Tadano TR-800XXL4 Service Manual

Page 1
Publication No. GR-800XXL-1/S2(U)-1E
01
Rough Terrain Crane
TR-800XXL-4
Applicable Serial No. 545870, 545961--
Model
2006
PRINTED IN JAPAN 0608 K
Service Manual
GR-800XXL-1/S2(U)-1E
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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
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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 princip le of operatio n 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.
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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.
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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 washi ng, drai nin g 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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Foreword
1
WA04-2070E
Foreword
This service manual describes the composition of the Model TR-800XXL-4 rough terrain crane, its repair, check and adjustment methods and other relevant matters. Note that this service manual does not provide the information in the separate service manuals given below.
This service manual applies to the cranes with the specification numbers given below. 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.
SPEC. NO. SERIAL.
KAGAWA, JAPAN
NO.
MFG.DATE
.
ISA04-001601
Spec. No. Applicable serial No.
GR-800-1-00211 545870--
2. Separate service manual
Separate Service Manual Information No. General Cautions SA01-01-2E Load Moment Indicator (AML) W301-0136E Multiplex Data Transmitter W303-0257E Torque Converter Transmission
W561-0101E
Driving Axle W563-0052E
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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WA04-2070E
Foreword
3. Outline of specifications
Spec. No.
Item
GR-800-1-00211
2M2D
(North America)
No. of boom sections 5
No. of jib stages 2
Single top Option
Main winch Fitted
Auxiliary winch Fitted
Winch brake Automatic brake (Neutral brake)
Winch
Drum rotation indicator Touch-type (Option)
Weight Counterweight Removable type
Load moment indicator (AML) AML-L2C
Auto. stop solenoid valve energizing type Normally energized
AML external indicator lamp Fitted
Oil cooler Fitted
Air conditioner Option
Emergency steering Option
Engine model MITSUBISHI 6M60-TLA3B
Tires 29.5 × 25 - 22PR, 29.5 × 25 - 28PR
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WA04-2070E
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, cm2square 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 lbf/in2, psi
1 1X10-3 1X10-6 1.01972X10-5 14.5X10-5 1X103 1 1X10-3 1.01972X10-2 14.5X10-2 1X106 1X103 1 1.01972X10 14.5X10
9.80665X104 9.80665X10 9.80665X10-2 1 14.22 6895 6.895 0.006895 0.07031 1
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WA04-2070E
Foreword
Work, energy
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
inch-pound,
in-lbf
1 1X10-2 1.01972X10-1 1.01972X10-3 0.00737 0.0885
1X102 1 1.01972X10 1.01972X10-1 0.7376 8.851
9.80665 9.80665X10-2 1 1X10-2 0.0723 0.868
9.80665X102 9.80665 1X102 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 F F F F F
-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: toC=5(ToF-32)/9, ToF=(9×toC+160)/5
Force
N kgf lbf
1 1.01972X10-1 2.24809X10-1
9.80665 1 2.20461
4.44822 0.45359 1
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WA04-2070E
Outrigger System Swing System Boom Elevating System Winch System Boom Telescoping System Safety System
Cab Control System
Steering System Brake System Suspension 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
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WA04-2070E
Foreword
5. Contents
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
General
General Cautions Refer to separate manual SA01-01-2E
A
Hydraulic Power Generating System
Hydraulic Power Generating System B-1 Hydraulic Pump
(Double Variable Displacement Pump)
B-2
Hydraulic Pump (Double Gear Pump)
B-3
Hydraulic Pump (Gear Pump, Emergency Steering) (Option)
B-4
Hydraulic Valve (Emergency Steering) (Option)
B-5
Flow Control Valve B-6
Pressure Reducing Valve (Pilot Pressure) B-7
Solenoid Control Valve (Outrigger) B-8
Rotary Joint B-9 Hydraulic Pilot Control Valve
(Elevating, Telescoping, Winch)
B-10
Sequence Valve (Pilot Pressure) B-11
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
B
Hydraulic Motor (Oil Cooler) B-16
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
Hydraulic Power Generating System
Jib Lock pin B-17
Jib Offset Cylinder B-18
Check valve (Gauge Isolator) B-19
B
Outrigger System
Outrigger System C-1
Jack Cylinder C-2 Pilot Check Valve
(Jack Cylinder Retracting Prevention)
C-3
Extension Cylinder C-4
(UCHIDA) C-5
(TOKIMEC) C-6
Solenoid Valve (Slide/Jack)
(NACHI) C-7
C
Check Valve (Outrigger Extending Preve ntion)
C-8
Swing System
Swing System D-1
Swing Assembly D-2
Hydraulic Pilot Control Valve (Swing) D-3
Hydraulic Motor (Swing) D-4
D
Swing Speed Reducer D-5
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
Boom Elevating System
Elevating System E- 1
Elevating Cylinder E-2
Counterbalance Valve (Elevating) E-3
E
Winch system
Winch System F-1
Winch F-2
Hydraulic Motor (Winch) F-3
Counterbalance Valve (Winch) F-4
F
Hydraulic Valve (Winch Brake Release) F-5
Boom Telescoping system
Teles c oping S ystem G-1
Boom (Five-Section Boom) G-2
Jib G-3
Telescoping Cylinder G-4
Counterbalance Valve (Telescoping) G - 5
Hose Reel G-6
Hydraulic Valve G-7
G
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
Safety System
Safety System H-1
Load Moment Indicator (AML) Refer to separate manual W301-0136E
Boom Length and Angle Detector H-2
Outrigger Extension Length Detector H-3
H
Solenoid Valve (Auto Stop) H-4
Cab
Crane Cab Glass K-1
Air Conditioner (Option) K-2
Hydraulic Motor(Air conditioner, Option) K-3
Solenoid Valve(Air conditioner, Option) K-4
K
Control System
Control System L-1
Remote Control Valve (Lever) L-2
Remote Control Valve (Pedal) L-3
