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

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

02

Rough Terrain Crane

GR-700EX-

Model

GR-700EXL-

Applicable Serial No. 545870 --

1

1

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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

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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.

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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.

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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.

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WA01-0041E

Foreword

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.

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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

2

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

2

1×10

1×10

6

1 1×10-4 1.55×10-1 1.07639×10-3

1×104 1 1.55×103 1.07639×10

2

square meter, m2square inch, in2 square foot, ft

kilometer,

2

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,

cm

3

, 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,

3

m

cubic inch, in

-5

-2

1 5.78704×10

1.728×103 1

3

cubic foot, ft

3

-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

3

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

4

WA04-2091E

GROUP INDEX

A

Hydraulic Power Generating System

B

Outrigger System

C

Swing System

D

Boom Elevating System

E

Winch System

F

Boom Telescoping System

G

Safety System

H

I

J

Cab

K

Control System

L

M

N

O

P

Q

R

Steering System

S

Brake System

T

Suspension System

U

V

W

X

Data, Adjustment and Checks

Y

System Diagrams

Z

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WA04-2091E

5. Contents

Chapter

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

A

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

B

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

6

WA04-2091E

Chapter

B

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

C

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

D

Hydraulic Pilot Control Valve (Swing) D-3

Hydraulic Motor (Swing) D-4

7

WA04-2091E

Chapter

D

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

E

Counterbalance Valve (Elevating) E-3

Winch system

Winch System F-1

Winch F-2

F

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

G

Telescoping Cylinder G-4

Counterbalance Valve (Telescoping) G-5

Hose Reel G-6

Hydraulic Valve G-7

8

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

H

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)

K

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

L

Solenoid Valve
(Boom Telescoping/Aux. Hoist)

Solenoid Control Relief Valve
(Elevating Slow Stop)

Solenoid Valve (Air) L-7

L-5

L-6

9

WA04-2091E

Chapter

Section

Foreword

GR-700E-1-00211

2M2D

(Europe)

Spec. No.

GR-700E-1-00212

2M2D

(General Export)

Electrical System

N

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

Driving Power Transmission System

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

R

Driving Axle Refer to separate manual W563-0053E

Steering System

Steering System S-1

Priority Valve S-2

Orbitrol S-3

S

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

T

Air Dryer T-5

Brake (Parking Brake) T-6

Brake Chamber T-7

Solenoid Valve (Air) T-8

S-6

10

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

U

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

Y

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

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

Z

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

12

WA04-2091E

Chapter

Z

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

13

WA04-2091E

B

B

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

i

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

ii

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.

1

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.

2

WB02-0280E

B-1 B-1

Hydraulic Power Generating System

Hydraulic Circuit for Crane

Applicable serial No.

：545520 ~

1

△

[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.

3

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.

4

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.

5

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

6

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

7

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

8

467
728

W101-0272E

271 401 262

IW101-0270E03

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Regulator

Z

962

412

924 627 701801

624 651

652 621 496 887

629402625728

724

9

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

10

W101-0272E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

2. Theory of operating of regulator section

11

W101-0272E

B-2 B-2

Hydraulic Pump (Double Variable Displacement Pump)

Hydraulic oil (P) from the pump flows to areas A

and B shown in Figs. 1 and 2 via the path in the

regulator casing.

The oil also flows to small-diameter end H of the

servo piston.

The oil flowing to area A applies leftward pressure

to the compensation piston.

When the pump pressure is below a certain level,

the spool does not move because the leftward

force of the compensation piston on the spool is

less than the pressure of the compensation spring.

In this situation, the seating area C closes and the

seating area E opens. Therefore the oil at the

servo piston’s large-diameter end G flows out

12

W101-0272E

B-2. B-2.

Hydraulic Pump (Double Variable Displacement Pump)

from the port D to the drain line via the spool.

Then the servo piston’s large-diameter end G is

pushed by the pressure exerted on the

small-diameter end H, to stay in the maximum

discharge rate position.

When the pump pressure exceeds the 1st turning

point (P1 in Fig. 3), the leftward force of the

compensation piston on the spool overcomes the

pressure of the compensation spring and the

spool is moved to the left. As a result, seating

area E closes, and seating area C opens. The

hydraulic oil in area B flows to the servo piston’s

large-diameter end G via the port D pushing the

servo piston to the right decreasing the discharge

flow rate. The rightward movement of the servo

piston is transferred to the feedback lever via the

fulcrum J . The feedback lever revolves around

the pin on the top of the fulcrum plug. A pin (A) is

inserted in both the end of the feedback lever and

the hole of the sleeve. When the feedback lever

revolves, the sleeve moves to the left, and seating

areas C and E open where the Hydraulic powers

of the small and large-diameter ends of the servo

piston are balanced. When the pump pressure

decreases, the compensation spring pushes back

the spool, causing seating area C to close and

seating area E to open. The hydraulic oil at the

servo piston’s large-diameter end G is discharged

into the drain line, causing the servo piston to

move the left, increasing the discharge rate. The

movement of the servo piston is transferred to the

sleeve via the feedback lever, and seating areas

C and E open or close so that the servo piston,

under the pressures on both ends, follows the

movement of the spool.

As explained above, the discharge rate of the

pump is controlled by the balance of pressure on

the spool, the pressure setting compensation

spring, and the balance of pressure on the large

and small-diameter ends of the servo piston. The

maximum and minimum discharge rates are set

by adjustment screws 954 and 953, respectively.

The 1st turning point is set by the adjustment

screws. Gradients of the pressure discharge lines

are determined by the spring constant.

3. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

366-533-50001

366-540-20000

0

△

0

△

13

W101-0272E

B-3 B-3

Hydraulic Pump (Double Gear Pump)

B-3 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.

1. Structure

123

IW101-013001

1.Gear pump assy 2.Connecting section 3.Gear pump assy

14

W101-0131E

B-3 B-3

Hydraulic Pump (Double Gear Pump)

Gear pump assy-1

18 19 17 16 2 8,9 1 7 313

6,10

12

1.Body

2.Bearing box

3.Bearing box

6.Front cover

Connecting section-2

7.Side plate

8.Backup ring

9.Rubber string

10.Hex. socket head bolt

2 1 4

314215

IW101-013002

12.O-ring

13.Drive gear

14.Driven gear

15.Rear cover

3

16.Dowel pin

17.Oil seal

18.Oil seal

19.Retaining ring

IW101-013004

1.Coupling 2.O-ring 3.Dowel pin 4.Hex. socket head bolt

15

W101-0131E

B-3. B-3.

Hydraulic Pump (Double Gear Pump)

Gear pump assy-3

13 16 2 8,9 1 7 3

6,10

12

1.Body

2.Bearing box

3.Bearing box

6.Front cover

7.Side plate

8.Backup ring

9.Rubber string

10.Hex. socket head bolt

2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

314215

IW101-013003

12.O-ring

13.Drive gear

14.Driven gear

15.Rear cover

16.Dowel pin

0

366-533-00000
366-519-00000
366-531-70000

16

W101-0131E

△
△
△

0

0

B-4. B-4.

