Page 1
Publication No. TM-2000-1/S1(U)-1E
01
Boom T ruck
TM-2000-1
Applicable Serial No. EX0069～
Model
Service Manual
TM-2000-1/S1(U)-1E
◯
ｃ2006
PRINTED IN JAPAN
0609 K
Page 2
Safet
y
1
WA01-0041E
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.
DANGER
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
WARNING
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
a minor or moderate injury.
CAUTION
Page 3
Safet
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2
WA01-0041E
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.
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
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
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.
Page 4
Safet
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3
WA01-0041E
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.
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.
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
3.1 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.
Page 5
Safet
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4
WA01-0041E
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
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.
4.1 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.
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.
Page 6
Foreword
1
WA04-2140E
Foreword
This manual contains information on the systems
and components of TM-2000-1 series cranes.
It also contains repair, inspection, and adjustment
procedures for those systems and components.
To be sure of performing repair and service
operations correctly ,read this manual in conjunction
with the separate operation and maintenance
manual and the separate parts catalog.
Whenever a part need to be replaced, check the
part sales unit in the parts catalog.
1. Applicable unit No.
Boom nameplate
(1) Unit No.
(2) Lot No.
UNI T
NO.
LOT NO.
IWA04-062001
(1)
(2)
Frame nameplate
(1) Unit No.
(2) Serial No.
(3) Date of mounting
SPEC. NO.
SERIAL.
NO.
MFG. DATE .
IWA04-062002
KAGAWA,JAPAN
(1)
(2)
(3)
1.1 Unit No. of the TM-2000-1 series
Spec.
Boom
nameplate
unit No.
Frame nameplate
unit No.
TM-2000-1-104 411-431-10010
TM-2000-1-114 411-431-10020
TM-2000-1-204 411-431-10050
TM-2000-1-214 411-431-10060
TM-2000-1-304 411-431-10030
TM-2000-1-314 411-431-10040
TM-2000-1-404 411-431-10070
TM-2000-1-414
411-431-20040
411-431-10080
2. Separate service manual
Separate service
manual
Publication No.
General Caution SA01-01-2E
Please note that, for product improvement, some
changes may have been incorporated in the
machine that are not covered in this manual.
Page 7
2
WA04-2140E
Foreword
3. Outline of specifications
Spec. No.
Item
TM-2000-1
-104
TM-2000-1
-304
TM-2000-1
-114
TM-2000-1
-314
TM-2000-1
-204
TM-2000-1
-214
TM-2000-1
-404
TM-2000-1
-414
No. of boom
sections
5-section
Winch Hydraulic motor driven, planetary gear speed reduction, provided with automatic brake
Outriggers
extended width
Min.7.15’ Mid.13.1' Max.18.7'
Crane mount
position
Cab back mount Rear mount
Rear stabilizers
extended width
Min.7.38’ Max.11.48' –
Front outriggers
extended width
– Min.7.15’ Mid.13.1' Max.18.7'
Swing
Non-continuous 375°
rotation
Continuous rotation
Non-continuous 375°
rotation
Continuous rotation
Operation
Manual
Radio
remote
controls
Manual
Radio
remote
controls
Manual
Radio
remote
controls
Manual
Radio
remote
controls
Safety devices
Anti-two-block with alarm
Hook safety latch
Level gauge
Hydraulic safety valves, check valves and holding valves
Over load shutoff with load indicator
Load / Boom angle indication
Audible warning
External warning lamps
Page 8
3
WA04-2140E
Foreword
4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km
1 0.1 0.001 0.03937 0.00328 1 1.6093
10 1 0.01 0.3937 0.03281 0.6214 1
1000 100 1 39.37 3.281 – –
25.4 2.54 0.0254 1 0.08333 – –
304.8 30.48 0.3048 12 1 – –
Area
square millimeter, mm2 square centimeter, cm
2
square meter, m2square inch, in2 square foot, ft
2
1 0.01 0.000001 0.00155 -
100 1 0.0001 0.155 0.001076
1000000 10000 1 1550 10.764
645.2 6.452 0.000645 1 0.006944
92903 929.03 0.0929 144 1
Volume
cubic
centimeter,
cm
3
, cc
cubic meter, m
3
cubic inch, in3cubic foot, ft
3
gallon,
gal
cubic inch, in
3
liter, lit, L
1 0.000001 0.0610 0.0000353 1 231 3.785
1000000 1 61024 35.31 0.004329 1 0.01639
16.39 0.0000164 1 0.000579 0.2642 61.02 1
28320 0.02832 1728 1 – – –
Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
1 0.001 0.03527 0.0022 – –
1000 1 35.27 2.205 0.001 0.001102
28.349 0.02835 1 0.0625 0.00002835 0.00003125
453.592 0.4536 16 1 0.0004536 0.0005
1000000 1000 35274 2205 1 1.102
907185 907.2 32000 2000 0.9072 1
Pressure
Pa kPa MPa kgf/cm2 lb/in2, psi
1 1×10-3 1×10-6 1.01972×10-5 14.5×10-5
1×103 1 1×10-3 1.01972×10-2 14.5×10-2
1×106 1×103 1 1.01972×10 14.5×10
9.80665×104 9.80665×10 9.80665×10-2 1 14.22
6895 6.895 0.006895 0.07031 1
Page 9
4
WA04-2140E
Foreword
Torque
N-cm N-m kgf-cm kgf-m foot-pound, ft-lb
inch-pound,
in-lb
1 1×10-2 1.01972×10-1 1.01972×10-3 0.00737 0.0885
1×102 1 1.01972×10 1.01972×10-1 0.7376 8.851
9.80665 9.80665×10-2 1 1×10-2 0.0723 0.868
9.80665×102 9.80665 1×102 1 7.233 86.8
135.58 1.3558 13.83 0.1383 1 12
11.3 0.113 1.1525 0.01153 0.08333 1
Centigrade-Fahrenheit
°F °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
-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(T°F -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 2.20461
4.44822 0.45359 1
Page 10
5
WA04-2140E
Outrigger System
Swing System
Boom Elevating System
Winch System
Boom Telescoping System
Safety System
Radio-control System
System Diagrams
Data, Adjustment and Checks
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
A
GROUP INDEX
Hydraulic Power Generating System
Page 11
6
WA04-2140E
Foreword
5. Contents
Spec. No.
TM-2000-1
Chapter
Section
-104 -304 -114 -314 -204 -214 -404 -414
General
A
General Cautions
Refer to separate manual
SA01-01-2E
Hydraulic Pressure Generating System
Manual Control Valve(Boom elevating,
telescoping, swing, outrigger, high / low
shift)
B-1
Manual Control Valve (Outrigger) B-2
Manual Control Valve (Winch) B-3
Hydraulic Pump B-4
Sequence Valve (Pilot pressure) B-5
Solenoid Valve (Auto stop) B-6
Solenoid Valve (Winch high speed and
swing brake)
B-7
Solenoid Valve (Winch unload) B-8
Solenoid Valve (Outrigger select) B-9
Pressure Regulator Valve (Outrigger) B-10
Hydraulic Valve B-11
Shuttle Valve B-12
Rotary Joint – B-13 – B-13
B
Outrigger System
Jack Cylinder (Front and rear stabilizer) C-1 –
C
Jack Cylinder (Outrigger and front
outrigger)
C-2
Page 12
7
WA04-2140E
Foreword
Spec. No.
TM-2000-1
Chapter
Section
-104 -304 -114 -314 -204 -214 -404 -414
Pilot Check Valve (Front and rear
stabilizer)
C-3 –
Pilot Check Valve (Outrigger jack and
front outrigger jack)
C-4
Power Slide Cylinder (Outrigger and front
outrigger)
C-5
Power Slide Cylinder (Rear stabilizer) C-6 –
Relief Valve (Front stabilizer) C-7 –
Pressure Sensor (Front stabilizer) C-8 –
C
Swing System
Hydraulic Motor (Swing) D-1
Swing Speed Reducer D-2
Swing Bearing D-3
D
Boom Elevating System
Boom Elevating Cylinder E-1
Counterbalance Valve (Elevating) E-2
E
Winch System
Winch F-1
Hydraulic Motor (Winch) F-2
Counterbalance Valve (Winch) F-3
F
Page 13
8
WA04-2140E
Foreword
Spec. No.
TM-2000-1
Chapter
Section
-104 -304 -114 -314 -204 -214 -404 -414
Boom Telescoping System
General description of telescoping
system
G-1
Boom (Five-section boom) G-2
Telescoping Cylinder G-3
Counterbalance Valve (Telescoping) G-4
G
Safety Devices
AMA (Load moment indicator) H-1
Boom Length / Angle Detector H-2
Outrigger extension detector H-3
H
Radio-control System
Configurations of Radio-control System
–
V-1
–
V-1
–
V-1
–
V-1
Radio-control Valve
–
V-2
–
V-2
–
V-2
–
V-2
Accelerator Cylinder
–
V-3
–
V-3
–
V-3
–
V-3
Measures for Emergency Case
–
V-4
–
V-4
–
V-4
–
V-4
V
Data, Adjustment and Checks
Service Data Y-1
Adjustment and Checks Y-2
Y
Page 14
9
WA04-2140E
Foreword
Spec. No.
