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MANUAL
TELESCOPING SYSTEM
REPAIR
MANUAL
CRANE CONTROLS
L01-0030R.
LOCATIONS OF COMPONENTS
L01-0030R.
GENERAL
FUNCTIONS OF UNITS
1. Master cylinder
1.
.
,
,
.
2.
,
,
.
MASTER CYLINDER
Fig. 1
. 1
1. Lock nut
2. Push rod
3. Boot
4. Stop ring
5. Cylinder body
6. Stopper
7. Piston ass'
7-1. Piston
7-2. Cup
7-3. Cup
7-4. Backup ring
7-5. Valve rod
7-6. Valve cup
PRINCIPLE OF OPERATION
1. During actuation
When push r o d is pushed, and
piston
starts to advance, valve
cup (tEK^ is seated by valve spring
closing the oil passage, and
thereby generating hydraulic
pressure.
1.
2.
3.
4.
5.
6.
7.
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
8.
9.
10.
11.
12.
13.
14.
15.
16.
(2)
,
,
.
2.
2. When releasing
REMOUNTING
(2)
< ) .
@
, ,
,
, <7^
,
.
< 53 ^
, ClzE)
(6) ,
(J-^ ,
.
0,2 0,5 /2
@ .
,
.
.
" " ("
"
"
")
Y.
NOTE
Make adjustment and bleed the
accelerator circuit in accordance
with ^Adjustment and checks ( Install
ing and adjusting master cylinde r),
(Bleeding accelerator circuit)^ in
Chapter Y.
DISASSEMBLY
1. Discharge the brake fluid from the
oil tank.
1.
2.
,
.
3.
,
@
..
4.
CAUTION
5.
5 ,
U
.
CLENING
CAUTION
1) Metal parts
, , ,
.,
,
.
1)
,
.
2)
,
.
,
30 .
CHECKING
1) Cylinder body, piston
Inspect sliding surfaces, and replace
parts showing scratches, rust, or
excessive wear.
2) Rubber parts
Replace the rubber parts when they
are damaged or aged. In addition,
even without any defects, replace
all the rubber parts used more than
1 year.
1)
,
,
.
2)
,
,
.
,
1 , ,
.
REASSEMBLY
1.
NOTE
Take care not to damage the sliding
surfaces of the cylinder and the
piston and the seal areas of the
cups, when inserting.
,
7-1
, ,
-
.
.
,
.
2.
3.
@
,
.
,
@
.
4.
4. Install boot
5.
12. ,
.
TEST
1.
, 0,5 1,0 /2
,
3
.
2.
-
( , 30 ) ,
,
.
1. Function test
With a small amount of brake fluid
present in the oil tank, apply air
pressure of 0.5 1.0 k g / c m 4 7 . 1 1
14.2 psi) through the discharge
port, and make sure that when the
piston is advanced approximately
3 mm, (0.12 in.), the air flow to
the oil tank is stopped.
2. Operational test
With the oil tank filled with brake
fluid, make sure that when the push
rod is continuously reciprocated
within 30 mm (1.18 in.), the piston
follows the push rod motion smoothly,
and brake fluid comes out intermit
tently from the discharge port.
MAINTENANCE STANDARDS
Item
Maintenance standards
Routine
check
Operation conditions
level, a nd leak.
1 0 0 0 hr
check
or 6 - m o n t h
Master
2000-hr
check
or
D i s a s s e m b l e m a s t e r c y l i n d e r a nd c h e c k all parts. R e
p l a c e all r u b b e r p a r t s , a n d e x e c u t e all t e s t s g i v e n
above.
,
.
1-year
1000
6
2000
cylinder
of m a s t e r
function
cylinder,
brake
fluid
test.
.
, .
.
. " .
CONTROL CYLINDER
Fig. 1
.
1.
2.
3.
4.
Piston
Cup
Cylinder body
Push rod
5. Boot
6. Cap
7. Bleeder screw
REMOUNTING
1
1.
2.
3.
4.
5.
6.
7.
NOTE
Make adjustment and bleed the
accelerator circuit in accordance with
'Adjustm ent and checks (Installing
and adjusting master cylinde r),
(Bleeding accelerator circuit)" in
Chapter Y.
CLEANING
.
" " ("
"
"
. ")
Y.
CAUTION
NEVER USE SUCH MINERAL OILS AS
KEROSENE AND GASOLINE, SINCE
THEY WILL CAUSE SWELLING AND
IMPAIR THE FUNCTIONING OF RUBBER
PARTS.
, , ,
.,
,
.
1) Metal parts
1)
,
.
2)
,
.
,
30
.
CHECKING
1)
,
,
.
2)
,
,
.
,
1 ,
,
.
REASSEMBLY
,
.
NOTE
^ not to damage the sliding
surfaces of the cylinder and the
piston and the seal areas of the
cups, when inserting
MAINTENANCE STANDARDS
Maintenance standards
Item
Routine
check
Operation conditions
2000-hr
or
Disassemble
1 -y e a r
check
2000
control
of c o n t r o l
cylinder
cylinder,
and c h e c k all
p l a c e all r u b b e r p a rts.
,
.
.
a nd
leak.
parts.
Re
R E PAIR
MANUAL
DATA, ADJUSTMENT
AND CHECKS
.
SPECIFICTIONS
HYDRAULIC UNIT
1. Hydraulic pump
1.
1)
1) Pump speed
Idling speed (IDL.)
600
rpm
:
600
2) Discharge rate
2150
104.0 cc/rev
83.2 cc/rev
36.4 cc/rev
2)
PI
104,0 3 /
83,2 3/
36,4 3/
2.
()
535 3/
3.
1) : 210 3/
2) : 16
WEIGHT TABLE
TG-500E-2-90101
.
,
,
.
ADJUSTMENT (Pressure)
()
HYDRAULIC CIRCUIT
PRESSURE SETTING TABLE
PRESSURE ADJUSTMENT
:
30 50
(
"DAPHNY Hydrau
lic Fluid WR22";
:
305)
1.
1)
1 (
RV1)
(SL8: . )
,
.
, .
:
2150
/ (.)
rpm (MAX.)
rpm^tlDL. )
2 (
RV2)
.
,
.
:
2150 / (.)
3)
( PR1)
.
(SL8: . )
,
.
, .
( ):
4)
rpm (IDL.)
5)
(
PR2)
(SL9: . )
,
.
,
.
( )
rpm (MAX.)
(
PR3)
.
,
.
:
2150
/ (.)
ADJUSTMENT (Electric)
, ()
SWITCH ADJUSTMENT
NOTE
For the locations of the switches,
refer to Chapter Z ELECTRIC
CIRCUIT ( Location of electrical p a rts).
1. Switch S 1(M ain winch winding detection)
Switch S 2(M ain winch unwinding detection)
Switch S3 (A u x ilia ry winch winding
detection )
Switch S4( A u xilia ry winch unwinding
detection )
Switch S6(Boom extending detection)
Switch S7 ( Boom elevating detection )
Switch S8 ( Boom lowering detection )
.
Z,
S1 (
)
S2 (
)
S3 (
)
S4 (
)
S6 (
)
S7 (
)
S8 (
)
S1, S3, S7
Spool
,
(
)
,
1,0 2,0 -
( ).
2.
S12 (
)
S13 (
)
A
@
,
5 .
,
( COM-NC
) , ,
, .
3.
S18 (
)
,
5 8 .
SWING SYSTEM
, , - () " (
)" .
1.
S w i n g brake adjustment
1) Completely release the swing brake
lever.
2) Remove the brake cover of the swing
drive unit. Turn the adjuster with
a screwdriver until the brake lin
ings are pressed against the brake
drum. Back off the adjuster 6 to 7
notches, and an appropriate gap
0.2 to 0.3 mm (0.008 to 0.012 in.)
is obtained.
Adjuster
1)
.
2)
.
6 7 , 0,2 0 , 3
(0,008 0,012 ).
Brake drum hole
3)
,
75% ( )
.
[ ]
:
12
75% : 9
[Reference]
Max. stroke: 12 notches
75% stroke: Approx. 9 notches
. stroke
75% s t r o k e
75%
2.
1
)
.
2)
, , oo , .
, ,
.
REPAIR
MANUAL
SAFETY DEVICES
LOCATIONS OF COMPONENTS
GENERAL
FUNCTIONS OF UNITS
1. Moment Limiter
1.
()
1) Moment detector
1)
The moment detector is incorporated
in the elevating cylinder piston
rod, and converts, by means of
strain gauges, the total moment
created by the hoisted load and the
boom self-weight into an electric
signal that is transmitted to the
moment limiter main body.
2) Boom length detector
The boom length detector is in
stalled on the boom side, and con
verts, by means of a potentiometer,
the extended length of the boom
into an electric signal that is
transmitted to the moment limiter
main body.
,
,
, ,
.
2)
,
,
,
3)
,
,
,
,
.
4)
,
.
5)
-
, ,
, ;
,
.
,
90% 100%
,
,
.
2. Solenoid valve
If the AML gets out of order on when
the actual moment reaches 100% of
the rating or the hook block is over
hoisted, an electric signal (auto,
stop) is send from the moment limiter
main body to this valve.
When the solenoid valve is of a nor
mally energized type, it is then de
energized. When it is of a normally
de-energized type, it is then ener
gized .
Irrespective of the type of solenoid
valve, this valve serves to lead the
vent circuits for the relief valves
incorporated in the manual control
valve to the tank.
The pressurized oil from the pump is
then drained through the relief
valves to the tank, to stop the
crane operation.
2.
,
,
100% ,
,
( ).
,
-
, , ,
- , ~
.
,
,
.
3.
3. Check valve
The vent circuits for relief valves
RVl and RV2 incorporated in the
manual control valve are combined
in the check valves and led to the
solenoid valve.
DESCRIPTION OF SYSTEM
Refer to the repair manual for the
AML.
(RV1
RV2),
, ;
,
.
. ,
MOMENT LIMITER
1. GENERAL
1.
()
.
.
Fig. 1 STRUCTURAL DRAWING
Moment detector
M o m e n t limiter
main body
@ Boom angle
detector
--------- U
(D Operating condition
selector unit
^ '
-
^^
A l a r m and automatic
stop circuit
Boom length
detector
. 2
-
AML MAIN BODY
Analog detecto
power source
Moment detector
.
Operating condition
selector sw. signal
input
i+12V
f-12V
S
--------r
, :
Display lamp
,
Display lamp
+24.
J^l_2V+^22V|+5\^jCoHTpobm
og detector impressing
r source
1
CPU BOARD
INDICATOR BOARD
RAM
ROM
CPU
t detector impressing
source
I
circuit L
Latch
driver
La t c h
driver
bar indica
LED for|
1 luraination
3ut
777
interface
Latch
driver
III II I
. .
L E D for I
i 1 l u m i n a t io n ,
\c
L E D for I
1 1 l u m i n a tion
^ g<5
> IllnJ
cj
I
Or
ctJvD
Latch
driveer
Actual
41 1<:
LE D for I
illumination
LCD ILLUMI
NATION BOARD
I-
\
_______
L E D for 1
i
11] 1 umi n_^t :
OCl
load display
1-1. .