Shuttle Valve (Lever, Pedal) L-4 Solenoid Valve
(Boom Telescoping/Aux. Hoist)
L-5
Solenoid Control Relief Valve (Elevating Slow Stop)
L-6
Solenoid Valve (Air) L-7
L
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10
WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
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 W563-0052E
Steering System
Steering System S-1
Priority Valve S-2
Orbitrol S-3
Steering Cylinder S-4
Solenoid Valve (Steering Mode) S-5
S
Pilot Check Valve (Rear Steering Cylinder Lock)
S-6
Brake System
Brake System T-1
Brake (Service Brake) T-2
Brake Valve T-3
Booster (Brake) T-4
Air Dryer T-5
Brake (Parking Brake) T-6
Brake Chamber T-7
T
Solenoid Valve (Air) T-8
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
Suspension System
Suspension System U-1
Suspension Lock Cylinder U-2 Pilot Check Valve
(Suspension Lock Cylinder)
U-3
Solenoid Valve (Suspension Lock Check Release)
U-4
U
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
Adjustment and Checks Y-5
Check (Crane Operation) Y-6
Check (Driving Devices) Y-7
Oils and Grease Table Y-8
Mass T able Y-9
Specifications Y-10 Boom Connecting Pin and Thread Size
Table
Y-11
Y
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
System Diagrams
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
Electric Circuit (MDT, Carrier/Lower) Z-6
Location of Installation
Location of Hydraulic Parts (Upper) Z-7
Location of Hydraulic Parts (Lower) Z-8
Location of Air Parts Z-9
Location of Electric Parts (Inside Cab) Z-10 Location of Electric Parts
(Swing T able, Boom)
Z-11
Location of Electric Parts (Relay Assembly/Upper)
Z-12
Location of Electric Parts (AML) Z-13
Location of Electric Parts (Lower) Z-14 Location of Electric Parts
(Box Assembly/Lowe r)
Z-15
Harness Diagrams
Harness (Connector No. Table) Z-16
Harness (Inside Cab) Z-17
Z
Harness (Swing Table, Left) Z-18
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WA04-2070E
Foreword
Spec. No.
Chapter
Section
GR-800-1-00211
2M2D
(North America)
Harness (Swing Table, Right) Z-19
Harness (Boom) Z-20
Harness (AML, Upper) Z-21
Harness (Overwind) Z-22
Harness (Lower, Main) Z-23
Harness (Lower, Sub) Z-24
Z
Harness (Lower, Electronic Governor) Z-25
Page 19
i
B
Hydraulic Power Generating System
Contents
B-1 Hydraulic Power Generating System
..................................................1
1. General..................................................... 1
B-2 Hydraulic Pump (Double Variable
Displacement Pump)...............4
1. Structure................................................... 4
2. Theory of operating of regulator section .. 10
3. Air bleeding procedure............................ 12
B-3 Hydraulic Pump
(Double Gear Pump)..............13
1. Structure................................................. 13
2. Air bleeding procedure............................ 15
B-4 Hydraulic Pump (Gear Pump,
Emergency Steering).............16
1. Structure................................................. 16
B-5 Hydraulic Valve (Emergency
Steering) (Option)..................17
1. Structure................................................. 17
B-6 Flow Control Valve.........................19
1. Structure................................................. 19
B-7 Pressure Reducing Valve
(Pilot Pressure)......................20
1. Structure................................................. 20
B-8 Solenoid Control Valve
(Outrigger)..............................21
1. Structure................................................. 21
B-9 Rotary Joint ....................................26
1. Structure................................................. 26
2. Potentiometer..........................................33
2.1 Adjustment................................................33
2.2 Soldering...................................................33
B-10 Hydraulic Pilot Control Valve
(Elevating, Telescoping, Winch)
.................................................34
1. Structure................................................. 34
B
Page 20
ii
B-11 Sequence Valve (Pilot Pressure)..46
1. Structure................................................. 46
B-12 Solenoid Valve (Pilot Pressure)....49
1. Structure................................................. 49
B-13 Solenoid Control Valve (Jib Set)...51
1. Structure................................................. 51
B-14 Pilot Check Valve (Jib Set)............57
1. Structure................................................. 57
B-15 Solenoid Valve (Oil Cooler)...........58
1. Structure................................................. 58
B-16 Hydraulic Motor (Oil Cooler).........60
1. Structure................................................. 60
2. Air bleeding procedure............................ 60
B-17 Jib Lock Pin....................................61
1. Structure................................................. 61
B-18 Jib Offset Cylinder.........................62
1. Structure................................................. 62
B-19 Check Valve (Gauge lsolator).......63
1. Structure................................................. 63
Page 21
B-1 B-1
Hydraulic Powe r Generating System
1
WB02-0261E
B-1 H ydraulic Power Generating System
1. General
NOTICE]
If the machine is not equipped with the optional emergency steering, two points “A” are directly joined and four 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. T his double var iab le 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.
Hydraulic Circuit for Carrier
Page 22
B-1 B-1
Hydraulic Powe r Generating System
2
WB02-0261E
[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 val ve f or a utom atic s top is sh ifted, 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.
Hydraulic Circuit for Crane
545520 ~
1
Applicable serial No.
Page 23
3
WB02-0261E
B-1. B-1.
Hydraulic Powe r 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.
Page 24
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
4
W101-0272E
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.