TM-2000-1
Chapter
Section
-104 -304 -114 -314 -204 -214 -404 -414
System Diagrams
Hydraulic Circuit
(Spec. No.: TM-2000-1-104, 114, 204,
214)
Z-1
Hydraulic Circuit
(Spec. No.: TM-2000-1-304, 314, 404,
414)
Z-2
Electric Circuit
(Spec. No.: TM-2000-1-104, 204)
Z-3
Electric Circuit
(Spec. No.: TM-2000-1-114, 214)
Z-4
Electric Circuit
(Spec. No.: TM-2000-1-304, 404)
Z-5
Electric Circuit
(Spec. No.: TM-2000-1-314, 414)
Z-6
Location of Hydraulic Parts Z-7
Location of Electrical Parts Z-8
Z
Page 15
i
B
Hydraulic Power Generating System
Contents
B-1 Manual Control Valve (Boom
elevating, telescoping, swing,
outrigger, high/low shift).................1
1. Structure................................................... 1
B-2 Manual Control Valve
(Outrigger)................................7
1. Structure................................................... 7
B-3 Manual Control valve
(Winch)...................................11
1. Structure..................................................11
B-4 Hydraulic Pump..............................13
1. Structure .................................................... 13
B-5 Sequence Valve
(Pilot pressure)......................14
1. Structure................................................. 14
B-6 Solenoid Valve
(Auto stop).............................17
1. Structure................................................. 17
B-7 Solenoid Valve (Winch high speed
& swing brake).......................19
1. Structure ................................................. 19
B-8 Solenoid Valve
(Winch unload).......................21
1. Structure ................................................. 21
B-9 Solenoid Valve
(Outrigger select)...................22
1. Structure ................................................. 22
B-10 Pressure Regulator Valve
(Outrigger)..............................24
1. Structure ................................................. 24
B-11 Hydraulic Valve ..............................25
1. Structure ................................................. 25
B-12 Shuttle Valve...................................26
1. Structure ................................................. 26
B-13 Rotary Joint....................................27
1. Structure ................................................. 27
B
Page 16
B-1 B-1
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
1
W113-0400E
B-1 Manual Control Valve
(Boom elevating, telescoping, swing, outrigger, high/low shift)
[NOTE]
There is a case that the appearance and so on differ from the parts for this crane. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this crane and
the parts sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A1 – A4
B1 – B4
P1
G1/2 58.8 – 68.6 43.3 – 50.5
P2 G3/8 39.2 – 49.0 28.9 – 36.1
T G1 98.1 – 117.7 72.3 – 86.8
G1 – G3 G1/4 24.5 – 29.4 18.0 – 21.6
General View
Page 17
B-1 B-1
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
2
W113-0400E
1. Body assy
2. Valve (Swing)
3. Body assy
4. Valve (Elevation)
5. Valve (Telescoping)
6. Valve (Confluence)
7. Plate
8. O-ring
9. O-ring
10. Relief valve (RV1)
11. Relief valve (RV2)
12. Relief valve (RV3)
13. Relief valve (PR1)
14. Stud bolt
15. Nut
22. Plug
23. O-ring
Cross section
Body assy
Page 18
B-1 B-1
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
3
W113-0400E
11. Relief valve (RV2)
12. Relief valve (RV3)
22. Plug
23. O-ring
33. Check valve
34. Spring
35. Retainer
36. O-ring
37. Oil seal
38. Retainer
39. Retainer
40. Spring
41. Spool end
42. Cover
43. Hexagon socket bolt
44. Hexagon socket bolt
52. Valve
53. Spring
54. Plug
55. O-ring
56. Screw
57. Screw
58. Valve
59. Spring
60. Retainer
61. Plug
62. O-ring
Valve
(Swing)
Body assy
Page 19
B-1 B-1
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
4
W113-0400E
13. Relief valve (PR1)
33. Check valve
34. Spring
35. Retainer
36. O-ring
37. Oil seal
38. Retainer
39. Retainer
40. Spring
41. Spool end
42. Cover
43. Hexagon socket bolt
44. Hexagon socket bolt
45. Plug
77. O-ring
78. Retainer
79. Spring
80. Retainer
81. Rod end
82. Cover
83. Cover
84. Hexagon socket bolt
Valve
(Elevation)
Valve
(Confluence)
Valve
(Telescoping)
Page 20
B-1 B-1
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
5
W113-0400E
10. Relief valve (RV1)
11. Relief valve (RV2)
62. O-ring
103.O-ring
104.Spring
105.Retainer
106.O-ring
107.O-ring
108.Body
109.Regulator valve
110.Spring
111. Screw
112.O-ring
113.Nut
114.Cap nut
128.Stopper
129.Retainer
137.O-ring
140.Backup ring
141.Backup ring
142.Backup ring
143.Backup ring
Relief valve (RV1)
Relief valve (RV2)
Page 21
6
W113-0400E
B-1. B-1.
Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high/low shift)
12. Relief valve (RV3)
13. Relief valve (PR1)
109.Regulator valve
110.Spring
111. Screw
113.Nut
114.Cap nut
137.O-ring
151.Body
154.O-ring
155.Backup ring
156.Spring
157.Body
158.O-ring
159.Backup ring
160.O-ing
△
0
366-382-50000
Relief valve (RV3)
Relief valve (PR1)
Page 22
B-2 B-2
Manual Control Valve(Outrigger)
7
W113-0440E
B-2 Manual Control Valve (Outrigger)
[NOTE]
There is a case that the appearance and so on differ from the parts for this crane. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this crane and
the parts sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Cover assy
2. Valve (Front stabilizer)
3. Valve (Ext / Ret)
4. Valve assy
5. Valve (Outrigger / Right)
6. Valve
7. Body assy
8. Nut
9. Relief valve (RV5)
10. O-ring
11. Bolt
12. Plug
13. O-ring
14. Plug
15. O-ring
General View
Page 23
B-2 B-2
Manual Control Valve(Outrigger)
8
W113-0440E
2. Body assy
3. Valve (Swing)
23. O-ring
24. Oil seal
25. Retainer
26. O-ring
27. Bracket
28. Retainer
29. Spring
30. Spool end
31. Cover
32. Retainer
33. Hexagon socket bolt
34. Hexagon socket bolt
35. Check valve
36. Spring
Valve (Front stabilizer)
Valve(Extension/Retraction)
Page 24
B-2 B-2
Manual Control Valve(Outrigger)
9
W113-0440E
5. Valve(Outrigger / Right)
6. Valve
23. O-ring
24. Oil seal
25. Retainer
26. O-ring
31. Cover
32. Retainer
33. Hexagon socket bolt
56. Retainer
57. Spool end
58. Case
59. Spring
60. Retainer
61. Steel ball
63. Hexagon socket bolt
Valve (Outrigger/Right)
Valve(Rear Stabilizer & Outrigger/Left)
Page 25
10
W113-0440E
B-2. B-2.
Manual Control Valve(Outrigger)
9. Relief valve (RV5)
83. Spring
84. O-ring
85. O-ring
86. O-ring
90. Spring
94. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, V, T G1/2 58.8 – 68.6 43.3 – 50.5
A, B,C3 G3/8 39.2 – 49.0 28.9 – 36.1
Gauge port G1/4 24.5 – 29.4 18.0 – 21.6
Relief valve(RV5)
△
4
366-382-80000
Page 26
B-3
B-3
Manual Control valve (Winch)
11
W113-0431E
B-3 Manual Control valve (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
General view
Page 27
12
W113-0431E
B-3.
B-3.
Manual Control valve (Winch)
1. Body
2. Body
4. Plug
5. O-ring
7. O-ring
8. O-ring
9. Cover
10. Cover
11. Washer
12. Hexagon socket bolt
14. Spring
15. Spring seat
16. Packing
17. Bolt
18. Fork end
19. Poppet
20. Spring
21. Cap
22. O-ring
23. Relif valve
24. Stud bolt
25. Nut
26. Spring washer
29. Flange
30. O-ring
31. Hexagon socket bolt
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P2 G1 372 - 412 274‐303
t1 M10 54 - 66 39 - 48
t2 M12 88 - 108 64 - 79
t3 M16 100 - 120 73 - 88
△
0
366-382-60000
△
0
366-383-70000
Page 28
B-4. B-4.
