Tadano GR-700EX-1, GR-700EXL-1 Service Manual

Publication No. GR-700EXL-1/S2-2E

Rough Terrain Crane

GR-700EX-

Model

GR-700EXL-

Applicable Serial No. 545870 --

Safet

Safety

Most accidents that occur during machine operation and maintenance are caused by failure to observe basic safety rules and precautions. Before operating your machine or performing maintenance, read and become familiar with all the safety precautions and recommendations given in this section. Remember that failure to observe even a single precaution could involve you and the people around the machine in a serious accident.

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

Safety precautions and recommendations are outlined in this section and are also included in the operation and maintenance instructions given in subsequent sections. Warning labels are also provided on the machine. The cautionary instructions in this manual are identified as "DANGER", "WARNING", "CAUTION" or "NOTICE". These terms are defined as follows:

[NOTICE]

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

It is virtually impossible to anticipate every situation that might present a hazard. The safety precautions given in this manual and on the machine labels are not exhaustive. It is important, therefore, to strictly follow the instructions in this manual and be sensitive to potential dangers in order to prevent bodily injury and damage to the machine.

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

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

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

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

DANGER

WARNING

CAUTION

WA01-0041E

Safet

1. Fundamental cautions

Servicemen inexperienced in the units of this machine should be cautious about safety operations. They must acquire sufficient knowledge about the equipment before dismounting and disassembling it. Before dismounting each component, a serviceman should read this service manual thoroughly and find out the weight of the component, then lift it by proper means.

The following are cautions to be observed all the time.

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

fatal accidents, as there is a possibility that the vehicle loses its balance and falls down on a worker in a dismounting process of certain units.

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

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

2. Cautions in working

2.1 General

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

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

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

5. Before starting maintenance, remove cables to the battery and allow the capacitors to discharge. Pull out the ignition key and hang a tag saying, "Don't start the engine." in the cab.

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

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

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

3. Protect wire ropes and plastic lifting slings by covering corners with pads so that they are not bent sharply by directly contacting corners. Keep the sling angle of wire ropes within 60°and as vertical as possible.

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

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

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

WA01-0041E

Safet

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

8. Watch your step in the following cases:

When stepping up to or stepping down from the

upper surface of a boom for replacing wire ropes and applying grease. Be careful not to stumble on protrusions on the upper surface of a boom. When greasing at the root of a elevating cylinder When checking engine oil, radiator coolant, or battery fluid. When replacing a filter of air cleaner When getting on and off the cab

Be careful not to slip in the above operations in

winter as snow and ice may attach to the exterior of boom and it becomes very slippery.

2.2 Dismounting and disassembling

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

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

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

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

2.3 Remounting and assembling

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

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

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

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

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

3. Cautions in operation

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

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

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

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

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

3.1 Brake fluid replenishment

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

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

3.2 Handling of battery

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

Be extremely sure to avoid short circuits, sparks

and fire of cigarettes and the like when using a jumper cable. They are very dangerous. Charge up batteries and use them only in well ventilated places.

WA01-0041E

Safet

2. Battery fluid (dilute sulfuric acid) may cause loss of sight or burn injury.

If battery fluid stains an eye, skin, or clothes,

immediately wash down them with a great deal of water. If battery fluid enters into an eye, immediately wash it down with water and see a doctor for medical aid.

3. When removing terminals, remove the minus (－) terminal first. When connecting terminals, connect minus (－) terminal last.

3.3 Handling of radiator

1. Don't open the radiator cap while the coolant is still hot.

2. Check the coolant at the reservoir tank.

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

3.4 Cooling fan

4.1 Gasoline

1.Spill or leak: Review fire and explosion hazards before proceeding with clean up. Use appropriate personal protective equipment during clean up. Dike spill. Prevent liquid from entering sewers, waterways, or low areas. Soak up with sawdust, sand, oil dry or other absorbent material. Shovel or sweep up.

2.Remove source of heat, sparks, flame, impact, friction or electricity including internal combustion engines and power tools. If equipment is used for spill cleanup, it must be explosion proof and suitable for flammable liquid and vapor.

Note: Vapors released from the spill may create an

explosive atmosphere.

3.Waste disposal method: Treatment, storage, transportation and disposal must be in accordance with applicable federal, state, provincial, and local regulations. Do not flush to surface water or sanitary sewer system.

1. Stop the engine completely before checking the tension of the engine fan belt.

2. The oil cooler fan may rotate the moment the engine is started. Be sure to pull out the ignition key before accessing the cooling fan.