Latch
driver
/1
. .
Working radius .
display
O.U.U
Il E D for '
1lumina
Ji.i
LATCH
^ D R I V E R
->
Output gate
.
MAIN J3 J2 C/W
9999999
( LEFT
)( RIGHT)
9 0L M I N M I D M A X M I N M I D M A X ^ ' ^ ^ P ^ ^^'
^
^
^
^
-1 ^
02
FROKT
C
0 1 i F/J / RADI
H E C K ^ ^ P
99^99
Register
switch
-3
Moment zero
point adjuster
^1
indicator lamp
1ZV.+SV ^ "'
I ;
- Height
Input gate
limit
)
W o r k i n g radius limit.
Bo o m state
Right outrigger
!
Left outrigger
Upper
angle
1imit
Lower
angle
limit.
Check switch
^'"
[NOTE]
^
Angle detector
Moment detector
CN5
[]
Ha
,
(
) CN1 CN2.
() C N , CN5,
CN 6 CN7 ,
.
(
. TG-1200MG-1.)
CN5
[]||
CN@
CN6
DBA
DB5
DB6
DB7
CN7
2.
(1)
(1)
Moment detector
.
,
^.
-
,
(2)
(2)
.
(),
, .
- ; .
(3)
,
.
.
-
.
(4)
-
*
,
,
, .
, .
,
,
.
(5)
(
)
,
,
.
(6 )
(A T)
.
,
,
,
,
,
,
,
, -,
,
.
.
.
.
. 3
No.
1 POWER
2 SOURCE
3 ANGLE OUT (-)
4 ANGLE OUT (+)
5 BOOM ANG. IN
6 LENGTH IN
7 lANG. SHIELD
8 '. SHIELD
9 !0. OUT (+)
:
10 MO. OUT (-)
11 MO. IN (+)
12 MO. IN (-)
view
No.
1
2
3
4
5
6
7
8
9
10
CONNECTION .
EXT.
POWER
SLEW OUT (-)
SLEW OUT (+)
SLEW ANG. IN
JIB ANG. IN
SLEW SHIELD
POWER +24V
SOURCE (EXT.)
--
No.
13
14
15
16
17
18
19
20
21
22
CONNECTION
POWER
SOURCE
Dil C.W.E/N
DI2 F/JACK
D13 R/F
DI4 JIB
DI5 B/RET. 1
DI6 RET. 2
DI7 SLEW
DI8 OVER W.
CN2
No.
11
12
13
14
15
16
17
18
CONNECTION
POWER
ABO
ABl
AB2
I/O READ
I/O WRITE
RESET
23
24
25
76
27
78
29
30
31
32
33
34
N o.
19
20
21
22
?3
24
25
?6
27
2o
ALARM(FAIL)
ALARM (90)
ALARM (100)
OVERWIND RZ
ALARM (BACK) _
AUTO STOP
OVERWIND C/0
AML C/0
EMERGENCY C/O
BUZZER
LENGTH SW. 1
LENGTH SW. 2
CONNECTION
DBO
DBl
DB2
DB3
DR4
DB5
DB6
DB7
SPAN BOOM
ZERO LENGTH
SPAN BOOM
ZERO ANGLE
SPAN SLEW
ZERO ANGLE
SPAN JIB
ZERO ANGLE
CAL, RADIUS
CAL, LOAD
ADJUST, 1
ADJUST, 2
SPAN
MOMENT
ZERO
Side view
Front view
Adjuster indication
plate
Fuse ()
()
.
@ Fuse (5)
(5 A)
,
.
Input/Output board
(D Connector board
CPU board
Display board
(%)
.
,
.
Up to 89.9%
.-. ,.. .______________
Moment (X)
Buzzer
Crane motions
_______
_______________
[ i*i
1 1!1
Do not stop.
10 2)56'09955
G r e e n LEDs
89,9
Gr e e n LEDs i l l u m i n a t e i n c r e m e n t a l l y as moment
i n c r e a s e s , u n t i l a l l LEDs i n r a n ^ e A a r e on.
ratio
(%)
(%)
.___________ ____________________________________________
- -
90.0 - 9 9 . 9 %
?7^^ ^
i1!11
90,0 99,9
|\\\
2 0 X ^ 5 0 60 70 809515
Green L E D s
Orange L E D s
Do not st.c>p.
ratio
(%)
interm ittent
10 0 % and
over
100
Moment (Z)
, %
liPii
1
1
257099551
Green LEDs
.Orange LEDs
S top.
Red LEDs
continuous
"".
.
@
.
.
@
@
3 ,
(
%).
.
-
.
.
-
.
.
"
"
.
,
.
,
,
.
Height
limit
data
Height
limit
input
switch
-1
___
No.
Height
limit
indicator
lamp
Buzzer
"
store
data
Push
Flickers
Auto,
^ ( ),
^^
.
"
" ,
@
.
stop
Boom rising \
and extendingj
are stopped. /
ON
No auto. stop.
Height
=
-
;
-
<
Silent
State of boom:
Lowered or re
tracted after
a limit is
stored as in
No. 1.
;
1.
Flickers
=
: Displayed
height
: Stored
height
^
limit
/
Data
stored
Note
/Boom rising \
and extending
\are stopped. J
iHe
;
'
State of boom;
Raised or ex
tended to stored
limit (After
assuming state
No. 2)
:
2.
erase
data
Push
again
OFF
No.
Boom angle
upper
limit data
Boom angle
upper limit
input
switch
Boom angle
upper limit
indicator
lamp
BGDXHfrC
'
*
Buzzer
"
@ .
,
.
,
,
.
(
).
.
"
" ,
@
______________
..
Auto. Stop
Boom angle
Note
/Boom ris
ing is
\stopped.
store
data
Push
Flickers
!
:^ -
;
-
ON
Silent
No auto.
S t o p
State of boom:
Lowered after
a limit is
stored as in
No. 1.
:
1.
Data
stored
fBoom ris- \
ing is
^topped. /
Flickers
erase
data
Push
again
OFF
State of boom;
Raised to
stored limit
(after assuming
state No. 2)
:
2.
No.
limit data
Boom angle
lower limit
input
switch (g)
.
Boom angle
lower limit
indicator
lamp 1)
Buzzer.
"
"
@
.
,
.
,
,
.
(
) .
.
"
"
,
@
.
Auto,
stop
.
",
-
*
/ Boom
\
lowe:
I ing IS
j
^ S t o p p e d ./
store
data
Push
Flickers
Boom angle
Data
stored
Flickers
erase
data
Push
again
OFF
-
________
No auto,
stop
Ox -
: Dis
played
angle
: Stored
angle
limit/
0x = 0
X -
Silent
ON
Note
>
State of boom:
Raised after
a limit is
stored as in
No. 1.
:
^
1.
/Boom
/ lowering
I is \ s t o p p e d ./
State of boom:
Lowered to
stored limit
(after assuming
state No. 2)
^!
:
2.
No.
Working
radius
limit
data
Working
radius
limit input
switch @)
or
store
data
Working
radius limit
indicator
lamp
Buzzer
"
-
"______
Push.
Flickers
"
@
.
,
.
,
,
.
.
.
"
" @) ,
@
Auto,
/Boom 1- \
wering a^nd
extending
are
^stopped. .
Rx ^ R
/Rx: Dis-
played\
value
R
Stored
radius/
\
limit '
Working
radius
stop
ON
Silent No auto,
He stop
He .
Flickers
Boom lo \
wering and^
extending
are
Vstopped.
erase
data
Push
again.
OFF
CRx = R
Rx -
;
R -
____
Rx <
State of boom:
Raised or re
tracted after
a limit is
stored as in
No. 1.
:
1.
Data
stored
Note
Rx
State of boom:
Lowered or ex
tended to
stored limit
(After assuming
state No. 2)
:
2.
^ Lift request switch
5) Right outrigger indicator lamp
This lamp illuminates when right
outrigger state register switch is
pushed.
Left outrigger indicator lamps
This lamp illuminates when left
outrigger state register s w i t c h
is pushed.
On-rubber indicator lamps
Simultaneous pushing of right and
left outrigger state register switches
illuminate these lamps, extingguishing right and left outrigger in
dicator l a m p s ,
(The lamps also
illuminate when the main switch is
turned on.)
I Counterweight indicator lamp
With models TG-1200MG, TG-700EG and
TG-500ERG, this indicator does not
illuminate.
"
.
"
"
.
: " "
" "
@
"
"
@ . (
.)
""
. TG-1200MG, TG-700EG
TG-500ERG .
""
. (
.)
"
"
@
""
@ .
NOTE
If the jib used is a single-or twostage type, only the corresponding
on or two lamps illuminate.
That is, fo r a single-stage jib , the
2nd and 3rd stage indicator lamps
do not illuminate; and fo r a twostage jib , the 3rd stage indicator
lamp does not illuminate.
D Jib indicator lamps
These three lamps begin to flicker
when boom state register switvh
is pushed while single top indicator
i s on. (This state is employed
while the jib is being erected or
stowed.) Another pushing of the same
switch illuminates only the 1 st jib
stage indicator, extinguishing the
other two lamps; another push illumi
nates the 2 nd stage indicator in
addition to the 1 st stage indicator;
still another push illuminates the
3 rd stage indicator additionally.
' ""
"
" . (
.)
,
,
;
,
, ,
;
, ,
, .
.
,
,
, ,
,
, .
NOTE
The chart below shows the error
code numbers and error messages
to be displayed, and the location
of the faults causing those displays.
For detailed information, see
TROUBLESHOOTING.
"
-
.
,
-
.
"
"" (g)
.
,
,
.
. . "~
".
NOTE
W orking condition indicators consist
of the outrigger indicators, on-rubber
indicators, counterweight indicator,
over-front indicator, boom indicator,
single top indicator, and jib indicator.
-i^^rNot all the A M L faults are displayed
with e rro r code numbers and e rro r
messages.
For example, faults in the CPU and
display unit are not indicated by
e rro r code numbers and messages.
jV
,
" ",
"",
" ",
"",
"
" "".
.
,
.
""
$ Check switch
This switch is pushed in preoperational checks and whenever the AML
operation is suspected to be faulty,
to check the main unit. When the
main unit is in good order, it
assumes the following state.
All displays show entire display
segments.
All indicator lamps illuminate.
Buzzer sounds continuously.
Auto, stop circuit is operated.
Left outrigger state register switch
This switch is pushed to register
the state of the left side outriggers.
Right outrigger state register switch
This switch is pushed to register
the state of the right side outriggers.
Boom state register switch
This switch is for registering the
state of the boom, single top or jib.
It is pushed and released alternately
until the desired registration is made,
Moment zero fine adjuster
Used to zero the moment detector.
Use it finely also in the course of
pre-operational checks.
Adjuster angle range: approx. 270
, ,
,
.
,
.
.
.
.
,
.
.
,
:
,
.
-
,
.
Raise
:
Lower
.
.
: 270
("BOOM LENGTH SPAN")
:
15
15
15
("BOOM ZERO")
:
15
: 15
NOTE
: 15
("BOOM ANGLE ZERO")
:
15
.