Hydraulic Power Generating System

B-4 Hydraulic Pump (Gear Pump, Emergency Steering)

[NOTICE]

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

1. Structure

25 3 21

AB

C-C

23 13 21 1 4 22 32 31

12 5 11 22 2

C

D

C

IW101-014001

1.Front cover

2.Body

3.Drive gear

4.Driven gear

Thread size and tightening torque

Sign / Port Thread size

A, B G3/4 62 - 75 46 - 56

D G1/4 24 - 29 17 - 22

31 M10 48 - 51 35 - 38

5.Side plate

11.Gasket

12.Gasket

13.Oil seal

21.Bush (front cover)

22.Bush (body)

23.Retaining ring

25.Steel ball

Tightening torque

N-m ft-lbf

31.Hexagon socket head bolt

32.Plain washer

366-535-20000

△

2

17

W101-0142E

B-5 B-5

Hydraulic Valve (Emergency Steering) (Option)

B-5 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.

1. Structure

T

C

P2

P1

B

A

IW123-016001

P3

Y

P1

P3

P2

X X

T

Thread size and tightening torque

Sign / Port Thread size

P1, P3 G1 196 145

P2, T G3/4 167 123

Tightening torque

N-m ft-lbf

18

W123-0261E

Y

IW123-0260E01

B-5. B-5.

Hydraulic Valve (Emergency Steering) (Option)

Cross section along the line X-X, Y-Y

13 5 9 6 2 1

14

A

12

4

710

1.Body

2.Check valve

3.Spool

4.Check valve

B

Y-Y

5.Cover

6.Spring

7.Spring

8.Spring

11

3

8

9.O-ring

10.Plug

11.Plug

12.Plug

11

C

X-X

IW123-0260E02

13.Spring washer

14.Hexagon socket head bolt

0

366-406-60000

19

W123-0261E

△

B-6. B-6.

Flow Control Valve

B-6 Flow Control Valve

[NOTICE]

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

1. Structure

PB

7

4

T

1

PA

IW114-0130E02

PA

T

PB

IW114-0130E01

1.Valve body

2.Spool

3.Spring

4.Plug

Thread size and tightening torque

Sign / Port Thread size

5.Plug

6.O-ring

Tightening torque

N-m ft-lbf

2

3

5

6

IW114-0130E03

7.Relief valve assy

PA G3/4 167 123

T, PB G1/2 98 72

0

366-104-20000

20

W114-0132E

△

B-7. B-7.

Pressure Reducing Valve (Pilot Pressure)

B-7 Pressure Reducing Valve (Pilot Pressure)

[NOTICE]

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

1. Structure

P

A1

DR A2

(*1)

IW120-0120E01

P

(*1) : Apply the thread locking agent (LOCTITE 270 or the equivalent)

A1

A2DR

12345678910

IW120-0120E02

1.Body

2.Spool

3.O-ring

4.Sleeve

5.Filter

6.O-ring

Thread size and tightening torque

Sign / Port Thread size

P G1/2 98 72

A1 G3/8 49 36

A2, Dr G1/4 29.4 22

7.Spacer

8.O-ring

9.Spring

Tightening torque

N-m ft-lbf

21

W120-0121E

10.Plug

366-054-90000

△

1

r

B-8 B-8

Solenoid Control Valve (Outrigger)

B-8 Solenoid Control Valve (Outrigger)

[NOTICE]

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

1. Structure

AB

21

22

Sol. a1

R1

T

Connecto

(+): Red

IW112-015001

A

B

L

+ -

IW121-0542E01

(-): Blue

TP

L

L

P

G

Sol. b1

Sol. a1

R1

23

G

10 1 15

1.Body assy

10.P cover assy

15.T cover assy

21.Stud bolt

Thread size and tightening torque

Sign / Port Thread size

P, T, L

A, B G3/4 167 123

G G1/4 29.4 22

Sol. b1

IW112-015002

22.Nut

23.Spring washer

Tightening torque

N-m ft-lbf

G1 196 145

22

W112-0152E

B-8 B-8

Solenoid Control Valve (Outrigger)

P cover assy

(illustrated as 10 on page 21)

1.Cover

2.O-ring

3.O-ring

4.Shim

5.Plug

6.Plug assy

7.Relief valve assy

5

7

R1

2

P

3

4

2

1

G

6

IW112-015003

23

W112-0152E

B-8 B-8

Solenoid Control Valve (Outrigger)

Relief valve (illustrated as 7 on page 23)

P cover assy (2/2)

13 11 2 1 8 3 4 10 12 6 9 1475

P

T

1.Body

2.Plunger

3.Body

4.Poppet

5.Adjuster screw

6.Nut

7.Spring

8.Spring

9.Shim

10.O-ring

11.O-r ing

12.O-ring

IW112-011004

13.Backup ring

14.Cap

24

W112-0152E

B-8 B-8

Solenoid Control Valve (Outrigger)

Body assy (1/2)

(illustrated as 1 on page 21)

1.Body

2.Spool

3.Plug

4.Plunger

5.Spring

6.O-ring

7.O-ring

8.O-ring

9.Shim

10.Pilot cover assy

10

Sol. a1

7

9

8

6

3

5

A

1

2

7

B

4

Sol. b1

IW112-015004

25

W112-0152E

5

B-8. B-8.

Solenoid Control Valve (Outrigger)

Pilot cover assy (illustrated as 10 on page 21)

Body assy (2/2)

1.Cover

2.Plug

3.Spool

4.Spring

5.O-ring

6.Spring seat

7.Hexagon socket head bolt

8.Plug

9.Solenoid (DC24V)

10.Orifice

11.O-r ing

12.O-ring

13.Hexagon socket head bolt

14.Hexagon socket head bolt

15.Spring

8

14 6 10 15 11 13 12

1

8

7

9 5 3 4 2

IW112-01500

0

366-460-20000

26

W112-0152E

△

B-9 B-9

Rotary Joint

B-9 Rotary Joint

[NOTICE]

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

1. Structure

[NOTICE]

The parts marked with (*1) - (*10) require special attention for disassembling and assembling. The required
attention is described in the "Attention" on page 37.

27

W181-0440E

B-9 B-9

Rotary Joint

Upper (view A)

Lower (view B)

28

W181-0440E

B-9 B-9

Rotary Joint

1.Slip ring assy

2.Plain bearing

3.Packing

4.Ring seal

5.Body

6.Core

7.Shaft

8.Core

9.Plain bearing

Thread size and tightening torque

17 *1 (to secure the plate [18]) M8 11.8 – 13.7 9 - 10

21 *1 (to secure the slip ring ass’y [1]) M6 4.4 – 5.4 3.5 - 4

*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.