4. About waste disposal

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

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

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

4.By itself, the liquid is expected to be a RCRA ignitable hazardous waste.

4.2 Hydraulic oil

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

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

4.3 Motor oil

See HYDRAULIC OIL above.

WA01-0041E

Foreword

This service manual describes the composition of the Model GR-700EXL-1 and GR-700EX-1 rough terrain crane,

its repair, check and adjustment methods and other relevant matters. Note that this service manual does not

provide the information in the separate service manuals given below.

This service manual applies to the cranes with the specification numbers given below. Check the specification

number on the nameplate of your crane.

Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the

crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales

units in the parts catalog before replacing them.

1. Applicable spec. No. / Crane model

Crane model Spec. No. Applicable serial No.

GR-700EXL-1

GR-700EX-1

2. Separate service manual

Separate Service Manual Information No.

General Cautions SA01-01-2E

Overload Prevention Device (AML) W301-0215E

Multiplex Data Transmitter W303-0257E

Torque Converter

Transmission

SPEC. NO. SERIAL.

MFG.DATE.

NO.

KAGAWA, JAPAN

ISA04-001601

GR-700E-1-00211

545960 -- 546189

GR-700E-1-00212

GR-700E-1-00211 546199--

GR-700E-1-00212 546190--

W561-0101E

Driving Axle W563-0053E

Please note that, for product improvement, some changes may have been

incorporated in the machine that are not covered in this manual.

WA04-2091E

3. Outline of specifications

Foreword

Spec. No.

Item

No. of boom sections 5

No. of jib stages 2

Single top Option

Main winch Fitted

Auxiliary winch Fitted

Winch

Weight Counterweight Removable type

Overload Prevention Device (AML) AML-L B

Auto. stop solenoid valve energizing type Normally energized

Winch brake Automatic brake (Neutral brake)

Drum rotation indicator

Visual-type Option

Touch-type Option ―

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

(General Export)

