Tadano TT-800XXL1 Service Manual

Page 1
Publication No.
GT-800XXL-1/S1(U)-1E
01
Truck Crane
TT-800XXL-1
Applicable Serial No. 475326 ~~~
Model
2003
PRINTED IN JAPAN
0310 K
Service Manual
GT-800XXL-1/S1(U)-1E
Page 2
Safety
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
Safety
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
Safety
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 & 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 & remounting and disassembling & 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 & 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
Safety
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
WA04-1310E
Foreword
This service manual describes the composition of the Model TT-800XXL-1 truck crane, its repair, checks and
adjustment methods and other relevant matters. Note that this service manual does not provide the information
in the separate service manuals given below.
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.
GT-800-1-90102
475326
2. Separate service manual
Separate Service Manual Information No.
General Cautions SA01-01-2E
Load Moment Indicator (AML) W301-0232E
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
WA04-1310E
Foreword
3. Outline of specifications
Spec. No.
Item
GT-800-1-90102
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-LK
Auto. stop solenoid valve energizing type Normally energized
AML external indicator lamp Fitted
Oil cooler Fitted
Air conditioner Option
Carrier model FAUN / KF70-4
Carrier type Left hand steering, 8×4
Engine model Cummins QSM11
Page 8
3
WA04-1310E
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, cm2 square meter, m2 square inch, in2 square foot, ft2
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, in3 cubic foot, ft3
gallon,
gal
cubic inch, in3 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
Page 9
4
WA04-1310E
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
Page 10
5
WA04-1310E
Swing System
Boom Elevation System
Winch System
Boom Telescoping System
Safety System
Cab
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
Foreword
6
WA04-1310E
5. Contents
Spec. No.
Chapter
Section
GT-800-1-90102
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 B-2
Flow Control Valve B-3
Rotary Joint B-4
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
B-5
Sequence Valve (Pilot Pressure) B-6
~#475348 B-7
Solenoid Valve (Pilot Pressure)
#475349~ B-8
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
B-9
Pilot Check Valve (Jib Set) B-10
Solenoid Valve (Oil Cooler) B-11
Hydraulic Motor (Oil Cooler) B-12
Jib Lock pin B-13
Jib Offset Cylinder B-14
Counterweight Cylinder B-15
Pilot Check Valve B-16
B
Check valve (Gauge Isolator) B-17
Page 12
Foreword
7
WA04-1310E
Spec. No.
Chapter
Section
GT-800-1-90102
2M2D
(North America)
Swing System
Swing System D-1
Swing Ass’y D-2
Hydraulic Pilot Control Valve (Swing) D-3
Hydraulic Motor (Swing) D-4
Swing Speed Reducer D-5
D
Select Valve (Dolly) D-6
Boom Elevation System
Elevating System E-1
Elevating Cylinder E-2
Counterbalance Valve (Elevating) E-3
Select Valve (Dolly) E-4
E
Winch system
Winch System F-1
Winch F-2
Hydraulic Motor (Winch) F-3
Counterbalance Valve (Winch) F-4
Hydraulic Valve (Winch Brake Release) F-5
F
Page 13
Foreword
8
WA04-1310E
Spec. No.
Chapter
Section
GT-800-1-90102
2M2D
(North America)
Boom Telescoping system
Telescoping System G-1
Boom (Five-Section Boom) G-2
Jib G-3
Telescoping Cylinder G-4
Counterbalance Valve (Telescoping) G-5
Hose Reel G-6
G
Hydraulic Valve G-7
Safety System
Safety System H-1
Load Moment Indicator (AML) Refer to separate manual W301-0232E
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
~#475327 K-3
Hydraulic Motor (Air conditioner, Option)
#475328~ K-4
~#475354 K-5
K
Solenoid Valve (Air conditioner, Option)
#475355~ K-6
Page 14
Foreword
9
WA04-1310E
Spec. No.
Chapter
Section
GT-800-1-90102
2M2D
(North America)
Control System
Control System L-1
Remote Control Valve (Lever) L-2
~#475341 L-3
Remote Control Valve (Pedal)
#475342~ L-4
Shuttle Valve (Lever, Pedal) L-5
Solenoid Valve (Boom Telescoping/Aux. Hoist)
L-6
~#475348 L-7
L
Solenoid Control Relief Valve (Elevating Slow Stop)
#475349~ L-8
Data, Adjustment and Checks
Hydraulic Pressure Setting Table Y-1
Air Bleeding Procedure Y-2
Electric Switch Adjustment Y-3
Check (Crane Operation) Y-4
Adjustment and Checks Y-5
Oil and Grease Table Y-6
Mass Table Y-7
Y
Boom Connecting Pin and Thread Size Table
Y-8
Page 15
Foreword
10
WA04-1310E
Spec. No.
Chapter
Section
GT-800-1-90102
2M2D
(North America)
System Diagrams
Hydraulic Circuit Z-1
Electric Circuit Z-2
Electric Circuit (Outrigger Operation, Option)
Z-3
Location of Installation
Location of Hydraulic Parts Z-4
Location of Electrical Parts (Upper) Z-5
Location of Electrical Parts (Lower) Z-6
Location of Electrical Parts (Outrigger Operation, Option)
Z-7
Hydraulic, Electric, Carrier Equipment Comparison Table
Z-8
Harness Diagrams
Harness (Inside Cab) Z-9
Harness (Swing Table, Left) Z-10
Harness (Swing Table, Right) Z-11
Harness (Boom) Z-12
Harness (AML, Upper) Z-13
Harness (Lower) Z-14
Z
Harness (Outrigger Operation, Option) Z-15
Page 16
i
B
Hydraulic Power Generating System
Contents
Hydraulic Power Generating System
1. Functions of units...................................... 1
1.1 Hydraulic pump .......................................... 1
1.2 Rotary joint ................................................. 1
1.3 Hydraulic pilot control valve........................ 1
1.4 Sequence valve.......................................... 1
1.5 Flow control valve....................................... 1
1.6 Solenoid valve (for venting pressure for
remote control) ..................................... 1
1.7 Hydraulic motor (for oil cooler) ................... 1
1.8 Solenoid valve (for oil cooler) ..................... 1
Hydraulic Pump
1. Structure................................................... 2
1.1 General view............................................... 2
1.2 Inside view.................................................. 3
1.3 Pump Mounting .........................................11
1.4 Gear ass’y ................................................ 12
Flow Control Valve
1. Structure................................................. 14
Rotary Joint
1. Structure................................................. 15
2. Potentiometer ......................................... 21
2.1 Adjustment................................................ 21
2.2 Soldering .................................................. 21
Hydraulic Pilot Control Valve (Elevating,
Telescoping, Winch)
1. Structure ................................................. 22
Sequence Valve (Pilot Pressure)
1. Structure ................................................. 34
Solenoid Valve (Pilot Pressure) (~#475348)
1. Structure ................................................. 37
Solenoid Valve (Pilot Pressure) (#475349~)
1. Structure ................................................. 38
Solenoid Control Valve (Jib Set and
Counterweight Cylinder)
1. Structure ................................................. 40
Pilot Check Valve (Jib Set)
1. Structure ................................................. 46
Solenoid Valve (Oil Cooler)
1. Structure ................................................. 47
B
Page 17
ii
Hydraulic Motor (Oil Cooler)
1. Structure................................................. 49
2. Air bleeding procedure............................ 49
Jib Lock Pin
1. Structure................................................. 50
Jib Offset Cylinder
1. Structure................................................. 51
Counterweight Cylinder
1. Structure................................................. 52
Pilot Check Valve
1. Structure................................................. 53
Check Valve (Gauge lsolator)
1. Structure................................................. 54
Page 18
B-1. B-1.
