve while rotating and align they could cause oil leaks. Clean all metallic parts their spring grooves.
Page 220 S -3 S -3 Orbitrol 5. Insert pin into the holes of spool and sleeve and 10. Fit bushing on spool while rotating the bushing. adjust the position of the pin so that its both ends Then tap bushing with a plastic hammer down into will be flush with the outside surface of the sleeve.
Page 221: Rotor Section
S -3 S -3 Orbitrol 5.2 Rotor section [NOTICE] Make sure that the spool and sleeve assembly is slightly indented from the end surface with the 14 holes of housing. Wipe clean the end surface of the housing with a clean hand palm.
Page 222 S -3 . S -3 . Orbitrol 7. The position of star and the drive side pin is as 11.Place end cap on rotor set and line up the bolt shown in the following figure. holes. Ball [NOTICE] This procedure is of vital importance in determining the valve timing of the unit.
Page 223: 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 224: 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 225 S -5 S -5 Solenoid Valve (Steering Mode) Body section IW121-036003 Thread size and tightening torque Tightening torque Sign / port Thread size ft-lbf 6.9 - 7.8 5.1 - 5.8 a, b, c, d, e, f G 3/8 △ 346-407-02100 W121-0840E...
Page 226 S -5 S -5 Solenoid Valve (Steering Mode) Solenoid valve assy (SoL.32) Connector (+) : Red (-) : Black IW121-0542E01 IW121-032002 1. Nut 5. Packing 9. Spool 13. Plug 2. O-ring 6. O-ring 10. Centering washer 14. Spring pin 3. Solenoid core 7.
Page 227 S -5 S -5 Solenoid Valve (Steering Mode) Solenoid valve assy (SoL.30, 31) Connector (+) : Red (-) : Black IW121-084005 IW121-0542E01 1.Nut 4.Solenoid coil 7.O-ring 10.O-ring 2.O-ring 5.Spring 8.Cecter washer 11.Spool 3.Solenoid core 6.Packing 9.Body 12.Spring pin [NOTICE] Spool(11) is symmetric. Adjust the slit of centering washer(8) to body(9) side.
Page 228 S -5 . S -5 . Solenoid Valve (Steering Mode) Solenoid valve assy (SoL.33) Connector (+) : Red (-) : Black IW121-0542E01 IW121-084007 1.Nnt 5.Packing 9.Body 13.Plug 2.O-ring 6.O-ring 10.Centering washer 14.Spring pin 3.Solenoid 7.Body 11.Spool 4.Solenoid oil 8.O-ring 12.O-ring [NOTICE] Adjust the flute at the end of spool(9) to plug(13) side.
Page 229 Brake System Contents Dismouting and remounting ...... 9 T-1 Brake System ........1 Disassembly..........9 General............. 1 Disassembly of the mount plate....10 Disassembly of the body......10 T-2 Brake (Service Brake)...... 2 Cleaning and checking ......11 Structure and function ....... 2 Cleaning ............
Page 230 Operation of cylinder....... 18 Troubleshooting ........38 Booster not in operation ......18 Booster in operation ......... 18 Brakes are released ......... 19 T-6 Reducing Valve ......41 Removing of booster....... 19 Structure ..........41 Disassembly ........... 20 Principle of operation ......41 Disassembly of cylinder......
Page 231 T-8 Solenoid Valve (Air) ....... 47 Structure ..........47 T-9 Brake (Parking Brake) ....49 Structure ..........49 Disassembly ........... 50 Removing the brake shoes....... 50 Remocing cam shaft......... 50 Check ............ 51 Checking shoe lining assy......51 Checking adjuster assy ......51 Checking cam shaft........
Page 232: Brake System
T - 1 . T - 1 . Brake System Brake System 1. General Brake Circuit (air over hydraulic brake) WT02-0110E...
Page 233: 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 234: 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 235: Replacing The Pad Assy
T - 2 . T - 2 . Brake (Service Brake) 4. Replacing the pad assy 5. Washing and checking When the thickness of the brake lining has 5.1 Washing reduced to 4 mm (0.16 in) , replace the pad assy. CAUTION 1.
Page 236: 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 237 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 238: 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 239: 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 240: Operation Under Piping Rupture
T - 3 Brake Valve 2. Operation with only secondary system Plunger Return spring When the primary brake system is damaged, no Spring seat air pressure is generated in the primary system, Rubber spring so that no primary air pressure is available to work Piston on the relay piston for actuation of the secondary system.