2M2D

AML external indicator lamp Fitted

AML external buzzer Fitted ―

Oil cooler Fitted

Emergency engine stop system Fitted ―

Reversing steering compensator Fitted ―

Air conditioner Option

Emergency steering Fitted Option

Steering pump warning lamp Fitted ―

Over-unwinding prevention Option ―

Outrigger control box (Both sides of carrier) Option ―

Engine model MITSUBISHI 6M60-TLA3B

Tires 29.5 × 25 - 22PR, 29.5 × 25 - 28PR

WA04-2091E

Foreword

4. Conversion table

Length

millimeter, mm

1 1×10-1 1×10-3 3.93701×10-2 3.28084×10

1×10 1 1×10-2 3.93701×10-1 3.28084×10

centimeter,

meter, m inch, in, ” foot, ft, ’ mile, mi

-3

-2

1 1.60934

6.21373×10-1 1

1×103 1×102 1 3.93701×10 3.28084

2.54×10 2.54 2.54×10-2 1 8.33333×10

3.048×102 3.048×10 3.048×10

-1

1.2×10 1

-2

Area

square millimeter, mm2 square centimeter, cm

1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5

1×10

1 1×10-4 1.55×10-1 1.07639×10-3

1×104 1 1.55×103 1.07639×10

square meter, m2square inch, in2 square foot, ft

kilometer,

6.4516×102 6.4516 6.4516×10-4 1 6.94444×10-3

9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1

Volume

cubic centimeter,

, cc

1 1×10-6 6.10237×10-23.53147×10

1×106 1 6.10237×1043.53147×10 4.329×10-3 1 1.63871×10

1.63871×10 1.63871×10

2.83168×104 2.83168×10

cubic meter,

cubic inch, in

-5

-2

1 5.78704×10

1.728×103 1

cubic foot, ft

-5

-4

gallon, gal cubic inch, in3 liter, lit, L

1 2.31×102 3.78541

2.64172×10-16.10237×10 1

Mass

gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t

1 1×10-3 3.5274×10-2 2.20462×10-3 1×10-6 1.10231×10-6

1×103 1 3.5274×10 2.20462 1×10-3 1.10231×10-3

2.83495×10 2.8349×10-2 1 6.25×10-2 2.83495×10-5 3.12494×10-5

4.53592×102 4.53592×10-1 1.6×10 1 4.53592×10-4 5×10-4

1×106 1×103 3.5274×104 2.20462×103 1 1.10231

9.07185×105 9.07185×102 3.2×104 2×103 9.07185×10-1 1

-2

Pressure

Pa kPa MPa kgf/cm2 lbf/in2, psi

1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4

1×103 1 1×10-3 1.01972×10-2 1.45038×10-1

1×106 1×103 1 1.01972×10 1.45038×102

9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10

6.89476×103 6.89476 6.89476×10-3 7.03072×10-2 1

WA04-2091E

Foreword

Work, energy

N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf

1 1×10-2 1.01972×10-1 1.01972×10-3 7.37562×10-3 8.85074×10-2

1×102 1 1.01972×10 1.01972×10-1 7.37562×10-1 8.85074

9.80665 9.80665×10-2 1 1×10-2 7.23301×10-2 8.67961×10-1

9.80665×102 9.80665 1×102 1 7.23301 8.67961×10

1.355818×102 1.355818 1.38255×10 1.38255×10-1 1 1.2×10

1.12985×10 1.12985×10-1 1.152513 1.15213×10-2 8.33333×10-2 1

Centigrade-Fahrenheit

°F °C °F °C °F °C °F °C °F °C °F °C

-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11

-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67

inch-pound,

in-lbf

-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22

-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78

-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33

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

Force

N kgf lbf

1 1.01972×10-1 2.24809×10-1

9.80665 1 2.20462

4.44822 4.53592×10-1 1

WA04-2091E

GROUP INDEX

Hydraulic Power Generating System

Outrigger System

Swing System

Boom Elevating System

Winch System

Boom Telescoping System

Safety System

Cab

Control System

Steering System

Brake System

Suspension System

Data, Adjustment and Checks

System Diagrams

WA04-2091E

5. Contents

Chapter

General Cautions Refer to separate manual SA01-01-2E

Foreword

Section

General

Hydraulic Power Generating System

Spec. No.

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

2M2D

(General Export)

Hydraulic Power Generating System B-1

Hydraulic Pump (Double Variable Displacement Pump)

Hydraulic Pump (Double Gear Pump)

Hydraulic Pump (Gear Pump, Emergency Steering)

Hydraulic Valve (Emergency Steering) B-5

Flow Control Valve B-6

Pressure Reducing Valve (Pilot Pressure) B-7

Solenoid Control Valve (Outrigger) B-8

Rotary Joint B-9

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Sequence Valve (Pilot Pressure) B-11

B-2

B-3

B-4

B-10

Solenoid Valve (Pilot Pressure) B-12

Solenoid Control Valve (Jib Set) B-13

Pilot Check Valve (Jib Set) B-14

Solenoid Valve (Oil Cooler) B-15

Hydraulic Motor (Oil Cooler) B-16

WA04-2091E

Chapter

Foreword

Spec. No.

Section

Hydraulic Power Generating System

Jib Lock pin B-17

Jib Offset Cylinder B-18

Check valve (Gauge Isolator) B-19

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

2M2D

(General Export)

Outrigger System

Outrigger System C-1

Jack Cylinder C-2

Pilot Check Valve (Jack Cylinder Retracting Prevention)

Extension Cylinder C-4

Solenoid Valve (Slide/Jack)

Check Valve (Outrigger Extending Prevention)

Outrigger Operation Box C-9

(UCHIDA) C-5

(TOKIMEC) C-6

(NACHI) C-7

C-3

C-8

Swing System

Swing System D-1

Swing Assembly D-2

Hydraulic Pilot Control Valve (Swing) D-3

Hydraulic Motor (Swing) D-4

WA04-2091E

Chapter

Foreword

Spec. No.

Section

Swing Speed Reducer D-5

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

2M2D

(General Export)

Boom Elevating System

Elevating System E-1

Elevating Cylinder E-2

Counterbalance Valve (Elevating) E-3

Winch system

Winch System F-1

Winch F-2

Hydraulic Motor (Winch) F-3

Counterbalance Valve (Winch) F-4

Hydraulic Valve (Winch Brake Release) F-5

Boom Telescoping system

Telescoping System G-1

Boom (Five-Section Boom) G-2

Jib G-3

Telescoping Cylinder G-4

Counterbalance Valve (Telescoping) G-5

Hose Reel G-6

Hydraulic Valve G-7

WA04-2091E

Chapter

Section

Foreword

GR-700E-1-00211

2M2D

(Europe)

Spec. No.