("SLEW ANGLE SPAN")
:
15
("SLEW ANGLE
ZERO")
:
15
("JIB ANGLE SPAN")
:
15
( " ANGLE ZERO")
: 15
15
; 15
("BOOM ANGLE SPAN")
: 15
15
ik
@
. TG-1200MG, TG-700EG TG-500ERG.
: 15
: 15
("CAL, RADIUS")
(
).
:
("CAL, LOAD")
(
).
:
: 15
15
15
NOTE
Moment
span adjuster
15
"ADJUST, 2"
15
15
. TG1200MG TG-700EG.
"ADJUST, 2"
Screw turn range
(number of rotations):
"ADJUST, 1"
"ADJUST, 1"
Screw turn range
(number of rotations):
g)
15
"MOMENT SPAN"
("MOMENT SPAN")
15
15
15
("MOMENT ZERO")
,
,
:
.
15
+5
.
+12
+12
.
-12
.
+24
+24
.
12 +5
12 +5 ,
,
.
NOTE
" "
.
. TG-1200MG
.
(7)
,
90%
,
,
ort^ ,
.
(2)
, : (1 )
, (2 )
(2) Automatic stop circuit
(
This circuit is for stopping the
,
crane motion automatically when
,
(1 ) the crane is overloaded, (2 )
,
any one of the working range limit
) , (3)
ing functions (height limit, boom
angle upper and lower limits, and
(4)
working radius limit) is tripped,
.
(3 ) the rear stability control limit
is tripped, or (4) hook overhoisting
,
occurs. The motion in the danger di
,
rection only is disabled, and for
this, the circuit includes limit
,
switches for detecting the motion of
,
the control valve spools into the dan
,
ger side, and a solenoid valve in the
.
hydraulic circuit.
(
For the alarm (for overhoist and
)
overload) and automatic stop circuit,
terminals, and of CNl are
@) ,
@) CN1.
used. When an automatic stop signal
,
is output, the output states of these
terminals becomes as shown below.
.
Terminal No.
Normal operation
@)
OFF
OFF
ON
NOTE
''^W h e n the working range lim iting
functions or the rear sta b ility control
function is tripped, an auto, stop
signal is output, but the buzzer does
not sound.
When overhoist
auto, stop signal is
output.
,
,
ON
OFF
OFF
When overload
auto, stop signal
is output
OFF
ON
OFF
"M"
,
.
[ ]
[Reference circuit]
. TG-1200MG-1
TG-1200MG-1 circuit
AML - Ml
OVER WIND BZ
Solenoid valve
CN1
- AAAA ,
AUTO STOP
Buzzer
BUZZER
Winch-up detection
DB 0
DB 3
CN2
DB 4
Boom-up detection
(8 ) ,
---------^
------------ ---------- ,
,
.
DB 5
(>
NOTE
----i
,
.
,
.
...........
........
.......
....
,
,
.
.
.
ill , ^ 2 -^10
: ,
.
, (,
i 2 )
NOTE
^1 , ^ 2,
: boom length given in
the table of to ta l rated loads.
Wsi
WS 2
WS3
,
,
,
,
.
( ) .
,
,
,
.
...........
...............................
.........................
...................
.........
.
.
.
W s i , Ws z .
:
Wsi: i (
)
Ws 2 :
< ^ 9.2
Wss: 2 < 3
ill, ^ 2 ^iQ ,
.
,
( R L 4 ) .
.
NOTE
This function is not incorporated in
cranes in which all the boom sections
are designed to telescope simultane
ously.
The telescoping control output s e t
ting and the set value vary with the
crane model, as given in the adjusted
boom length table at the end of this
section.
The system processes signals re
ceived from the boom length detec
tor, and when the boom is extended
to a certain length, outputs a
signal to drive the boom section
change relay (included in the AML
main unit). This specific AML
model has two such relays (signal
channels).
(With a Model TG-1200MG-1 crane,
for example, the 2nd, 3rd, and
4th boom sections extend simul
taneously, until the boom length
as displayed on the AML reaches
3 5 .0m (just before these boom
sections are fully extended);
then at 35.0m, the system outputs
a signal to drive the boom section
change relay. Under this condition,
pushing the top boom extension
switch activates the solenoid valve
on the hydraulic valve, thereby
allowing the top boom section
to extend).
................
................
.........
...
'
,
,
.
.
.
(4)
,
(
), .
[, . TG-1200MG-1
,
, ,
35,0 (
), 35,0
,
.
,
.]
,
.
. .
.
TROUBLESHOOTING
1.
Checking procedures
1.
,
. " ",
,
.
.
, ,
,
,
.
.
NOTE
i^W hen disconnecting or connecting the
connectors of the A M L system, keep
the battery switch turned OFF.
2.
Repair procedures
d)
Moment detector
Boom angle detector
AML main body
:
1) ,
.
2) ,
.
.
-
.
2.
-
,
.
(1)
,
. "
" .
(D
@
(2) When the blocks or parts named below become faulty, repair them by
referring to the applicable sec
tions in this manual or crane elec
tric circuit diagram.
(D
(2)
,
.
(D
-
@
(3 ) ,
,
. "
"
.
(4)
, .
,
.
, .
, ,
.
,
..
,
,
.
301-0011R_________________________________ _______________________________________________301-0011R
TROUBLESHOOTING
1.
The LCD display and lamp lighting conditions in the display section
are faulty.
29
2.
Fault indicator lamp lights, and the crane stops autom atically.
"" ,
3.
Main unit modes cannot be changed by the pushing of switches on the panel ....... 43
(:
(
)
4.
5.
6.
7.
8.
Actual load and total rated load display values are incorrect.
9.
A M L output is fa u lty.
1.
The LCD display and lamp lighting conditions in the display section are faulty.
(When these faults are present, first turn on the check sw. before starting
to check.)
Fault 1.
Cause
Check procedure
Correction
Replace fuse.
(If blown, again,
replace power
supply board.)
F a u l t y power
supply board.
Replace power
supply board.
W i r e or sw. be
tween battery
& AML main body
is faulty; no
power to AML
(+24V indicator
lamp on power
supply board
is off).
........................................ -
Note
--------- -
Fault 2.
All the lamps light correctly in the check mode, but LCDs remain
totally off, partly off, flicker, or weak.
Check procedure
Cause
Correction
Note
Replace display
board.
F a u l t y display
board.
Fault 3.
All the LCDs display correctly, but one or more lamps remain off.
Cause
F a u l t y LCD
illumination
board.
Check procedure
Correction
Replace LCD
illumination
board.
Note
1.
.
(
" ,)
1.
, (
+24
,)
2,
3
,
(
,
,)
,
,
,
:
+12 , -12
+5 ,
"12
, +5" .
,
, ,
.
.
3,
CN1
,
.
,
,
.
(13 14: +) (1 2 : -)
CN1,
: 22 32
(2)
,
. ( .
+24 :
.)
(3)
.
,
, .
^
.
Fault 4.
The LCDs display correctly, but one of the lamps remains off.
Cause
Check procedure
F a u l t y display
board.
Fault 5.
, Correction
Note
Replace display
board.
Cause
Check procedure
Correction
Note
i
Replace LCD
illumination
board.
F a u l t y LCD
illumination
board.
Fault 6.
Cause
F a u l t y CPU
board.
Only the fault indicator lamp is on; the other lamps and the
LCDs remain off.
Check procedure
Correction
Replace CPU
board.
Note
4.
,
.
.
5.
(
) .
6 . " ,
' .
..
2.
The fa u lt indicator lamp lights, and the crane stops autom atically.
(Actual load display screen and total rated load display screen display an
error code number and error message, respectively.)
Fault
1.
Cause
Check procedure
F a u l t y power
supply board.
Fault
2.
3.
Check procedure
4.
Cause
F a u l t y CPU
board(A/D
converter)
Note
Replace GPU
board.
Check procedure
F a u l t y CPU
board(RAM).
Fault
are displayed.
Correction
Cause
Note
Replace power
supply board.
F a u l t y CPU
board(ROM).
Fault
Correction
Error code no. " 2 " and error message " E r r "
Cause
are displayed.
are displayed.
Correction
Note
Replace CPU
board.
Check procedure
are displayed.
Correction
Replace CPU
board.
Note
2.
"" ,
.
(
.)
1.
"1" ^trr'
"2" ^ ^
"3" ^ '
()
.
4.
()
.
3.
.
2.
"4" ^
(D (
-
)
.
M o m e n t detector
or cable is
faulty.
Fault
6.
Both 240(12)
Faulty CPU
board.
Cause
Check which is
fault, detector
or cable; replace
faulty one. (See
Note)
Check procedure
Replace CPU
board.
are displayed.
Correction
Faulty
adjustment.
Perform length
zero and span
adjustments.
B o o m length
detector, its
cable, or boom
angle detector
cable is
faulty.
Check which is
faulty, detector
or cable; replace
faulty one.
(See Note)
Correct reading:.
(3) - (4): 5000 30 0
(3) - (6 ):
500 10012
Faulty boom
angle detec
tor.
On detector side C N , un
plugged in @ above, measure
resistance across terminals
A and D and across and D.
Replace boom
angle detec
tor .
Correct reading:
(A) - (D): 1000 2 0 0
(C) - (D):
150 to 20000
F a u l t y CPU
board.
With CN un
plugged, if
resistance
across defec
tor side ter
minals A and
and resist
ance across
and D are
24012 , detec
tor is OK.
Replace CPU
board.
Note
With C N u n
plugged, if
resistance
across de
tector side
terminals
and D is 5000
30012 and
resistance
across and
D is 500
10012 , de
tector is OK.
,
CN1,
(9) ()>
(1 1 ) ( 12 )
.
: 240
,
,
(,
).
,
.
6 . "7
b~L
,
,
.
,
.
,
CN1,
CN
.
(3)
(4), (3) (6 )
CN1.
:
(3)
(4)
5000 300
(3)
(6 )
500 100
,
,
(,
).
(3)
D,
D
.
CN @
.
;
() (D)
1000 200
() (D)
150 20000
.
,
.
CN (3),
,
D
.
240 ,
.
CN(5),
D,
D
.
5000 300
500 100
,
.
Faulty
adjustment.
Boom angle de
tector, its
cable, or boom
length detectar
cable is faulty.
Perform boom
angle zero and
span adjustment,
Check which is
faulty, detector
or cable; replace
faulty one.
(See Note)
Correct reading:
(3 ) _ (4 ): 1000 2 0 0 ^i
(3 ) _ ( 5 ): 150 to 20000^i
)Faulty CPU
board.
Replace CPU
board.
With C N
unplugged.
if resis
tance
across de
tector
side ter
minals A
and D is
1 0 0 0 + 20012 ,
and resis
tance across
and D is
150 to
2000012 , de
tector is
OK.
,
,
.
(2)
,
.
,
CN1,
CN (5)
.
(3) (4),
(3) (5)
CN1.
:
(3) (4)
1000 200
(3) (5)
150 20000
,
,
(.
).
,.
CN @ ,
D,
D
.
1000 200
150 20000
,
.
C o m b i n a t i o n of
boom status
setting, work
status setting
and boom length
is wrong.
)Boom status or
work status
setting unit
is faulty.
Make correct
setting.