Page 241: 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 242: 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 243: 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 244 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 4. Put the springs, stem washer, and sleeve onto the IW202-0010E20 stem, and tighten the sleeve.
Page 245: 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 246: 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 247: 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 248: Function
T - 4 Booster (Brake) 1. Body 10. Spring 19. Piston assy 28. Spacer•A 2. Filter 11. Cap assy 20. Air cylinder 29. Guide 3. Nipple 12. O-ring 21. Bolt 30. Secondary cup 4. O-ring 13. Air breather assy 22. Nut and washer 31.
Page 249: Operation Of Cylinder
T - 4 Booster (Brake) 3. Operation of cylinder 3. In this state, the fluid holes (Φ 0.7×4 places) of the plunger are positioned on the left side of the 3.1 Booster not in operation primary cup lip, allowing the brake fluid to freely 1.
Page 250: Brakes Are Released
T - 4 Booster (Brake) 3.3 Brakes are released 4. Removing of booster 1. When the brake pedal is released, the 1. Park the carrier on a level surface, apply the compressed air that has been acting on the parking brake, and block wheels with chocks. booster is let out from the exhaust port of the 2.
Page 251: Disassembly
T - 4 Booster (Brake) 5. Disassembly 2. Loosen cap assembly by setting a spanner on the flats of cylinder body. [NOTICE] Take out check valve and spring from inside the Before disassembling, drain the brake fluid from cylinder body. inside the booster, and remove any mud or dirt adhering to the rear surface.
Page 252 T - 4 Booster (Brake) 5. Remove retaining ring at nipple. Filter is then Cup supporter removable. Cup spacer Plunger guide (include bushing) Spacer (A) Nipple Secondary cup guide O-ring Retainer ring Spacer (B) Primary cup Retaining ring Secondary Cup IW404-0020E12 IW404-0020E09 7.
Page 253: Disassembly Of Air Cylinder Assembly
T - 4 Booster (Brake) 6. Check 9. Remove switch assy by using a wrench on the hexagonal section. Then remove O-ring and 1. Rubber parts retainer. Check the cup and O-ring for damage, wear and The switch cannot be disassembled. aging.
Page 254: Reassembly
T - 4 Booster (Brake) 7. Reassembly To assemble, refer to the figure below, and follow the disassembly procedure in the reverse order. Greasing points and types of greases to be used Red seal Silicon grease G30M Rubber grease Rubber grease or silicon grease IW404-0020E16 Thread size and tightening torque tightening torque...
Page 255: Test
T - 4 Booster (Brake) 8. Test 8.1 Testing equipment Pressure gauge (1) Brake valve Air pressure Service line Cut valve Pressure regulating Air reservoir valve Pressure gauge (2) Pressure gauge (3) Air piping Wheel cylinder Fluid piping IW404-0030E08 8.2 Test method Standards Test Items Test conditions...
Page 256: Maintenance Standards
T - 4 . T - 4 . Booster (Brake) 9. Maintenance standards Item Maintenance Standards Wear Limit Remarks Tension of return spring 78.5 ± 9.8N At length of 118.9mm (17.6 ± 2.2 lbf) (13.3 lbf) (4.7in) Air tightness under no load 39.2kPa(5.7psi) At 0.6MPa (87psi) ―...
Page 257: 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 258 T - 5 Air Dryer View A To compressor Heater IW232-0040E02 W232-0040E...
Page 259 T - 5 Air Dryer Section B-B IW232-0040E03 View C Thermostat IW232-0040E04 W232-0040E...
Page 260 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 261: 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 262: 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 263: 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 264: Precautions For Handling
T - 5 Air Dryer 3. Precautions for handling 4. Maintenance and inspections [NOTICE] WARNING Be certain to use the desiccant specified by When performing inspections, use caution to NABCO (part No. 41213640010), and replace it with prevent dirt from entering the eyes. an amount that is within the specified range.
Page 265: Inspection And Part Replacement Every
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 266 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 267: 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 268: Tapping
T - 5 Air Dryer 6.2 Tapping 6.3 Cartridge (upper) [NOTICE] Applying grease to the raised part of the check DANGER valve will allow it to be inserted more easily. When tapping is not performed, the desiccant may deteriorate and be lost, with pieces blocking Use NABCO grease (grease pack 45499030090, the brake piping and preventing normal brake grease weight: approximately 10 g (0.022lb).