GR-700E-1-00212

2M2D

(General Export)

Safety System

Safety System H-1

Overload prevention Device (AML) Refer to separate manual W301-0215E

Boom Length and Angle Detector H-2

Outrigger Extension Length Detector H-3

Solenoid Valve (Auto Stop) H-4

Cab

Crane Cab Glass K-1

Air Conditioner (Option) K-2

Hydraulic Motor (Air conditioner, Option)

Solenoid Valve (Air conditioner, Option) (--#546165)

Solenoid Valve (Air conditioner, Option) (#546166--)

K-3

K-4

K-5

Control System

Control System L-1

Remote Control Valve (Lever) L-2

Remote Control Valve (Pedal) L-3

Shuttle Valve (Lever, Pedal) L-4

Solenoid Valve (Boom Telescoping/Aux. Hoist)

Solenoid Control Relief Valve (Elevating Slow Stop)

Solenoid Valve (Air) L-7

L-5

L-6

WA04-2091E

Chapter

Section

Foreword

GR-700E-1-00211

2M2D

(Europe)

Spec. No.

GR-700E-1-00212

2M2D

(General Export)

Electrical System

Multiplex Data Transmitter (MDT) Refer to separate manual W303-0257E

Driving Power Transmission System

Torque Converter and Transmission Refer to separate manual W561-0101E

Driving Axle Refer to separate manual W563-0053E

Steering System

Steering System S-1

Priority Valve S-2

Orbitrol S-3

Steering Cylinder S-4

Solenoid Valve (Steering Mode) S-5

Pilot Check Valve (Rear Steering Cylinder Lock)

Brake System

Brake System T-1

Brake (Service Brake) T-2

Brake Valve T-3

Booster (Brake) T-4

Air Dryer T-5

Brake (Parking Brake) T-6

Brake Chamber T-7

Solenoid Valve (Air) T-8

S-6

WA04-2091E

Chapter

Section

Foreword

GR-700E-1-00211

2M2D

(Europe)

Spec. No.

GR-700E-1-00212

2M2D

(General Export)

Suspension System

Suspension System U-1

Suspension Lock Cylinder U-2

Pilot Check Valve (Suspension Lock Cylinder)

Solenoid Valve (Suspension Lock Check Release)

Data, Adjustment and Checks

Hydraulic Pressure Setting Table Y-1

Air Pressure Setting Table Y-2

Air Bleeding Procedure Y-3

Electric Switch Adjustment Y-4

U-3

U-4

Adjustment and Checks Y-5

Check (Crane Operation) Y-6

Check (Driving Operation) Y-7

Oils and Grease Table Y-8

Mass Table Y-9

Specifications Y-10

Boom Connecting Pin and Thread Size Table

Y-11

WA04-2091E

Chapter

Foreword

Spec. No.

Hydraulic Circuit Z-1

Torque Converter Circuit Z-2

Brake Circuit (Pneumatic Circuit) Z-3

Electric Circuit (AML, Crane) Z-4

Electric Circuit (MDT, Carrier/Upper) Z-5

Section

System Diagrams

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

2M2D

(General Export)

Electric Circuit (MDT, Carrier/Lower) Z-6

Location of Installation

Location of Hydraulic Parts (Upper) Z-7

Location of Hydraulic Parts (Lower) Z-8

Location of Air Parts Z-9

Location of Electrical Parts (Inside Cab) Z-10

Location of Electrical Parts (Swing Table, Boom)

Location of Electrical Parts (Relay Assembly/Upper)

Location of Electric Parts (AML) Z-13

Location of Electric Parts (Lower) Z-14

Location of Electric Parts (Box Assembly/Lower)

Z-11

Z-12

Z-15

Harness Diagrams

Harness (Connector No. Table) Z-16

Harness (Inside Cab) Z-17

Harness (Swing Table, Left) Z-18

WA04-2091E

Chapter

Foreword

Spec. No.

Harness (Swing Table, Right) Z-19

Harness (Boom) Z-20

Harness (AML, Upper) Z-21

Harness (Overwind) Z-22

Harness (Lower, Main) Z-23

Harness (Lower, Sub) Z-24

Section

GR-700E-1-00211

2M2D

(Europe)

GR-700E-1-00212

2M2D

(General Export)