Page 25
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
5
W101-0272E
901724534702214548
531
532732789535808
886 717
406
774 111
261
824
127 123 710 251 490 312 466
725
114 885
313 141
467 728
271 401 262
954 719 124 151 152 113 406 710
792
953
IW101-0270E01
212 211 153 156 157 314
Valve plate for clockwise rotation
Apply adhesive (No. 1305N of Threebond make)
Apply (Sealub L101) to the oil seal surface circumferential
Valve plate for counter clockwise rotation
111.Drive shaft (F)
113.Drive shaft (R)
114.Spline coupl i ng
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
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
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
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
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
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
Tightening torque
Sign / Port Thread size
N-m ft-lbf
531,532 M20x1.5 240 177
808 M16 130 96
Main body
Page 26
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
6
W101-0272E
72453470221454 8
531
532732789535808
886 717 406
774 111
261
824
127 123 710 251 490 212 211 153 156 157
314
312
792
953
IW101-0270E02
Apply (Shealub L101) to the oil seal sur face circumferential
Apply adhesive (No. 1305N of Threebond make)
Valve plate for counter clockwise rotation
Enlarged view of the main body (the left side)
Page 27
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
7
W101-0272E
901
466 725
114 885
313
141
467 728
271 401 262
954 719 124 151 152 113 406 710
Valve plate for clockwise rotation
IW101-0270E03
Enlarged view of the main body (the right side)
Page 28
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
8
W101-0272E
IW101-012004
962 412
924 627 701801
624 651
724
652 621 496 887
629402625728
Z
Regulator
Page 29
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
9
W101-0272E
413 496 897 601
755 614
708
611
IW101-012006
View Z
402.Hex. socket head bolt
412.Hex. socket head bolt
413.Hex. socket head bolt
496.Plug
601.Casing
611.Feedback lever
614.Center plug
621.Compensator piston
624.Spring seat
625.Compensator spring
627.Spring seat
629.Spring case
651.Sleeve
652.Spool
701.O-ring
708.O-ring
724.O-ring
728.O-ring
755.O-ring
801.Nut
887.Pin
897.Pin
924.Hex. socket set screw
962.Steel ball
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
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
Page 30
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
10
W101-0272E
2. Theory of operating of regulator section
Page 31
B-2 B-2
Hydraulic Pump (Double Variable Displace ment Pump)
11
W101-0272E
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 press ure of th e com pens ation s pring. 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
Page 32
12
W101-0272E
B-2. B-2.
Hydraulic Pump (Double Variable Displace ment 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, respecti ve l y. 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.
0
366-540-20000
0
366-533-50001
Page 33
B-3 B-3
Hydraulic Pump (Double Gear Pump)
13
W101-0131E
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
Page 34
B-3 B-3
Hydraulic Pump (Double Gear Pump)
14
W101-0131E
IW101-013002
18 19 17 16 2 8,9 1 7 313
6,10
12
314215
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
12.O-ring
13.Drive gear
14.Driven gear
15.Rear cover
16.Dowel pin
17.Oil seal
18.Oil seal
19.Retaining ring
2 1 4
3
IW101-013004
1.Coupling 2.O-ring 3.Dowel pin 4.Hex. socket head bolt
Gear pump assy-1
Connecting section-2
Page 35
15
W101-0131E
B-3. B-3.
Hydraulic Pump (Double Gear Pump)
IW101-013003
131628,9173
6,10
12
314215
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
12.O-ring
13.Drive gear
14.Driven gear
15.Rear cover
16.Dowel pin
2. Air bleeding procedure
Refer to “Air Bleeding Procedure” in chapter Y.
Gear pump assy-3
0
366-533-00000
0
366-519-00000
0
366-531-70000
Page 36
B-4 B-4
Hydraulic Powe r Generating System
16
W101-0142E
B-4 Hydraulic Pump ( Gear Pump, Emer gency 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
23 13 21 1 4 22 32 31
12 5 11 22 2
C
D
AB
C-C
C
IW101-014001
1.Front cover
2.Body
3.Drive gear
4.Driven gear
5.Side plate
11.Gasket
12.Gasket
13.Oil seal
21.Bush (front cover)
22.Bush (body)
23.Retaining ring
25.Steel ball
31.Hexagon socket head bolt
32.Plain washer
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G3/4 62 - 75 46 - 56
D G1/4 24 - 29 17 - 22
31 M10 48 - 51 35 - 38
2
366-535-20000
Page 37
B-5 B-5
Hydraulic Valve (Emergency Steering) (O ption)
17
W123-0261E
B-5 H ydraulic Valve (Emergenc y 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
IW123-016001
T
C
A
B
P1
P2
P3
IW123-0260E01
P1
P3
P2
T
X X
Y
Y
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P3 G1 196 145
P2, T G3/4 167 123
Page 38
18
W123-0261E
B-5. B-5.
Hydraulic Valve (Emergency Steering) (O ption)
IW123-0260E02
14
710
B
11
3
11
C
4
8
13 5 9 6 2 1
A
12
Y-Y
X-X
1.Body
2.Check valve
3.Spool
4.Check valve
5.Cover
6.Spring
7.Spring
8.Spring
9.O-ring
10.Plug
11.Plug
12.Plug
13.Spring washer
14.Hexagon socket head bolt
Cross section along the line X-X, Y-Y
0
366-406-60000
Page 39
B-6. B-6.
Flow Control Valve
19
W114-0132E
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
IW114-0130E01
PA
PB
T
IW114-0130E03
7
4
2
1
3
6
5
1.Valve body
2.Spool
3.Spring
4.Plug
5.Plug
6.O-ring
7.Relief valve assy
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
PA G3/4 167 123
T, PB G1/2 98 72
0
366-104-20000
IW114-0130E02
PB
PA
T
Page 40
B-7. B-7.