Hydraulic Power Generating System
1
WB02-0270E
Hydraulic Power Generating System
1. Functions of units
1.1 Hydraulic pump
This pump consists of double variable
displacement piston pump and double gear pump.
Pump A1 is used for the winch circuit, pump A2
for the boom telescoping, boom elevation and
winch circuits, pump A3 for the swing circuit, and
pump A4 for the winch accumulater, remote
control, swing brake release, jib setting, c/w
mounting/dismounting, oil cooler drive moter and
air conditioner (option) circuit.
1.2 Rotary joint
The rotary joint allows pressurized oil from the
hydraulic pump and current from the battery to be
sent to the swing table, and at the same time
allows operation of the accelerator from the swing
table.
1.3 Hydraulic pilot control valve
By moving the spool utilizing the external pilot
pressure from the remote control valve, it changes
the direction of the pressurized oil introduced from
the port P into the hydraulic cylinder or inlet/outlet
port of the hydraulic motor and controls the oil
flow by changing the displacement of the spool.
1.4 Sequence valve
1. This valve incorporates a sequence valve and a
reducing valve.
2. The reducing valve regulates the oil pressure
below the specified value; the sequence valve
regulates it above the specified value.
1.5 Flow control valve
This valve is installed on the A4 pump circuit and
ensures fixed amount oil flow to the hydraulic
motor for the air conditioner and oil cooler, as well
as prevents troubles caused by pulsation.
1.6 Solenoid valve (for venting pressure for
remote control)
It supplies and vents the pilot pressure for the
remote control. While the solenoid valve is
deenergized, the oil flow to the remote control
valve is shut off, making crane operation
impossible.
1.7 Hydraulic motor (for oil cooler)
1. If the crane is used under high load for a long time
in summer, the hydraulic oil temperature will rise
over 70°C (158°F), leading to oil deterioration
such as oxidation and reduced oil viscosity that
can cause leaks in the pump and motor and
reduce volume capacity.
2. To prevent such troubles, the returned oil is
force-cooled (while the motor is driven by the oil
delivered from the A4 pump). (The forced-cooling
operation is available also during traveling
because the A4 pump always delivers oil while the
engine is running.)
1.8 Solenoid valve (for oil cooler)
It serves to start/stop the hydraulic motor which
drives hydraulic oil cooler. When the oil cooler is
functioning, it is energized and drives the
hydraulic motor.
Page 19
B-2 B-2
Hydraulic Pump
2
W101-0280E
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
1.1 General view
Hydraulic Symbols
Symbol Name Size
A1, A2 Delivery port SAE11 /4 (High pressure type)
A3, A4 Delivery port SAE1 (Standard type)
S1 Suction port SAE3 (Standard type)
S3, S4 Suction port SAE11 /4 (Standard type)
L1, L2 Drain port G3/4
U1, U2 Air bleeding port G3/8 (Plug)
X1, X2 Pilot port G1/4
Page 20
B-2 B-2
Hydraulic Pump
3
W101-0280E
1.2 Inside view
Variable displacement piston pump
Page 21
B-2 B-2
Hydraulic Pump
4
W101-0280E
1.
Control section (C.C.W. rotation)
2.Control section (
C.W rotation
)
3.Cover section
4.Rotary section
5.Piston section
6.Hanger section (left rotation)
7.Hanger section (
right rotation
)
8.shaft section (front)
9.shaft section (rear)
11.Adapter ring
12.Front housing
13.Rear housing
14.Cover
15.Coupling
16.O-ring
18.Hex. socket head bolt
19.O-ring
20.Plug
21.O-ring
22.Plug ass’y
26.O-ring
27.Hex. socket head bolt
28.Coupling
30.Gear pump
35.Name plate
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
T2 - 212 - 282 156.4 - 208
T3 - 62 - 82 45.7 - 60.5
T4 - 12 - 15 8.8 - 11
T5 - 28 - 35 20.6 - 25.8
T6 - 56 - 70 41.3 - 51.6
T7 - 28 - 35 20.6 - 25.8
T8 - 230 - 270 169.6 - 199.1
T9 - 126 - 157 93 - 115.8
1. Be careful to the direction when installing 6. and 7. (Refer to the
hanger section in attached paper)
2. Adjust the gap of shim A in 8. and 9. sections to 0.05-0.1mm
(0.002-0.004 in).
3. Be careful to the direction when installing 11. (Install 11. so that the discharge ports of the variable
displacement pump and gear pump become same direction.)