10.Support

11.Grease nipple

12.Plain bearing

13.Ring seal

14.Packing

15.Ring seal

16.Bolt

17.Flange bolt

18.Plate

Sign / port

16 *1 M12 74 - 82 55 - 61

25 *1 M8 23.5 – 27.5 17 - 20

29 - 16 - 24 12 - 17

19.Plug

20.Support

21.Flange bolt

22.Clamp

23.Nut

24.Plate

25.Hexagon socket head bolt

26.Ring seal

27.Pipe

Thread

size

Tightening torque

N-m ft-lbf

28.Fitting

29.Flare nut

30.Elbow fitting

31.Support

32.Grease nipple

33.O-ring

Hydraulic section

P1

P1’ Gauge

P2 Boom elevating, Boom telescoping

P2’ Gauge

P3 Swing, Steering

P4 Steering (left)

P5 Steering (right)

P6 Option

T1 Tank

T2 Tank

DR Drain

Sign / port Thread size

Winch

Outriggers pilot

Upper
Lower
Upper - - ­Lower G1/4 29.4 22
Upper G1/4 29.4 22
Lower - - ­Upper
Lower
Upper G1/4 29.4 22
Lower - - ­Upper G3/4 167 123
Lower G1 196 145
Upper
Lower
Upper
Lower
Upper
Lower
Upper
Lower
Upper G3/4 167 123
Lower - - ­Upper
Lower

G1 196 145

G1 196 145

G1/2 98 72

G1/2 98 72

G1/2 98 72

- - -

G1/2 98 72

Tightening torque

N-m ft-lbf

29

W181-0440E

B-9 B-9

Rotary Joint

Pneumatic section

Tightening torque

N-m ft-lbf

A1 Air supply

A2 Service brake (primary)

A3 Service brake (secondary)

L.L.C. section

Sign / port Thread size

W1 Heater (IN)

W2 Heater (OUT)

Sign / port Thread size

Upper Rc3/8 49 - 69 36 - 51
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
Lower G1/4 29.4 22

Tightening torque

N-m ft-lbf
Upper
Lower
Upper
Lower

Rc3/8 49 - 69 36 - 51

Rc3/8 49 - 69 36 - 51

Attention

(*1): Face the "

(*2): Apply water-proof sealant equivalent to THREE

BOND 4101. Do not apply grease.

(*3): Apply thread locking agent equivalent to

THREE BOND 1401 to lock the threads.

(*4): Apply grease (EP2) when attaching.

(*5): Do not use an organic solvent.

(*6): Do not remove the shaft (8) from the core (7). It

is press-fit within the core.

(*7): To prevent rust, apply grease (EP2) when

assembling.

(*8): Tapped hole (2 places) for slinging. The

applicable thread size is M10.

･" mark toward FRONT.

(*9): The "

figure.

(*10): Do not use an organic solvent. The grease

grooves must be directed as shown below.

･" marks must be directed as shown in the

30

W181-0440E

B-9 B-9

Rotary Joint

Slip ring Assy

21 28

22 20 31

31

C C

15

B

23

D

24

A

A

7

3

E

B

IW181-0260E03

27 26

2

D

19
30

25

E

T1

13

5

11

12

F

F

B-B

IW181-0260E04

10

4

12

8

29

6

3

9

7

16,17

18

1

P

A-A

P

IW181-0260E05

31

W181-0440E

IW181-0290E03

B-9 B-9

Rotary Joint

36 14

E-E

C-C

IW181-0260E07

IW181-0260E09

25

24

23

1.Shaft

2.Ring set plate

3.Bearing

4.Ring

5.Ring

6.Ring set plate

7.U nut

8.Support

9.Stud bolt

D-D

IW181-0260E08

10.BH+CB

11.Spacer

12.Spacer

13.BH+CB

14.Support

15.Base

16.Dry lock nut

17.Coned disc spring

18.Guide

32,33

F-F

IW181-0260E10

19.O-ring

20.Potentiometer

21.Cover

22.Packing

23.Lever

24.Pin

25.Guide

26.Air breather

27.Hose joint

28.Hose band

29.Hexagon socket set screw

30.Machine screw

31.Bolt

32.Bolt

33.Spring washer

36.Hexagon socket head bolt

Thread size and tightening torque

Sign / port Thread size

16*1, T1*1 M6 4.9 3.6

31, 32, 36 M4 1.5 1.1

30 M3 0.63 0.5

*1：Apply LOCTITE 496 (strong quick-drying glue) to threaded sections.

Tightening torque

N-m ft-lbf

32

W181-0440E

B-9 B-9

Rotary Joint

Wiring diagram

LOWER (Slip ring) UPPER (Brush holder)

G

3
2

2 1

34

12

78

56

11 12

910

14253

6

123

21

3

241

3

Connector

626 1 26

3223

627 12 27

628 11 28

629 10 29
630 9 30
20 8 20
21 7 21
22 6 22
4 5 24
615 4 15
16 3 16
618 2 18
19 1 19

12 6 12
13 5 13
614 4 14
8 3 8
9 2 9
10 1 10

907 3 7
911 2 111
5 1 25

17 3 17
6 1 6
2 2 5

1CC 4 3
1DD 3 4
1AA 2 1
1BB 1 2

Y

Y

Y

Y
Y

Y

Y

Y
Y

Y

Y

Y
Y

Y

Y

Y
Y

Y

Y

Y

Y

Y

Y

Y

W

W

W

W

W

W

Ring No.

W

1

3
2

Pot2

1

3
2

Pot1

1

30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13

Y

12
11

Y

10

9
8
7

6
5
4
3
2
1

R

B
B

Y

26 1 626

Y

23 2 3

Y

27 12 627

Y

28 11 628

Y

29 10 629

Y

30 630

Y

20 8

Y

21 7 21

Y

22 6 22

Y

Y

15 4 615

Y

16 3 16

Y

18 2 618

Y

19 1 19

Y

12 6 12

Y

13 5 13

Y

14 4 614

Y

8 3 8

Y

9 2 9

Y

10 1 10

Y

7 3 907

Y

11 2 911

Y

25 1 5

Y

17 1 17

W

6 2 6

W

5 3 2

W

3 4 1 C C

W

4 3 1 D D

W

1 2 1 A A

W

2 1 1 B B

6
5
4

9

20

424 5

36251

1 2

43
87

12 1 1

36251

321

12

132

21
65

10 9

3

4

4

4

：

Connector terminal No.

Mark No.

33

Silver-plating ring

W181-0440E

IW181-0290E04

B-9. B-9.

Rotary Joint

2. Potentiometer

2.1 Adjustment

1. Install the potentiometer as shown in the figure

below. However, tighten the bolt for fixing the lever

lightly. (Do not fix the lever to the potentiometer

shaft because you must turn the potentiometer

shaft using the slotted screwdriver to adjust the

position of the shaft.)

Slotted screwdriver

Hexagon socket head bolt Potentiometer

3. Turn the potentiometer shaft using a slotted

screwdriver so that the resistance between the

upper terminals 1 and 2 is minimum between 1

ohm and 15 ohm. Leave the terminals (6 pieces)

of the potentiometer disconnected.