Pressure Reducing Valve (Pilot Pressure)
20
W120-0121E
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
IW120-0120E01
DR A2
P
A1
IW120-0120E02
P
A1
A2DR
(*1)
12345678910
(*1) : Apply the thread locking agent (LOCTITE 270 or the equivalent)
1.Body
2.Spool
3.O-ring
4.Sleeve
5.Filter
6.O-ring
7.Spacer
8.O-ring
9.Spring
10.Plug
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P G1/2 98 72
A1 G3/8 49 36
A2, Dr G1/4 29.4 22
1
366-054-90000
Page 41
B-8 B-8
Solenoid Control Valve (Outrigger)
21
W112-0152E
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
T
AB
P
Sol. a1
Sol. b1
G
R1
L
IW112-015001
R1
A
TP
L
L
G
B
Sol. a1
Sol. b1
21 22 23
10 1 15
IW112-015002
1.Body assy
10.P cover assy
15.T cover assy
21.Stud bolt
22.Nut
23.Spring washer
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T, L
G1 196 145
A, B G3/4 167 123
G G1/4 29.4 22
(+): Red (-): Blue
+ -
IW121-0542E01
Connector
Page 42
B-8 B-8
Solenoid Control Valve (Outrigger)
22
W112-0152E
2
1
6
5
7
4
P
G
R1
3
2
IW112-015003
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
Page 43
B-8 B-8
Solenoid Control Valve (Outrigger)
23
W112-0152E
1311218341012 69 1475
IW112-011004
T
P
1.Body
2.Plunger
3.Body
4.Poppet
5.Adjuster screw
6.Nut
7.Spring
8.Spring
9.Shim
10.O-ring
11.O-ring
12.O-ring
13.Backup ring
14.Cap
P cover assy (2/2)
Relief valve (illustrated as 7 on page 23)
Page 44
B-8 B-8
Solenoid Control Valve (Outrigger)
24
W112-0152E
Sol. a1
Sol. b1
A
B
10
9
1
2
7
7
8
6
3
5
4
IW112-015004
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
Body assy (1/2)
(illustrated as 1 on page 21)
Page 45
25
W112-0152E
B-8. B-8.
Solenoid Control Valve (Outrigger)
871461015 111312
1
8
9 5 3 4 2
IW112-01500
5
0
366-460-20000
1.Cover
2.Plug
3.Spool
4.Spring
5.O-ring
6.Spring seat
7.Hexagon socket head bolt
8.Plug
9.Solenoid (DC24V)
10.Orifice
11.O-ring
12.O-ring
13.Hexagon socket head bolt
14.Hexagon socket head bolt
15.Spring
Body assy (2/2)
Pilot cover assy (illustrated as 10 on page 21)
Page 46
B-9 B-9
Rotary Joint
26
W181-0440E
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.
Page 47
B-9 B-9
Rotary Joint
27
W181-0440E
Upper (view A)
Lower (view B)
Page 48
B-9 B-9
Rotary Joint
28
W181-0440E
1.Slip ring assy
2.Plain bearing
3.Packing
4.Ring seal
5.Body
6.Core
7.Shaft
8.Core
9.Plain bearing
10.Support
11.Grease nipple
12.Plain bearing
13.Ring seal
14.Packing
15.Ring seal
16.Bolt
17.Flange bolt
18.Plate
19.Plug
20.Support
21.Flange bolt
22.Clamp
23.Nut
24.Plate
25.Hexagon socket head bolt
26.Ring seal
27.Pipe
28.Fitting
29.Flare nut
30.Elbow fitting
31.Support
32.Grease nipple
33.O-ring
Thread size and tightening torque
Tightening torque
Sign / port
Thread
size
N-m ft-lbf
16 *1 M12 74 - 82 55 - 61
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
25 *1 M8 23.5 – 27.5 17 - 20
29 - 16 - 24 12 - 17
*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.
Hydraulic section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper
Winch
Lower
G1 196 145
Upper - - -
P1
Outriggers pilot
Lower G1/4 29.4 22 Upper G1/4 29.4 22
P1’ Gauge
Lower - - ­Upper
P2 Boom elevating, Boom telescoping
Lower
G1 196 145
Upper G1/4 29.4 22
P2’ Gauge
Lower - - ­Upper G3/4 167 123
P3 Swing, Steering
Lower G1 196 145 Upper
P4 Steering (left)
Lower
G1/2 98 72
Upper
P5 Steering (right)
Lower
G1/2 98 72
Upper
P6 Option
Lower
G1/2 98 72
Upper
T1 Tank
Lower
- - -
Upper G3/4 167 123
T2 Tank
Lower - - ­Upper
DR Drain
Lower
G1/2 98 72
Page 49
B-9 B-9
Rotary Joint
29
W181-0440E
Pneumatic section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper Rc3/8 49 - 69 36 - 51
A1 Air supply
Lower G1/4 29.4 22 Upper Rc3/8 49 - 69 36 - 51
A2 Service brake (primary)
Lower G1/4 29.4 22 Upper Rc3/8 49 - 69 36 - 51
A3 Service brake (secondary)
Lower G1/4 29.4 22
L.L.C. section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper
W1 Heater (IN)
Lower
Rc3/8 49 - 69 36 - 51
Upper
W2 Heater (OUT)
Lower
Rc3/8 49 - 69 36 - 51
Attention
(*1): Face the "" mark toward FRONT. (*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.
(*9): The "" marks must be directed as shown in the
figure.
(*10): Do not use an organic solvent. The grease
grooves must be directed as shown below.
Page 50
B-9 B-9
Rotary Joint
30
W181-0440E
Slip ring Assy
A
B
A
B
31
IW181-0260E03
27 26
B-B
IW181-0260E04
29
P
IW181-0260E05
T1
D
E
F
D
E
F
C C
22 20 31
7 3
2
11
12
6 3
7
1
8 16,17
18
19
24
23
15
21 28
9
4
10
12
5
13
30 25
P
A-A
IW181-0290E03
Page 51
B-9 B-9
Rotary Joint
31
W181-0440E
36 14
C-C
IW181-0260E07
23
32,33
25
24
D-D
IW181-0260E08
E-E
IW181-0260E09
F-F
IW181-0260E10
1.Shaft
2.Ring set plate
3.Bearing
4.Ring
5.Ring
6.Ring set plate
7.U nut
8.Support
9.Stud bolt
10.BH+CB
11.Spacer
12.Spacer
13.BH+CB
14.Support
15.Base
16.Dry lock nut
17.Coned disc spring
18.Guide
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
Tightening torque
Sign / port Thread size
N-m ft-lbf
16*1, T1*1 M6 4.9 3.6
31, 32, 36 M4 1.5 1.1
30 M3 0.63 0.5
*1Apply LOCTITE 496 (strong quick-drying glue) to threaded sections.