4. Be careful to the falling when assembling 19.
Page 22
5
W101-0280E
B-2 B-2
Hydraulic Pump
1.Requlator cover
2.Body
3.Guide
4.Barrel
5.Spool
6.Spring seat
7.Spring seat
9.Guide
10.Adjust screw
11.Arm
12.Spring
13.Spring
14.Spring
15.Spring
16.Parallel pin
17.Parallel pin
18.Parallel pin
19.O-ring
20.O-ring
21.O-ring
22.O-ring
23.O-ring
24.Hex. socket head bolt
25.Hex. socket head bolt
26.Nut
27.Plug
28.Hex. socket head bolt
29.Orifice
30.Shim
31.Shim
32.Shim
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
T1 M6 12 - 15 8.8 - 11
T2 M6 12 - 15 8.8 11
T3 M8 28 - 35 20.6 – 25.8
T4 M8 28 - 35 20.6 – 25.8
Control Section 1, 2 (This view shows “Right rotation”)
Page 23
6
W101-0280E
B-2 B-2
Hydraulic Pump
1.Cover
2.Control plate
3.Control plate
5.Plug
6.Hex. socket head bolt
7.Parallel pin
8.O-ring
9.O-ring
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
T1 M16 23 - 28 17 – 20.6
Apply THREE BOND 1305 to the plug 5 (12 places)
Cover section 3
Page 24
7
W101-0280E
B-2 B-2
Hydraulic Pump
1.Piston
2.Cylinder block
4.Retainer
6.Guide
7.Spring
8.Parallel pin
9.Spring seat
10.C-retaining ring
1.Piston
2.Cylinder
3.Cylinder
4.Piston
5.Spring
Rotary section 4
Piston section 5
Page 25
8
W101-0280E
B-2 B-2
Hydraulic Pump
1.Joint (control piston) 2.Hanger 3.Metal 4.Orifice
Hanger section 6, 7
Page 26
9
W101-0280E
B-2 B-2
Hydraulic Pump
1.Shaft
2.Seal case
4.Shim
5.Bearing
6.Bearing
7.Oil seal
8.C-retaining ring
9.O-ring
1.Shaft
2.Shim
4.Bearing
5.Bearing
7. Apply the qrease equivalent to MORITON
GREASE NO.2 (Product by “SUMICO”) to the lip
of oil seal 7.
Shaft section 8 (front) Shaft section 9 (rear)
Page 27
10
W101-0280E
B-2 B-2
Hydraulic Pump
1.Frame
2.Body
3.Body
4.Case
5.Gear
6.Gear
7.Gear
8.Gear
9.Side plate
10.Side plate
11.Seal ring
12.Coupling
13.Bush
14.Stud bolt
15.Bearing
16.Square ring
17. ------
18.O-ring
19.C-retaining ring
20.Plain washer
21.Plug
22.Plain washer
23.Nut
24.Parallel pin
25.O-ring
26.Hex. socket head bolt
27.Spring washer
28.Stud bolt
29.Stud bolt
Gear pump 30
0
366-537-80000
Page 28
B-2 B-2
Hydraulic Pump
11
W101-0280E
1.3 Pump Mounting
1. Hydraulic pump is attached to the gear ass’y.
2. The drive power from P.T.O is transferred to the
hydraulic pump by the propeller shaft and gear
ass’y.
[NOTICE]
L: Installation dimension of propeller shaft
Standard .......................900 mm (35.4 in)
Maximum allowance .....920 mm (36.2 in)
Minimum allowance ......880 mm (34.6 in)
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
Bolt•1 M16 139 - 155 102.5 - 114.3 Bolt•2 M16 139 - 155 102.5 - 11 4.3 Bolt•3 (*1) M12 81 - 91 59.7 - 67.1 Bolt•4 (*1) M8 23 - 27 17 - 20 Bolt•5 M12 81 - 91 59.7 - 67.1 Bolt•6 (*1) M12 34 - 41 25.1 - 30.2 Nut•1 M14 58 - 67 42.8 - 49.4 Nut•2 M24 58 - 137 42.8 - 101.1 (*1): Apply LOCTITE 277
Page 29
B-2 B-2
Hydraulic Pump
12
W101-0280E
1.4 Gear ass’y
[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.
Structure
(*1): Apply Three-Bond 1215 or its equivalent
to the surface and put it together.
(*2): Apply Three-Bond 1215 or its equivalent
to the circumference side and apply
lithium grease to lip part.
Page 30
13
W101-0280E
B-2. B-2.
Hydraulic Pump
1. Gear case
2. Gear case
3. Ball bearing
4. Oil seal
5. Input shaft
6. Idle gear
7. Collar
8. Idle shaft
9. Ball bearing
10. Idle gear
11. Collar
12. Idle shaft
13. Ball bearing
14. Output shaft
15. Hex. socket plug
16. Snap ring
17. Air bleeder
18. Bushing
19. Elbow
20. Hex. socket plug
21. Oil seal
22. Hex. socket head bolt
23. Hex. socket head bolt
24. Parallel pin
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
15 (*3) R3/8 35.3 26.0 17 (*3) - 35.3 26.0 18 (*3) - 78.5 57.9 19 (*3) R3/4×Rc3/4 78.5 57.9
20 (*3) Rc3/4 78.5 57.9 22 (*4) M12 114 84.1 23 (*4) M12 114 84.1
(*3): With seal tape
(*4): Apply Three-Bond 1305 or its equivalent
Page 31
B-3.
B-3.
Hydraulic Pump
14
W11 4-0131E
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 ass’y
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
PA G3/4 167 123
T, PB G1/2 98 72
IW114-0130E02
PB
PA
T
0
366-104-20000
Page 32
B-4
B-4
Rotary Joint
15
W181-0300E
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
A
B
Apply grease (EP2).
Grooves
Apply waterproof sealant. (Equivalent to THREE-BOND 4101. Do not apply grease.)
Apply grease (EP2).
Fill the clearance with grease at assembly.
Apply thread locking compound (equivalent to THREE-BOND 1401).
Apply waterproof sealant to the whole periphery (equivalent to THREE-BOND 4101).
Apply thread locking compound (equivalent to THREE-BOND 1401).
Apply grease (EP2). Apply thread locking compound
(equivalent to THREE-BOND 1401).
Apply grease (to prevent corrosion).
Apply a small amount of grease (to prevent corrosion).
109
3
14
4
15 148
W2
W1
12
26
13
AC
DR
P4
12
13
5
P3
6
13
7
4
P2
P1
3
2
T
Face the mark toward the front.
1
21
IW181-0300E01
Apply thread locking compound (equivalent to THREE-BOND 1401).
Page 33
B-4
B-4
Rotary Joint
16
W181-0300E
27
GR2
11
GR1
Tap for slinging (2 places)
(M10)
IW181-0300E02
FRONT
AC2
P4
P3
AC1
P2
P1
P2'
11
DR
T2
T1
T'
T'
W2
W1
19
A
Upper (view A)
Lower (view B)
Page 34
B-4
B-4
Rotary Joint
17
W181-0300E
1.Slip ring ass’y
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.Plate
21.Flange bolt
22.Clamp
23.Nut
24.Plate
25.Hex. socket head bolt
26.Ring seal
27.Plug
Thread size and tightening torque
Tightening torque
Thread
Thread
size
N-m ft-lbf
16 *1 M12 74 - 82 55 - 61
17 *1 (to secure the plate [18]) M8 13 - 15 9.6 - 11
21 *1 (to secure the slip ring ass’y [1]) M6 4 - 6 3 - 4.4
25 *1 M8 23 - 28 17 - 20
*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.