3

2

1

Terminal 3

Terminal 2

Terminal 1

Potentiometer

Slotted screwdriver

Upper terminals 1, 2 and 3

Bolt (Tighten lightly.)

Lever

IW181-0260E12

2. While keeping the stamp mark on the guide

oriented as shown in the figure below, adjust the

potentiometer as described in the following steps.

(If you adjust the potentiometer with the slip ring

assy installed on the crane, direct the boom

over-left to orient the stamp mark as shown in the

figure below.)

Slip ring assy

4. Remove the hexagon socket head bolts (4 pieces),

2.2 Soldering

1. After finishing the potentiometer adjustment,

Lower terminals 1, 2 and 3

IW181-0260E14

take out the potentiometer and fully tighten the

bolt for fixing the lever. Then install the

potentiometer and make sure that the resistance

between the upper terminals 1 and 2 is 15 ohm or

less.

remove the hexagon socket head bolts (4 pieces)

and take out the potentiometer. Then solder the

wiring to the terminals (6 pieces).

2. To insulate the terminals (6 pieces) from one

another, coat the terminal section with epoxy

Stamp mark

Guide

IW181-0260E13

34

adhesive (equivalent to 3M DP-420).

W181-0440E

346-305-71000

△

7

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

B-10 Hydraulic Pilot Control Valve (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.

1. Structure

35

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

C1 C2

Vent

Vent

(down) (down) (extending) (lowering)

b1 b2

b3 b4

T2

P2

a3 a4

Telescoping
(retracting)

T1

Aux. winch
(up)

B1 B2 B3 B4

A1 A2 A3 A4

a1 a2

Main winch
(up)

b3,b4

C3

a3,a4

Elevating
(raising)

P1

IW134-0270E02

36

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Thread size and tightening torque

Sign / port Thread size

C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 22

A3,B3,A4,B4 G3/4 167 123

P1,P2,A1,B1,A2,B2 G1 196 145

Tightening torque

N-m ft-lbf

37

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Cross section of whole body

BA

Aux. winch

Main winch

BA

14 13

Telescoping

Elevating

IW134-011012

38

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

1

C

12

・

8

C

Aux. winch

D

D

Main winch

12

・

9

E

2

F

3

Telescoping

E

F

G

4 7 16

A-A

Elevating

IW134-0270E03

G

39

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Aux. winch

Main winch

515 6

1.Winch selector valve

2.Telescoping selector valve

3.Elevating selector valve

4.End cover

5.O-ring

6.O-ring

7.Hex. socket head bolt

8.Main relief valve

B-B

9.Main relief valve

12.Hex. socket head bolt

13.Plug

14.O-ring

Telescoping

Elevating

IW134-011004

15.Plug

16.Eye bol

Thread size and tightening torque

Sign / port Thread size

7 M12 57 - 59 42 - 43

12 M10 44 - 49 32.5 - 36

13 G1/4 24.5 - 29.4 18 - 22

15 - 10 - 12 7 - 9

Tightening torque

N-m ft-lbf

40

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Winch selector valve

6242019 2122 1

25,24,23,13

18 17 15 28 27 26 28 14

Overload relief valve

9 8 12,23,24,25

7

11 10

30

29

16,17

C-C (Aux. winch) , D-D (Main winch)

18 17 15 28 27 26 28 16,175

IW134-0270E04

1

Main relief valve

E-E

41

W134-0271E

IW134-0110E07

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

1.Winch selector valve body

2.Spool (main,aux. winch)

3.--------------------------------

4.Flow control valve

(main winch), (aux. winch)

5.Flow control valve (junction)

6.O-ring

7.Spring seat

Thread size and tightening torque

Sign / port Thread size

Overload relief valve

(Main winch), (Aux. winch)

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

8.Return spring

9.Return spring

10.Spring seat

11.Spool end

12.Pilot cover

13.Pilot cover

14.Orifice

15.Spring (flow control valve)

11*1 - 18 - 20 13 - 14

14*2

30*1 M8 12 - 14 8.5 - 10

16 M33 98 - 118 72 - 87

18 - 98 - 118 72 - 87

21 - 78.5 - 88.3 58 - 65

23 M8 27.5 - 29.4 20 - 22

26 G 3/8

28 -

16.Plug

17.O-ring

18.Spring retainer

(flow control valve)

19.Check valve

20.Spring (check valve)

21.Plug (check valve)

22.O-ring

Tightening torque

N-m ft-lbf

M27×1.5 78 - 88 58 - 65

M6 5 - 6 3.5 - 4.5

39.2 - 49

10 - 12 7 - 9

23.Hex. socket head bolt

24.Plain washer

25.Spring washer

26.Plug

27.O-ring

28.Plug

29.Steel ball

30.Hex. socket set screw

29 - 36

42

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Telescoping selector valve

3029524 3 22 21 23 24 1

Overload relief valve

11 10

27,26,25,13

6 19,20 18 17 28 14 16 15

F-F (Telescoping)

1.Telescoping selector valve

body

2.Spool (telescoping)

3.Flow control valve

(telescoping)

4.Steel ball

5.Hex. socket set screw

6.O-ring

Thread size and tightening torque

Sign / port Thread size

Overload relief valve (Telescoping) M27×1.5 77 - 88 58 - 65

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

7.Spring seat

8.Return spring

9.Return spring

10.Spring seat

11.Spool end

12.Pilot cover

13.Pilot cover

14.Steel ball

5*1 M8 12 - 14 8.5 - 10

11*1 - 18 - 20 13 - 14

15*1 - 18 - 20 13 - 14

17*2 M6 5 - 6 3.5 - 4.5

19 M33 98 - 118 72 - 87

23 - 78.5 - 88.3 58 - 65

25 M8 27.5 - 29.4 20 - 22

28 - 10 - 12 7 - 9

29 G3/4 78.5 – 88.3 58 - 65

15.Plug (shuttle valve)

16.O-ring

17.Orifice

18.Spring (flow control valve)

19.Plug

20.O-ring

21.Check valve

22.Spring (check valve)

8

7 9 12,25,26,27

19,20

IW134-0270E03

23.Plug (check valve)

24.O-ring

25.Hex. socket head bolt

26.Plain washer

27.Spring washer

28.Plug

29.Plug

30.O-ring

Tightening torque

N-m ft-lbf

43

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Elevating selector valve

22,21,20,13

6 16,17 15 14 23

19185 4 18 19 12

G-G (Elevating)

Overload relief valve

11 10

8

7 9 12,20,21,22

3

16,17

IW134-0110E09

1.Elevating selector valve body

2.Spool (elevating)

3.Flow control valve (elevating)

4.Steel ball

5.Hex. socket set screw

6.O-ring

Thread size and tightening torque

Sign / port Thread size

Overload relief valve

（Elevating）

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

7.Spring seat

8.Return spring

9.Return spring

10.Spring seat

11.Spool end

12.Pilot cover

5*1 M8 12 - 14 8.5 - 10

11*1 - 18 - 20 13 - 14

14*2 M6 5 - 6 3.5 - 4.5

16 M33 98 - 118 72 - 87

18 G3/4 78.5 - 88.3 58 - 65

20 M8 27.5 - 29.4 20 - 22

23 - 10 - 12 7 - 9

13.Pilot cover

14.Orifice

15.Spring (flow control valve)