Page 52
32
W181-0440E
B-9 B-9
Rotary Joint
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
9 8 7
6 5 4 3 2 1
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
Pot2
Pot1
26 1 626
23 2 3
7 3 907 11 2 911 25 1 5
17 1 17 6 2 6 5 3 2
3 4 1CC 4 3 1DD 1 2 1AA 2 1 1BB
12 6 12 13 5 13 14 4 614
8 3 8 9 2 9 10 1 10
27 12 627 28 11 628 29 10 629 30 630
20 21 7 21 22 6 22
424 5 15 4 615 16 3 16 18 2 618 19 1 19
3 2 1 6 5 4
3 2 1
3 2 1
W W W W
G
2 1
12 56 910
34 78 11 12
14253
6
123
21
3
241
3
132
4
36251
4
1 2
43 87
12 11
21 65
10 9
36251
4
321
3
12
Ring No.
Connector terminal No.
Connector
Mark No.
IW181-0290E04
LOWER (Slip ring) UPPER (Brush holder)
9
20 8
Silver-plating ring
W R
B
B
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
Y
W
W W W W
Y
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
Wiring diagram
Page 53
33
W181-0440E
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.)
IW181-0260E12
Hexagon socket head bolt Potentiometer
Slotted screwdriver
Lever
Bolt (Tighten lightly.)
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.)
Guide
IW181-0260E13
Stamp mar
k
Slip ring assy
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.
IW181-0260E14
Potentiometer
Slotted screwdriver
Lower terminals 1, 2 and 3
Terminal 1
Upper terminals 1, 2 and 3
Terminal 2
Terminal 3
3
2
1
4. Remove the hexagon s oc ket he ad bolts (4 pieces), 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.
2.2 Soldering
1. After finishing the potentiometer adjustment, 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 adhesive (equivalent to 3M DP-420).
7
346-305-71000
Page 54
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
34
W134-0271E
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
Page 55
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
35
W134-0271E
C1 C2
Vent
(down) (down) (extending) (lowering)
Aux. winch (up)
Main winch (up)
Telescoping (retracting)
Elevating (raising)
a3,a4
b3,b4
C3
B1 B2 B3 B4
T2
A1 A2 A3 A4
P2
T1
a1 a2
a3 a4
b1 b2
b3 b4
P1
IW134-0270E02
Vent
Page 56
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
36
W134-0271E
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
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
Page 57
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
37
W134-0271E
BA
BA
14 13
IW134-011012
Aux. winch
Main winch
Telescoping
Elevating
Cross section of whole body
Page 58
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
38
W134-0271E
C
D
E
F
G
C
D
E
F
G
1
2
3
4 7 16
12
8
12
9
A-A
Aux. winch
Main winch
Telescoping
Elevating
IW134-0270E03
Page 59
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
39
W134-0271E
515 6
IW134-011004
B-B
Aux. winch
Main winch
Telescoping
Elevating
1.Winch selector valve
2.Telescopi ng sel ect or valve
3.Elevating selector valve
4.End cover
5.O-ring
6.O-ring
7.Hex. socket head bolt
8.Main relief valve
9.Main relief valve
12.Hex. socket head bolt
13.Plug
14.O-ring
15.Plug
16.Eye bol
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
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
Page 60
40
W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
IW134-0270E04
29
30
6242019 2122 1
25,24,23,13
18 17 15 28 27 26 28 14
7
11 10
9 8 12,23,24,25
16,17
Overload relief valve
C-C (Aux. winch) , D-D (Main winch)
IW134-0110E07
18 17 15 28 27 26 28 16,175
Main relief valve
E-E
1
Winch selector valve
Page 61
41
W134-0271E
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
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)
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
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
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
(Main winch), (Aux. winch)
M27×1.5 78 - 88 58 - 65
11*1 - 18 - 20 13 - 14 14*2
M6 5 - 6 3.5 - 4.5
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
39.2 - 49
29 - 36
28 -
10 - 12 7 - 9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections. *2: Apply LOCTITE 270 (thread locking agent) to threaded sections.
Page 62
42
W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
Overload relief valve
3029524 3 22 21 23 24 1
27,26,25,13
6 19,20 18 17 28 14 16 15
7 9 12,25,26,27
11 10
19,20
8
F-F (Telescoping)
IW134-0270E03
1.Telescopi ng sel ect or valve body
2.Spool (telescoping)
3.Flow control valve (telescoping)
4.Steel ball
5.Hex. socket set screw
6.O-ring
7.Spring seat
8.Return spring
9.Return spring
10.Spring seat
11.Spool end
12.Pilot cover
13.Pilot cover
14.Steel ball
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)
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
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve (Telescoping) M27×1.5 77 - 88 58 - 65
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
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections. *2: Apply LOCTITE 270 (thread locking agent) to threaded sections.
Telescoping selector valve
Page 63
43
W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
IW134-0110E09
19185 4 18 19 12
22,21,20,13
6 16,17 15 14 23
7 9 12,20,21,22
11 10
16,17
8
3
G-G (Elevating)
Overload relief valve
1.Elevating selector valve body
2.Spool (elevating)
3.Flow control valve (elevating)
4.Steel ball
5.Hex. socket set screw
6.O-ring
7.Spring seat
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)
16.Plug
17.O-ring
18.Plug
19.O-ring
20.Hex. socket head bolt
21.Plain washer
22.Spring washer
23.Plug
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
Elevating
M27×1.5 78 - 88 58 - 65
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
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections. *2: Apply LOCTITE 270 (thread locking agent) to threaded sections.