See **Input
patterns that
cause error
code 12 and
message l_,jE
to be dis
played** in
data table at
end of this
section.
If incorrect,
correct wiring,
s w., etc. ac
cording to
crane electric
circuit
diagram.
With some
models,
status input
can be made
to some ter
minals only
when power
is on.(Such
terminals
are relay
terminals)
Refer to
crane elec
tric circuit
diagram.
Correct:
Actual input pattern should
conform to tabulated
pattern.
F a u l t y power
supply board.
See **Combination of
operating
condition
signals**
in data
table at end
of this
section.
Replace power
supply board.
.
(
).
,
,
.
,
,
,
,
,
. @ .
,
CN1.
(1 2 )
(15 19)
CN1
.
,
.
.
:
.
,
,
,
.
.
,
. (
.)
.
.
. "
"
.
(3)
.
. "
,
" 12 "
Luf
B o o m telescop
ing sequence is
incorrect.
Faulty boom
retraction
detector
switch.
Reset correctly.
If incorrect,
correct wiring,
sw., etc. accord
ing to crane
electric circuit
diagram.
Correct:
Actual input pattern
should not conform
to tabulated pattern.
F a u l t y power
supply board.
Replace power
supply board.
See Boom
lengths and
input pat
terns that
cause error
code 13 and
message i i_[ to
be displayed
at end of
this section
With some
models, input
can be made
to some ter
minals only
when power is
on. (Such ter
minals are re
lay terminals
See "boom
lengths and
input patterns
that cause
error code 13
and message
l l E
to be
displayed at
end of this
section.
.
.
,
,
.
,
,
,
, .
(D
,
CN1.
(1 2 )
CN1
,
,
,
,
.
,
,
.
:
.
,
,
,
.
,
.
.
(
.)
.
.
. "
,
"13"
L l E
(3)
.
. "
,
"13"
L l E
C o m b i n a t i o n of
boom status and
work status
settings is
wrong.
'Boom status
or work status
setting unit
is faulty.
Set correctly.
See "Combinatioti of
operating
condition
signals** in
data table.
If incorrect,
correct wiring,
s w . , etc. ac
cording to crane
electric circuit
diagram.
With some
models,
status input
can be made
to some ter
minals only
when power
is on. (Such
terminals are
relay ter
minals) Refer
to crane ele
ctric circuit
diagram.
Correct:
Actual input pattern
should conform to
tabulated pattern.
F a u l t y power
supply board.
Fault
11.
Cause
F a u l t y CPU
board.
Displays given are other from those given for Faults 1 through 10;
fault indicator lamp illuminates, and auto, stop occurs.
Check procedure
Check that check mode does not
come on when check switch is
pushed.
Correction
Replace CPU board.
Note
.
-
.
,
,
,
,
,
. (2) .
,
CN1.
(1 2 )
(15 19) CN1
.
,
.
.
:
.
,
,
,
.
-
.
,
.
(
.)
,
.
, "
-
"
.
(3)
.
11.
. "
-
"
.
, , 1 10,
"" ,
,
"".
3.
Main unit modes cannot be changed by tlie pushing of switches on the panel.
Fault
1.
Cause
Check procedure
Faulty display
board.
Fault
2.
Check procedure
F a u l t y display
board.
3.
Replace display
board.
Note
Cause
Fault
Correction
--------------
Correction
Note
Replace display
board.
Pushing the work range limit input switches cannot enter or cancel
the desired setting..
Cause
F a u l t y display
board.
Check procedure
Correction
Note
3.
( ) .
1.
, .
.
2.
- .
'^
.
3.
(D
.
4.
1.
Cause
Incorrect
adjustment
Fault
2.
Check procedure
Correction
Adjust according
to the adjustment
procedure.
Cause
Check procedure
L e n g t h detec
tor, its cable,
or boom angle
detector cable
is faulty.
Correction
Check which is
faulty, detector
or cable; replace
faulty one.
(See Note)
Correct reading:
(3) - (4) :5000 300i2
(3) - (6) : 500 lOOQ.
Faulty boom
angle detector,
On C N , unplugged i n above,
measure resistance across de
tector side terminals A and D,
and across and D.
Replace boom
angle detector.
Correct reading:
(A) - (D)
: 1000 2 0 0 ^
(C) - (D)
: 150 to 20000^2
Faulty CPU
board.
Note
Replace CPU
board.
Note
With C N
unplugged,
if resist
ance across
detector
side ter
minals
and D is
5000300 0. ,
and resist
ance across
and D is
5001100
detector is
OK.
4.
.
1.
,
.
;
; ;
(
).
(I)
,
.
,
CN1,
CN
.
(3)
(4), (3) (6)
CN1.
:
(3) (4)
5000 300
(3) (6)
500 100
,
,
(,
).
D,
.
D
.
CN @
.
:
() (D)
1000 200
() (D)
150 20000
.
,
.
.
2.
, 1
CN (5),
D,
D
.
5000 300
500 100
,
.
5.
1.
Error is large, but the value changes smoothly as the boom rises
and lowers.
Check procedure
Cause
Incorrect
adjustment
Fault
2.
Correction
Adjust according
to adjustment
procedure.
Cause
Check procedure
Correction
Boom angle de
tector, its
cable, or
length detec
tor cable is
faulty.
Check which is
faulty, detector
or cable: replace
faulty one.
(See Note.)
Correct value :
(D - ; 1000 200 ft
- : 150 to 20000
Faulty CPU
board
Note
Note
With C N
unplugged,
if resist
ance across
detector
side termi
nals A and
D is 1000
200 Q. and
resistance
across
and D is
150 to
20000 ,
detector is
OK.
5.
.
1.
,
.
,
,
.
2.
;
; ;
(
).
,
.
,
CN1, CN (5)
. ;
(3) (4),
(3) (5) CN1.
:
(3) (4)
1000 200
(3) (5)
150 20000
,
,
(.
).
CN @ ,
D,
D
.
1000 200
150 20000
,
.
6.
1.
Cause
Check procedure
Faulty
adjustment
Correction
Note
1) Perform zero
adjustment ac
cording to ad
justment
procedure.
2) Adjust the
span acording to adjust
ment pro
cedure .
Correct value:
given on indication
plate in crane cab.
Fault
2.
Cause
Check procedure
Correction
status and
work status are
set incorrect
ly, or setting
units are
faulty.
If incorrect, set
correctly or re
pair wiring and
switches accord
ing to crane elec
tric circuit
diagram.
Faulty power
supply board.
Replace power
supply board.
Note
6.
(%) .
1,
. ,
, .
1) 1)
. ,
,
(%)
.
:
0,0 0,5%
2) 2)
10 50,
,
.
.
:
.
2.
- .
8 10
"2. "
" ,
", ,
(
).
,
,
, .
.
Fault
3.
Cause
Check procedure
Correction
Note
L e n g t h value,
boom angle
value are
faulty.
Repair or
replace.
preamplifier.
Replace pre
amplifier.
3.
;
; ;
(
).
, "4,
.
" "5.
.
1
()
, 5
"2.
" ,
",
(8) (9
12) CN1
;
500 .
:
. 100
,
,
(,
).
CN (3),
(
D)
.
100
,
.
7.
1.
Error is large.
Cause
Check procedure
Correction
Note
Large boom
length display
value error.
(D Large boom
angle display
value error.
B o o m status
is set
incorrectly.
Set correctly.
In this
case, moment% dis
play is
also in
correct.
F a u l t y boom
status setting
unit.
If incorrect,
repair accord
ing to crane
electric cir
cuit diagram.
In this
case, moment% dis
play is
also in
correct.
(5)Faulty
adjustment
Adjust.
7.
.
1.
. "4.
".
.
(2) . "5.
".
.
-
.
8 "2.
""
,
", ,
- .
(%)
.
8 "2.
""
,
", ,
- .
,
.
(%)
.
, .
.
8.
actual load and tota l rated load display values are incorrect.
Fault
1.
Error is large.
Cause
Check procedure
Large error in
moment % dis
play value.
Large error in
working radius
display value.
Faulty
adjustment
Correction
Note
<
Set correctly.
In this case,
moment% dis
play is also
incorrect.
If incorrect, re
pair according to
crane electric
circuit diagram.
In this case,
moment% dis
play is also
incorrect.
Adjust.
8.
.
1.
() . "6.
(%)
".
(%)
.
(2) , "7.
".
.
-
,
8, 9 10
.
"2.
"" ,
", ,
.
1
-
8, 9 10
"2,
"" ,
", ,
.
,
.
,
,
,
.
(%)
.
(%)
,
9.
A M L output is faulty.
Fault
1.
Cause
Check procedure
Correction
B l o w n fuse
(for relay)
Replace fuse.
(If it blows re
peatedly, check
for short circuit
between CNl con
nector side ter
minals (23
through 34) and
chassis ground.
F a u l t y auto,
stop circuit.
If incorrect,
correct according
to crane electric
circuit diagram.
F a u l t y lever
manipluation
detector
switch.
F a u l t y over
wind detector
switch.
Note
5A
With some
modeIs,lever
manipulation
detector
switch input
is made to
some ter
minals only
when power
is on.(Such
input ter
minals are
relay ter
minals. )
If incorrect,
correct according
to crane electric
circuit diagram.
Correct : 0 )
Wor k i n g range
limit has been
stored by
mistake.
Erase limit
data.
F a u l t y power
supply board.
Replace power
supply board.
R e l a y (in AML
main unit)
Replace case
assy .
Check that
angle limit,
load limit,
and rear
stability
limit are
not being
exceeded.
9.
.
1.
.
( ,
100%.)
5
, .
(
,
.
:
(23 34)
CN1
.)
@
,
,
CN1.
(13 14) (28)
.
CN1 , .
.
:
.
.
- ,
, ,
)? CN2.
.
.
(19 26)
CN2 (1
2) CN1.
,
:
, (
( )
.
. )
.
._________
-
,
,
CN1.
(1 .
2) (22) CN1.
.
:
(5)0 ,
.
,
,
(6)
( (1)^(5)) - .
.
,
,(7) (
(-^)) .
)
.
(
).
Correction
Check procedure
Cause
F a u l t y auto,
stop circuit,
)Faulty lever
manipulation
detector
switch.
If incorrect, re
pair according to
crane electrical
circuit diagram.
If incorrect, re
pair according to
crane electrical
circuit diagram.
Correct:
With terminals without
switch (or relay), resist
ance should be infinite
(^
).
Faulty over
wind detector
switch.
Replace power
supply board.
R e l a y (in AML
main unit)
Replace case
assy .
3.
With some
models, lever
manipulation
detector
switch input
is made to
some ter
minals only
when power is
on.(Such in
put terminals
are relay
terminals.)
Refer to
crane elec
trie circuit
diagram.
If incorrect, re
pair according to
crane electrical
circuit diagram.
Faulty power
supply board.
Fault
Note
Cause
C r a n e buzzer
circuit is
faulty.
Check procedure
Turn off power, and unplug
CNl. Turn on power with CNl
unplugged.
Correct : Buzzer stops
P o w e r supply
board is
faulty.
Correction
If incorrect, re
pair according to
crane electric
circuit diagram.
Replace power
supply board.
Note
!