16.Plug

17.O-ring

18.Plug

Tightening torque

N-m ft-lbf

M27×1.5 78 - 88 58 - 65

19.O-ring

20.Hex. socket head bolt

21.Plain washer

22.Spring washer

23.Plug

44

W134-0271E

B-10 B-10

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Main relief valve
(Main winch, Aux. winch), (Elevating, Telescoping)

1.Socket

2.Valve

3.Spring

4.O-ring

5.Backup ring

20 19

6.O-ring

7.Packing

8.Body

9.O-ring

10.Cap nut

1413121110987632154

15

16

17

18

P

T

11.Adjust screw

12.O-ring

13.Nut

14.Body

15.Spring

IW134-011010

16.Valve

17.Valve seat

18.O-ring

19.Seal lead

20.Tie up wire

Thread size and tightening torque

Sign / port Thread size

1 - 28.4 - 30.4 21 - 22.4

10 M14×1 18.6 - 20.6 13.7 - 15.2

13 M14×1 18.6 - 20.6 13.7 - 15.2

14 - 38.2 - 40.2 28.2 - 29.6

Tightening torque

N-m ft-lbf

45

W134-0271E

B-10. B-10.

Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Overload relief valve
(Main winch), (Aux. winch), (Elevating), (Telescoping)

6754231981013121114

P

16 15

1.Socket

2.Valve

3.O-ring

4.Spring

Thread size and tightening torque

Sign / port Thread size

1 - 18.6 - 20.6 13.7 - 15.2

8 M27×1.5 78.5 - 88.3 58 - 65

13 M14×1 18.6 - 20.6 13.7 - 15.2

14 M14×1 18.6 - 20.6 13.7 - 15.2

5.Valve seat

6.O-ring

7.O-ring

8.Body

T

IW134-011011

9.Valve

10.Spring

11.Adjust screw

12.O-ring

Tightening torque

N-m ft-lbf

13.Nut

14.Cap nut

15.Tie up wire

16.Seal lead

0

366-405-40000

46

W134-0271E

△

B-11 B-11

Sequence Valve (Pilot Pressure)

B-11 Sequence Valve (Pilot Pressure)

[NOTICE]

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

1. Structure

Thread size and tightening torque

Sign / port Thread size

P, V G1/2 98 72

Dr G3/8 49 36

Pi, G G1/4 29.4 22

Tightening torque

N-m ft-lbf

47

W122-0113E

B-11 B-11

Sequence Valve (Pilot Pressure)

Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)

1.Body

2.Filter

3.Filter retainer

4.Back pressure regulating valve

5.Pressure reducing valve

6.Hexagon socket head bolt

7.Plug

8.O-ring

9.Plug

Thread size and tightening torque

Sign / port Thread size

3 G1/2 9.81 - 11.8 7.2 - 8.7
6 M6 9.81 - 10.8 7.2 - 8

5

4

Tightening torque

N-m ft-lbf

6

A-A

123

IW122-0112E01

Back pressure regulating valve
(illustrated as 4 in the cross section along the line A-A)

12673485

1.Spring cover

2.Stopper

3.Piston

4.Valve

5.Socket

6.Spring

7.O-ring

8.O-ring

Thread size and tightening torque

Sign / port Thread size

1 M24×1.5 58.8 – 68.6 43.4 – 50.6

Tightening torque

N-m ft-lbf

IW122-011004

48

W122-0113E

B-11. B-11.

Sequence Valve (Pilot Pressure)

Pressure reducing valve

(illustrated as 5 in the cross section along the line A-A)

1.Body

2.Spool

3.O-ring

4.Plug

7

91

11 10 8 6 3 5 12 2 13

5.Spring seat

6.Spring

7.Adjust screw

8.Body

9.O-ring

10.Nut

11.Cap nut

12.O-ring

4

IW122-011005

13.O-ring

0

366-038-80000

366-060-30000

49

W122-0113E

△
△

0

B-12 B-12

Solenoid Valve (Pilot Pressure)

B-12 Solenoid Valve (Pilot Pressure)

[NOTICE]

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

1. Structure

A2

T

A1

IW121-067001

P

701

Connector

IW121-0671E01

171

101.Casing

171.Hexagon socket head bolt

701.Solenoid valve (DC24V)

Thread size and tightening torque

Sign / port Thread size

P,T,A1,A2 G1/4 34 - 38 25 - 28

171 M5 6 - 8 4.5 - 6

T1 M8 26 - 32 20 - 24

T

A2 A1

P

101

T

1

IW121-067002

Tightening torque

N-m ft-lbf

50

W121-0672E

3

B-12. B-12.

Solenoid Valve (Pilot Pressure)

Solenoid valve assy

31 1

PAT

312 361 362 363 861 801 802

311.Spool

312.Sleeve

324.Spring

326.Retaining ring

361.O-ring

362.O-ring

Thread size and tightening torque

Sign / port Thread size

802 M6 6.9 - 7.9 5.1 - 5.8

326 324

IW121-06700

363.O-ring

801.Solenoid valve

802.Seal nut

Tightening torque

N-m ft-lbf

861. O-ring

0

367-401-00000

51

W121-0672E

△

B-13 B-13

Solenoid Control Valve (Jib Set)

B-13 Solenoid Control Valve (Jib Set)

[NOTICE]

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

1. Structure

CO

A2
B2

PP

GP T

Connector

+ -

IW121-0542E01

IW112-0220E01

(+) : Red

(-) : Black

A1
B1

52

W112-0222E

B-13 B-13

Solenoid Control Valve (Jib Set)

33

C･O

31

21

A

B

C

3218

D

B2 B1

A2 A1

T

P

OUT

IN

OUT

C

33

33

D

P. P

A

B

33

27,38

18.Name plate

21.Tigh rod

27.Plug

29.Hexagon socket head bolt

Thread size and tightening torque

Sign / port Thread size

P, T G1/2 98 72

A1, B1, A2, B2 G3/8 49 36

C•O G1/2 98 72

P•P G1/4 29.4 22

31.Nut

32.Ribbet screw

33.Ball

38.O-ring

Tightening torque

N-m ft-lbf

29

P.P

33

IW112-0220E02

53

W112-0222E

B-13 B-13

Solenoid Control Valve (Jib Set)

28 34 19 38 23 27 33

6.Collar

7.Spring folder

8.Plug

9.Spring

16.Solenoid

19.Body

20.Spring

22.Spring

23.Filter

25.Spool end

27.Plug

28.Hexagon socket head bolt

33.Ball

34.O-ring

35.O-ring

37.O-ring

38.O-ring

44.O-ring

16

6

35

8

7

22

25

44

35

33

35

28

16 34 19 38 27 23 20

A-A

IW112-0220E03

33

35

37

8

9

33

54

W112-0222E

4

4

B-13 B-13

Solenoid Control Valve (Jib Set)

14.Spol

15.Housing

17.Housing plunger

24.Housing

35.O-ring

43.O-ring

14

14

35

24

17

3

15

35

B-B

IW112-0220E0

55

W112-0222E

B-13 B-13

Solenoid Control Valve (Jib Set)

T

P

C-C

IW112-0220E05

C O

D-D

56

IW112-0220E06

W112-0222E

7

B-13. B-13.