Elevating selector valve
Page 64
44
W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
T
P
20 19
15 16 17 18
14 13 12 11 10 9 8 7 6 3 2 1 5 4
IW134-011010
1.Socket
2.Valve
3.Spring
4.O-ring
5.Backup ring
6.O-ring
7.Packing
8.Body
9.O-ring
10.Cap nut
11.Adjust screw
12.O-ring
13.Nut
14.Body
15.Spring
16.Valve
17.Valve seat
18.O-ring
19.Seal lead
20.Tie up wire
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
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
Main relief valve (Main winch, Aux. winch), (Elevating, Telescoping)
Page 65
45
W134-0271E
B-10. B-10.
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
IW134-011011
T
P
6754231981013121114
16 15
1.Socket
2.Valve
3.O-ring
4.Spring
5.Valve seat
6.O-ring
7.O-ring
8.Body
9.Valve
10.Spring
11.Adjust screw
12.O-ring
13.Nut
14.Cap nut
15.Tie up wire
16.Seal lead
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf 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
Overload relief valve (Main winch), (Aux. winch), (Elevat in g) , (Telescoping)
0
366-405-40000
Page 66
B-11 B-11
Sequence Val ve (Pilot Pressur e)
46
W122-0113E
B-11 Sequence Va lve (Pilot Pressur e)
[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 67
B-11 B-11
Sequence Val ve (Pilot Pressur e)
47
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 val ve
5.Pressure reducing valve
6.Hexagon 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 68
48
W122-0113E
B-11. B-11.
Sequence Val ve (Pilot Pressur e)
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 69
B-12 B-12
Solenoid Valve (Pilot Pressure )
49
W121-0672E
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
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.Hexagon socket head bolt
701.Solenoid valve (DC24V)
IW121-0671E01
Connector
Page 70
50
W121-0672E
B-12. B-12.
Solenoid Valve (Pilot Pressure )
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
0
367-401-00000
Page 71
B-13 B-13
Solenoid Control Valve (Jib Set)
51
W112-0222E
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
IW112-0220E01
A2
CO
PP
B2
A1
GP T
B1
+ -
IW121-0542E01
Connector
(+) : Red
(-) : Black
Page 72
B-13 B-13
Solenoid Control Valve (Jib Set)
52
W112-0222E
CO
IW112-0220E02
33
3218
31
33
33
33
33
29
27,38
21
B2 B1
A2 A1
P.P
T
P
OUT
OUT
P.P
IN
A
C
C
D
D
A
B
B
18.Name plate
21.Tigh rod
27.Plug
29.Hexagon socket head bolt
31.Nut
32.Ribbet screw
33.Ball
38.O-ring
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
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
Page 73
B-13 B-13
Solenoid Control Valve (Jib Set)
53
W112-0222E
IW112-0220E03
16
6
35
35
28
28 34 19 38 23 27 33
25 44
35 33
33
37 8
9
35
33
16 34 19 38 27 23 20
22
7
8
A-A
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
Page 74
B-13 B-13
Solenoid Control Valve (Jib Set)
54
W112-0222E
B-B
IW112-0220E0
4
14 35
14
24
17
4
3
15 35
14.Spol
15.Housing
17.Housing plunger
24.Housing
35.O-ring
43.O-ring
Page 75
B-13 B-13
Solenoid Control Valve (Jib Set)
55
W112-0222E
IW112-0220E05
P
T
C-C
IW112-0220E06
D-D
C O
Page 76
56
W112-0222E
B-13. B-13.
Solenoid Control Valve (Jib Set)
IW112-0220E
07
42 12 2 41 1 40 10 4 30 3365131139
1.Spring
2.Needle valve
3.Nut
4.Gasket
5.Spring
10.Housing
11.Sleeve
12.Sleeve
13.Poppet
30.Screw
36.O-ring
39.O-ring
40.O-ring
41.O-ring
42.O-ring
Relief valve
0
366-489-20000
Page 77
B-14. B-14.
Pilot Check Valve (Jib Set)
57
W115-0271E
B-14 Pilot Check Va lve (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
B
DC
A
IW115-027002
765 34
819210
11
1.Body
2.Sleeve
3.Poppet
4.Spring
5.Piston
6.O-ring
7.Backup ring
8.O-ring
9.O-ring
10.O-ring
11.Plug
12.Plug
Thread size and tightening torque
Tightening torque
Sign /port Thread size
N-m ft-lbf
A,B,C,D G1/4 29.4 22
X-X
1
366-241-40000
Page 78
B-15 B-15
Solenoid Valve (Oil Cooler)
58
W121-0253E
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
ae
bf
PA TB
IW121-025001
IW121-025002
4
3
2
1
P
B
A
T
bf
a
e
T1
1.Solenoid valve assy 2.Body 3.Valve 4.Plug
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7 - 8 5 - 6
Page 79
59
W121-0253E
B-15. B-15.
Solenoid Valve (Oil Cooler)
+ -
IW121-0542E01
Connector
TT
AB
P
IW121-025003
12 9 1 15 8 7 11 2T2
T1
3
1.Body
2.Plug
3.Spool
7.Spring seat
8.Square ring
9.O-ring
11.Spring
12.Solenoid (DC24V)
15.Hexagon socket head bolt
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
2 - 44 - 49 32 - 36 15 M5 7 5 T1 - 39 - 49 29 - 36 T2 - 4.4 – 5.4 3 - 4
Solenoid valve assy
(+): Red (-): Blue
1
366-457-50000
Page 80
B-16. B-16.