,
. CN1, ,
.
:
.
.
(2)
,
CN2. ,
(19 26) ,
.
CN2
(1 2) CN1,
.
( ,
,
) .
:
,
( )
.
. (
,)
.
.
(3)
,
CN1.
,
.
(1
2) (22) CN1. .
:
.
(
)
.
(5) (
AOF)
( ^(3) ) .
3.
(|)
.
,
CN1, ,
,
:
.
.
.
Fault
4.
Cause
buzzer
circuit is
faulty.
Check procedure
Correction
If incorrect,
repair according
to crane electric
circuit diagram.
Note
Fault
5.
Replace power
supply board.
Cause
Length display
adjustment is
faulty.
Check procedure
Check boom length display
value around telescoping
control output length.
Correction
Adjust.
If incorrect,
repair according
to crane electric
circuit diagram.
Replace power
supply board.
Note
,
CN1.
(13 14) (32)
CN1 ,
.
:
.-
(2)
.
5.
,
.
.
,
.
:
.
.
(2)
,
CN1.
(13 14) (33, 34)
CN1 ,
.
:
.
,
.
(3)
.
npoBepotj
Fault
6.
Cause
Check procedure
L e n g t h display
value adjust
ment is
faulty.
(D Telescoping
control signal
output circuit
is faulty.
7.
Adjust.
If incorrect, re
pair according to
crane electric
circuit diagram.
Replace power
supply board.
Cause
Check procedure
B o o m angle
display value
adjustment is
faulty.
F a u l t y auto,
stop circuit.
Correction
Note
Adjust.
Correct operation :
Auto, stop occurs.
Turn off power and unplug
F a u l t y lever
CN2. With control lever moved
manipulation
detector switch. to danger side (boom raising),
measure resistance across CN2
connector side terminal (23)
and CNl connector side
terminal (1 or 2).
If incorrect,
repair according
to crane elec
trical circuit
diagram.
If incorrect,
repair according
to crane elec
trical circuit
diagram.
Correct : oo(Q^)
Faulty power
supply board.
Replace power
supply board.
Replace case
assy .
Note
Power supply
Fault
Correction
With some
models,lever
manipulation
detector
switch input
is made to
some ter
minals only
when power
is on.(Such
input ter
minals are
relay ter
minals. )Re
fer to crane
electric
circuit
diagram.
6.
1)
,
.
;
.
.
(2)
,
CN1,
.
:
.
(3)
.
________________
7.
(2)
.
(3)
.
(5) (
)
,
.
.
.
,
.
:
.
.
,
CN1,
.
:
.
,
CN2.
(23)
CN2 (1
2) CN1,
(
).
:
(^(3))
(^(3))
,
.
,
.
.
.
,
,
,
(
.)
.
.
Fault
8.
Cause
Boom angle dis
play value ad
justment is
faulty.
Faulty auto,
stop circuit.
Check procedure
Check angle display value
around rear stability con
trol signal output angle.
Correction
Note
Adjust.
If incorrect,
repair according
to crane electric
circuit diagram.
If incorrect,
repair according
to crane electric
circuit diagram.
Correct
F a u l t y power
supply board.
)Relay (in AML
main unit .)
Replace power
supply board.
Replace case
assy.
With some
models,lever
manipulation
detector
switch input
is made to
some ter
minals only
when power
is on.(Such
input ter
minals are
relay ter
minals.) Re
fer to crane
electric
circuit
diagram.
8.
-.
,
,
.
:
.
.
()
,
. CN1.
(13 14) (28)
CN1 ,
.
:
.
,
.
,
,
.
,
. (
.)
. .
(3)
.
,
CN2.
(23) CN2
(1 2)
CN1.
:
(
) .
^ (
)
( ^(3) ) .
Mounting drawing
CN
CN
(1)
(1)
MOMENT DETECTOR
DISASSEMBLY
1) Disconnect connector C N
the cable support.
and remove
1) CNC^
.
2)
.
3) (D. ,
4)
,
.
Moment detector
REASSEMBLY
,
.
1)
(, )
^
..
NOTE
The
are
Do
tely
.
.
iJr
.
.
.
,
. ,
.
Adhesive tape
Moment detector
'
Desiccant
Piston rod
MOMENT LIMITER
on the moment
2) Install 0-rings
detector.
2) 0-
(3)
.
3)
.
4) 6
3
.
,
.
Set screw
-
...
__ 1 :
Punching
3 .0
(2)
DISMOUNTING
TV
^
^
J _
1) Disconnect
Disconnec connector C N , and remove
the cable support.
1) CN ,
^
^
.
2)
.
REMOUNTING
Remounting the angle detector by re
versing the disassembly procedures.
NOTES
Do not touch the two surfaces
of the boards by hand during
disassembly and reassembly
processes.
When removing the display board,
LCD illum ination board, CPU board,
and power supply board, pull them
out w ithout tiltin g them.
The CPU and power supply boards
come out approx. 10 mm when the
board retaining levers are pushed
open; then pull them out in the
direction shown below.
Take care not to pinch any parts
on the board with the fingers.
When any one of the fro n t panel,
display board, and LCD illum ination
board requires removal, remove the
three all together as an assembly;
then disassemble.
Removing
1) Unscrew screws, and remove the
side cover.
(3)
,
,
P-ROM
.
.
,
,
,
,
.
10 ,
.
,
.
,
,
.
,
,
,
.
. . 4 . 75.
3-1.
1) 0 ,
.
2) ,
.
3) ,
.
4) ()
.
(
.)
5) ,
6) .
6) Replace the display board with
a new part.
"'
.
Remounting
Reverse the removing processes.
3-2.
Removing
1) Unscrew screws, and remove the
side cover.
2) Unscrew screws, and remove the
escutcheon.
3) Remove the front panel, display
board, and LCD illumination
board (2) as an assembly from the
main unit case.
4) Unplug connectors @ and from
the LCD illumination board. (They
come off when the retaining levers
are pushed open.)
1) ,
.
2) ,
.
3) ,
.
4) ()
.
(
.)
5) .
5) Unscrew screws
Remounting
Reverse the removing processes.
3-3. CPU board
Removing
1) Unscrew screws, and remove the
side cover.
6)
.
.
3-3.
1) ,
.
2)
,
@
10 , .
3) .
Remounting
Reverse the removing processes.
Removing
Remounting
1)
,
0,
2)
,
10 ,
.
3) .
3-5. Preamplifier
3-5.
Removing
1) Unscrew screws0 ,
side cover.
Remounting
Reverse the removing processes.
1) @ ,
.
2) ) ,
,
3) .
F ig.4
body
Connector
. 4
Fuse (5)
(5 )
(1) ,
No,
Replaced part
_______________
Block
Part
Boom angle detector
_________
Boom length
detector
Required adjustment
_________
Potentiometer or
length detector
assembly
Moment detector
1
2__ ____ __________________
Front panel
None
Display board
LCD illumination
Jboard
CPU board
!---1---------------
None
Pre-amplifier
None
(
-
)
'
None
.
pa6oTM..TRg
Lever manipulation
detector
'
Operating condition
selector unit
None
None
(2)
,
:
Notes:
1)
.
Following conditions:
Crane is set up level on a firm,
uniformly supporting surface, with
outriggers fully extended.
,
.
'",
Error
message
(Total rated
load display
screen)
,
.
,
,
,
,
- ,
,
,' ,
.
() :
Solution
(
(^ -
-[
-
3) AJJLadJust^
the sequence eiven in this
manual.
in
( 6) ,
(%)
(-) ,
"110% :
'^
, ,
100%.
2)
,
.
3)
.
, ,
.
4) .
. 8.
(3)
:
: ****
(2)
:
" '*
Conditions
Boom state register switch: **boom**
(D Outrigger state register switches:
**max. extension**
Boom direction: over side or rear
Moment display: between 0 and 100%.
(3)
:
100%
n o t e (D
NOTE (D ___
NOTE
When the length detector has only
been installed, and its cord has not
yet been unwound and rewound,
make it wound on the drum in
natural state by once telescoping
the boom through the entire length.
(D The values CJ , 0 J and TEJ and
the adjusting methods vary with
crane models. Refer to the adjust
ment boom length table at the end
of this section fo r this data.
TOM ,
,
,
,
.
@ [], [D] []
. . "
"
.
(4)
:
:
: "
(2)
:
" "
:
:
(5) :
100%
NOTE
^
() Angle display e rro r = Angle display value - s p rit level type angle meter reading
= -
.
Conditions
Boom state register switch: "boom"
(D Outrigger state register switches:
"max. extension"
Base jib section select switch"
"unused"
Counterweight select switch: "Ot"
Boom direction: over front for
TG-700EG, 500ERG; over rear for
TG-1200MG
(3)
(5)
.
:
: ""
(2)
:
" "
(3) :
" "
(4)
"Ot"
(5) :
. TG-700EG,
TG-500ERG; .
TG-12 0 0 M G
NOTE
[]
. , "
"
.
(,
. TR),
,
(
) ,
.
(%)
,
'
3 .
(D "0,0%"
,
.
(6)
Conditions
Same as for the moment zero
,
ad j ustment.________________ _
.
Elevate the boom until the angle display is 10'
,
50^______
______
____
N0
If the moment display value is diffrent
from the value(for 50) engraved on the
plate, make the angle display adjust
ment again, and then make the moment
zero adjustment again.
(50 ),
.
YES
Check moment zero
adjustment.
Within specified tolerance?
.
(
?)_______
YES
N0
END
10 50
.
( 10
.)
, ? _____
N0
- 1
END
" ,
, .
NOTE
ii!^ T h e 'A M L preoperational check'" plate
Is installed either on the crane cab
door inside wall or underneath the
window of the crane cab.
" "
.
,
,
:
: ""
(2)
:
" "
:
' :
" "
(5) : "18,8t"
Conditions
Boom state register switch: boom*
(D Outrigger state register switches:
"max. extension**
Base jib section select switch:
**unused*
Boom direction: over front for
TG-700EG, 500ERG; over rear for
TG-1200MG
Counterweight select switch: **0t**
:
: '*
(D
:
"
(3) :
" "
:
. TG-700EG,
TG-500ERG; .
TG-1200MG
(5) : **0t"
.NOTE
(D
10.
,
10.
is 50.
.
5.
_NOTE d )
0,0 0,5%
0,0 0 ,
END
NOTE
,
,
.
(2) [J] .
"
"
.
[]
[J] (.
).
, . TG-1200MG-1
[] 2,6 , [J]
30,0 42,9 .