Hydraulic Pump
13
W101-0340E
B-4 Hydraulic Pump
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Gear pump (No.1)
2. Gear pump (No.2)
3. Gear pump (No.3)
4. Coupling
5. Coupling
6. Distance piece
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
T1 - 294 217
T2 - 55 - 69 40.6 - 50.9
△
0
366-541-30000
Page 29
B-5 B-5
Sequence Valve (Pilot pressure)
14
W122-0113E
B-5 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
Tightening torque
Sign / port Thread size
N-m ft-lbf
P, V G1/2 98 72
Dr G3/8 49 36
Pi, G G1/4 29.4 22
Page 30
B-5 B-5
Sequence Valve (Pilot pressure)
15
W122-0113E
123
4
A-A
5
IW122-0112E01
6
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
3 G1/2 9.81 - 11.8 7.2 - 8.7
6 M6 9.81 - 10.8 7.2 - 8
IW122-011004
12673485
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
1 M24×1.5 58.8 – 68.6 43.4 – 50.6
1.Body
2.Filter
3.Filter retainer
4.Back pressure regulating valve
5.Pressure reducing valve
6.Hex. socket head bolt
7.Plug
8.O-ring
9.Plug
Back pressure regulating valve
(illustrated as 4 in the cross section along the line A-A)
1.Spring cover
2.Stopper
3.Piston
4.Valve
5.Socket
6.Spring
7.O-ring
8.O-ring
Cross section along the line A-A
(back pressure regulating valve, pressure reducing valve)
Page 31
B-5. B-5.
Sequence Valve (Pilot pressure)
16
W122-0113E
IW122-011005
7
11 10 8 6 3 5 12 2 13
91
4
1.Body
2.Spool
3.O-ring
4.Plug
5.Spring seat
6.Spring
7.Adjust screw
8.Body
9.O-ring
10.Nut
11.Cap nut
12.O-ring
13.O-ring
Pressure reducing valve
(illustrated as 5 in the cross section along the line A-A)
△
0
366-060-30000
△
0
366-038-80000
Page 32
B-6 B-6
Solenoid Valve (Auto stop)
17
W121-0910E
B-6 Solenoid Valve (Auto stop)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Body
2. Distance piece
3. Filter element (100μ)
4. Plug
5. Plug
6. O-ring
7. O-ring
8. Solenoid valve assy
Solenoid valve assy
Hydraulic symbol
Page 33
18
W121-0910E
B-6. B-6.
Solenoid Valve (Auto stop)
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B, T G1/4 29.4 22
4 G3/8A 30 - 37 22.1 - 27.3
T1 M5 6.9 – 8.9 5 – 6.5
△
0
367-402-00000
Page 34
B-7
B-7
Solenoid Valve (Winch high speed & swing brake)
19
W121-0900E
B-7 Solenoid Valve (Winch high speed & swing brake)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
IW121-067001
A2
T
P
A1
T
1
IW121-067002
A2 A1
701
171
101
T
P
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P,T,A1,A2 G1/4 34 - 38 25 - 28
171 M5 6 - 8 4.5 - 6
T1 M8 26 - 32 20 - 24
101.Casing
171.Hex. socket head bolt
701.Solenoid valve (DC12V)
Page 35
20
W121-0900E
B-7. B-7.
Solenoid Valve (Winch high speed & swing brake)
IW121-06700
3
311
312 361 362 363 861 801 802
326 324
PAT
311.Spool
312.Sleeve
324.Spring
326.Retaining ring
361.O-ring
362.O-ring
363.O-ring
801.Solenoid valve
802.Seal nut
861. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
802 M6 6.9 - 7.9 5.1 - 5.8
Solenoid valve assy
△
1
367-401-90000
IW121-0671E01
Connector
Page 36
B-8. B-8.
Solenoid Valve (Winch unload)
21
W121-0870E
B-8 Solenoid Valve (Winch unload)
[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 parts sales unit described in the parts catalog before starting disassembling operations.
1. Structure
IW121-0460E0
2
BA
P
P
T
T
1. Body
2. Plunger
3. Spring
4. Plug
5. Plug
6. O-ring
7. Solenoid valve assy
10. Orifice
11. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T G3/4 A 107.8 - 122.5
79.5 – 90.3
Mounting bolt for
solenoid
(p
art no.7)
6.9 – 8.9
5.1 – 6.5
Hydraulic symbol
Overall plan
Solenoid valve Assy
△
0
366-402-10000
Page 37
B-9 B-9
Solenoid Valve (Outrigger select)
22
W121-0880E
B-9 Solenoid Valve (Outrigger select)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the parts sales unit described in the parts catalog before starting disassembling operations.
1. Structure
T1
IW121-0880E02
A1
701
171
101
T
P
101. Body 171. Hexagon socket bolt 701.Solenoid valve assy
(DC12V)
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T, A1 G1/4 34 - 38
25 - 28
171 M5 6 – 8
4.5 – 6
T1 M8 26 - 32
20 – 24
IW121-0880E04
T
P
A1
Page 38
23
W121-0880E
B-9. B-9.
Solenoid Valve (Outrigger select)
IW121-0880E03
311
312 361 362 363 861 801 802
326 324
PAT
311. Spool
312. Sleeve
324. Spring
326. Retaining ring
361. O-ring
362. O-ring
363. O-ring
801.Solenoid valve
802.Seal nut
861. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
802 M6
6.9～7.9 5.1 – 5.8
Solenoid valve assy
Page 39
B-10. B-10.
Pressure Regulator Valve(Outrigger)
24
W131-0020E
B-10 Pressure Regulator Valve (Outrigger)
[NOTE]
There is a case that the appearance and so on differ from the parts for this crane. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this crane and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
2. O-ring 3. Spring 5. Plug 7. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G 3/8 44 - 54 32.4 – 39.8
Specification {Cracking pressure 0.22 – 0.36MPa(31.9 – 52.2psi) A --->B
0.29 – 0.44MPa(42.0 – 63.8psi) B --->A}
General View
△
0
366-062-40000
Page 40
B-11. B-11.
Hydraulic Valve
25
W123-0122E
B-11 Hydraulic Valve
[NOTE]
There is a case that the appearance and so on differ from the parts for this crane. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this crane and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
B
T
Dr AC P.P
IW123-012001
IW123-012002
TB
P.P
AC Dr
173
4 26 5
1.Valve body
2.Spool
3.Plug
4.Plug
5.Spring seat
6.Spring
7.O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
AC, B, Dr, T G1/4
29 22
P. P
G1/4
29 22
△
0
366-473-80000
△
0
366-467-20000
Page 41
B-12. B-12.
Shuttle Valve
26
W128-0150E
B-12 Shuttle 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
2.Joint 3. O-ring 4. Steel ball
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G1/4 29.4 22
△
0
366-242-50000
Page 42
27
W181-0391E
Ｂ -13. Ｂ -13.
Rotary Joint
Ｂ -13.
27
B-13 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 disassem bly 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.Body 2.Core 3.Slip ring assy 4.Plain bearing 5. Plain bearing 6.Plate
7. Plate 8.Packing 9.Ring seal 10.Bolt 11.Bolt 12.Spring washer
13.Plain washer 14.Bolt 15.Bolt 16. Bolt 17. Bolt 18.Grease nipple
19. Grease nipple 20. Nipple 21. Sleeve 22. Nipple 23.Pipe 24. Nipple
25.Connector 26. Plate 27. Connector 28.Plate 29.Cap 30.Plug
31.Plug 32.Plug 33. Spring washer 34..Plain washer 35.Cap 36. Cover
1. Structure
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G1 196 145
C,D,E,G G3/4 167 123
H G1/2 98 72
K G3/8 49 36
I,J G1/4 29 22
△
0
316-317-41000
△
1
316-317-41000
Page 43
i
C
Outrigger System
Contents
C-1 Jack Cylinder (Front and rear
stabilizer)..................................1
1. Structure................................................... 1
2. Check valve Retaining Bolt Tightening
Torques ......................................... 1
C-2 Jack Cylinder....................................2
1. Structure................................................... 2
C-3 Pilot Check Valve (Front and rear
stabilizer)..................................3
1. Structure................................................... 3
C-4 Pilot Check Valve
(Outrigger jack)........................4
1. Structure................................................... 4
C-5 Power Slide Cylinder (Outrigger)....5
1. Structure................................................... 5
C-6 Power Slide Cylinder (Rear
stabilizer)..................................6
1. Structure................................................... 6
C-7 Relief Valve (Front stabilizer)..........7
1. Structure ................................................... 7
C-8 Pressure Sensor
(Front stabilizer).......................8
1. Structure ................................................... 8
C
Page 44
C-1. C-1.
Jack Cylinder (Front & rear stabilizer)
1
W151-0270E
C-1 Jack Cylinder (Front and rear stabilizer)
[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. Plain bearing
3. Rod cover
4. O-ring
5. Packing
6. Backup ring
7. Dust seal
8. Rod
2. Check valve Retaining Bolt Tightening Torques
General View
Check Valve
△
0
360-355-70000
△
0
360-355-90000
△
0
360-356-40000
Page 45
C-2. C-2.