Page 269: 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 270 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 271 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 272: Reducing Valve
T - 6 Reducing Valve Reducing Valve 4. By closing and opening the flow passage with valve assembly, the pressure at the delivery port [NOTICE] is maintained at a set level below the input level. There is a case that the appearance and so on differ from the parts for this machine.
Page 273: Cleaning And Checking
T - 6 . T - 6 . Reducing Valve 5. Cleaning and checking 4. Install spring•3 and spring seat•2, and install spring cage•1. 1. Cleaning Wash all metal parts and plastic parts in clean 5. Adjust the pressure setting in accordance with the kerosine, and dry.
Page 274: 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 275: Function
T - 7 Brake Chamber 2. Function DANGER 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 276: Cleaning And Checking
T - 7 Brake Chamber Clamp ring Pressure plate Spring Push rod Adapter Special jig IW576-0020E03 4. Cleaning and checking against the pressure plate by a spring. 4.1 Cleaning 2. In order to neutralize this force, use the special jig to first pull out the push rod by approximately 5 1.
Page 277: 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 278: 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 279 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 IN, OUT Rc1/4...
Page 280: Brake(Parking Brake)
T - 9 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 281: Disassembly
T - 9 Brake (Parking Brake) 2.2 Removing the cam shaft 2. Disassembly 1. Make sure that the alignment marks are present 2.1 Removing the brake shoes at the connection between cam shaft and lever. Put the marks if they are unclear. 1.
Page 282: Check
T - 9 Brake (Parking Brake) 3. Check 4. Reassembly [NOTICE] [NOTICE] Before checking, remove worn lining powder, mud, When assembling, apply grease to the sliding parts and any other dirt form all parts. Also wipe away (marked with *1 and *2 on page 1.) deposited oils (lubricants).
Page 283: Adjustment
T - 9 . T - 9 . Brake (Parking Brake) 5.2 Connecting the spring chamber 5. Adjustment 1. Keep the parking brake lever at the 0 point (center 5.1 Adjusting the brake of lever play). [NOTICE] 2. Compress the spring chamber to the end of its Perform the brake adjustments before the brake is stroke (stroke end when extended by air pressure).
Page 284 Suspension System Contents U-1 Suspension System......1 General............. 1 U-2 Spring Lock Cylinder (Front) ..2 Structure ........... 2 U-3 Spring Lock Cylinder (Rear) ... 3 Structure ........... 3 U-4 Pilot Check Valve (Spring Lock Cylinder) .... 4 Structure ........... 4 U-5 Solenoid Valve (Lock Check Release)....
Page 285: Suspension System
U-1 . U-1 . Suspension System Suspension System 1. General Hydraulic Circuit for Suspension 1. Leaf springs are employed for both the front and 3. There are two kinds of pressure controlling valves rear axle suspensions. in the spring lock hydraulic circuit, namely a relief valve and a pressure reducing valve.
Page 286: Spring Lock Cylinder (Front)
U-2 . U-2 . Spring Lock Cylinder (Front) Spring Lock Cylinder (Front) [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 287: Spring Lock Cylinder (Rear)
U-3 . U-3 . Spring Lock Cylinder (Rear) Spring Lock Cylinder (Rear) [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 288: Pilot Check Valve
U-4 . U-4 . Pilot Check Valve (Spring Lock Cylinder) Pilot Check Valve (Spring 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 289: Solenoid Valve
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 290 U-5 . U-5 . Solenoid Valve (Spring Lock Check Release) Solenoid valve assy (-) : Blue (+) :Red Connector (2P) 157 156 IW121-032201E 1.Body 15.Hexagon socket head bolt 71.Spring 157.Solenoid (DC24V) 2.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...
Page 291 Data, Adjusting and Checks Contents Service brake circuit........ 12 Y-1 Hydraulic Pressure Setting Table... 1 Winch ............1 Swing circuit..........12 Swing motor ..........12 Elevating........... 2 Swing control back-pressure valve ...12 Swing ............3 Winch circuit (main and aux.) ....13 Winch motor ..........13 Outrigger...........