Solenoid Control Valve (Jib Set)

Relief valve

42 12 2 41 1 40 10 4 30 3365131139

1.Spring

2.Needle valve

3.Nut

4.Gasket

5.Spring

10.Housing

11.Sle eve

12.Sleeve

13.Poppet

30.Screw

36.O-ring

39.O-ring

IW112-0220E0

40.O-ring

41.O-ring

42.O-ring

0

366-489-20000

57

W112-0222E

△

B-14. B-14.

Pilot Check Valve (Jib Set)

B-14 Pilot Check Valve (Jib Set)

[NOTICE]

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

1. Structure

BA

DC

IW115-027001

765 34

B

A

DC

81 9210

X-X

11

IW115-027002

1.Body

2.Sleeve

3.Poppet

Thread size and tightening torque

Sign /port Thread size

A,B,C,D G1/4 29.4 22

4.Spring

5.Piston

6.O-ring

7.Backup ring

8.O-ring

9.O-ring

Tightening torque

N-m ft-lbf

58

W115-0271E

10.O-ring

11.Plug

12.Plug

366-241-40000

△

1

B-15 B-15

Solenoid Valve (Oil Cooler)

B-15 Solenoid Valve (Oil Cooler)

[NOTICE]

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

1. Structure

4

bf

3

2

a

bf

1

ae

PA

TB

T1

e

P

B

A

T

IW121-025001

1.Solenoid valve assy 2.Body 3.Valve 4.Plug

Thread size and tightening torque

Sign / port Thread size

a, b, e, f G1/2 98 72

T1 M5 7 - 8 5 - 6

Tightening torque

N-m ft-lbf

59

W121-0253E

IW121-025002

B-15. B-15.

Solenoid Valve (Oil Cooler)

Solenoid valve assy

Connector

(+): Red

+ -

(-): Blue

1.Body

2.Plug

3.Spool

T1

7.Spring seat

8.Square ring

9.O-ring

IW121-0542E01

3

AB

TT

P

12 9 1 15 8 7 11 2T2

IW121-025003

11.Spring

12.Solenoid (DC24V)

15.Hexagon socket head bolt

Thread size and tightening torque

Sign / port Thread size

2 - 44 - 49 32 - 36

15 M5 7 5

T1 - 39 - 49 29 - 36

T2 - 4.4 – 5.4 3 - 4

Tightening torque

N-m ft-lbf

60

W121-0253E

366-457-50000

△

1

B-16. B-16.

Solenoid Valve (Oil Cooler)

B-16 Hydraulic Motor (Oil Cooler)

[NOTICE]

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

1. Structure

25 14 2 4 7 5 32 8 10 1 33 34 13

D

A,B

27 12 21 17 19 20 16 22 23 3

1.Front case

2.Rear case

3.Shaft

4.Cylinder block

5.Piston retainer

7.Spherical retainer

Thread size and tightening torque

Sign /port Thread size

A, B G3/8 64 47

D G1/4 40 30
21 M5 4 - 6 2.9 - 4.3
25 M8 34 - 39 25 - 29
34 M5 2 - 3 1.4 - 2.2

8.Spherical pin

10.Collar

12.Spring

13.Straight key

14.Plain washer

16.Oil seal

17.Needle bearing

19.Thrust roller bearing

20.Thrust plate

21.Hexagon socket head but

bolt

22.Ball bearing

Tightening torque

N-m ft-lbf

IW102-012001

23.Retaining ring

25.Hexagon socket head bolt

27.O-ring

32.Piston assy

33.Seal plate

34.Flat head machine screw

2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

61

W102-0122E

366-632-60000

366-631-10000

366-631-20000

△
△

△

0

0

0

B-17. B-17.

Jib Lock Pin

B-17 Jib Lock Pin

[NOTICE]

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

1. Structure

1.Spring pin

2.plate

3.Plain bearing

4.Ring seal

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

*2 : Apply sealant equivalent to three bond 1104.

Thread size and tightening torque

Sign / port Thread size

A, B G1/4 29.4 22

5.O-ring

6.Piston

7.Cylinder

8.Rod

Tightening torque

N-m ft-lbf

9.Rod cover

10.Plain bearing

11.O-r ing

12.Damper ring

13.Packing

14.Backup ring

15.Dust seal

0

360-531-60000

62

W180-0021E

△

B-18. B-18.

Jib Offset Cylinder

B-18 Jib Offset Cylinder

[NOTICE]

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

1. Structure

1.Cylinder

2.Split pin

3.Nut

4.Piston

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

Thread size and tightening torque

Sign / port Thread size

A, B G1/4 29.4 22

5.Plain bearing

6.O-ring

7.Rod

8.Rod cover

9.O-ring

10.Damper ring

11.packing

12.Backup ring

Tightening torque

N-m ft-lbf

13.Plate

14.Dust seal

15.---

16.Plain bearing

0

360-520-90000

63

W180-0031E

△

B-19. B-19.

Check Valve (Gauge Isolator)

B-19 Check Valve (Gauge lsolator)

[NOTICE]

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

1. Structure

Hydraulic symbols

8254367

1

P3P2P1

IW116-012001

SP'

S

P1 P2 P3

Thread size and tightening torque

Sign / port Thread size

P1, P2, P3, P’ G 1/4 29.4 22

S

Mounting bolt M8 13 - 15 9.6 - 11.0

1. Body

2. Plug

3. Poppet

4. Spring

IW116-012002

Tightening torque

N-m ft-lbf

G 3/8 49.0 36

M18×1.5 127 - 147 93 - 108 TT-300XL-1 only

5. O-ring

6. Screw

64

W116-0123E

Remark

7. Plug

8. O-ring

366-244-50000

366-251-20000

△
△

1

0

Contents

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

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

C-2 Jack Cylinder....................................5

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

C

C

Outrigger System

C-7 Solenoid Valve (Slide/Jack)

(NACHI)...................................10

1. Structure .................................................. 10

C-8 Check Valve (Outrigger Extending

Prevention).............................11

C-3 Pilot check Valve (Jack Cylinder

Retracting Prevention) ............ 6

1. Structure .................................................... 6

C-4 Extension Cylinder ..........................7

1. Structure .................................................... 7

C-5 Solenoid Valve (Slide/Jack)

(UCHIDA) .................................. 8

1. Structure .................................................... 8

C-6 Solenoid Valve (Slide / Jack)

(TOKIMEC) ...............................9

1. Structure ...................................................11

C-9 Outrigger Operation Box ...............12

1. Structure .................................................. 12

2. Connector diagram.................................. 13

3. Specifications........................................... 13

3.1 General .....................................................13

3.2 Bipolar toggle switch .................................13

3.3 Monopolar toggle switch ...........................13

3.4 Push switch...............................................13

3.5 Diode.........................................................13

3.6 Lamp assembly.........................................13

1. Structure .................................................... 9

i

C-1 C-1

Outrigger System

C-1 Outrigger System

1. General

Hydraulic Circuit

1. The outrigger controls use the solenoid control

valve to select between extension or retraction for

each cylinder. The solenoid valve selects between

operation of the extension cylinder and the jack

cylinder.