Hydraulic section
Tightening torque
Thread Thread size
N-m ft-lbf
Upper
P1 Winch
Lower
G1 196 145
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
Lower G1 196 145 Upper
P4 Option
Lower
G1/2 98 72
Upper RC3/8 49 - 69 36 - 51 AC
1
Accelerator
Lower G3/8 49 36 Upper G1/2 98 72 AC
2
Accelerator (Air bleeding)
Lower - - ­Upper
T1 Tank
Lower
- - -
Upper G3/4 167 123
T2 Tank
Lower - - ­Upper
DR Drain
Lower
G1/2 98 72
L.L.C. section
Tightening torque
Thread 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
Page 35
B-4
B-4
Rotary Joint
18
W181-0300E
Slip ring ass’y
A
B
A
B
31
IW181-0260E03
27 26
B-B
IW181-0260E04
29
P
IW181-0260E05
[NOTICE]
On the following serial No., the connecting
structure of the potentiometer (20) and the shaft (1) and number of brush are partially different from the illustration IW181-0290E03. TT-800XXL-1 ; 475326
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
IW181-0290E0
3
Page 36
B-4
B-4
Rotary Joint
19
W181-0300E
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.Hex. socket set screw
30.Machine screw
31.Bolt
32.Bolt
33.Spring washer
36.Hex. socket head bolt
Thread size and tightening torque
Tightening torque
Thread 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 37
B-4
B-4
Rotary Joint
20
W181-0300E
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 62 6
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 61 4
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 61 5 16 3 16 18 2 61 8 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 38
21
W181-0300E
B-4.
B-4.
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
IW181-0260E1
3
Stamp mark
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 socket head 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).
0
346-307-62000
1
346-306-92000
Page 39
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
22
W134-0270E
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 40
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
23
W134-0270E
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
IW134-0270E0 2
Vent
Page 41
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
24
W134-0270E
Thread size and tightening torque
Tightening torque
Thread 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 42
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
25
W134-0270E
BA
BA
14 13
IW134-011012
Aux. winch
Main winch
Telescoping
Elevating
Cross section of whole body
Page 43
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
26
W134-0270E
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 44
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
27
W134-0270E
5 156
IW134-011004
B-B
Aux. winch
Main winch
Telescoping
Elevating
1.Winch selector valve
2.Telescoping selector valve
3.Elevating selector valve
4.End cover
5.O-ring
6.O-ring
7.Hex. socket head bolt
8Main relief valve
9.Main relief valve
12.Hex. socket head bolt
13.Plug
14.O-ring
15.Plug
16.Eye bolt
Thread size and tightening torque
Tightening torque
Thread 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 45
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
28
W134-0270E
IW134-0270E04
29
30
624201921 22 1
25,24,23,13
18 17 1528 27 26 28 14
7
11 10
9812,23,24,25
16,17
Overload relief valve
C-C (Aux. winch) , D-D (Main winch)
IW134-0110E07
18 17 1528 27 26 28 16,175
Main relief valve
E-E
1
Winch selector valve
Page 46
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
29
W134-0270E
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
Thread 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 47
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
30
W134-0270E
Overload relief valve
302952432221 23 24 1
27,26,25,13
6 19,20 18 1728 14 16 15
7912,25,26,27
11 10
19,20
8
F-F (Telescoping)
IW134-0270E03
1.Telescoping selector 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
Thread 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 48
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
31
W134-0270E
IW134-0110E09
191854 18 19 12
22,21,20,13
6 16,17 15 1423
7912,20,21,22
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
Thread 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 49
B-5
B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
32
W134-0270E
T
P
20 19
15
16
17
18
14 13 12 11 109 8 7 6 3 2 1 54
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
Thread Thread size
N-m ft-lbf
1 - 28.4 - 30.4 21 - 22.4
10 M11 18.6 - 20.6 13.7 - 15.2
13 M11 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 50
33
W134-0270E
B-5.
B-5.
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
Thread 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 M11 18.6 - 20.6 13.7 - 15.2
14 M11 18.6 - 20.6 13.7 - 15.2
Overload relief valve (Main winch), (Aux. winch), (Elevating), (Telescoping)
0
366-405-40000
Page 51
B-6 B-6
Sequence Valve (Pilot Pressure)
34
W122-011 2E
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
Thread Thread size
N-m ft-lbf
P, V G 1/2 58.8 – 68.6 43.4 – 50.6
Dr G3/8 39.2 - 49 28.1 – 36.1
Pi, G G1/4 24.5 29.4 18.1 – 21.7
Page 52
B-6 B-6
Sequence Valve (Pilot Pressure)
35
W122-011 2E
1 23
4
A-A
5
IW122-0112E01
6
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
3 G1/2 9.8111.8 7.2 - 8.7
6 M6 9.8110.8 7.2 - 8
IW122-011004
1 2673485
Thread size and tightening torque
Tightening torque
Thread 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
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 53
B-6. B-6.
Sequence Valve (Pilot Pressure)
36
W122-011 2E
IW122-011005
7
11 108 6 3 512213
9 1
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 54
B-7. B-7.
Solenoid Valve (Pilot Pressure) (~#475348)
37
W121-0242E
Solenoid Valve (Pilot Pressure) (~#475348)
[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 T2
4
2 T1
3
T
A2
A1
P
IW121-024002
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
P, T, A1, A2 G1/4 34 - 38 25 - 28
2 M22×1 39 - 49 29 - 36 3 G1/4 34 - 38 25 - 28
T1 - 5 - 6 3.5 - 4.5 T2 M8 26 - 32 20 - 24
0
366-458-90000
1.Casing
2.Solenoid valve (DC24V)
3.Plug
4.O-ring
Page 55
B-8
B-8
Solenoid Valve (Pilot Pressure) (#475349~)
38
W121-0670E
Solenoid Valve (Pilot Pressure) (#475349~)
[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
T1
IW121-067002
A2 A1
701
171
101
T
P
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
P, T, A 1,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 (DC24V)
Page 56
39
W121-0670E
B-8. B-8.