Page 292 Straight ahead detection Charging pump (for torque converter) ..25 proximity switch ......16 Pump speed ..........25 Pump displacement ........25 Y-5 Adjustment and Checks ....17 Emergency steering pump (option)..25 Drive system ........... 17 Pump speed ..........25 Accelerator sensor assembly and Pump displacement ........25 adjustment..........
Page 293: 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 Engine...
Page 294: Elevating
Hydraulic Pressure Setting Table 2. 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 295: Swing
Hydraulic Pressure Setting Table 3. 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...
Page 296: Outrigger
Hydraulic Pressure Setting Table 4. 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.
Page 297: Steering
Hydraulic Pressure Setting Table 5. 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.
Page 298: Pilot Pressure
Hydraulic Pressure Setting Table 6. 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 Pilot (IDL.)
Page 299: Accumulator Unload Relief Valve
Hydraulic Pressure Setting Table 7. Accumulator unload relief valve 7.1 Adjusting the pressure [NOTICE] Oil temp: 50 ± 5°C (Operating oil: Tadano hydraulic oil LL) Perform switching while engine is idling, then increase engine speed. Engine Set pressure Item speed...
Page 300: Checking Operation
Hydraulic Pressure Setting Table 7.2 Checking operation [NOTICE] [NOTICE] Perform no operations during steps 2 ~ 4 below. Before checking operation, check the pressure adjustment of the unload relief valve. 2. The pressure drops until the accumulator Conditions pressure reaches the pressure at which pressure Engine speed : 770 (min accumulation starts (on-load pressure).
Page 301: Hook-In
Y-1 . Y-1 . Hydraulic Pressure Setting Table Hook-in [NOTICE] Oil temp: 50 ± 5°C (Operating oil: Tadano hydraulic oil LL) Engine Set pressure Item speed Check procedure (min 1. Turn the PTO switch ON. 2. Fully retract and lower the boom (Indicator lamp Hook-in (IDL.)
Page 302: Air Pressure Setting Table
Y-2 . Y-2 . Air Pressure Setting Table Air Pressure Setting Table 1. Air pressure setting table Set pressure Item Remarks On-load 690 - 730 100 - 106 Check that regeneration occurs Pressure regulator at the air dryer during Unload 810 - 859 117 - 125 unloading.
Page 303: Air Bleeding Procedure
Air Bleeding Procedure Air Bleeding Procedure 1. Double gear pump and variable displacement pump [NOTICE] Be sure that the following conditions are met before starting the engine. • PTO : OFF • A/C : OFF • Oil cooler : OFF The following is also possible.
Page 304: Service Brake Circuit
Air Bleeding Procedure 2. Service brake circuit 3. Swing circuit 3.1 Swing motor [NOTICE] The vehicle has two boosters; one for the front [NOTICE] wheel brakes and the other for the rear wheel Do not apply any load to the motor before brakes.
Page 305: Winch Circuit (Main And Aux.)
Air Bleeding Procedure 4.2 Winch brake release circuit 4. Winch circuit (main and aux.) 4.1 Winch motor [NOTICE] Do not apply any load to the motor before performing air bleeding. Bleed the winch motor by following either (1) or (2). 1.
Page 306: Hydraulic Pilot Circuit
Y-3 . Y-3 . Air Bleeding Procedure AML vent solenoid valve 5. Hydraulic pilot circuit [NOTICE] Right rear of swing frame Set the hydraulic oil temperature to 50°C (122°F) or higher, set the PTO switch to ON, let the engine idle.
Page 307: Electric Switch Adjustment
Electric Switch Adjustment Electric Switch Adjustment 3. Jib lock pin detection proximity switch Adjust the switch position so that the dimension A 1. 4th/top boom full retraction detection becomes 4-5 mm (0.16-0.2 in) with the jib stowed. limit switch (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent).
Page 308: Switch
Y-4 . Y-4 . Electric Switch Adjustment 5. Straight ahead detection proximity switch Set the rear wheels in a straight-forward position, and adjust the switch position so that the dimension A becomes 2.5-3 mm (0.1-0.12 in). (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent).
Page 309 Adjustment and Checks Adjustment and Checks 7. Lock five places shown in Figure in paint after 1. Drive system adjustment is finished. 1.1 Accelerator sensor assembly and adjustment 1. Installation points of lever D. Press-fit it in the thrust at the time of tightening the nut for the lever fixation so that the load should not join direction of thrust of the sensor axis.