Jack Cylinder
2
W151-0291E
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. Spring pin
3. Piston
4. Plain bearing
5. Packing
6. Backup ring
7. Backup ring
8. O-ring
9. Backup ring
10. Rod
11. Rod cover
12. O-ring
13. Packing
14. Backup ring
15. Dust seal
16. Retaining ring
17. Plain bearing
General View
△
0
360-357-10000
△
0
360-357-20000
Page 46
C-3. C-3.
Pilot Check Valve (Front & rear stabilizer)
3
W115-0351E
C-3 Pilot Check Valve (Front and rear stabilizer)
[NOTE]
There is a case that the appearance and so on differ from the parts for this crane. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this crane and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Plug
2. O-ring
3. Spring
4. Poppet
5. Piston
6. O-ring
7. Body
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A-B port G 1/4 24.5 - 29.4 18.1 - 21.7
Plug-1 G 3/8 44.1 - 53.9 32.5 - 39.8
Mounting bolt M 10 43 - 49 31.7 - 36.1
General View
△
1
366-239-30000
Page 47
C-4. C-4.
Pilot Check Valve (Outrigger jack)
4
W115-0560E
C-4 Pilot Check Valve (Outrigger jack)
[NOTE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Body
2. Plug
3. O-ring
4. Poppet
5. Spring
6. Piston
7. O-ring
8. Backup-ring
9. Seat
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
Mounting bolt T1 M 10 43 - 49 31.7 - 36.1
General View
△
0
366-248-00000
Page 48
C-5. C-5.
Power Slide Cylinder (Outrigger)
5
W153-0090E
C-5 Power Slide Cylinder (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
1. Cylinder
2. Nut
3. Packing
4. Backup ring
5. O-ring
6. Piston
7. Rod
8. Rod cover
9. O-ring
10. Packing
11. Backup ring
12. Dust seal
General View
△
0
360-433-10000
Page 49
C-6. C-6.
Power Slide Cylinder (Rear stabilizer)
6
W153-0140E
C-6 Power Slide Cylinder (Rear stabilizer)
[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. Dust seal
2. Backup ring
3. Packing
4. O-ring
5. Rod cover
6. Cylinder
7. Rod
8. Piston
9. Packing
10. Backup ring
11. O-ring
12. Nut
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
12 – 98 72.3
△
2
360-429-60000
△
2
360-429-50000
Page 50
C-7. C-7.
Relief Valve (Front stabilizer)
7
W111-0280E
C-7 Relief Valve (Front stabilizer)
[NOTE]
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
IW111-012002
3. Spring
4. O-ring
5. O-ring
6. O-ring
7. Body
10. Spring
11. Screw
12. Nut
13. Nut
14. O-ring
16. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T Rc 1/2 71 - 97 52.3 – 71.5
7 78.5 – 88.3 57.9 – 65.1
Mounting bolt M 8 13 - 15 9.5 – 11.0
General View
△
1
366-062-90000
Page 51
C-8. C-8.
Pressure Sensor (Front stabilizer
)
8
W337-0040E
C-8 Pressure Sensor (Front stabilizer)
[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
Setup value----------17.7MPa (180.5 kgf/cm2)
[NOTE]
The adjustment of pressure detector is unnecessary.
General View
△
1
366-828-90000
Use example
Specification
Page 52
i
D
Swing System
Contents
D-1 Hydraulic Motor
(Swing) .....................................1
1. Structure................................................... 1
D-2 Swing Speed Reducer .....................3
1. Structure................................................... 3
2. Removing of hydraulic motor .................... 4
3. Disassembly of reducer ............................ 4
4. Assembly of reducer................................. 5
5. Installation of hydraulic motor ................... 5
D-3 Swing Bearing..................................6
1. Structure................................................... 6
2. Notes for installation ................................. 7
D
Page 53
D-1 D-1
Hydraulic Motor (Swing)
1
W102-0570E
D-1 Hydraulic Motor (Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Hydraulic symbol
Page 54
2
W102-0570E
D-1. D-1.
Hydraulic Motor (Swing)
1.Housing
2.Rotary Assy
3.Shaft Assy
4.Cover Assy
5.Piston
6.Retaining Ring
7.Plate
8.Plate
9.Retaining Ring
10.Oil Seal
11.Ring
12.O-ring
13.O-ring
14.O-ring
16.Spring
17.Distance Piece
20.Plug Assy
31.Shaft
32.Bearing
33.Bearing
34.Retaining Ring
35.Retaining Ring
41.Cover
43.Plate
44.Pin
46.Hexagon Socket Bolt
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
Note
Pp G1/4 29 21 Pilot port
A, B G3/4 167 123
R1,R2 G3/8 49 36 Drain port
△
0
366-636-50000
Page 55
D-2 D-2
Swing Speed Reducer
3
W511-0280E
D-2 Swing Speed Reducer
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. This reducer is two-stage planetary-gear speed reducing mechanism.
2. The rotation power of the hydraulic motor is transmitted in the following order.
Motor output shaft
Sun gear (20) planetary gear (15) carrier A (22) Sun gear (12)
Planetary gear (26)
carrier B (10) reducer output shaft (1)
Page 56
D-2 D-2
Swing Speed Reducer
4
W511-0280E
1. Output shaft
2. Bolt
3. Spring washer
4. Retainer (A)
5. Casing
6. Ball bearing
7. Retainer (B)
8. Snap ring
9. Plug
10. Carrier (B)
11. Snap ring
12. Sun gear (B)
13. King pin (A)
14. Plate
15. Planetary gear (A)
16. Needle bearing
17. Ring
18. Plug (G1/2)
19. Seal washer
20. Sun gear (A)
21. Plate
22. Carrier (A)
23. Snap ring
24.Ring
25. Plate
26. Planetary gear (B)
27. Needle bearing
28. Plate
29. King pin (B)
30. Roller bearing
31. Oil seal
32. Sleeve
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
2 M8 23.5 – 27.5
17.3 – 20.3
18 G1/2 175 – 196
129.1 – 144.6
2. Removing of hydraulic motor
[NOTICE]
After fixing the swing frame, remove the hydraulic
motor and the reducer to prevent the swing frame
from self-rotating.
1. Before disassembly, mark to each mating surface
2. Drain oil from the hydraulic motor and the reducer.
3. After removing bolts (2) (eight places) securing
the hydraulic motor, remove the motor by using
pulling-out screw (2-M8) on the motor flange.
[NOTICE]
Support the hydraulic motor, 20kg (44.1lbf), firmly to
prevent falling.
3. Disassembly of reducer
[NOTICE]
Disassembly and assembly should be always
performed in a clean place caring dust and so on.
Careful work is necessary.
Do not beat and lever to prevent burrs and
breakages that cause impossible assembly and
performance deteriorations.
1. Take out parts from sun gear-A (20) to carrier
B(10).
[NOTICE]
King pins (13), (29) are fitted by shrinkage fitting,
space (14) is fitted by caulking.
2. Remove snap ring (8) and retainer-B (7), and
remove output shaft (1) from casing (5) by using a
press.
[NOTICE]
Sleeve (32) shrinkage fit, can not be removed.
Page 57
5
W511-0280E
D-2. D-2.
Swing Speed Reducer
4. Assembly of reducer
1. Press-fit retainer-A (4) and roller bearing (30) to
output shaft (1).
[NOTICE]
Apply lithium type grease between retainer-A (4)
and oil seal (31).
2. Build output axis Assy into the casing (５).
[NOTICE]
Apply THREE BOND 1215 on the mating surface
between the casing (5) and retainer-A (4).
4.Press-fit ball bearing (6), install retainer-B (7), and
hold it in position with snap ring (8).
5. Hereafter, assemble carrier-B(10) to sun gear-A
(20) in reverse order of "Disassemly of reducer."
[NOTICE]
Confirm sun gear-A (20) turns lightly by your hand.
5. Installation of hydraulic motor
1. Tighten hydraulic motor by bolt (2).
[NOTICE]
Apply THREE BOND 1104 on the mating surface
between the hydraulic motor casing and the swing
reducer.
2. Apply THREE BOND 1215 on the mating surface
between the hydraulic motor casing and the swing
reducer.
3. Supply gear oil into the reducer via plug (9).
(about 1.2L (73.2 in
3
))
△
0
360-814-51000
Page 58
D-3 D-3
Swing Bearing
6
W512-0200E
D-3 Swing Bearing
[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. Swing bearing
2. Bolt (M20x70)
3. Plain washer
4. Bolt (M22x90)
5. Plain washer
6. Swing Assy
7. Bolt (M18x55)
8. Plain washer
General View
Page 59
7
W512-0200E
D-3. D-3.