Solenoid Valve (Pilot Pressure) (#475349~)
IW121-06700
3
311
312361 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
Thread Thread size
N-m ft-lbf
802 M6 6.9 - 7.9 5.1 - 5.8
Solenoid Valve ass’y
0
367-401-00000
Page 57
B-9 B-9
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
40
W11 2-0240E
Solenoid Control Valve (Jib Set and Counterweight 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
P・P
IW112-0240E01
A3
C・O
B3
A2 B2
A1
GP T
B1
Page 58
B-9 B-9
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
41
W11 2-0240E
18.Name plate
21.Tigh rod
27.Plug
29.Hex. socket head bolt
31.Nut
32.Ribbet screw
33.Ball
38.O-ring
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
P, T G 1/2 98 72
A1, B1, A2, B2, A3, B3,
G3/8 49 36
C•O G1/2 98 72
P•P G1/4 29.4 22
Page 59
B-9 B-9
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
42
W11 2-0240E
IW112-0220E03
16
6
35
35
28
28 34 1938232733
25
44
35
33
33
37
8
9
35
33
16341938272320
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.Hex. socket head bolt
33.Ball
34.O-ring
35.O-ring
37.O-ring
38.O-ring
44.O-ring
Page 60
B-9 B-9
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
43
W11 2-0240E
B-B
IW112-0240E03
14
35
14
24
17
43
15
35
14.Spool
15.Housing
17.Housing plunger
24.Housing
35.O-ring
43.O-ring
Page 61
B-9 B-9
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
44
W11 2-0240E
IW112-0220E05
P
T
C-C
IW112-0220E06
D-D
C O
Page 62
B-9. B-9.
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
45
W11 2-0240E
IW112-0220E
07
42 12241140 104303365131139
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
366-404-20000
Page 63
B-10. B-10.
Pilot Check Valve (Jib Set)
46
W11 5-0270E
Pilot Check Valve (Jib Set)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
BA
DC
IW115-027001
B
DC
A
IW115-027002
765 34
8 1 9
2
10
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
Thread Thread size
N-m ft-lbf
A,B,C,D G1/4 29.4 22
X-X
1
366-241-40000
Page 64
B-11 B-11
Solenoid Valve (Oil Cooler)
47
W121-0251E
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 ass’y 2.Body 3.Valve 4.Plug
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7 - 8 5 - 6
Page 65
48
W121-0251E
B-11. B-11.
Solenoid Valve (Oil Cooler)
TT
AB
P
IW121-025003
129 11587 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.Hex. socket head bolt
Thread size and tightening torque
Tightening torque
Thread 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 ass’y
1
366-457-50000
Page 66
B-12. B-12.
Hydraulic Motor (Oil Cooler)
49
W102-0121E
Hydraulic Motor (Oil Cooler)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
27 122117 1920162223 3
25 142 4 7 532 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 bearing
20.Thrust plate
21.Hex. socket head button bolt
22.Ball bearing
23.Retaining ring
25.Hex. socket head bolt
27.O-ring
32.Piston ass’y
33.Seal plate
34.Flat head machine screw
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
A, B G3/8 49 36
D G1/4 29.4 22
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
Page 67
B-13. B-13.
Jib Lock Pin
50
W180-0020E
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
Thread Thread size
N-m ft-lbf
A, B G1/4 29.4 22
0
360-531-60000
Page 68
B-14. B-14.
Jib Offset Cylinder
51
W180-0030E
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 pressurized side.
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
A, B G1/4 29.4 22
0
360-520-90000
Page 69
B-15. B-15.
Counterweight Cylinder
52
W180-0040E
Counterweight 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
IW180-0040E01
1 23456 78910
1
2
11
15
12 13 14
1.Cylinder
2.Split pin
3.Nut
4.Piston
5.plain bearing
6.O-ring
7.Rod
8.Rod cover
9.Plain bearing
10.O-ring
11.Damper ring
12.Packing
13.Backup ring
14.Dust seal
15.Orifice
*1 : Face the notch or the lip toward the pressurized side.
*2 : Apply LOCTITE638 (Do not stick out the end face)
0
360-532-60000
Page 70
B-16. B-16.
Pilot Check Valve
53
W11 5-0042E
Pilot Check 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
109 8
11
C
AB
D
75,641 2 123
IW115-004002
1.Body
2.O-ring
3.Piston
4.Sleeve
5.O-ring
6.Backup ring
7.Check valve
8.O-ring
9.Spring
10.Plug
11.O-ring
12.Backup ring
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
A G1/4 29.4 22
B G1/4 29.4 22
0
366-242-30000
AB
CD
IW115-023001
Page 71
B-17. B-17.
Check Valve (Gauge lsolator)
54
W11 6-0121E
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
Thread Thread size
N-m ft-lbf
P1, P2, P3, P’ G 1/4 29.4 22
S G 3/8 49.0 36
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
Page 72
i
D
Swing System
Contents
Swing System
1. Description of the units ............................. 1
1.1 Swing drive unit .......................................... 1
1.2 Hydraulic pilot control valve........................ 1
1.3 Solenoid valve (swing free/lock selet) ........ 1
1.4 Select valve (dolly) ..................................... 1
2. Swing slow stop........................................ 1
2.1 Condition for slow stop ............................... 1
2.2 Control element .......................................... 1
Swing Ass’y
1. Structure................................................... 2
2. Swing bearing mounting bolt..................... 3
2.1 Bearing Inner ring bolts .............................. 3
2.2 Bearing outer ring bolts .............................. 4
Hydraulic Pilot Control Valve (Swing)
1. Structure................................................... 5
Hydraulic Motor (Swing)
1. Structure................................................. 12
Swing Speed Reducer
1. Structure................................................. 14
Select Valve (Dolly)
1. Structure ................................................. 16
D
Page 73
D-1. D-1.
Swing System
1
WD02-0230E
Swing System
1. Description of the units
1.1 Swing drive unit
1. A hydraulic motor with wet-type brake and the
double reduction planetary gear is integrated in
the unit. This unit converts the pressurized oil
delivered from the pump into the low-speed
high-torque turning force to employ it for driving
the swing structure.
1.2 Hydraulic pilot control valve
1. It shifts the flowing direction of the pressurized oil
by the pilot pressure in order to control the
rotating direction of the hydraulic swing motor.
2. The proportional valve provided for swing slow
stop stops the swing movement gradually.
1.3 Solenoid valve
(swing free/lock select)
1. When it is energized, it delivers the pressurized oil
to the brake cylinder of the swing drive unit to
release the swing brake.
1.4 Select valve (dolly)
1. To travel with a dolly hitched to the rear of the
carrier, it is required that the hydraulic circuits for
the boom elevating cylinder and swing motor be
free so that the boom can follow the movements
of the dolly while travelling.
2. Swing slow stop
2.1 Condition for slow stop
Slow stop function is activated when the crane is
in the condition marked with a circle.
Swing stop
Not cancelled
Slow stop function
Override
OFF
Override
ON
Cancelled
Stop by swing range
restriction
O × ×
2.2 Control element
The current value and starting angle of deviation
outputted to the solenoid proportional valve for
slow stop are limited by the following conditions:
(Applicable to stop by range restriction)
• Boom length and lift status (full retraction, full
extension, single top lift, jib lift)
• Swing speed (The angular velocity is
automatically calculated inside the AML.)