Page 310 Adjustment and Checks Accelerator sensor output diagram Accelerator sensor handling note 1. Force must not be applied to the sensor internal stopper when you adjust the nut for the sensor shaft fixation. (Do not receive turning effort with the stopper when you turn the nut in the direction of the stopper from the state that the shaft stops with the stopper.
Page 311 Adjustment and Checks 1.2 Engine speed 3. Parking brake adjustment procedure [NOTICE] 3.1 Adjusting parking brake clearance Before checking the engine speed, run the engine to warm it up. (Torque converter oil should reach 1. Jack up the crane and keep the parking brake approximately 50°C (122°F).) lever disengaged.
Page 312 Adjustment and Checks 4. Tire steering angle adjustment [NOTICE] Before the tire steering angle adjustment, bleed the steering cylinders, check the side slip amount of each tire by the procedures (1) and (2) below. (1) Set the outriggers and set the steering mode to 4-wheel steering.
Page 313 Adjustment and Checks 5. Adjusting boom telescoping wire ropes 5.1 Adjusting the telescoping wire ropes for the top and 5th boom sections 1. With the boom fully retracted, tighten adjustment nut A of the adjuster for the top boom section retraction wire rope.
Page 314 Adjustment and Checks wire rope, so that the top boom section is spaced 3. Evenly tighten the adjustment nuts C (2 nuts) at slightly apart (1 ~ 5 mm(0.04-0.2in)) from the 5th the screw end of the top boom section extension boom section.
Page 315 Adjustment and Checks 5.2 Adjusting the telescoping wire ropes for the 3rd boom section 1. Fully retract the boom, then loosen the 3rd boom section extension wire rope. Base boom Fastened at rear end 2nd boom section For 3rd boom section fastening support of 3rd boom section rear sheave...
Page 316 Y-6 . Y-6 . Mass Table Mass Table Spec. No. Part Name TR-150-4-00101 TR-150-4-00102 1M1D 2M2D (North America) (North America) Boom assy (including telescoping 2400kg (5290 lb) 2650kg (5840 lb) cylinder, jib-1 and jib-2) (excluding jib) Boom Telescoping cylinder 300 kg (660 lb) 2-stage Jib Not fitted 180kg (400 lb)
Page 317 Y-7 . Y-7 . Specifications Specifications Idling speed: 699 - 736min 1. Engine speed Max. speed: 2476 - 2569min 3.2 Pump displacement • Engine model : CUMMINS QSB3.9-2A • T/C model :MT19200000 23.1 + 13.9cm /rev (1.4 + 0.85in /rev) 1.1 Idling speed 4.
Page 318 Thread size Rod end pin Φ100 M30×3.5 Elevating cylinder Base pin Φ110 M30×3.5 Boom base pin Φ100 M30×3.5 Applicable model: TR-150XL-4 (mm) Part Name Diameter Thread size Rod end pin Φ60 Elevating cylinder Base pin Φ70 M24×3.0 Boom base pin Φ60...
Page 319 System Diagrams Contents Z-1 Hydraulic Circuit ......1 Z-12 Location of Electric Parts (Relay Assembly/Upper) ..16 Z-2 Torque Converter Circuit ....3 Z-13 Location of Electric Parts (Lower)........17 Z-3 Brake Circuit (Pneumatic Circuit)... 4 Z-14 Location of Electric Parts (Box Assembly/Lower) ..18 Z-4 Electric Circuit (AML, Crane) ..
Page 320 Z - 1 Hydraulic Circuit Hydraulic Circuit WZ01-1540E...
Page 321: Hydraulic Circuit
Z - 1 . Z - 1 . Hydraulic Circuit [NOTICE] This hydraulic circuit is employed both for 2M2D specifications and 1M1D specifications. For the crane "1M1D" without the auxiliary winch, 7 portions (*2) are plugged. When the optional emergency steering is not installed, two points "A" are directly joined and 3 portions "*1" are plugged.
Page 322: Torque Converter Circuit
Z - 2 . Z - 2 . Z - 2 . Torque Converter Circuit Torque Converter Circuit △ 347-408-30000 WZ05-0300E...
Page 323: Brake Circuit (Pneumatic Circuit)
Z - 3 . Z - 3 . Z - 3 . Brake Circuit (Pneumatic Circuit) Brake Circuit (Pneumatic Circuit) △ 347-411-20000 WZ06-0340E...
Page 324: Electric Circuit (Aml, Crane)
Z - 4 Electric Circuit (AML, Crane) Electric Circuit (AML, Crane) CN No. Usage Coordinates Page CN No. Usage Coordinates Page Air solenoid valve (air horn) Condenser (C2) (washer motor) AML (Load moment indicator) vent solenoid valve Washer motor (roof) Hook-in solenoid valve Washer motor (front) Remote control pressure vent solenoid valve...
Page 325 Z-4. Z-4. Z-4. Electric Circuit (AML, Crane) 〔Notice〕 Relay (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. Make Jib lock pin detection proximity switch 2M2D,6+2...
Page 326 Z - 5 Electric Circuit (MDT, Carrier/Upper) Electric Circuit (MDT, Carrier/Upper) N No. Usage Coordinates Page CN No. Usage Coordinates Page Room lamp Power window switch (outside cab) Bubble level (illumination) Power window switch Harness with cab (room lamp, roof wiper motor, working lamp) Roof wiper switch Front wiper relay (intermittent wiper) Working lamp switch...