Solenoid Valve (Oil Cooler)
60
W102-0122E
B-16 Hydraulic Mo tor (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
27 12 21 17 19 20 16 22 23 3
25 14 2 4 7 5 32 8 10 1 33 34 13
D
A,B
IW102-012001
1.Front case
2.Rear case
3.Shaft
4.Cylinder block
5.Piston retainer
7.Spherical retainer
8.Spherical pin
10.Collar
12.Spring
13.Straight key
14.Plain washer
16.Oil seal
17.Needle bearing
19.Thrust roller bearin g
20.Thrust plate
21.Hexagon socket head but bolt
22.Ball bearing
23.Retaining ring
25.Hexagon socket head bolt
27.O-ring
32.Piston assy
33.Seal plate
34.Flat head machine screw
Thread size and tightening torque
Tightening torque
Sign /port Thread size
N-m ft-lbf
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
2. Air bleeding procedure
Refer to “Air Bleeding Procedure” in chapter Y.
0
366-631-10000
0
366-631-20000
0
366-632-60000
Page 81
B-17. B-17.
Jib Lock Pin
61
W180-0021E
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
5.O-ring
6.Piston
7.Cylinder
8.Rod
9.Rod cover
10.Plain bearing
11.O-ring
12.Damper ring
13.Packing
14.Backup ring
15.Dust 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
Tightening torque
Sign / port Thread size
N-m ft-lbf
A, B G1/4 29.4 22
0
360-531-60000
Page 82
B-18. B-18.
Jib Offset Cylinde r
62
W180-0031E
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
5.Plain bearing
6.O-ring
7.Rod
8.Rod cover
9.O-ring
10.Damper ring
11.packing
12.Backup ring
13.Plate
14.Dust seal
15.---
16.Plain bearing
*1 : Face the notch or the lip toward the pre ssurized side.
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
A, B G1/4 29.4 22
0
360-520-90000
Page 83
B-19. B-19.
Check Valve (Gauge Isolator)
63
W116-0123E
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
P3P2P1
SP'
IW116-012001
1
P1 P2 P3
S
8254367
IW116-012002
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
Remark
P1, P2, P3, P’ G 1/4 29.4 22
G 3/8 49.0 36
S
M18×1.5 127 - 147 93 - 108 TT-300XL-1 only
Mounting bolt M8 13 - 15 9.6 - 11.0
1. Body
2. Plug
3. Poppet
4. Spring
5. O-ring
6. Screw
7. Plug
8. O-ring
Hydraulic symbols
0
366-251-20000
1
366-244-50000
Page 84
i
C
Outrigger System
Contents
C-1 Outrigger System.............................1
1. General..................................................... 1
C-2 Jack Cylinder....................................3
1. Structure................................................... 3
C-3 Pilot check Valve (Jack Cylinder
Retracting Prevention)............4
1. Structure................................................... 4
C-4 Extension Cylinder..........................5
1. Structure................................................... 5
C-5 Solenoid Valve (Slide/Jack)
(UCHIDA)..................................6
1. Structure................................................... 6
C-6 Solenoid Valve (Slide/Jack)
(TOKIMEC) ...............................7
1. Structure................................................... 7
C-7 Solenoid Valve (Slide/Jack)
(NACHI).....................................8
1. Structure................................................... 8
C-8 Check Valve (Outrigger Extending
Prevention)...............................9
1. Structure................................................... 9
C
Page 85
C-1 C-1
Outrigger System
1
WC02-0202E
C-1 Outrigger System
1. General
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.
Hydraulic Circuit for Outrigger
Page 86
2
WC02-0202E
C-1. C-1.
Outrigger System
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.
Electric Circuit (Rela y RF3, Soleno id Valve)
Page 87
C-2. C-2.
Jack Cylinder
3
W151-0112E
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
6.Stopper
7.Spring pin
8.Piston
9.Packing
10.Backup ring
11.O-ring
12.Backup ring
13.O-ring
15.Rod cover assy
16.Packing
17.Backup ring
18.Dust seal
19.Damper ring
21.Backup ring
22.Plain bearing
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
3,5 M10 22 - 25 16 - 18
T1 M24 588 - 666 434 - 492
8
360-302-90000
Page 88
C-3. C-3.
Pilot Check Valve (Jack Cyli nder Retracting Prevention)
4
W115-0491E
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
B
5
4
67,8
2
3
1
A
CD
9
IW115-0490E01
1.Valve body
2.Plug
3.O-ring
4.Valve
5.Spring
6.Piston
7.O-ring
8.Backup ring
9.O-ring
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
A G1/4 29.4 22 B G1/4 29.4 22
Mounting
bolt
M10 43 - 49 32 - 36
1
366-200-00000
AB
CD
IW115-023001
Page 89
C-4. C-4.
Extension Cyli nder
5
W153-0012E
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
4.Piston
5.Rod
6.Rod cover
7.O-ring
8.Packing
9.Backup ring
10.Dust seal
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
A, B, C G3/8 49 36
D, E G1/4 29.4 22
2 M20 176 - 196 130 - 145
1
360-424-20000
Page 90
C-5. C-5.
Solenoid Valve (Slide/Jack) (U CHIDA)
6
W121-0263E
C-5 Solenoid Valve (Slide/Jack) (U CHIDA)
[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
PT
IW121-026001
+ -
IW121-0542E01
Connector
IW121-026003
11 9T27 3 8 15 1
A
P
B
TT
1.Body
3.Spool
7.Spring seat
8.Square ring
9.O-ring
11.Spring
12.Solenoid (DC24V)
15.Hex. socket head bolt
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
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
1
366-478-90000
(+): Red (-): Blue
Page 91
C-6. C-6.
Solenoid Valve (Slide/Jack) (T OKIMEC)
7
W121-0273E
C-6 Solenoid Valve (Slide/Jack) (T OKIMEC)
[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
PT
IW121-026001
+ -
IW121-0542E01
Connector
12
1 2 3 4 5 6 7 8 9 10 11
A
T
P T
B
IW121-027001
Note: Install the centering washer (10) with its slit directed toward the body (7).