Swing Bearing
2. Notes for installation
When installing the inner ring of the swing bearing, face the soft zone (stop plug) to the R position shown in
the figure on the previous page.
To tighten the bolts•2,4,7, follow the procedures below.
Tighten all the bolts temporarily with approximately half the specified tightening torque.
Then tighten the bolts securely. After tightening one bolt in this case, tighten the diagonally opposite bolt.
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
Note
2 M20 466 - 505
343.7 – 372.4
4 M22 628 - 672
463.2 – 495.6
7 M18 372 - 412
274.3 – 303.9
Apply a torque control agent to
the threaded sections of the
bolts.
△
1
313-015-20000
Page 60
i
E
Boom Elevating System
Contents
E-1 Boom Elevating Cylinder........1
1. Structure................................................... 1
2. Pressure detector for AMA........................ 2
E-2 Counterbalance Valve
(Elevating)................................3
1. Structure................................................... 3
E
Page 61
E-1 E-1
Boom Elevating Cylinder
1
W155-0310E
E-1 Boom Elevating Cylinder
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Grease nipple
2. Spring pin
3. Piston
4. Plain bearing
5. Packing
6. Backup ring
7. O-ring
8. Backup ring
9. Cylinder
10. Rod
11. Rod cover assy
12. O-ring
13. Damper ring
14. O-ring
15. Packing
16. Backup ring
17. Dust seal
18. Retaining ring
19. Backup ring
20. Plug
21. Orifice
Page 62
2
W155-0310E
E-1. E-1.
Boom Elevating Cylinder
2. Pressure detector for AMA
[NOTE]
The adjustment of pressure detector is unnecessary.
Cylinder side Rod side
△
0
360-275-80000
△
1
361-500-70000
△
1
361-801-10000
Page 63
E-2 E-2
Counterbalance Valve (Elevating)
3
W119-0282E
E-2 Counterbalance Valve (Elevating)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Body
2. Spool
3. Plug
4. Backup ring
5. Spring
6. O-ring
7. Plug
8. Plug
9. Plug
10. Poppet
11. Spring
12. O-ring
13. O-ring
General View
Page 64
4
W119-0282E
E-2. E-2.
Counterbalance Valve (Elevating)
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
Mounting bolt M10 34.3 - 39.2
25.3 - 28.9
A-B port
Plug-3.9
G 3/8 44.1 - 53.9
32.5 - 39.8
Plug - 7 G 1/2 53.9 - 63.7
39.8 - 47
△
2
366-055-20000
△
1
366-065-50000
Page 65
i
F
Winch System
Contents
F-1 Winch................................................1
1. Structure................................................... 1
F-2 Hydraulic Motor(Winch) ..................5
1. Operational explanation............................ 5
2. Structural explanation ............................... 5
3. Structure................................................... 6
F-3 Counterbalance Valve(Winch) ........7
1. Structure................................................... 7
F F
Page 66
F-1 F-1
Winch
1
W526-0350E
F-1 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
[NOTICE]
※1：The amount of the projection in the bolt thread should be 5mm(0.2in) or less.
※2：A proper oil quantity is shown by the oil level line in the drum state for checking, refueling, and
draining(as shown).
※3：If plate-15 can not be inserted between winch assy-1 and support-9, discard plate-15.
1.Winch ASSY
2.Bolt
3.Spring washer
4.Wedge
5.Cover
6.Bolt
7.Plain washer
8.Spring washer
9.Support
10.Bolt
11.Hexagon socket head bolt
12.Hexagon socket head bolt
13.Spring washer
14.Spring washer
15.Plate
Page 67
F-1 F-1
Winch
2
W526-0350E
1 Winch ASSY
1.Winch ASSY
2.Support
3.Hydraulic motor
4.Bolt
5.Spring washer
6.O-ring
7.Plug ASSY
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
4 M16 132-154 97-114
Page 68
F-1 F-1
Winch
3
W526-0350E
1 Winch ASSY
1.Bracket
2.Plug ASSY
3.O-ring
4.Spindol
5.Hexagon socket head plug
6.Snap ring
7.O-ring
8.Oil seal
9.Snap ring
10.Carrier(B)
11.Steel bearing ring
12.Steel bearing ring
13.Planetary gear
14.Needle roller bearing
15.Hexagon socket head plug
16.O-ring
17.Steel bearing ring
18.Kingpin(A)
19.Snap ring
20.Hexagon socket head bolt
21.Ball bearing
22.Steel bearing ring
23.Housing
24.Sun gear(A)
25.Drum
26.Slust plate
27.Sun gear(B)
28.Carrier(A)
29.Internal gear
30.Kingpin(B)
31.Idle gear
32.Steel bearing ring
33.Ball bearing
34.Ball bearing
35.Sleeve
36.Clip
37.Hexagon socket head bolt
38.O-ring
39.Spring
40.Ball bearing
41.Input shaft
42.Piston
43.Lock washer
44.O-ring
45.Backup ring
46.O-ring
47.Backup ring
48.Partner plate
49.Friction plate
50.Fixation plate(S)
51.Hexagon socket head bolt
Page 69
4
W526-0350E
F-1. F-1.
Winch
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
20 M12 78.5 58
37 ※3 M14 108-126 80-93
37 ※4 M14 118 87
51 M14 108-126 80-93
[NOTICE]:
※1：Caulking.
※2：Apply THREE BOND 1373N.
※5：Apply lithium grease or spindle oil.
※6：wrap sealing tape. Plug must not project from the surface.
※7：Apply THREE BOND 1215 when shrinkage fitting.
※8：Apply lithium grease between lips. Apply THREE BOND 1215 on outer side.
※9：Adjust the space with piston to L=1.1 to 1.3mm(0.04 to 0.05in).
△
0
360-736-00000
△
0
360-736-70000
△
0
313-114-90000
Page 70
F-2 F-2
Hydraulic Motor(Winch)
5
W102-0581E
F-2 Hydraulic Motor(Winch)
1. Operational explanation
When pressure oil is supplied from the other slit in
the control plate, half of pistons in the cylinder block
receive the pressure and are pushed out.
The pistons pushed out push the flange portion of
the drive shaft upward, and rotate the drive shaft.
At this time, the cylinder block slide on the control
plate.
When rotating, each of seven pistons reciprocates
between top dead center (OT) and bottom dead
center (UT), and then obtains strokes of (h)
according to inclination (a).
The amount of oil that corresponds to the sectional
area of the piston (F) × piston stroke (h) is supplied
from one of slits in the control plate at the process of
the piston of UT to OT.
2. Structural explanation
Cylinder block-9 is maintained rotatably with the
center pin and the control plate.
Cylinder block-9 is pressed against the control
plate by the corned disc springs at no-load running.
The pressure rises up between the cylinder block 9
and the control plate, balances cylinder block-9 and
the control plate, and a oil film is always formed
between them.
Bearings-16 and 17 are combined with bearing
case-11, and installed in drive shaft-10 .
These bearings receive the load caused in axially
and the radial.
Oil seal-24, O rings-6 and 19 are used for the seal of
the driving mechanism to the outside.
Page 71
6
W102-0581E
F-2. F-2.
Hydraulic Motor(Winch)
3. Structure
[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.Piston motor
2.Counterbalance valve
3.Housing
4.Cover
5.Parallel pin
6.O-ring
7.Hexagon socket head bolt
8.Plug
9.Cylinder block
10.Shaft
11.Case
12.Seal case
13.Shim
14.Plate
15.Retaining ring
16.Bearing
17. Bearing
18.Retaining ring
19.O-ring
20.Shim
21.Shim
22.Shim
23.Screw
24.Oil seal
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
7 M12 98-123 72-91
8 G1/4 19-23 14-17
△
1
366-630-10000
Page 72
F-3 F-3
Counterbalance Valve(Winch)
7
W119-0540E
F-3 Counterbalance Valve(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
1.Body
2.Spool
3.Piston
4.Orifice
5.Cover
6.Cover
7.Cover
8.Plunger
9.Bushing
10.Plug
11.Plug
12.Hexagon socket head bolt
13.Hexagon socket head bolt
14.Hexagon socket head bolt
15.Hexagon head bolt
16.O-ring
17.O-ring
18.O-ring
19.O-ring
20.O-ring
21.Spring
22.Spring
23.Spring
24.Relief valve
Page 73
8
W119-0540E
F-3. F-3.