Starting angle of deviation
Swing speed
Boom fully
retracted
Boom fully
extended
Single top
lift
Jib lift
(2-stage)
High
speed
35°- 45° 40°- 50° 40°- 50° 40°- 55°
Low
speed
20°- 40° 25°- 45° 25°- 45° 35°- 45°
Start point
Stop point
Angle where stop control starts during left swing. Determined by AML, which automatically calculates outrigger extension width, boom input conditions, and swing speed.
Deviation angle at start of control (Based on following data, regardless of boom length)
IWD02-0141E01
Page 74
D-2 D-2
Swing Ass’y
2
W514-0200E
Swing Ass’y
[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
Thread Thread size
N-m ft-lbf
1 M18 294 - 343 217 - 253
1.Bolt
2.Plain washer
Page 75
D-2 D-2
Swing Ass’y
3
W514-0200E
2. Swing bearing mounting bolt
2.1 Bearing Inner ring bolts
1,2
3,4
10
Front
3,4
1,2
5
67
8
6,9
IW514-0200E01
View A
A
"S" mark
50mm (19.7in)
[NOTICE]
Install the bearing inner ring with the "S" mark facing the front 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
Thread
Thread
size
N-m ft-lbf
2
(48 points)
M30 1620 - 1810 1195 - 1335
4 M12 69 - 82 51 - 60
1.Pain washer
2.Bolt (L=180mm)
3.Plain washer
4.Bolt
5.Support
6.Nut
7.Bolt
8.End
9.Spring washer
10.Pin
Page 76
4
W514-0200E
D-2. D-2.
Swing Ass’y
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
Thread
Thread
size
N-m ft-lbf
1
(42 points)
2
(3 points)
5
(2 points)
M27 11 77 - 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
3
338-502-20000
1
342-310-40000
Page 77
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
5
W134-0121E
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
Page 78
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
6
W134-0121E
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
P, R G 1 200 - 240 145 - 174
AM, BM G3/4 150 - 180 108 - 130
G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 25 - 28
Dr G1/4 34 - 38 25 - 28
Page 79
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
7
W134-0121E
A B
A
B
AM
RV
BM
Dr
G
P
RB RA
Sol.1
Sol.4
Pi2Pa
Pi1
Pb
Sol.3 Sol.2
706
253 263
702 703
351
152 701
701 151
352
353
IW134-012003
AM
RV
BM
Dr
G
P
Sol.1
Sol.4
IW134-012007
Cross section
Enlarged view (Sol.1, Sol.4, RV)
Page 80
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
8
W134-0121E
C
C
Dr
P
R
G
C2
C1
152
414 413 401 450 412 411 415 151
IW134-012004
A-A
Cross section along the line A-A
Page 81
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
9
W134-0121E
AM
RA
CA2
152
644
643
642
641
661
IW134-012005
B-B
Cross section along the line B-B
Page 82
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
10
W134-0121E
P
R
C1
BM
CB1 CA1
AM
Pi1
Pb
Sol.2Sol.3
Pi2
231 211 212 234 235
C-C
561 511 521 551 101
251
512522562552241251252221
252
152 201 243 242 222 261261
Pa
IW134-012006
Pi1
Pb
Sol.2Sol.3
Pi2
Pa
IW134-012008
Cross section along the line C-C
Enlarged view (Sol.2, Sol.3)
Page 83
11
W134-0121E
D-3. D-3.
Hydraulic Pilot Control Valve (Swing)
101.Casing
151.Plug
152.Plug
201.Spool
211.Spacer bolt
212.Stopper
221.Cover
222.Cover
231.Spring seat
234.Spring
235.Spring
241.O-ring
242.O-ring
243.O-ring
251.Orifice
252.Plug
253.Plug
261.Solenoid
inverse-proportional
reducing valve
263.O-ring
351.Hex. socket head bolt
352.Hex. socket head bolt
353.Hex. socket head bolt
401.Plug
411.Plunger
412.Spring
413.O-ring
414.Steel ball
415.Stopper
450.Air bleeder screw
511.Poppet
512.Poppet
521.Spring
522.Spring
551.Cap
552.Plug
561.O-ring
562.O-ring
641.Spring seat
642.Spring
643.Steel ball
644.Seat
661.O-ring
701.Relief valve
702.Solenoid relief valve
703.Relief valve
706.Solenoid valve (DC24V)
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
151 R1/4 20 - 24 14 - 17
152, 252 NPTF1/16 6 - 8 4.5 - 6
211 *1 M8 16 - 18 12 - 13
251 *1 M5 3.5 - 4.5 2.5 - 3.5
253 G1/4 34 - 38 25 - 28
261 M22 39 - 49 29 - 36
351, 352, 353 M6 10.5 - 13.5 8 - 10
401 M24 58 - 70 43 - 51
450 M10 14.5 - 17.5 10.5 - 12.5
551 M33 190 - 210 140 - 155
552 M24 120 - 140 88 - 103
641 G1/8 8 - 10 6 - 7
701 M30 110 - 130 81 - 96
702 M22 39 - 49 29 - 36
703 M27 69 - 79 51 - 58
706 M22 39 - 49 29 - 36
*1: Apply LOCTITE 241 (thread locking agent) to threaded sections.
1
366-461-30000
0
366-489-60000
Page 84
D-4 D-4
Hydraulic Motor (Swing)
12
W102-0500E
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
PB
DR
AB
IW102-050001
PB
IW102-050002
A
A
DR
DR
PB
A(B) A
464
707 712 472 106 438 303
433
444
451131743742111116123122124113301
437
491
101
401702706114118121117432106443
471
304
485
A-A
Page 85
13
W102-0500E
D-4. D-4.
Hydraulic Motor (Swing)
101.Drive shaft
106.Spacer
111.Cylinder
113.Spherical bush
114.Cylinder spring
116.Push rod
117.Spacer
118.Spacer
121.Piston
122.Shoe
123.Guide plate
124.Shoe plate
131.Valve plate
301.Casing
303.Valve cover
304.Font cover
401.Hex. socket head bolt
432.Stop ring
433.Stop ring
437.Iocking ring
438.Iocking ring
443.Roller bearing
444.Roller bearing
451.Spring pin
464.Plug
471.O-ring
472.O-ring
485.O-ring
491.Oil seal
702.Brake piston
706.O-ring
707.O-ring
712.Brake plate
742.Friction plate
743.Separator plate
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
PB G1/4 36 26.6
A, B G3/4 167 123
DR G1/2 108 80
464 G1/4 36 26.6
401 M20 430 317
0
366-635-90000
Page 86
D-5 D-5
Swing Speed Reducer
14
W511-0240E
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
30,31
IW511-024001
7
19
20,21
22
23
24
25
26
27
28
26
29
18
16,17
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Page 87
D-5. D-5.