Harness (Lower, Electronic Governor) Z-25

Outdoor Air (Minus 25°C or less) System Z-26

Anemometer System Z-27

WA04-2091E

Hydraulic Power Generating System

Contents

B-1 Hydraulic Power Generating System

..................................................1

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

B-2 Hydraulic Pump (Double Variable

Displacement Pump) ............... 5

1. Structure .................................................... 5

2. Theory of operating of regulator section .. 11

3. Air bleeding procedure............................. 13

B-6 Flow Control Valve.........................20

1. Structure .................................................. 20

B-7 Pressure Reducing Valve (Pilot

Pressure) ................................21

1. Structure .................................................. 21

B-8 Solenoid Control Valve

(Outrigger)..............................22

1. Structure .................................................. 22

B-3 Hydraulic Pump (Double Gear Pump)

................................................14

1. Structure .................................................. 14

2. Air bleeding procedure............................. 16

B-4 Hydraulic Pump (Gear Pump,

Emergency Steering)............. 17

1. Structure .................................................. 17

B-5 Hydraulic Valve (Emergency

Steering) (Option).................. 18

1. Structure .................................................. 18

B-9 Rotary Joint ....................................27

1. Structure .................................................. 27

2. Potentiometer .......................................... 34

2.1 Adjustment ................................................34

2.2 Soldering...................................................34

B-10 Hydraulic Pilot Control Valve

(Elevating, Telescoping, Winch)

.................................................35

1. Structure .................................................. 35

B-11 Sequence Valve (Pilot Pressure) ..47

1. Structure .................................................. 47

B-12 Solenoid Valve (Pilot Pressure) ....50

1. Structure .................................................. 50

B-13 Solenoid Control Valve (Jib Set)... 52

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

B-14 Pilot Check Valve (Jib Set) ............ 58

1. Structure .................................................. 58

B-15 Solenoid Valve (Oil Cooler)...........59

1. Structure .................................................. 59

B-16 Hydraulic Motor (Oil Cooler) ......... 61

1. Structure .................................................. 61

2. Air bleeding procedure............................. 61

B-17 Jib Lock Pin.................................... 62

1. Structure .................................................. 62

B-18 Jib Offset Cylinder.........................63

1. Structure .................................................. 63

B-19 Check Valve (Gauge lsolator) .......64

1. Structure .................................................. 64

B-1 B-1

Hydraulic Power Generating System

B-1 Hydraulic Power Generating System

1. General

Hydraulic Circuit for Carrier (for Europe)

[NOTICE]

Emergency steering and steering pump low pressure warning are standard equipment for Europe.

1. The hydraulic power for this crane is generated by

the double variable displacement pump, double

gear pump, and gear pump for the emergency

steering circuit.

2. The double variable displacement pump supplies

oil to the circuits of elevating, telescoping, main

winch, and auxiliary winch. This double variable

displacement pump is driven only when the PTO

switch is turned on.

3. The double gear pump supplies oil to the circuits

of outrigger,steering, swing, pilot pressure, jibset,

air conditioner (option), and oil cooler.

4. The gear pump and the hydraulic valve in the

emergency steering circuit are standard. They are

provided for the case when the double gear pump

malfunctions.

WB02-0280E

B-1 B-1

Hydraulic Power Generating System

Hydraulic Circuit for Carrier (for General Export)

[NOTICE]

If the machine is not equipped with the optional emergency steering, two points "A" are directly joined and three portions "*1" are plugged.

1. The hydraulic power for this crane is generated by

the double variable displacement pump, double

gear pump, and optional gear pump for the

emergency steering circuit.

2. The double variable displacement pump supplies

oil to the circuits of elevating, telescoping, main

winch, and auxiliary winch. This double variable

displacement pump is driven only when the PTO

switch is turned on.

3. The double gear pump supplies oil to the circuits

of outrigger,steering, swing, pilot pressure, jibset,

optional air conditioner, and oil cooler.

4. The gear pump and the hydraulic valve in the

emergency steering circuit are optional. They

are provided for the case when the double gear

pump malfunctions.

WB02-0280E

B-1 B-1

Hydraulic Power Generating System

Hydraulic Circuit for Crane

Applicable serial No.

：545520 ~

△

[NOTICE]

If the machine is not equipped with the optional air conditioner, two points "B" are directly joined.

Circuits for elevating, telescoping, main and auxiliary winches

1. The hydraulic oil provided from the pumps is

controlled (onloaded/unloaded) by the solenoid

valve for automatic stop. 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). When the PTO switch is turned

on, the solenoid valve for automatic stop is shifted,

making the condition of this circuit onloaded.

2. The pressurized oil delivered through the P1 port

of the rotary joint is supplied to the circuits for the

main winch and the auxiliary winch.