Counterbalance Valve(Winch)
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
12 M6 12-15 9-11
13 M8 28-35 21-26
14 M10 55-69 41-51
15 M12 88 65
A M10 43-49 32-36
B M10 43-49 32-36
△
0
366-053-70000
Page 74
i
G
Boom Telescoping System
Contents
G-1 General description of
telescoping system.................1
1. Functions of units...................................... 1
1.1 Telescoping cylinder ................................... 1
1.2 Counterbalance valve................................. 1
2. Wire rope mechanism............................... 1
2.1 Wire rope mechanism A
(for extending the 3rd boom section) ... 1
2.2 Wire rope mechanism B
(for retracting the 4th boom section) .... 2
2.3 Wire rope mechanism C (for extending
the 4th boom section /retracting
the 3rd boom section) .......................... 2
2.4 Wire rope mechanism D
(for extending the top boom section) ... 3
2.5 Wire rope mechanism E
(for retracting the top boom section) .... 3
3. Relation between boom extending/retracting
operations and wire rope mechanisms ... 4
3.1 Boom extension.......................................... 4
3.2 Boom retraction .......................................... 4
4. Boom telescoping order............................ 4
4.1 Extending.................................................... 4
4.2 Retracting ................................................... 4
G-2 Boom (Five-section boom)..............5
1. Structure ................................................... 5
2. Dismounting the boom assembly and
preparation of the boom disassembly......7
2.1 Dismounting the boom assembly................7
2.2 Preparation of the boom disassembly ........8
3. Disassembling the boom......................... 10
3.1 Detaching the base boom section.............10
3.2 Pulling out
the boom telescoping cylinder ............11
3.3 Detaching the 2nd boom section ..............13
3.4 Detaching the 3rd boom section ...............13
3.5 Detaching the 4th boom section and
disassembling the top boom section........14
4. Inspection................................................ 15
4.1 Boom.........................................................15
4.2 Slide plate .................................................15
4.3 Sheave......................................................15
4.4 Wire rope for boom telescoping................15
5. Structure of the adjuster assy.................. 16
6. Tools needed for
boom assembling operation......... 17
6.1 Tool A ........................................................17
6.2 Tool B ........................................................18
7. Assembling the boom.............................. 19
7.1 Assembling the top boom section .............19
7.2 Assembling the 4th boom section .............21
G
Page 75
ii
7.3 Assembling the 3rd boom section............25
7.4 Assembling
the boom telescoping cylinder.......... 28
7.5 Assembling the 2nd boom section ...........29
7.6 Assembling the base boom section ......... 34
8. Mounting the boom assy......................... 37
G-3 Telescoping Cylinder.....................38
1. Structure ......................................................... 38
G-4 Counterbalance Valve
(Telescoping) .......................40
1. Structure ......................................................... 40
Page 76
G-1 G-1
General description of telescoping system
1
WG02-0480E
G-1 General description of telescoping system
1. Functions of units
1.1 Telescoping cylinder
This cylinder is located inside the boom.
It is connected to the base boom section and the 2nd boom section with pins to extend and retract the 2nd
boom section.
1.2 Counterbalance valve
This valve serves to prevent the telescoping cylinder from spontaneously retracting by a load during a boom
retracting operation, and to make it retract at a speed in proportion to the oil quantity supplied to the
telescoping cylinder.
This valve further serves to prevent the telescoping cylinder from retracting when the piping between this
valve and the manual control valve is damaged.
2. Wire rope mechanism
The 3rd, 4th and top boom sections are extended/retracted by the following five wire rope mechanisms.
2.1 Wire rope mechanism A (for extending the 3rd boom section)
This mechanism extends the 3rd boom section at the same time when the 2nd boom section is extended.
The wire ropes are passed within the boom in the following order.
・Base boom section → sheave at the front end of the telescoping cylinder → rear end of the 3rd boom
section
Page 77
G-1 G-1
General description of telescoping system
2
WG02-0480E
2.2 Wire rope mechanism B (for retracting the 4th boom section)
This mechanism retracts the 4th boom section at the same time when the 2nd boom section is retracted.
The wire rope is passed within the boom in the following order.
・Rear end of the 4th boom section → rear end of the 2nd boom section → base boom section (adjuster assy)
→ equalizer sheave (on the upper surface of the 2nd boom section) → rear end of the 2nd boom section
→ rear end of the 4th boom section
2.3 Wire rope mechanism C (for extending the 4th boom section /retracting the 3rd boom section)
The wire rope mechanism C serves for both extending and retracting operations.
・Extending operation: This mechanism extends the 4th boom section at the same time when the 3rd boom
section is extended.
・Retracting operation: This mechanism retracts the 3rd boom section at the same time when the 4th boom
section is retracted.
The wire ropes are passed within the boom in the following order.
・Front end of the base boom section → front end of the 3rd boom section → rear end of the 4th boom
section → front end of the 3rd boom section
Page 78
G-1 G-1
General description of telescoping system
3
WG02-0480E
2.4 Wire rope mechanism D (for extending the top boom section)
This mechanism extends the top boom section at the same time when the 4th boom section is extended.
The wire ropes are passed within the boom in the following order.
・Front end of the 3rd boom section → front end of the 4th boom section → rear end of the top boom section
2.5 Wire rope mechanism E (for retracting the top boom section)
This mechanism retracts the top boom section at the same time when the 4th boom section is retracted.
The wire ropes are passed within the boom in the following order.
・Front end of the 3rd boom section → rear end of the 4th boom section → rear end of the top boom section
Page 79
4
WG02-0480E
G-1. G-1.
General description of telescoping system
3. Relation between boom
extending/retracting operations and
wire rope mechanisms
3.1 Boom extension
・2nd boom section:
This has no relation to any of the wire rope
mechanisms.
This is extended by the telescoping cylinder.
・3rd boom section:
This is extended by the wire rope mechanism A.
・4th boom section:
This is extended by the wire rope mechanism C.
・Top boom section:
This is extended by the wire rope mechanism D.
3.2 Boom retraction
・2nd boom section:
This has no relation to any of the wire rope
mechanisms.
This is retracted by the telescoping cylinder.
・3rd boom section:
This is retracted by the wire rope mechanism C.
・4th boom section:
This is retracted by the wire rope mechanism B.
・Top boom section:
This is retracted by the wire rope mechanism E.
4. Boom telescoping order
4.1 Extending
1. When the 2nd boom section is extended, the 3rd
boom section is also extended at the same time
by the wire rope mechanism A.
2. When the 3rd boom section is extended, the 4th
boom section is also extended at the same time
by the wire rope mechanism C.
3. When the 4th boom section is extended, the top
boom section is also extended at the same time
by the wire rope mechanism D.
As a result, all of the 2nd, 3rd, 4th and top boom
sections are extended all together.
4.2 Retracting
1. When the 2nd boom section is retracted, the 4th
boom section is also retracted at the same time by
the wire rope mechanism B.
2. When the 4th boom section is retracted, the 3rd
boom section is also retracted at the same time by
the wire rope mechanism C. Additionally the top
boom is retracted at the same time by the wire
rope mechanism E as well.
As a result, all of the 2nd, 3rd, 4th and top boom
sections are retracted all together.
Page 80
5
G-2
Boom (Five-section boom)
5
G-2
W536-1040E
G-2
G-2 Boom (Five-section boom)
1. Structure
General View
△
3
312-049-90100
Page 81
G-2
Boom (Five-section boom)
6
W536-1040E
G-2
[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. ---------
2. ---------
3. ---------
4. ---------
5. ---------
6. Pin
7. Snap pin
8. Pin
9. Plate
10. Sheave assembly
11. Spacer
12. Spacer
13. Pin
14. Plate
15. Sheave assembly
16. Spacer
17. Wire rope
18. Nut
19. Wire rope
20. Nut
21. Nut
22. Wire rope
23. Wire rope
24. Wire rope
25. Hexagon socket head bolt
26. Support
27. Plug
28. Nameplate
29. Tapping screw
30. Cap
31. Grease nipple
32. Grease nipple
33. Pin
34. Plate
35. Cover
36. Pin
37. Support
38. Sheave assembly
39. Spacer
40. Pin
41. Spacer
42. Guide
43. Plate
44. Roller assembly
45. Roller assembly
46. Pin
47. Pin
48. Spacer
49. Pin
50. Snap pin
51. Sheave assembly
52. Pin
53. Retaining ring
54. Lock washer
55. Nut
56. Sheave assembly
57. Pin
58. Bolt
59. Support
60. Bolt
61. Sheave assembly
62. Spacer
63. Spacer
64. Button bolt
65. Pin
66. Plate
67. Slide plate
68. Machine screw
69. Plain bearing
70. Plate
71. Retainer
72. Retainer
73. Slide plate
74. Retainer
75. Retainer
76. Slide plate
77. Slide plate
78. Support
79. Slide plate
80. Plate
81. Plate
82. Slide plate
83. Shim
84. Shim
85. Slide plate
86. Plate
87. Plate
88. Slide plate
89. Plate
90. Support assembly
91. Hexagon socket head bolt
92. Slide plate
93. Slide plate
94. Shim
95. Shim
96. Bolt
97. Plain washer
98. Support
99. Hexagon socket head bolt
100. Bolt
101. Spring washer
102. Bolt
103. Bolt
104. Bolt
105. Bolt
106. Bolt
107. Bolt
108. Bolt
109. Bolt
110. Bolt
111. Spring washer
112. Hexagon socket head bolt
113. Hexagon socket head bolt
114. Bolt
115. Spring washer
116. Pin
117. Spacer
118. ---------
119. Sheave assembly
120. Pin
121. Retaining ring
122. Pin
123. Retaining ring
124. Adjuster assembly
125. Bolt
126. Spring washer
127. Bolt
128. Plain washer
129. Sheave assembly
130. Pin
131. Retaining ring
132. Support
133. Bolt
134. Shim
135. Pin
136. Bolt
137. Spring washer
138. Support
139. Bolt
140. Bolt
141. Pin
142. Retaining ring
143. Slide plate
144. Slide plate
145. Nut
146. Bolt
147. Plate
148. Plate
149. Plate
150. Plate
151. Slide plate
152. ---------
153. ---------
154. ---------
155. ---------
156. Shim
157. Shim
158. Plate
159. Plate
160. Bolt
161. Bolt
162. Set screw
163. Cover
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2. Dismounting the boom assembly and