Swing Speed Reducer
15
W511-0240E
[NOTICE]
Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer bracket (19).
Inject lithium based grease to the mating faces of the retainer (2) and the roller bearing (3).
After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into casing(4).
Apply lithium based grease to the inner circumference of oil seal(5).
The amount of the gear oil is approx. 1 gal (US). (3.8 L).
Do not disassemble the king pins (8), (27) nor spacer (13).
1.Spur gear
2.Retainer
3.Roller bearing
4 Casing
5.Oil seal
6.Ball bearing
7.Plug
8.King pin
9.Carrier
10.Bearing washer
11.Needle bearing
12.Planetary gear
13.Spacer
14.Carrier
15.Bearing washer
16.Bolt
17.Spring washer
18.Sun gear
19.Bracket
20.Bolt
21.Spring washer
22.Snap ring
23.Coupling
24.Planetary gear
25.Needle bearing
26.Bearing washer
27.King pin
28.Sun gear
29.Snap ring
30.Bolt
31.Seal washer
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
20 M16 206 152
Mounting bolt (*1) M18 294 - 343 217 - 253
*1: Apply torque control agent to threaded sections.
0
360-816-51000
Page 88
D-6. D-6.
Select Valve (Dolly)
16
W129-0120E
Select Valve (Dolly)
[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. Valve body
3. Ball
8. Valve seat
10. Valve stem
14. Retainer
21. Pointer
26. Lever
36. Collar
40. Support
46A. Name plate
46B. Name plate
46C. Name plate
101. Bolt
105. Hex. socket set screw
106. Machine screw
109. Thrust washer
109. Plain washer
116. Pin
125. Backup ring
126A. O-ring
126B. O-ring
142. Rivet
145. Pad lock
0
366-381-10000
IW129-0120E02
Page 89
i
E
Boom Elevation System
Contents
Elevating System
1. Description of the units ............................. 1
1.1 Elevating cylinder ....................................... 1
1.2 Counterbalance valve................................. 1
1.3 Select valve (dolly) ..................................... 1
Elevating Cylinder
1. Structure................................................... 2
Counterbalance Valve (Elevating)
1. Structure................................................... 4
2. Function.................................................... 6
2.1 When control valve is
at the neutral position ........................... 6
2.2 While actuator is being pushed up ............. 6
2.3 While actuator descends ............................ 6
Select Valve (Dolly)
1. Structure................................................... 7
E
Page 90
E-1. E-1.
Elevating System
1
WE02-0230E
Elevating System
1. Description of the units
1.1 Elevating cylinder
1. The elavating cylinder serve to elevate the boom.
2. A pressure sensor is installed to input the value to
the AML for calculating load moment.
1.2 Counterbalance valve
1. This valve serves to prevent the cylinder piston
rod from pushed in by the load during boom
lowering to maintain the lowering speed at a level
determined by the oil entry flow rate to the
cylinder.
2. It also prevent the retraction of the piston rod
when the piping between it and the manual control
valve is broken.
1.3 Select valve (dolly)
1. To travel with a dolly hitched to the rear of the
carrier, it is required that the hydraulic circuits for
the boom elevating cylinder and swing motor be
free so that the boom can follow the movements
of the dolly while travellring.
Page 91
E-2 E-2
Elevating Cylinder
2
W155-0240E
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
IW155-0240E01
G1/2
G3/4
33,34
30,31
22,23
22,23
22,23
22,23
272524424120,21 2626 28,29 19
32
28,29
44 43 37
Page 92
3
W155-0240E
E-2. E-2.
Elevating Cylinder
IW155-0220E02
35 38 12
119821 3391110
13,14 154,5 4,6 7,40
1.Cylinder
2.Spring pin
3.Plain bearing
4.Packing
5.Backup ring
6.Backup ring
7.O-ring
8.Piston
9.Rod ass’y
10.Rod cover ass’y
11.O-ring
12.Damper ring
13.Packing
14.Backup ring
15.Dust seal
16.Retainer
17.Spring washer
18.Bolt
19.Support
20.Fitting
21.O-ring
22.Fitiing
23.O-ring
24.Pipe
25.Pipe
26.T-fitting
27.Pipe
28.Clamp ass’y
29.Sleeve
30.Bolt
31.Spring washer
32.Counterbalance valve ass’y
33.Fitting
34.O-ring
35.Orifice
36.Grease nipple
37.Pipe
38.O-ring
39.Head cover
40.Backup ring
41.Pipe
42.Pipe
43.Select valve ass’y
44.Hex. socket head bolt
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
A G3/4 108 - 123 80 - 90
B G1/2 54 - 64 40 - 47
C, D G3/8 25 - 30 18.5 –220.
30 M8 24 - 27 17 - 20
0
360-265-90000
Page 93
E-3 E-3
Counterbalance Valve (Elevating)
4
W11 9-0211 E
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
IW119-021001
B
A
P. P
B
P.P
A
7654 2-62-52-3 2-4 2-9 2-10
2-11 2-12 2-13 2-14
2-2 2-1 2-16 2-151
2-8
3-7
3-8
3-6
3-5
3-4
3-3
3-1 3-2
2-7
IW119-021002
1.Valve block
2-1.Valve seat
2-2.O-ring
2-3.O-ring
2-4.Backup ring
2-5.O-ring
2-6.Backup ring
2-7.O-ring
2-8.Backup ring
2-9.Spool
2-10.Orifice
2-11.Steel ball
2-12.Spring
2-13.Holder
2-14.Spring
2-15.Cap
2-16.O-ring
3-1.Valve seat
3-2.O-ring
3-3.O-ring
3-4.Backup ring
3-5.Poppet
3-6.Spring
3-7.Cap
3-8.O-ring
4.Orifice
5.Filter element
6.Snap ring
7.Stopper
Page 94
5
W11 9-0211 E
E-3 E-3
Counterbalance Valve (Elevating)
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
A G3/4 167 123
P.P G3/8 49 36
2-1 - 177 - 196 130 - 145
2-15 - 127 - 147 94 - 108
3-1 - 108 - 127 80 - 94
3-7 - 59 - 78 43 - 58
Mounting bolt M8 24 - 27 17 - 20
Page 95
6
W11 9-0211 E
E-3. E-3.
Counterbalance Valve (Elevating)
2. Function
C
a
B
P.P
A
b
IW119-021003
This counterbalance valve prevents the actuator
from being driven by the load and its own weight
faster than the speed corresponding to the oil
supply rate.