Page 327 Z-5. Z-5. Z-5. Electric Circuit (MDT, Carrier /Upper) Combination switch Combination meter Electric Circuit switch (horn) (AML, Crane) RSj:1.5kΩ/1W 1.Number within [ ] indicate the circuit identification numbers (the numbers of the wiring terminals) Lever P 2.The size of wires not indicated is CAVS 0.5mm (0.0008in Terminal assy 3.Wire specification codes are based on JASO D607.
Page 328 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 N-12 MDT (lower) CN4 Fuse box (L) I-22 Spring lock check release solenoid valve Solenoid control valve (outrigger, suspension) MDT (lower) CN5 Fuse box (L)
Page 329 Z-6. Z-6. Z-6. Electric Circuit (MDT, Carrier /Lower) Engine body 〔 79〕 Gy Fuse box 2PIN Transmission WATER IN FUEL BATT(+) SERVICE Engine (ECM)(Cummins) Lower MDT SENSOR BATT(-) TOOL [NOTICE] 1.Number within [ ] indicate the circuit identification numbers (the numbers of the wiring terminals) CN604 POWER AMP040mkⅠ...
Page 330: Location Of Hydraulic Parts
Z - 7 . Z - 7 . Z - 7 . Location of Hydraulic Parts (Upper) Location of Hydraulic Parts (Upper) WZ07-1490E...
Page 331: Location Of Hydraulic Parts
Z - 8 . Z - 8 . Z - 8 . Location of Hydraulic Parts (Lower) Location of Hydraulic Parts (Lower) WZ07-1500E...
Page 332: Location Of Air Parts
Z - 9 . Z - 9 . Z - 9 . Location of Air Parts Location of Air Parts WZ08-0290E...
Page 333: 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) △ 343-536-11000 WZ02-2580E...
Page 334: Location Of Electric Parts
Z -1 1 . Z - 1 1 . Z -1 1 . Location of Electric Parts (Swing Table, Boom) Z-11 Location of Electric Parts (Swing Table, Boom) WZ02-2590E...
Page 335: 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) △ 343-535-61500 △ 343-630-93000 WZ02-2600E...
Page 336: Location Of Electric Parts
Z -1 3 . Z - 1 3 . Z -1 3 . Location of Electric Parts (Lower) Z-13 Location of Electric Parts (Lower) △ 349-309-80000 WZ02-2610E...
Page 337 Z -1 4 . Z - 1 4 . Z -1 4 . Location of Electric Parts (Box Assembly/Lower) Z-14 Location of Electric Parts (Box Assembly/Lower) △ 349-309-82000 △ 349-309-82300 △ 349-309-01000 WZ02-2620E...
Page 338 Z -1 5 Z - 1 5 Z - 1 5 Harness (Connector No. Table) Z-15 Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page Straight ahead detection proximity switch A-13 4th/top boom extending switch (TDN array) Spring lock check release solenoid valve...
Page 339 Z -1 5 Z - 1 5 Z - 1 5 Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page MDT (lower) CN1-1 Rear combination lamp (R) A-16 Rotary joint MDT (lower) CN1-2 Backup lamp J-15...
Page 340 Z -1 5 . Z - 1 5 . Z -1 5 . Harness (Connector No. Table) CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page Cord reel Harness (AML) Overwind (two-blocking) Cord reel To inside cab harness Turn signal (R) Overwind (two-blocking) switch...
Page 341 Z-16. Z-16. Z-16. Harness (Inside cab) Z-16 Harness (Inside cab) ルームランプ作業灯 1.250 1.25YR ルーフワイパモータ P.T.O.SW ドラムインジケータ旋回ブレーキ過巻停止解除 (908) (905) 1.25LW 1.25L 1.25LG ドラムインジケータ (M/S)切替 1.25Lg 1.25Lg 1.25Lg 1.25L (833) (909) (906) コンデンサC1 (926) ルーフワイパモータ非常用O/R ジブ有無ノイズ防止状態設定ランプ切替ランプ...
Page 342: Harness (Connector No.table)
Z -1 7 . Z - 1 7 . Z -1 7 . Harness (Swing Table, Right) Z-17 Harness (Swing Table, Right) △ 343-528-02011 △ 343-528-02110 WZ04-2020E...
Page 343: Harness (Swing Table, Left)
Z -1 8 . Z - 1 8 . Harness (Swing Table, Left) Z-18 Harness (Swing Table, Left) △ 343-535-62020 WZ04-2030E...
Page 344: Harness (Boom)
Z -1 9 . Z - 1 9 . Harness (Boom) Z-19 Harness (Boom) Boom, base △ 343-528-12031 WZ04-2040E...
Page 345: Harness (Aml, Upper)
Z -2 0 . Z - 2 0 . Z -2 0 . Harness (AML, Upper) Z-20 Harness (AML, Upper) △ 343-628-11102 WZ04-2050E...
Page 346: Harness (Overwind)
Z -2 1 . Z - 2 1 . Z -2 1 . Harness (Overwind) Z-21 Harness (Overwind) WZ04-2060E...
Page 347 Z-22. Z-22. Z-22. Harness (Lower, Main) Z-22 Harness (Lower, Main) リードスイッチリードスイッチスライド (ロックピン出検出) (ロックピン入検出) (FR) ソレノイドバルブ (SPロックチェック解放) 近接スイッチコンビネーションプレッシャスイッチサーモセンダ (直進検出) ランプ(RH) (4WD検出) (トルコンオイル) ヘッドランプアワメータ (RH) (オプション) フューエルセンダジャッキ 1.25BrB 1.25B (FR) バックアップソレノイドバルブランプ ∼ (カニ) Earth バックブザー...
Page 348: Harness(Lower, Air)
Z -2 3 . Z - 2 3 . Z -2 3 . Harness (Lower, Air) Z-23 Harness (Lower, Air) △ 349-309-80200 WZ04-2080E...
Page 349: Harness
Z -2 4 . Z - 2 4 . Harness (Lower, Electronic Governor) Z-24 Harness (Lower, Electronic Governor) △ 349-309-80300 WZ04-2090...
Page 350 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...