preparation of the boom disassembly
2.1 Dismounting the boom assembly
1. Extend the outrigger and set the crane level.
2. Confirm all the crane functions.
3. Swing the boom over the rear.
4. Unwind the winch wire rope enough to lay down
the hook block on the ground.
5. Prepared wooden spacer of the thickness of "5in.".
(For disassembly and assembly)
6. Put the "5 in." spacer between the elevating
cylinder and the swing frame.
7. Lower the boom until the elevating cylinder comes
in contact with the spacer.
8. Stop the engine.
9. Relieve the pressure in the circuit by operating all
control levers back and forth.
10. Remove hydraulic hoses for winch and tel.
cylinders.
* Put plugs to all connectors.
11. Disconnect all electric wires between boom and
swing frame.
12. Remove hook block and rope socket.
13. Slightly hoist the boom assy to relieve the boom’s
weight on the pivot pins.
* Boom Assy weight: Approx. 3,000 lbs. (1350kg)
14. Remove elevating cylinder's upper pivot pin.
15. Remove Boom bottom pivot pin.
16. Dismount Boom Assy.
* This boom's bottom is V-shaped.
* Boom Assy must be placed level for easy
disassembling.
1,2,3,4
6
13
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2.2 Preparation of the boom disassembly
[NOTICE]
◆Refer to the boom length and angle detector replacement procedures in Chapter H before disassembling the
boom.
1. Dismount Winch Assy.
2. Prepare 30’ 6” (9300mm) electric cable. - Dummy
cable
3. Lock the Boom Length Detecter (BLD) cable drum
to prevent it from turning.
* If BLD drum is over-wound, potentiometer may
be damaged.
4. Disconnect BLD cable at top boom head inside.
5. Connect dummy cable to BLD cable.
6. Pull out BLD Cable from back side of boom.
2
4
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7. Disconnect dummy cable from BLD cable.
* Leave dummy cable inside boom.
8. Disconnect Hose Joint from tel. cylinder.
* Put plug.
7
8
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3. Disassembling the boom
[NOTICE]
Follow the disassembling procedure described here
only after removing the winch and the boom
length/angle detector.
Refer to Chapter H “boom length/detector
replacement procedure” for the removing
procedure.
3.1 Detaching the base boom section
1. Fully retract the boom.
2. Remove the adjuster assy from the front end of
the base boom section.
[NOTICE]
Before removing the wire rope, measure and record
the dimension Lb, which can be used for reference
during reassembly.
3. Remove the wire ropes for extending the 3rd
boom section from the rear end of the base boom
section.
[NOTICE]
Before removing the wire ropes, measure and
record the dimension La, which can be used for
reference during reassembly.
4. Remove the wire ropes for extending the 4th
boom section from the front end of the base boom
section and fix them at the front end of the 4th
boom section with a wire etc.
[NOTICE]
Before removing the wire ropes, measure and
record the dimension Lc, which can be used for
reference during reassembly.
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5. Pull out the pin fxing the boom telescoping
cylinder to the base boom section.
6. To remove the slide plates from the base boom
section, pull out the 2nd boom section about 400
to 600 mm (1.3 to 2 ft).
7. Remove the slide plates from the side and lower
surfaces at the front end of the base boom
section.
[NOTICE]
When removing the slide plates from the lower
surface, be sure to remove them with the retainers.
8. Draw out the 2nd boom section and others from
the base boom section.
3.2 Pulling out the boom telescoping cylinder
1. Remove the sheaves for extending the top boom
section and the wire rope guide from the front end
of the 4th boom section.
2. Remove the wire ropes for extending the top
boom section from the front end of the 3rd boom
section and fix them at the front end of the top
boom section with a wire etc.
[NOTICE]
Before removing the wire ropes, measure and
record the dimension Ld, which can be used for
reference during reassembly.
3. Remove the wire ropes for retracting the top boom
section from the front end of the 3rd boom section
and fix them at the front end of the 4th boom
section with a wire etc.
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4. Pull and extend the 4th boom section about 200
mm (8 in).
[NOTICE]
If step 5 and subsequent steps are performed
without extending the 4th boom section, it will be
impossible to pull out the boom telescoping cylinder
from the boom.
Do not retract the 4th boom section until the 3rd
boom section is removed.
5. Remove the two guide rollers for the boom length
detector cord.
6. Remove the support for the wire rope guide at the
rear end of the 2nd boom section.
7. Remove the bolts and disassemble the support A
for the wire rope for extending the 3rd boom
section.
Remove the parts on the support A from the rear
end of the 3rd boom section.
[NOTICE]
When it is attempted to remove the support A, it will
hit the wire rope for retracting the 4th boom section.
To avoid this, slacken the wire rope for retracting
the 4th boom section as shown in the figure below
and move it to one side within the boom.
8. Remove the pin fixing the boom telescoping
cylinder to the 2nd boom section and pull out the
boom telescoping cylinder about 1 m (3.3 ft).
9. Remove the support B from the rear end of the
3rd boom section and put it on the boom
telescoping cylinder.
10. Pull out the boom telescoping cylinder with the
support B and the wire ropes for extending the 3rd
boom section from the boom.
(Mass of cylinder: approx. 600 kg (1325 lbs))
11. Remove the wire rope for retracting the 4th boom
section from the rear end of the 4th boom section.
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3.3 Detaching the 2nd boom section
1. Remove the slide plates from the side and lower
surfaces at the front end of the 2nd boom section.
2. Draw out the 3rd boom and others from the 2nd
boom section.
3.4 Detaching the 3rd boom section
1. Remove the sheave (1) for extending the 4th
boom section and the wire rope guide from the
front end of the 3rd boom section.
2. Remove the wire ropes for extending the 4th
boom section from the front end of the 3rd boom
section and fix them at the front end of the 4th
boom section with a wire etc.
[NOTICE]
If the 4th boom section is in a retracted condition,
the support at the front end of the wire rope may be
caught by the 4th boom section. In such a case,
pull out and extend the 4th boom section about 200
mm (8 in).
3. Remove the slide plates from the side and lower
surfaces at the front end of the 3rd boom section.
4. Draw out the 4th boom and top boom from the 3rd
boom section.
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3.5 Detaching the 4th boom section and
disassembling the top boom section
1. Remove the sheave (2) for extending the 4th
boom section from the 4th boom section.
2. Release the wire ropes for extending the 4th
boom section and pull out them from the 4th boom
section.
3. Remove the sheave for retractng the top boom
section and the wire rope guide from the rear end
of the 4th boom section.
4. Release the wire ropes for retracting the top boom
section and pull out them to the rear of the 4th
boom section.
5. Remove the slide plates from the side and lower
surfaces at the front end of the 4th boom section.
6. Remove the plates from the upper surface of the
4th boom section.
7. Draw out the top boom section from the 4th boom
section.
8. Remove the wire ropes for extending the top
boom section from the top boom section.
9. Remove the wire ropes for retracting the top boom
section from the top boom section.
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4. Inspection
4.1 Boom
Check the boom for torsion, deformation, warp,
and/or cracks.
4.2 Slide plate
Replace cracked or severely worn parts.
4.3 Sheave
Replace damaged, deformed, or severely worn
parts.
4.4 Wire rope for boom telescoping
If any of the following conditions (1) through (5) are
found, replace the wire rope.
[NOTICE]
If the end of wire rope is not in proper condition,
repair or cut.
1. In running ropes: six randomly distributed broken
wires in one lay, or three broken wires in one
strand in one lay.
2. Wear of one-third of the original diameter of
outside individual wires. Evidence of kinking,
crushing, bird caging, or any other damage
resulting in distortion of the rope structure.