1.Nut
2.O-ring
3.Solenoid core (DC24V)
4.Solenoid coil (DC24V)
5.Packing
6.O-ring
7.Body
8.O-ring
9.Spool
10.Centering washer
11.Spring
12.Spring pin
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
1 - 8.8 - 10.8 6.5 - 8 3 - 18 - 22 13.3 - 16.2
Mounting bolt M5 6.9 - 7.8 5 - 6
1
366-465-40000
(+): Red (-): Black
Page 92
C-7. C-7.
Solenoid Valve (Slide/Jack) (N ACHI)
8
W121-0283E
C-7 Solenoid Valve (Slide/Jack) (N ACHI)
[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
PT
IW121-026001
+ -
IW121-0542E01
Connector
T T
AB
10 16
7 14 8 9 6 15 4 3 13 2 1
IW121-028001
P
1.Body
2.Spool
3.Retainer
4.Retainer
6.Spring
7.Nut
8.Rod
9.Solenoid guide (DC24V)
10.Solenoid coil (DC24V)
13.O-ring
14.O-ring
15.O-ring
16.O-ring
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
7 - 5 - 7 3.7 - 5.1
Mounting bolt M5 6 - 8 4.4 - 5.9
1
366-457-31000
(+): White (-): Black
Page 93
C-8. C-8.
Check Valve (Outrigger Extending Prevention)
9
W116-0112E
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
P2
CB
IW116-011001
P1
P2
CB
1657438 910211,12
IW116-011002
1.Body
2.Cover
3.Valve
4.Spring
5.Stopper
6.Stop ring
7.Valve
8.Spring
9.Stopper
10.O-ring
11.Hexagon socket head bolt
12.Spring washer
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m ft-lbf
P1 G1/2 98 72 P2 G1/2 98 72
0
366-245-40000
Page 94
i
D
Swing System
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
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
D
Page 95
D-1 D-1
Swing System
1
WD02-0211E
D-1 Swing System
1. General
[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.
Hydraulic Circuit for Swing
Remote Control Pressure Vent, Swing Free, Swing Brake Release
Page 96
2
WD02-0211E
D-1. D-1.
Swing System
2. The maximum pressure in the swing circuit is regulated by the relief valve. In case of sudden stoppage of swing movement, the overload relief valve (high pressure) in the circuit with unusually high pressure operates to protect the hydraulic motor for swing operation.
3. Circuit for free swing In this hydraulic circuit, the solenoid valve (swing free) and the swing relief proportional control valve control the vent ports of the two overload relief valves (high pressure). As the set pressure of the swing relief proportional control valve is low, the overload relief valve (high pressure) in the circuit with internal pressure higher than the set pressure is activated at low pressure. The overload relief valve (high pressure) is activated at low pressure only when the swing control lever is located at the neutral position.
4. Circuit for swing automatic stop The right swing proportional control valve, the left swing proportional control valve and the swing relief proportional control valve serve to automatically stop the swing movement. These valves control the swing operation according to the output from the AML. The swing relief proportional control valve automatically stops the swing movement only when the swing free/lock selector switch is set to “FREE” side.
5. Circuit for swing brake release In this hydraulic circuit, the solenoid valve (swing brake release) controls the pilot pressure to the brake release port of the hydraulic motor for swing operation.
6. Circuit for remote control pressure vent In this hydraulic circuit, the solenoid valve (remote control pressure vent) controls the pilot pressure to the remote control valve.
Page 97
D-2 D-2
Swing Assembly
3
W514-0161E
D-2 Swing Assembly
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
[NOTICE]
Apply torque control agent to the threaded sections of the bolts.
Thread size and tightening torque
Tightening torque
Sign/port Thread size
N-m ft-lbf
1 M18 294 - 343 217 - 253
1.Bolt
2.Plain washer
Page 98
D-2 D-2
Swing Assembly
4
W514-0161E
2. Swing bearing mounting bolt
2.1 Bearing Inner ring bolts
1,2
"S" mar
k
4,5
1,3
11
1,3
1,3
1,3
Front
4,5
1,2
1,3
6
7
8
9
7,10
IW514-0140E01
View A
A
[NOTICE]
Install the bearing inner ring with the "S" mark facing the rear of the carrier.
Apply torque control agent to the threaded sections of the bolts.
Install the plain washer, orienting its chamfer on the internal periphery as shown below.
Thread size and tightening torque
Tightening torque
Sign/port
Thread
size
N-m ft-lbf
2
(44 points)
3
(4 points)
M30 1620 - 1810 1195 - 1335
5 M12 69 - 82 51 - 60
1.Pain washer
2.Bolt (L=185mm)
3.Bolt (L=155mm)
4.Plain washer
5.Bolt
6.Support
7.Nut
8.Bolt
9.End
10.Spring washer
11.Pin
Page 99
D-2. D-2.
Swing Assembly
5
W514-0161E
2.2 Bearing outer ring bolts
C
IW514-0140E02
A
A
B
C
D
FRONT
Swing table
B
D
D
D
C
1 3
1 3
6
5
3
3
4
4
3
2
B
D
[NOTICE]
Apply torque control agent to the threaded sections of the bolts.
Install the plain washer, orienting its chamfer on the internal periphery as shown below.
Thread size and tightening torque
Tightening torque
Sign / port
Thread
size
N-m ft-lbf
1
(42 points)
2
(3 points)
5
(2 points)
M27 1177 - 1275 868 - 940
1.Bolt (L=160mm)
2.Bolt (L=190mm)
3.Plain washer (50points)
4.Nut (5points)
5.Reamer bolt (L=185mm)
6.Plain washer (2points)
1
343-007-20000
0
347-621-32000
2
342-310-40000
Applicable serial No. 545543 --
2
2
168
Page 100
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
6
W134-0123E
D-3 Hydraulic Pilot Control Valve (Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
G
(+):Red
(-):Blue
IW134-0122E01
AM
RV
BM
Dr
P
Pa
Pa'
Pi2
Pb
Pb'
Pi1
G
R
Sol.1
Sol.4
Pi2Pa
Pi1
Pb
Sol.3
Sol.2
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