2. During outrigger extension, the pressure oil from

the pump passes through the solenoid control

valve and solenoid valve to enter the cylinders.

3. At this time, back pressure is generated in the

return oil by the pilot check valve. The return oil

then passes through the solenoid control valve

and returns to the tank.

4. During outrigger retraction, the pressure oil

passes through the solenoid control valve and

pilot check valve, and operates on the retraction

side of the extension and jack cylinders. Only the

circuit of the cylinder selected by the solenoid

valve retracts.

5. The maximum puressure in the outrigger hydraulic

circuit is regulated by the relief valve.

1

WC02-0290E

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.

2

WC02-0290E

C-1 C-1

Outrigger System

Electric Circuit For Europe

〔

〔

43〕WB

〔

62〕Y

〔

249〕RL

236〕YB

D50
D51

236A〕RY

〔

236B〕LY

〔

249A〕R

〔
〔 249B〕LR

45〕PB

〔

44〕WY

〔

42〕WR

〔
〔 41〕W

46〕WL

〔

0〕B

〔

D52
D53

249B〕LR

〔

46〕WL

〔

141B〕RL

〔

236B〕LY

〔

〔 62〕Y

43〕WB

〔

45〕PB

〔

44B〕RL

〔

〔 42〕WR

41B〕RW

〔

〔 0〕B

9

10

11
12
14
13

Gr

R

P
O

Sb

L

G

Y

Br

W

B

Relay
RF3

723651

Outrigger operation box

(Left side)

41〕W

〔
〔 44〕 WY
〔 46〕 WL
〔

0〕B

〔 44B〕 RL
〔 41B〕 RW

〔 141B〕 RL

236A〕RY

〔

〔 0〕 B

〔 561〕 R

106〕YW

〔

4

107〕YB

〔

8

〔 108〕YO

3

84

1210911

〔 109〕YG

7

+14

2

〔 110〕RW

-13

111〕RB

〔

6

112〕RL

〔

1
5

113〕RG

〔

5

8
14
13
12

9

Relay
RD5

Relay
RB8

Solenoid valve
(slide/jack)

560

〔

〕RY

Multiplex data transmitter
(Lower)

〔 249A〕R

46〕WL

〔

141A〕BR

〔

236A〕RY

〔

〔 62〕Y

43〕WB

〔

41〕W

〔

〔 42A〕WL

44〕WY

〔

45A〕LB

〔

B

〔 0〕

〔
〔
〔
〔

141〕RB
560〕RY
0〕B
561〕R

Gr

R

P

O

Sb

L

G

Y

Br

W

B

Relay
RB6

43〕WB

〔
〔

62〕Y

Solenoid valve
(extending/retracting)

561〕R

〔

236B〕LY

〔

0〕B

〔

141A〕BR

〔

42〕WR

〔
〔 45〕PB

46〕WL

〔

0〕B

〔

45A〕LB

〔

42A〕WL

〔

Outrigger operation box

(Right side)

Power supply

Relay
RB7

5

8
14
13
12

9

Relay
RD4

IWC02-0290E01

3

WC02-0290E

C-1. C-1.

Outrigger System

[In case of for Europe only, the control outside the cab

is applied.]

1. The controls are located at the both sides of the

carreir.

2. You can extend or retract only the sliders in the

same side of the crane as the controls operated.

Relay RD5: Selector relay for left side [SLIDE]

RD5
relay coil

energized close jack

de-energized open slide

Relay RD4: Selector relay for right side [SLIDE]

RD4
relay coil

energized close jack

de-energized open slide

3. If the right and left controls are opetated

simultaneously, the switch pressed first becomes

activated.

Relay RB7: Power supply selector relay

(This contact [CLOSES] when right side ext./ret.

switch’s selection is selected before the left side

one)

Relay RB8: Power supply selector relay

(This contact [CLOSES] when left side ext./ret.

switch’s selection is selected before the right side

one)

a-contact selected operation

operates any
jacks

operates
left slide only

a-contact selected operation

operates any
jacks

operates
right slide only

4. The Lower outrigger controls cannot be used

while the upper outrigger controls are in use.

Relay RB6: Power supply control relay for both lower outrigger operation box.

outrigger ext./ret. operating
switch selection timing

lower is before upper de-energized close lower outrigger operation

upper is before lower energized open upper outrigger operation

RB6 relay coil b-contact priority

4

WC02-0290E

C-2. C-2.

Jack Cylinder

C-2 Jack Cylinder

[NOTICE]

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

1. Structure

1.Cylinder

2.Rod

3.Bolt

4.Spring washer

5.Bolt

Thread size and tightening torque

Sign / port Thread size

3,5 M10 22 - 25 16 - 18

T1 M24 588 - 666 434 - 492

6.Stopper

7.Spring pin

8.Piston

9.Packing

10.Backup ring

11.O-r ing

12.Backup ring

13.O-ring

15.Rod cover assy

16.Packing

Tightening torque

N-m ft-lbf

5

W151-0112E

17.Backup ring

18.Dust seal

19.Damper ring

21.Backup ring

22.Plain bearing

360-302-90000

△

8

C-3. C-3.

Pilot Check Valve (Jack Cylinder Retracting Prevention)

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

[NOTICE]

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

1. Structure

9

AB

CD

CD

IW115-023001

5

4

67,8

2

1.Valve body

2.Plug

3.O-ring

Thread size and tightening torque

Sign / port Thread size

A G1/4 29.4 22

B G1/4 29.4 22

Mounting

bolt

4.Valve

5.Spring

6.Piston

M10 43 - 49 32 - 36

A

Tightening torque

N-m ft-lbf

B

IW115-0490E01

7.O-ring

8.Backup ring

9.O-ring

3

1

366-200-00000

△

1

6

W115-0491E

C-4. C-4.

Extension Cylinder

C-4 Extension Cylinder

[NOTICE]

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

1. Structure

1.Cylinder

2.Nut

3.Seal ring

Thread size and tightening torque

Sign / port Thread size

A, B, C G3/8 49 36

D, E G1/4 29.4 22

2 M20 176 - 196 130 - 145

4.Piston

5.Rod

6.Rod cover

7.O-ring

8.Packing

9.Backup ring

Tightening torque

N-m ft-lbf

7

W153-0012E

10.Dust seal

360-424-20000

△

1

r

C-5. C-5.

Solenoid Valve (Slide/Jack) (UCHIDA)

C-5 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.