The pressurized oil delivered through the P2 port

is provided to the circuits for elevating and

telescoping. This oil, however, is supplied to the

circuits for the main winch and the auxiliary winch

while neither elevating nor telescoping operation

is done.

WB02-0280E

B-1. B-1.

Hydraulic Power Generating System

Circuit for pilot pressure, jibset, air conditioner(option), and oil cooler

1. The pressurized oil delivered through the P6 port

of the rotary joint is supplied to these circuits.

Pressurized oil reduced by the sequence valve is

supplied to the circuit for the pilot pressure.

2. The pilot pressure is supplied to the swing brake

release circuit, main winch brake release circuit,

auxiliary winch brake release circuit, and pilot

circuits for crane operations.

3. The pressurized oil delivered through the

sequence valve is supplied to the circuits for the

jibset, air conditioner(option), and oil cooler.

WB02-0280E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

B-2 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.

1. Structure

This pump is a variable displacement piston pump. The angle of the swash plate is controlled by the regulator.

W101-0272E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Main body

Apply adhesive (No. 1305N of Threebond make)

532732789535808

953

886

Apply (Sealub L101) to the oil seal surface circumferential

111.Drive shaft (F)

113.Drive shaft (R)

114.Spline coupling

123.Roller bearing

124.Needle bearing

127.Bearing spacer

141.Cylinder block

151.Piston

152.Shoe

153.Set plate

156.Spherical bush

157.Cylinder spring

211.Shoe plate

717

406

774

111

824

261

127

123

710

251

490 312 466

212 211 153 156 157 314

Valve plate for counter clockwise rotation

212.Swash plate

214.Tilting bush

251.Support

261.Seal cover (F)

262.Seal cover (R)

271.Pump casing

312.Valve block

313.Valve plate (R)

314.Valve plate (L)

401.Hex. socket head bolt

406.Hex. socket head bolt

466.Plug

467.Plug

Thread size and tightening torque

Sign / Port Thread size

Tightening torque

N-m ft-lbf

401 M16 240 177

406 M6 12 8.8

466 G1/4 36 26.5

467 G1/2 110 81

490 NPTF1/16 8.8 6.5

531

792

490.Plug

531.Tilting pin

532.Servo piston

534.Stopper (L)

535.Stopper (S)

548.Feed back pin

702.O-ring

710.O-ring

717.O-ring

719.O-ring

724.O-ring

725.O-ring

728.O-ring

901724534702214548

954 719 124 151 152 113 406 710

725

114 885

313 141

467

271 401 262

728

Valve plate for clockwise rotation

732.O-ring

774.Oil seal

789.Backup ring

792.Backup ring

808.Nut

824.Snap ring

885.Valve plate pin

886.Spring pin

901.Eye bolt

953.Hex. socket set screw

954.Set screw

981.Name plate

983.Pin

Sign / Port Thread size

Tightening torque

N-m ft-lbf

531,532 M20x1.5 240 177

808 M16 130 96

IW101-0270E01

W101-0272E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Enlarged view of the main body (the left side)

Apply (Shealub L101) to the oil seal surface circumferential

532732789535808

953

886

717

406

774

Apply adhesive (No. 1305N of Threebond make)

792

531

724534702214548

111

824

261

127

123

710

251

490 212 211 153 156 157

Valve plate for counter clockwise rotation

314

312

IW101-0270E02

W101-0272E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Enlarged view of the main body (the right side)

901

954 719 124 151 152 113 406 710

466

114 885

313

141

725

Valve plate for clockwise rotation

467 728

W101-0272E

271 401 262

IW101-0270E03

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Regulator

962

412

924 627 701801

624 651

652 621 496 887

629402625728

724

W101-0272E

IW101-012004

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

413 496 897 601

755

614

708

402.Hex. socket head bolt

412.Hex. socket head bolt

413.Hex. socket head bolt

496.Plug

601.Casing

611.Feedback lever

Thread size and tightening torque

Sign / Port Thread size

402 M6 12 8.8

412,413 M8 29 24.1

496 NPTF1/16 8.8 6.5

614 G1/4 36 26.5

801 M8 17 12.5

614.Center plug

621.Compensator piston

624.Spring seat

625.Compensator spring

627.Spring seat

629.Spring case

View Z

651.Sleeve

652.Spool

701.O-ring

708.O-ring

724.O-ring

728.O-ring

Tightening torque

N-m ft-lbf

611

IW101-012006

755.O-ring

801.Nut

887.Pin

897.Pin

924.Hex. socket set screw

962.Steel ball

W101-0272E

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