,
,
, 105%
18.8
18,8
X 1000 Kg
. TG-1200M
Outriggers extended fully
Ha
Boom Jib length (m) * 4 !Boom
Boom1 length (m) * 2
Jib length ( )*4
Working
angle
12.5
18.2
23.9
29.6
35.3
42.9
5J0+11.1 5.0+18.9 5.0+26.0
*3 11.1 18.9 26.0
100.0
3.5
4.0 2.5
80
2.0
80 6.0
3.2
1.5
90.0
3.8
79 6.0
3.75 2.3
79
3.2
2.0
1.5
4.0
85.0 45.0
78 6.0
78
3.2
3.55 2.15
2.0
1.5
4.5
75.0 45.0
77 6.0
3.35 2.05
77
3.1
2.0
1.5
5.0
66.0 45.0
3.0 1.8
1.7
75 5.4
75
2.65
1.3
60.0 45.0
72 4.8
2.6 1.55
72
5.5
2.15
1.35
1.05
6.0
54.0 45.0
36.0
29.0
70 4.4
2.4 1.4
70
1.85
1.15
0.9
6.5
50.0 45.0
36.0
29.0
68 4.0
2.2 1.3
68
1.6
0.95
0.75
7.0
45.0 42.0
36.0
29.0
22.0
65 3.45 1.9 1.15
65
1.3
0.75
0.55
41.0 39.0
29.0
22.0
7.5
36.0
62 3.0
1.7 1.05
62
1.05
0.6
8.0
36.0 36.7
34.0
29.0
22.0
60 2.75 1.55 1.0
60
0.9
0.5
29.0
22.0
1.4 0.95
8.5
32.0 32.7
32.0
58 2.5
58
0.75
9.0
29.7
27.0
22.0
28.8 29.5
1.25 0.85
55
0.6
55 2.1
10.0
23.6 24.3
24.5
24.6
22.0
52 1.35 0.85 0.6
^ 1 . 1.
''X .
o b u ie T ,
M
20.7
11.0
20.0
13.0
50 0.95 0.55
19.5 20.0
20.6
*2: c t d <
.
12.0
17.0
17.7
17.8
13.0
48 0.6
17.6
*3 :
,
14.0
13.0
13.2
13.3
13.4
13.0
16.0
18.0
20.0
22.0
24.0
26.0
28.0
< Jo ^
32.0
34.0
36.0
9.9
10.2
8.0
6.2
4.8
10.3
8.1
6.4
5.0
4.0
3.0
2.0
10.4
8.1
6.4
5.0
4.0
3.0
2.0
1.7
1.1
11.0
9.0
7.0
6.0
5.0
4.0
3.2
ly C b A c l,
2.0
1.5
1.1
(J)
- [J]
X 100%
[J]
0 [] [D] . "
"
.
(,
, TR),
,
.
(7) ,
Working radius
display ad
justment
Load display
adjustment
,
:
: ""
(D
:
* "
(3) :
:
'* *'
(D : '*18,8t"
NOTE
*W ith the models provided w ith the
telescoping control signal output
function, extend the boom to the
stroke end by manipulating the
emergency telescoping switch.
The [D ] value varies with crane
models. Refer to adjustment boom
length table at the end of this
section fo r this data.
For the load to be lifted and the
w orking radius, refer to the tota l
rated load table.
For example, with TG -1200M G -1,
the maximum boom length is 42.9 m,
the maximum load fo r this boom
length is 13.0 tons, and the maximum
rated working radius fo r this toad
is 14.0 m. Therefore, make adjustment
by liftin g a tota l rated load of 13.0
tons at a working radius of 14.0 m.
[Adjusting method when an appropriate
test weight is not available]
Adjust while liftin g a known weight
lighter than the to ta l rated load at
the above working radius. Note that
the accuracy obtained is slightly
in ferio r in this method.
,
,
,
[D]
. .
" "
.
.
. ,
. TG-1200MG-1
42,9 , -
13,0 .
14,0 .
,
,
13,0 14,0.
[
]
,
,
.
,
.
Working
TXi
3.5
3.8
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
10.0
11.0
12.0
<>
16.0
18.0
20.0
22.0
24.0
26.0
28.0
30.0
32.0
34.0
36.0
Counterweight 18.8
: 18,8
X 1000 kg
Ha
42.9
13.0
13.0
Q3.(!)
11.0
9.0
7.0
6.0
5.0
4.0
3.2
2.6
2.0
1.5
1.1
, ,
.
.
,
1/50 1/25 ,
, .
,
,
.
1.
361-306-30000 (CR-3226LDRSY)
2.
361-306-40000 (CR-3226LDRAS)
1.
3 6 1 -3 0 6 -3 0 0 0 0 (C R -3 2 2 6 L D R S Y )
3 6 1 -3 0 6 -4 0 0 0 0 ( C R -3 2 2 6 L D R A S )
Core wire
\
)
Shield wire
Reducer
Potentiometer
1/50
2.
2.
361-306-60000 (CR-3233LDRS)
3 6 1 -3 0 6 -6 0 0 0 0 (C R -3 2 3 3 L D R S )
Core wire
Shield wire
Shield wire
Reducer
Potentiometer
Terminal connection
Connector
Resistance : 508020 Q.
Electrical turning angle : 355 2
Mechanical turning angle : 360, continuous rotation
:
508020
:
3552
:
360
1/50
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
Plate
Case
Drum a s s
Slip ring a s s y
Contact a s s
Contact a s s
Bearing case
Bearing
Retaining ring
Retaining ring
Reducer
Gear
Gear
Bracket
Potentiometer
Spring
Cover
Clip
Clip
Clamp
Cord guide
Bush
Packing
Packing
Packing
Connector
Connector
Cord lock
Holder plate
Terminal
Terminal
Nut
Washer
Machine screw
Bolt
Bolt
Machine screw
Machine screw
Machine screw
Machine screw
Machine screw
Machine screw
Set screw
Washer
Washer
Spring washer
Spring washer
Spring washer
Nut
Connector
Cable
Plug
Terminal
Terminal
Cord
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30 .
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
,
: " " , "3
" "3
" .
.
1.
1.
Replacing cord
(. .)
1.
@ @
,
,
.
2.
3.
@ ,
.
4.
@
(15) ,
.
5.
,
,
@
.
NOTE
NOTE
6.
,
(2) .
, ,
.
0 ) (2 )
()
7.
8. Remove slip ring a s s e m b l y and holder plate (g) from the drum assembly,
and separate the cord from the slip
ring by unsoldering.
8.
@)
() .
9.
,
.
The
w ork
pages
length
given
,
, (
) .
.
10.
.
'
[ ]
,
.
-marker
^
Drum e n d / ^
Co
NOTE
Core w ire :
Shield w ire :
11.
,
.
:
.
:
.
NOTE
12.
,
, ,
.
13.
,
,
.
,
,
,
..
,
.
Adhesive tape
. string
. string
14.
15.
(23 ,
(2)
.
&
)
.
16.
(3^^ ,
@
.
17.
,
(2) .
18.
@
,
@
,
, ,
.
1/4
, ,
,
-) .
,
-
,
. "
.
19.
()
& .
.
:
12 -.
20.
,
, .
, .
0-marker
21.
.
,
.
,
.
.
.
:
12 -.
Screwdriver
Gear
Black
White
Set screw
^
Bracket
Multimeter
22.
,
,
.
23.
.
(.
.)
24.
@
,
@)
,
.
@
25.
()
,
@
.
26.
(g)
@) ,
@
.
.
insulating tape.
"HI-BOND ,
.
Cord
Lead wire
27.
,
.
Connector
2.
2.
,
.
,
" .
3.
3.
Replacing potentiometer
1. Unscrew c l a m p ,
and cover @ .
and remove b o l t s
, ,
,
.
.
NOTE
When the cord or the recoil spring
is also defective, remove the detector
assembly from the boom before s ta rt
ing to repiar it. When only the poten
tiom eter is defective, the detector
assembly need not be removed.
1.
@
,
@
2.
@
,
@ .
(13)
,
,
,
.
NOTE
5.
.
(.
.)
,
,
.
.
:
"SHINETSU SILI
CONE KE45RTV" "
., ." .
Recommended sealant:
SHINETSU SILICONE KE45RTV by
Shinetsu Chemical Co., Ltd.
5. Install a new potentiometer and con
nect the leads. (Refer to the ter
minal connection in the structure
drawing.)
Bracket
Potentiometer
Insulating sealant
6 .
Loosen set screws of reducer gear
@ a n d potentiometer gear until
the gears can turn.
Turn the potentiometer gear about 1/4
turn with fingers and make sure that
the gear returns to its original
position by the force of spring @ .
If not, loosen bolts and adjust
the position of bracket .
,
.
1/4
, ,
,
.
,
.
Gear
7.
.
.
:
12 -.
8.
,
.
0-marker
Cord lock
9.
,
. "
", . 21.
ADJUSTMENT
1.
Cord lock
0-marker
,
.
2.
.
(. .)
GENERAL
Principle of operation
The spherical sensor probe of the
device and an energized (live) hot
line act like a capacitor with the
air in between working as a dielectric;
and a small alternating voltage is
produced at the probe. The amplifier
in the sensor unit, which also provides
impedance matching, amplifies the
induced voltage and outputs a signal
voltage to the sensitivity selection
circuit in the ^ l a r m main unit. The
output signal of the sensitivity
selection circuit is again amplified
by another amplifier before being
transferred to the level check circuit
which compares the signal level with
the reference level and, if the
reference level is exceeded, triggers
the alarm.
[Sensitivity range]
Range
(AC-KV)
, , ,
. ,
,
,
.
.
.
D i s t a n c e at w h i c h
a l a r m is g i v e n (m)
6.6
3 ~ 10
10
3 ~ 10
110
6 ~ 20
- ()
,
,
(
..).
, ,
,
.
,
.
, ,
,
.
[ ]
,
..
6,6
10
110
,
,
3 10
3 10
6 20
, ,
,
()
.
Operation flowchart
Capacitor
Fig.
.
1
1
Sensor unit
View ()
()
Alarm unit
A l a r m lamp
__
Spare lamp
Voltage selection
knob
-
Alarm buzzer
Printed circuit
board
TROUBLESHOOTING
1. Check procedure when an untimely
alarm is given.
The cable breakage detection circuit
in the device gives an alarm when
the cable is broken. If the device
gives an alarm when there are no
power cables in the vicinity, check
the device as follows:
,
.
,
-
.
2.
.
, ,
'
.
TESTS
After mounting the device and connect
ing the cables, perform operational
tests as follows: (See Fig. 2)
( . 2).
1.
"6,6 ",
,
"" .
2.
,
"6,6 ", 2-
, .
,
.
3.
-
, ,
.
(
,
.)
116-0020R
116-0020R
CHECK VALVE
Hydraulic symbol
Fig. 1
. 1
1.
2.
3.
4.
5.
Body
Plug
Plug
Filter
Spring
6.
7.
8.
9.
0-ring
0-ring
Plug
Steel ball
1.
2.
3.
4.
5.
6 . -
7 . -
8 .
9 .
.
,
,
.
,
,
.
116-0020R.
116-0020R.
DISASSEMBLY AND REASSEMBLY
CAUTION
"
" ()
,
.
,
.
,
.
,
. .
, ,
.
,
.
MAINTENANCE STANDARDS
M a in te n a n c e s t a n d a r d s
Ite m
F ilte r
R e p la c e
24 .
3 6 6 - 2 0 0 - 2 0 0 0 0 , 366 -2 0 3 -1 0 0 0 0
at
ev ery
24 m o n th s.
121-0010R
121-0010R
SOLENOID VALVE
.
,
, ,
.
.
,
.
Hydraulic symbol
Electric symbol
Fig. 1
. 1
1.
2.
3.
4.
5.
6.