2.1 When control valve is at the neutral position
The actuator holding pressure is sealed by seat
“a” of the main spool and seat “b” of the check
valve.
2.2 While actuator is being pushed up
1. The pressurized oil entering through port A of the
control valve enters chamber C, flows out through
port B by opening the check valve, and enters the
holding side of the actuator.
2. At this time, since port PP is connected to the tank
circuit, the main spool is kept forced to the valve
body by the spring, and remains inactive.
2.3 While actuator descends
1. The hydraulic oil directly flowing from the control
valve to the actuator also enters through port PP
to exert force to the main spool to move the main
spool.
2. Consequently, the holding hydraulic pressure in
port B is vented to port A.
3. At this time, the main spool motion is smoothened
by orifices.
2
366-051-70000
Page 96
E-4. E-4.
Select Valve (Dolly)
7
W129-0130E
Select Valve (Dolly)
[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. Valve body
2. Cover
3. Ball
9. Valve seat
10. Valve stem
13. Adapter
21. Pointer
26. Lever
40. Support
46.A Name plate
46.B Name plate
46.C Name plate
60. Shim
101. Bolt
102.A Hex. socket head bolt
102.B Hex. socket head bolt
105.A Hex. socket set screw
105.B Hex. socket set screw
106. Machine screw
109. Thrust washer
109. Plain washer
116. Pin
118. Spring pin
125.A Backup ring
125.B Backup ring
126.A O-ring
126.B O-ring
126.C O-ring
142. Rivet
145. Pad lock
0
366-381-20000
IW129-0120E02
Page 97
i
F
Winch System
Contents
Winch system
1. Description of the units ............................. 1
1.1 Hydraulic motor .......................................... 1
1.2 Counterbalance valve................................. 1
1.3 Hydraulic valve ........................................... 1
1.4 Solenoid valve (telescoping/aux. hoist) ...... 1
Winch
1. Structure................................................... 2
Hydraulic Motor (Winch)
1. Structure................................................... 4
2. Air bleeding procedure.............................. 6
Counterbalance Valve (Winch)
1. Structure................................................... 7
2. Function.................................................... 8
2.1 Balancing and holding functions ................ 8
2.2 Overload relief function .............................. 8
3. Principle of operation ................................ 9
3.1 When control valve is in neutral ................. 9
3.2 Hoisting up.................................................. 9
3.3 Hoisting down............................................. 9
Hydraulic Valve (Winch Brake Release)
1. Structure ................................................. 10
F F
Page 98
F-1. F-1.
Winch System
1
WF02-0200E
Winch System
1. Description of the units
1.1 Hydraulic motor
1. A hydraulic motor provided with multiple wet brake,
which converts the pressurized oil delivered from
the motor into the turning force.
2. When a winch lever is operated, this motor
releases the brake by the pressurized oil delivered
from the hydraulic valve, as well as transmits the
turning force.
3. The motor power is transmitted to the winch drum.
While the rotating speed is reduced and torque is
increased with by the spur gear reduction device.
1.2 Counterbalance valve
1. This valve gives back pressure to the return circuit
in order to prevent abrupt load falling or motor
rotation and ensure the hoist-down speed
corresponding to the oil rate delivered from the
hydraulic motor.
2. When high hold pressure is generated between
the winch motor and the counterbalance valve
due to quick switching of the winch operation
selector valve, the overload relief valve opens to
let the pressure escape to the tank in order to
prevent damage.
1.3 Hydraulic valve
1. Selects applying or releasing of the automatic
brake for the main and aux. winch. When the
winch lever is operated to hoist up or down,
pressure created by this operation shifts the valve.
Consequently, the pressurized oil from the
accumulator flows into the automatic brake
cylinder, presses the spring and releases the
brake, allowing the drum to rotate.
2. When the winch lever is returned to neutral, the
valve is spring-returned to the neutral position as
the pilot pressure decreases, and the oil in the
winch brake cylinder flows to the tank.
Consequently the brake is applied by the spring.
1.4 Solenoid valve (telescoping/aux. hoist)
1. Delivers the pilot pressure from the remote control
valve to either the block of the boom telescoping
side or auxiliary winch operation side of the
hydraulic pilot control valve when the
telescoping/aux. winch operation selector switch
is shifted to "Telescoping".
Page 99
F-2 F-2
Winch
2
W526-0121E
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
17
12,13
21
24,25,2622
2728
4123
30
18 1920
5
7 8
11
15
16
14
9,10
12,13
3,4
12,13
29
9,10
31 32
IW526-012002
A- A
Page 100
3
W526-0121E
F-2. F-2.
Winch
Note: Apply THREE-BOND 11 04 to the following 5 places: mating face of the gear case (18) and the gear case
cover (37); mating face of the gear case (18) and the bracket (1); mating face of the gear case (18) and the
bearing retainer (7); mating face of the gear case (18) and the bearing retainer (21); mating face of the gear case
(18) and the bearing retainer (22). When installing the oil seals (5) and (23), apply THREE-BOND 1215 to their
external periphery and inject lithium based grease to their internal periphery. Apply NEVER-SEEZ to the
following 2 places: toothed mating face of the drum shaft (30) and the drum boss (27); cylindrical mating face of
the drum shaft (30) and the drum (29). The amount of the gear oil is approx. 1.1 gal. (4 L). Do not disassemble
the sleeve (41).
1.Bracket
3.Bolt
4.Spring washer
5.Oil seal
7.Bearing retainer
8.Ball bearing
9.Nut
10.Washer
11.Collar
12.Bolt
13.Spring washer
14.Drum gear
15.Collar
16.Ball bearing
17.Ball bearing
18.Gear case
19.Spur gear
20.Ball bearing
21.Bearing retainer
22.Bearing retainer
23.Oil seal
24.Bolt
25.Spring washer
26.Lock plate
27.Drum boss
28.Pin
29.Drum
30.Drum shaft
31.Ball bearing
32.Bearing stand
33.Bolt
34.Spring washer
35.Plug
36.Elbow joint
37.Gear case cover
38.Plug
41.Sleeve
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m ft-lbf
3 *1 M14 177 - 190 130 - 140
12 M12 69 - 82 51 - 61
24 M20 353 - 392 260 - 289
33 M8 32 - 34 24 - 25
35 *2 R3/4 106 - 132 78 - 98
38 *3 R3/8 44 - 62 33 - 46
Mounting bolt M20 431 - 471 318 - 347
*1: Apply THREE-BOND 1305 to threaded sections. *2: Oil filler port. *3: Oil level port on the top and drain port on the bottom.
0
360-730-30000
0
360-731-80000
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