3. Evidence of any heat damage from any cause.
4. Reductions from nominal diameter of more than:
1/64 inch for diameters up to and including 5/16
inch
1/32 inch for diameters 3/8 to 1/2 inch inclusive
3/64 inch for diameters 9/16 to 3/4 inch inclusive
1/16 inch for diameters 7/8 to 1-1/18 inches
inclusive
3/32 inch for diameters 1-1/4 to 1-1/12 inches
inclusive
5. In standing ropes: more than two broken wires in
one lay in sections beyond end connections, or
more than one broken wire at an end connection.
Page 91
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16
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5. Structure of the adjuster assy
[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.
Use the illustration below for a reference when disassembling the adjuster assy.
Page 92
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17
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6. Tools needed for boom assembling operation
The following tools are needed to assemble the boom. They should be prepared by yourself.
6.1 Tool A
[NOTICE]
All dimensions in the drawings are in millimeters.
The materials, thread sizes and pitches are described based on JIS (Japanese Industrial Standard).
- Assembly drawing
- Tool main body
Material: SS400
Page 93
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- Tool fixing pin and plate
Material: SS400
6.2 Tool B
[NOTICE]
The thread size is based on JIS (Japanese Industrial Standard).
Bolt: M12 coarse thread with thread length 50 mm (2 in) or more
Nut: M12 coarse thread, height less than 13 mm (1/2 in)
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7. Assembling the boom
7.1 Assembling the top boom section
1. To facilitate installaton of the cord of the boom
length/angle detector, prepare the following cord
or wire (later called as “temporary cord”).
- 1.6 mm (1/16 in) to 4.8 mm (3/16 in) in diameter
- 9300 mm (30 ft 6 in) or longer
2. Fix the temporary cord to the support at the front
end of the top boom section and stretch it to the
rear end of the top boom section.
3. Pass the temporary cord through the cord guide
for the boom length/angle detector and pull it out
to the rear of the top boom section.
[NOTICE]
Pull out the temporary cord at least 1500 mm (4 ft
11 in) from the rear end of the top boom section.
4. Install protective covers on the top boom section.
5. Install the wire ropes for extending and retracting
the top boom section.
[NOTICE]
Make sure the retaining rings are securely put in
place and the wire rope ends are secured.
6. Temporarily fix the other ends of the wire ropes for
extending the top boom section at the end of the
boom with a wire etc.
[NOTICE]
Fix the wire ropes while pulling them to the front
end of the boom to prevent them from hanging
down.
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7. Measure the following internal widthwise
dimension of the 4th boom section.
- At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end
(welded portion)
[NOTICE]
The measured dimension will be used when the
clearances are adjusted at step 10.
8. Apply grease to the surfaces inside the 4th boom
section on which the slide plates of the top boom
section slide.
9. Install the slide pates at the rear end of the top
boom section.
10.Adjust the clearances of the slide plates on the
side surfaces of the boom based on the
dimension measured at step 7.
Adjust the clearances to the following by
increasing or decreasing the number of shims.
- 0.5 mm (1/64 in) or less in total when the values
at right and left are added
[NOTICE]
After this adjustment, apply thread locker
(ThreeBond 1305) to screws that are used for fixing
the slide plates.
Then lightly tighten the screw and back off a quarter
turn.
11. Apply grease to the surfaces outside the top
boom section on which the slide plates of the 4th
boom section slide and the slide plates at the rear
end of the top boom section.
12. While pulling the temporary cord and the wire
ropes for retracting the top boom section to the
rear of the boom, insert the top boom section into
the 4th boom section to the point about
2 m (6.6 ft) before full retraction.
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7.2 Assembling the 4th boom section
1. Install the slide plates to the lower surface at the
front end of the 4th boom section.
2. Install the slide plates to the side surfaces at the
front end of the 4th boom section. Adjust the
clearances to the following by increasing or
decreasing the number of shims.
- 0.5 mm (1/64 in) or less in total when the values
at right and left are added
[NOTICE]
Try to minimize the difference between the right and
left clearances.
When installing the slide plates, pass the wire ropes
for extending the top boom section as shown below.
3. Retract the top boom section to the point about
100 mm (4 in) before full retraction.
4. Install the sheaves for extending the top boom
section at the front end of the 4th boom section.
5. Release the wire ropes for extending the top
boom section and place them in the grooves of
the sheaves for extending the top boom section.
Then install the wire rope guide for the sheaves
for extending the top boom section.
6. Fully retract the top boom section.
7. Pass the wire ropes for retracting the top boom
section through the openings at the upper surface
of the 4th boom section.
8. Place the wire ropes for retracting the top boom
section in the grooves of the sheaves for
retracting the top boom section.
Then insert the sheaves for retracting the top
boom section through the openings at the upper
surface of the 4th boom section and fix them with
pins.
[NOTICE]
Install the sheaves with their clinched sides facing
outwardly.
After installing the sheave, bend one of tabs of the
toothed washer over a slot of the lock nut.
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9. Temporarily fix the ends of the wire ropes for
retracting the top boom section at the front end of
the 4thboom section with a wire etc.
Install the wire rope guides at the rear end of the
4th boom section.
[NOTICE]
Fix the wire ropes while pulling them to the front
end of the boom to prevent them from hanging
down.
If the right/left wire rope guides are reversed, they
will hit the 3rd boom section when the 4th boom
section is inserted into the 3rd boom section.
Make sure that the wire rope guides are installed in
the following condition.
10. Install the slide plates inside the 4th boom
section.
11.Place the wire ropes for extending the 4th boom
section in the grooves of the sheaves (2) for
extending the 4th boom section.
12. Install the sheaves (2) for extending the 4th boom
section to the 4th boom section.
[NOTICE]
When installing the sheave pins, pay attention to
the direction of the anti-rotation plate.
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13. Adjust the clearances for the sheaves (2) for
extending the 4th boom section.
Adjust the clearances to the following by
increasing or decreasing the number of plates that
are placed between the sheave and sheave pin.
- 0.6 mm (3/128 in) or less in total when the
values at right and left are added
Tightening torque of fixing bolts of sheave pin:
- 49.0 – 58.8N・m {36.1 – 43.3 ft・lbf}
[NOTICE]
After this adjustment, apply thread locker
(ThreeBond 1305) to bolts that are used for fixing
the sheave pins and tighten them.
14. Fix both ends of the wire ropes for extending the
4th boom section at the front end of the 4th boom
section with a wire etc.
[NOTICE]
Fix the wire ropes while pulling them to prevent
them from hanging down.
15. Measure the following internal widthwise
dimension of the 3rd boom section.
- At 1.0 to 1.4 m (3.3 to 4.5 ft)from the front end
[NOTICE]
The measured dimension will be used when the
clearances are adjusted at step 18.
16. Apply grease to the surfaces inside the 3rd boom
section on which the slide plates of the 4th boom
section slide.
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17. Install the slide pates at the rear end of the 4th
boom section.
18. Adjust the clearances of the slide plates on the
side surfaces of the boom based on the
dimension measured at step 15.
Adjust the clearances to the following by
increasing or decreasing the number of shims.
- 0.5 mm (1/64 in) or less in total when the values
at right and left are added
[NOTICE]
After this adjustment, apply thread locker
(ThreeBond 1305) to screws that are used for fixing
the slide plates.
Then lightly tighten the screw and back off a quarter
turn.
19. Apply grease to the surfaces outside the 4th
boom section on which the slide plates of the 3rd
boom section slide and the slide plates at the rear
end of the 4th boom section.
20. While pulling the temporary cord to the rear of the
boom, insert the 4th boom section into the 3rd
boom section to the point about 2 m (6.6 ft)before
full retraction.
[NOTICE]
Be sure to insert the 4th boom section while
changing the positions of the wire ropes for
retracting the top boom section to prevent them
from being pinched between the supports at the
front end of the 3rd boom section and the 4th boom
section.
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7.3 Assembling the 3rd boom section
1. Install the slide plates to the lower surface at the
front end of the 3rd boom section.
2. Install the slide plates to the side surfaces at the
front end of the 3rd boom section. Adjust the
clearances to the following by increasing or
decreasing the number of shims.
- 0.5 mm (1/64 in) or less in total when the values
at right and left are added
[NOTICE]
Try to minimize the difference between the right and
left clearances.
3. Release the wire ropes for extending the 4th
boom section. Attach the support to an end of
the wire rope for extending the 4th boom section.
(for two wire ropes)
[NOTICE]
Pay attention to the direction of the support.
4. Position the support with the wire rope by
pressing it against the stopper at the front end of
the 3rd boom section and fix the support in that
condition to the 3rd boom section. (for two wire
ropes)
5. Pass the wire ropes for extending the 4th boom
section from the other ends in the grooves of the
sheaves (1) for extending the 4th boom section.
6. Install the wire rope guide for the sheaves (1) for
extending the 4th boom section and temporarily
fix the wire ropes for extending the 4th boom
section.
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