Valve body
Spool
Plug
Spring
0-ring
0-ring
7. 0-ring
8. Hex. socket head
bolt
10. Solenoid
11. Hex. socket head
bolt
DISMOUNTING
1.
2.
3.
4.
5.
-
6. -
7. -
8.
10.
11.
WARNING
WHEN THE CIRCUIT IS SUSPECTED TO
RETAIN HIGH PRESSURE OIL, BE SURE
TO VENT PRESSURE BEFORE DISMOUNT
ING THE VALVE.
,
,
.
121-0010R
121-0010R
REMOUNTING
NOTE
- 0 , 4 0,5 . .
,
(
) ,
: -
-,
.
,
"
"
.
Check valve
Solenoid valve
Fig. 2
Fig. 3
. 2
. 3
[- ]
,
"",
(. 2).
[- ]
,
"" "",
(. 3).
,
,
()
Y "
" .
,
,
.
121-0010R.
121-0010R.
WHEN DISASSEMBLING AND REASSEM
BLING, ALSO OBSERVE'GENERAL CAU
TIONS ( HYDRAULIC UNITS)4N CHAPTER
A TO WORK CORRECTLY.
WHEN DISASSEMBLING AND REASSEM
BLING THE VALVE, TAKE CARE TO
PREVENT DAMAGE TO THE THREADS,
FINISHED SURFACES AND SEALING
PARTS, AND AVOID IMPROPER HAN
DLING. WHILE DISASSEMBLING, TAKE
NECESSARY MEASURES TO ASSURE
THAT ALL THE PARTS WILL BE RE
ASSEMBLED IN THEIR ORIGINAL
POSITION&
WASH THE DISASSEMBLED PARTS IN
KEROSINE, AND CHECK THEIR SLIDING
SURFACES, SEALING PART MOUNTING
SEATS, AND THREADS CORRECT MINOR
DENTS, SCUFF, RUST OR BURR WITH
FINE ABRASIVE CLOTH OR OILSTONE.
WHEN THE SURFACES ARE NICKED,
WORN OR OTHERWISE DAMAGED SUBSTANTIALLY . REPLACE THE PARTS.
IN PRINCIPLE, REPLACE ALL THE SEAL
ING PARTS. OBSERVE'GENERAL CAU
TIONS ( SEALING PARTS)' IN CHAPTER
A IN INSTALLING THEM, TAKING
CARE TO INSTALL IN THE CORRECT
ORIENTATION.
WHEN REASSEMBLING, TAKE EXTREME
CARE NOT TO ALLOW THE ENTRY OF
DUST AND OTHER FOREIGN MATTER,
AND APPLY HYDRAULIC OIL FOR L U BRICATION TO THE SLIDING SURFACES.
INSERT THE SPOOL STRAIGHT, TAKING
CARE NOT TO PRY, AND CHECK ITS
SMOOTH MOVEMENT AFTER IN
SERTION,
" "
() ,
.
,
.
,
.
,
.
, ,
.
,
.
, ,
.
" " (
) ,
,
.
,
.
.
,
,
.
, .
Z04-00S0R
Z04-00S0R
Z03-0200R.
Z03-02D0R.
MANUAL CONTROL
VALVE
(RVl)
, ,
, ,
: ,
,
.
,
:
,
.
.
1.
(RVl)
1 ,
,
,
.
2.
(RV2)
2 ,
RV1.
3.
.
(PR1):
(PR2):
(PR3):
:
(PR4):
2. Relief valve
(RV2)
: for m a i n w i nch
: for auxiliary w i nch
: for b o o m elevation
: for b o o m elevation
4. F l o w control valve
4.
,
, ,
,
.
.
(FC1):
(FC2):
5.
(HV)
.
(HV)
Hydraulic symbol
Main winch
. winch
Telescoping.
Elevating
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
PR2,
(PR3)
PR4)
Cover a s s
Control valve a s s
Flow control valve a s s
Control valve a s s y
Tundem plate
Control valve a s s y
Control valve a s s y
Cover a s s
Tie rod
Tie rod
Nut
Relief valve a s s y
Port relief valve a s s y
Port relief valve a s s y
Port relief valve a s s y
Hydraulic valve a s s y
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
(
)
,
,
.
,
,
.
" "
()
, .
,
.
,
.
,
.
, ,
.
, ,
,
.
.
, ,
.
" "
( ) ,
,
.
-
,
.
.
, -'
,
.
, .
3 6 6 - 3 3 7-30000
REPAIR
MANUAL
TELESCOPING SYSTEM
LOCATIONS OF COMPONENTS
GENERAL
FUNCTIONS OF UNITS
1.
,
.
2.
,
,
.
3.
2.
4.
,
1 2.
DESCRIPTION OF SYSTEM
(Refer to the c irc u it diagram in Chapter Z.)
1. Extension circuit
When the boom extends, the second
boom section extends first, and
then the third and top boom
sections extend simultaneously.
Hydraulic oil from the manual con
trol valve flows through the h y
draulic valve and the counterbalance
valve and enters the No. 1 cylinder,
to extend the second boom section.
W hen the second boom section ap
proaches the travel end, a voltage
is applied to the CNl-33 terminal
(LENGTH SW. 1) of the AML. Therefore,
w hen the second b oom section is
fully, extended and 3rd/top boom
(. Z.)
,
(.
, ,
,
,
1,
.
,
CN1-33 ("LENGTH SW.
1" (". - 1") .
,
,
(SN16),
(SL5)
, -
extension s w i
t ch (SN16) is pushed,
hydraulic valve solenoid (SL5) is
energized, switching the hydraulic
circuit from the No. 1 cylinder
circuit to the No. 2 cylinder
circuit, and thus sending hydraulic
oil to the No. 2 cylinder via the
hose reel and the counterbalance
valve, to extend the third and top
b oom sections.
W hen the third and top boom sections
are extended slightly, 3rd/top b o o m
full retraction detector switch (S18)
is freed, causing relay (RLl) to
hold the solenoid energizing circuit
in the energized state; therefore,
after the boom is extended to some
extent, 3rd/top boom extension
switch (SN16) may be released.
The top boom section is connected
to the third boom section (tel
escoped by the No. 2 cylinder) via
wire ropes, and exactly follows
its movement.
2. Retraction circuit
The boom sections retract in the
reverse order of extension.
Although hydraulic oil is sent
from the manual control valve to
both No. 1 and No. 2 cylinders,
only the No. 2 cylinder is allowed
to retract because the return line
of the No. 1 cylinder is blocked
at the hydraulic valve.
When the No. 2 cylinder approaches
the travel end, 3rd/top boom full
retraction switch (S18) is tripped,
causing solenoid (SL5) to break the
solenoid energizing circuit. When
the solenoid is deenergized, the
hydraulic valve is shifted from the
No. 2 cylinder circuit to the No. 1
cylinder circuit, and the second
boom starts to retract.
If the hydraulic valve is shifted
before the No. 2 cylinder reaches
the travel end, an orifice in the
hydraulic valve vents the trapped
oil in the No. 2 cylinder during
retraction of the No. 1 cylinder,
to retract the No. 2 cylinder to
the travel end.
1
2,
2,
.
,
(S18)
,
(RL1)
,
(SN16).
,
( 2).
.
1 2 , ,
1
,
2 .
2
,
(S18) ,
(SL5.
2
1 ,
.
2 ,
2
,
,
1 ,
2
.
BOOM
CONSTRUCTION
74.
Retaining
75.
Bolt
7 6.
Slide
77.
Shim
section
78.
Shim
Base
79.
Pin
section
80.
Retaining
1.
Top
2.
Third
boom
3.
Second
4.
section
boom
section
5.
12.
boom
boom
Support
81.
Pin
Hex.
socket
82.
Pin
head
bolt
83.
Plain
84.
Set
85.
Slide
13.
Slide
24.
Spring
plate
27.
Bolt
86.
Shim
28.
Pin
87.
Shim
29.
Plate
88.
Nut
30.
Bolt
89.
Bolt
31.
Spring
32.
washer
washer
ring
plate
ring
bearing
screw
plate
91.
Bolt
Bolt
93.
Plate
33.
Plate
94.
Spring
34.
Guide
95.
Plate
36.
Hex.
socket
96.
Shim
head
bolt
97.
Shim
washer
37.
Sheave
98.
Slide
plate
38.
Pin
100.
Slide
plate
39.
Spacer
101.
Slide
plate
40.
Wire
103.
Slide
plate
41.
Adjuster
108.
Bolt
42.
Nut
109.
Hex.
socket
head
bolt
43.
Nut
45.
Guide
46.
Bolt
47.
Wire
ass'
rope
ass'y
110.
Bolt
131.
Slide
plate
plate
a s s '
rope
141.
Slide
plate
48.
Slide
49.
Retainer
50.
Retainer
51.
Slide
52.
Retainer
164.
Slide
plate
53.
Retainer
174.
Slide
plate
ass'y
154.
54.
Slide
56.
Bolt
57.
Plain
washer
58.
Slide
plate
59.
Shim
plate
Shim
61.
Hex.
socket
head
bolt
62.
Pin
63.
Bolt
64.
Spring
65.
Bolt
66.
Spring
67.
Plate
68.
Slide
69.
Pin
70.
Spacer
71.
Sheave
72.
Bolt
73.
Pin
plate
ass'y
184.
Slide
191.
Retainer
plate
192.
Retainer
ass'y
204.
60.
Slide
ass'y
plate
Slide
plate
ass'y
214.
Slide
plate
ass'y
washer
washer
plate
ass'y
221.
Plug
223.
Grease
nipple
1.
2.
3.
4.
5.
12.
13.
24.
27.
28.
29.
30.
31.
32.
33.
34.
36.
37.
38.
39.
40.
41.
42.
43.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
91.
93.
94.
95.
96.
97.
98.
100.
101.
103.
108.
109.
110.
131.
141.
154.
164.
174.
184.
191.
192.
204.
214.
221.
223.
1.
D IS M O U N T IN G
Set
up
the
crane
1.
level.
.
2.
Remove
the
wire
rope
wind
the
winch
main
hook,
on the
aux.
and
winch
winch
wind
drum.
wire
the
2.
Similarly,
rope
on
the
Bring
the
boom
to
0,
and
stop
the
3.
Remove
,
the
jib
with
an
overhead
crane.
4.
5.
Remove
the
end
detector
cord
section,
let
the
cord,
cord
to
remove
other
and
3rd/top
the
cord
fasten
and
cord
boom
the
boom
reel
take
fasten
the
(for
full
switch).
end
case.
reels
boom
length
top
the
detector
wind
the
detector
the
and
the
of
from
5.
of
the
cables
detector,
the
for
Then,
the
moment
the
boom
at
the
connectors
of
the
boom
the
swing
angle
detector,
to
at
detector
and
and
other
wires
the
lower
part
separate
them
from
M AKE
THE
SURE
S L IN G S
STRENG TH
6.
THAT
THE
USED
HAVE
TO
CRANES
AND
SUPPO RT TH E
S U F F IC IE N T
) ,
W A R N IN G
table.
()
length
disconnect
boom
retraction
cords
the
of
Similarly,
anemometer
in
engine.