Tadano TR-150XL-4 Service Manual

B Hydraulic Power Generating System

Hydraulic Power Generating

Hydraulic Pump (Double Variable Displacement Pump)

Hydraulic Pump

Hydraulic Pump

Hydraulic Valve

Steering) (Option)

Solenoid Control Valve

Rotary Joint

Hydraulic Valve (Pilot Pressure)

Check Valve (Gauge Isolator)

C Outrigger System

Outrigger System

Jack Cylinder

Pilot Check Valve

Extension Cylinder

Solenoid Valve (Slide/Jack)

Solenoid Valve (Slide/Jack)

Solenoid Valve (Slide/Jack)

Check Valve (Outrigger Extending Prevention)

D Swing System

Swing System

Swing Assembly

Hydraulic Motor (Swing)

Swing Speed Reducer

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)

Winch Brake Band

Boom Telescoping System

Telescoping System

Boom (Six-Section Boom)

Jib

Telescoping Cylinder

Counterbalance Valve

Safety System

Safety System

Boom Length and Angle Detector

Outrigger Extension Length

Solenoid Valve

Table of Contents

Crane Cab Glass

Air Conditioner

Hydraulic Motor (Air Conditioner)

Solenoid Valve (Air Conditioner)

Control System

Control System

Remote Control Valve

Accelerator Sensor

Solenoid Valve (Air)

Steering System

Steering System

Priority Valve

Orbitrol

Steering Cylinder

Solenoid Valve (Steering Mode)

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Tadano TR-150XL-4