1. Structure

Connecto

AB

PT

IW121-026001

A

TT

B

P

+ -

IW121-0542E01

(+): Red

(-): Blue

1.Body

3.Spool

Thread size and tightening torque

Sign / port Thread size

15 M5 6.9 - 8.9 5.1 - 6.5

T1 - 3.9 - 4.9 2.9 - 3.6

T2 - 38.3 - 41.2 28.3 - 30.4

7.Spring seat

8.Square ring

11 9T27 3 8 15 1

IW121-026003

9.O-ring

11.Spring

Tightening torque

N-m ft-lbf

8

W121-0263E

12.Solenoid (DC24V)

15.Hex. socket head bolt

366-478-90000

△

1

C-6. C-6.

Solenoid Valve (Slide/Jack) (TOKIMEC)

C-6 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.

1. Structure

Connector

AB

PT

IW121-026001

12

T

P T

A

B

1 2 3 4 5 6 7 8 9 10 11

Note: Install the centering washer (10) with its slit directed toward the body (7).

+ -

IW121-0542E01

(+): Red

(-): Black

IW121-027001

1.Nut

2.O-ring

3.Solenoid core (DC24V)

Thread size and tightening torque

Sign / port Thread size

1 - 8.8 - 10.8 6.5 - 8

3 - 18 - 22 13.3 - 16.2

Mounting bolt M5 6.9 - 7.8 5 - 6

4.Solenoid coil (DC24V)

5.Packing

6.O-ring

7.Body

8.O-ring

9.Spool

Tightening torque

N-m ft-lbf

9

W121-0273E

10.Centering washer

11.Spring

12.Spring pin

366-465-40000

△

1

C-7. C-7.

Solenoid Valve (Slide/Jack) (NACHI)

C-7 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.

1. Structure

Connector

AB

PT

IW121-026001

10 16

T T

P

AB

7 14 8 9 6 15 4 3 13 2 1

+ -

IW121-0542E01

(+): White

(-): Black

IW121-028001

1.Body

2.Spool

3.Retainer

4.Retainer

Thread size and tightening torque

Sign / port Thread size

7 - 5 - 7 3.7 - 5.1

Mounting bolt M5 6 - 8 4.4 - 5.9

6.Spring

7.Nut

8.Rod

9.Solenoid guide (DC24V)

10.Solenoid coil (DC24V)

13.O-ring

14.O-ring

15.O-ring

Tightening torque

N-m ft-lbf

10

W121-0283E

16.O-ring

366-457-31000

△

1

C-8. C-8.

Check Valve (Outrigger Extending Prevention)

C-8 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.

1. Structure

P1

CB

1 6 5 7 4 3 8 9 10 2 11,12

1.Body

2.Cover

3.Valve

Thread size and tightening torque

4.Spring

5.Stopper

6.Stop ring

P2

P2

IW116-011001

P1

CB

7.Valve

8.Spring

9.Stopper

IW116-011002

10.O-ring

11.Hexagon socket head bolt

12.Spring washe

Sign / port Thread size

P1 G1/2 98 72

P2 G1/2 98 72

Tightening torque

N-m ft-lbf

11

W116-0112E

C-9 C-9

Outrigger Operation Box

C-9 Outrigger Operation Box

[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

[NOTICE]

The illustration below shows the left side of the vehicle.

For the controls on the right side, the arrangement of the switches are different.

3

1

12

11

s

ten

x

E

a

tr

e

R

4

n

o

c

r

e

g

g

i

r

t

Ou

F

on

i

on

i

t

c

R

5

l

o

r

t

R

R

6

2

N

LR

O

F

F

O

e

d

i

10

G

W

R

B

Y

Br

SbO

L

Gr

P

l

S

k

c

a

J

9

F

L

8

7

View from end of connector

1.Box assy

2.Gromment

3.Push switch (RF)

4.Push switch (RR)

5.Lamp assy

6.Push switch (accelerator)

7.Toggle switch (lights)

8.Push switch (LR)

IW326-0180E01

9.Push switch (RF)

10.Toggle switch (slide/jack)

11.Push switch (all)

12

W326-0180E

12.Toggle switch

(extension/retraction)

C-9. C-9.

Outrigger Operation Box

2. Connector diagram

24V 1.0A or 10mA

24V 30mA
24V 1.5A

24V 1.5A

Power

24V

supply

24V 1.5A
24V 1.5A
24V 1.5A

24V 1.5A
24V 10mA

1 : point of contact (toggle switch)

*

2

1

3

5

4

6

retraction
jack

2

1

3

5

4

6

extention
slide

0.75 Gr

0.75 R

0.75 Sb

0.75 L

0.75 P

0.75 G

0.75 Y

0.75 Br

0.75 W

0.75 O

0.75 B

3A

1A

1.25WG

2

1

3

5

4

6

1.25O

3A

NO

COM

NO

COM

NO

COM

3
2

Slide

Jack

1.25GB

10

6

*1

N

2

1

3

5

4

6

*1

12

Ext.

N

Ret.

11

NO

COM

9

NO

COM

8

7

NO

COM

3

4

3. Specifications

3.1 General

Power voltage: DC20V ~ 30V

Service temp. range: -25° ~ +70°C

3.2 Bipolar toggle switch

Current capacity: Resistance load 20 A

lnducatance load 10 A

Contact connection resistance:

10mΩ or less (initial)

3.3 Monopolar toggle switch

Current capacity: Lamp load 2 A

Contact connection resistance:

10mΩ or less (initial)

IW326-0180E02

3.4 Push switch

Current capacity: Resistance load 10 A

lnducatance load 4 A

3.5 Diode

12-diode sect.: Average rectified current: 3A

Peak inverse voltage: 600V

1-diode sect. : Average rectified current: 1A

Peak inverse voltage: 600V

3.6 Lamp assembly

Rating: 24V, 3W

[NOTICE]

Coat the full surface of all diodes (13 total) with

ThreeBond #2901 or equivalent product.

347-314-21000

347-314-22000

1

△

1

△

13

W326-0180E

D

Contents

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

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

D-2 Swing Assmbly ................................ 3

1. Structure .................................................... 3

2. Swing bearing mounting bolt ..................... 4

2.1 Bearing Inner ring bolts .............................. 4

2.2 Bearing outer ring bolts .............................. 5

Swing System

D

D-3 Hydraulic Pilot Control Valve

(Swing) .....................................6

1. Structure .................................................... 6

D-4 Hydraulic Motor (Swing)................ 12

1. Structure .................................................. 12

D-5 Swing Speed Reducer ................... 14

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

i

D-1 D-1

Swing System

D-1 Swing System

1. General

Hydraulic Circuit for Swing

Remote Control Pressure Vent, Swing Free, Swing Brake Release

[NOTICE]

The remote control valve and the hydraulic pilot
control valve are connected at the two points having
the same symbols such as "a5" and "b5".

1. The swing operation is controlled by the hydraulic

pilot method. The pilot pressure from the remote

control valve controls the hydraulic pilot control

valve.

1

WD02-0211E