4.
drum.
3.
6500
BOOM
A S S 'Y .
6.
Support
with
Boom
7.
the
a s s y
Slightly
boom
elevation
as
(one
the
part
of
of
the
approx.
forward
crane,
cylinders
Hold
shown,
Weight
weight:
lift
with
weight.
forward
the
boom
6,500
kg
crane.
the
and
from
part
free
the
elevation
extract
elevation
each):
and
approx.
pins
kg.
the
the
boom
cylinders
@) .
cylinder
500
of
,
,
.
7.
@).
500
Fig. 2
. 2
8.
N O TE
Be c a u se
th e
v a rio u s
d e te c to r
c a b le s
a n d w ire s a re d is c o n n e c te d , tu r n
O N th e A M L e m e rg e n c y s w itc h
w h e n m o v in g th e e le v a tio n c o n tr o l
le v e r
to
th e
r e tr a c t
p o s itio n .
,
,
.
.
A ft e r r e tr a c tin g th e e le v a tio n
c y lin d e r p is to n ro d s , s to p th e
e n g in e .
S t ar t the e n g i n e , f u l l y r e t r a c t
e l e v a t i o n c y l i n d e r p i s t o n rods,
the
un
,
,
,
.
9.
,
1 ,
,
2.
,
.
T H E H O SE&
T H E HOSE R EE L HOSE IS U N D E R
SPR IN G FO RCE FO R E X T R A W IN D IN G .
BE SURE T O H O LD T H E D R U M W H EN
D ISC O N N EC TIN G T H E HOSE.
9.
cylinders.
,
.
,
.
NOTE
10
,
.
,
.
11.
,
,
.
Fig. 3
. 3
REMOUNTING
NOTE
,
Remount the boom by m ostly
reversing the dism ounting
processes.
1. Lift up the boom a s s w it h two
cranes, and bring it to a position
above the boom pivot pin location.
(Fig. 3)
, .
, ,
(. 3).
NOTE
2.
,
.
,
,
,
.
3, Lower the crane supporting the rear
part of the boom, and remove the
sling.
.
3.
,
,
.
4.
CAUTION
CONNECT THE HOSE REEL HOSE TO
THE TELESCOPING CYLINDER AFTER
GIVING THE SPECIFIED NUMBER OF
EXTRA TURNS (SEE THE SECTION FOR
THE HOSE REEL)
,
.
(. "
".)
CAUTION
5.
, .
@)
(. 2).
,
.
6. ,
@)
.
7. ,
, .
8.
,
, ,
.
9.
.
DISASSEMBLY
NOTE
When the base boom section
need not be dismounted, disa
ssemble only the 2nd boom section
onw ard, leaving the base boom
section on the swing table.
1. Extract p i n ) connecting the base
boo m section and the No. 1 cylin
der. Then unscrew n u t s , and remove
anti-buckling bolts
.
Fig. 4
. 4
2. Remove slide plate a s s iesC|o)
from the side plates of the base
boo m section.
,
,
.
1.
1
, ,
@ , ,
.
2.
,
WARNING
3.
(J41^ ,
''^74^
,
1 .
(. 6).
,
,
.
,
.
4.
7 , , ,
, ,
(. 7).
Fig. 7
. 7
Fig. 6
. 6
5. With the No. 1 cylinder supported
with a crane, extract p i n s ; also
extract pin
connecting the No. 2
cylinder and the second boom sec
tion; then unscrew n u t s , and re
move anti-buckling bolts
5.
1
,
,
,
2
, ,
,
,
.
Fig. 8
. 8
NOTE
6.
7.
.
,
,
.
@
.
@ (
)
.
7.
(@)
.
Fig. 9
. 9
During extraction of the third boom
section from the second boom sec
tion, the position of the No. 1
cylinder relative to the No. 2
cylinder may shift, resulting in
possible damage to the hydraulic
hose . To prevent this, fasten the
cylinders to each other with wires,
etc.
8 .
1
2,
,
.
..
Hydraulic hose
NOTE
9.
,
. 3 4.
,
@
,
.
1
.
,
.
10
11.
,
(. 12).
2
, ,
( 1 2)
(. 13).
13)
Bolt
Fig. 12
. 12
Support
Fig. 13
. 13
12.
@ ,
,
.
@
.
Fig. 14
. 14
13. Remove sheave a s s i e s , s p a c e r
and other related parts from the
forward end of the third boom
section, and remove the top boom
section from the third boom
section as in Processes 2 through
4.
13.
Fig. 15
. 15
,
,
,
. 2 4.
CHECKS
1) Boo m
1)
deformation,
2) Slide plate
, ,
.
2)
,
, .
3)
,
,
, .
4)
,
:
b. Kinked
. ;
c. Having six or more wires broken
wit hin one lay. or 3 or more wires
broken in one strand w i thin one lay.
d. For extension wire rope (nominal
dia.: 24mm) having a reduction in
diameter exceeding 7 percent of the
nominal diameter.
e. For retraction wire rope (nominal
dia: 10mm) having a reduction in
diameter exceeding 7 percent of the
nominal diameter.
f. Deteriorated by heat
. ;
.
6 ,
3 ;
.
(
: 24 )
7% ;
.
(
: 10 )
7% ;
. .
REASSEMBLY
NOTE
Reassemble by reversing the
disassembly processes, observing
the follow ing
1) A p p l y grease to the b o om sliding sur
faces before starting to reassemble,
and apply grease to the cylinder
connecting pins and the slide plates
during assembly.
,
.
1)
.
.
2)
.
(
)
0 0,3 .
3) ,
,
,
5
.
boom section
3rd boom section
Fig.
.
16
16
4)
,
.
5) @ ,
.
@
.
6)
1
.
(
1 2
.)
Fig. 17
. 17
7) T i g h t e n b o l t s ),
and
f or
7)
^5)
,
,
1/4 .
fixing
the a n t i - b u c k l i n g b o l t s
th e No. 1 a nd
follows:
With
2 cylinders
the p i n i n s t a l l e d ,
, 1
2 ,
.
@
Y ,
().
.
8)
for
as
and
the b o l t
l o c k w i t h nut
Nut
Fig. 18
. 18
th is
a d ju s tm e n t w ith o u t
B e fo re s ta r tin g a d ju s tm e n t, b a c k
o f f th e w ir e ro p e a d ju s tin g b o lts
a n d n u ts 2 to 3 tu r n s fr o m th e
p o s itio n s m e a s u re d a n d re c o rd e d
1.
d is a s s e m b ly .
A d ju s tin g
e x te n s io n
1) R e t r a c t
w ire
the b o o m a n d
2 3
,
.
ro p e
lower
it
to
the h o r i z o n t a l .
N O TE
D u rin g th e a d ju s tm e n t, te le s c o p e
th e 3 rd a n d to p b o o m s e c tio n s w ith
th e 3 rd & to p b o o m te le s c o p in g
s w itc h
1.
1) ,
.
2)
1 ,
.
ON.
2) E x t e n d t he 3rd an d top b o o m s e c t i o n s
ap p r o x . 1 m, a nd m e a s u r e d i m e n s i o n s
lo a d in g
c ra n e .
b e fo re
and
,
.
Fig.
.
19
19
3) .
4)
,
( )
10 .
Fig. 20
. 20
2.
) is approx.
5)
,
( )
10 .
10 mm.
2.
1) ,
.
2)
1 ,
.
( ).
Fig. 21
. 21
3) E x t e n d
tions
the
3rd an d
a pp ro x.
3)
1 .
top b o o m s e c
1 m.
4)
, .
N O TE
L o o s e n th e lo c k b o lt b e fo r e t ig h t e n
in g th e a d ju s t n u t. D o n o t t ig h t e n
th e a d ju s t n u t e x c e s s iv e ly .
T ig h t e n th e lo c k n u t a f t e r a d ju s tm e n t .
4) T i g h t e n the b o o m r e t r a c t i n g
nu t t h r o u g h d i s t a n c e .
.
.
adjust
Lock nut
Lock bolt
Adjusting nut
Fig. 22
. 22
5) G r a d u a l l y r e t r a c t the 3 rd and top
b o o m s e c t i o n s , a nd c h e c k tha t the
3r d b o o m s e c t i o n s t o p p e r an d the top
boom section stopper come into con
ta ct s i m u l t a n e o u s l y w i t h the 2 nd
a n d th e 3 rd b o o m s e c t i o n ends.
5)
, ,
.
Stopper
Fig. 23
. 23
6)
If e i t h e r of the s t o p p e r s lags b e
h i n d th e o t he r, e x t e n d the 3rd and
top b o o m s e c t i o n s a g a i n an d a d j u s t
the nu t
as f o l l o w s .
6)
,
.
When
t he
3rd b o o m s e c t i o n
is f a s t e r ,
fu r t h e r .
When
th e
loosen
,
, ,
.
,
, ,
.
the a d j u s t n ut
to p b o o m s e c t i o n
is f a s t e r ,
7) R e t r a c t
tighten
stopper
stopper
the a d j u s t
nut.
th e b o o m fully.
7) .
TEST
NO TE
B le e d th e te le s c o p in g c y lin d e rs
c o m p le te ly a n d a p p ly g re a s e to th e
b o o m s lid in g s u rfa c e s b e fo re s t a r t
in g th e te s ts .
1.
O p e ra tio n
te s t
T e l e s c o p e the b o o m s e v e r a l t imes, a n d
m a k e s u r e t h at t he t e l e s c o p i n g o p e r a
t i o n is i n order.
2.
B oom
la te r a l
w a rp
te s t
[Condition]
6 max.
Crane levelness
Full e x t e n s i o n
Boom length
Maximum
Boom elevation
Boom direction
Over-front,
Over-rear, Over-right, Over-left
Oth e r conditions:
F r e e f r o m s o l a r h e a t a nd w i n d
1.
, ,
.
2.
[ ]
:
6
:
:
,
:
.
Fig. 24
. 24
1) T h e h o o k d i s p l a c e m e n t
(A in s k e t c h )
u n d e r the a b o v e t e s t c o n d i t i o n s
u n d e r n o load m u s t be b r o u g h t w i t h i n
100 m m in all b o o m d i r e c t i o n s by
shim adjustment.
2) A f t e r s h i m a d j u s t m e n t , the h o o k d i s
p l a c e m e n t (A in s k e t c h ) u n d e r the
a b o v e t e st c o n d i t i o n s u n d e r the
t ot al
rated
load m u s t
be w i t h i n
6 0 0 mm.
W h e n the d i s p l a c e m e n t is m o r e
t he s p e c i f i e d l imit, r e a d j u s t
shim.
3.
O th e r
f u n c t io n a l
C h e c k all
than
the
te s t
the e l e c t r i c
1)
,
(
,)
100 .
2)
,
( .)
,
,
1 600 .
.
and e l e c
3.
( ,
.),
,
.
TELESCOPING CYLINDER
CONSTRUCTION
Fig. 1
1
.
1.
Spring
pin
11.
Support
1.
2. N u t
12.
Rod
2.
3. P a c k i n g
4. B a c k u p r i n g
5. P i s t o n
6. 0 - r i n g
13.
14.
15.
22.
Packing
D u s t seal
Plain bearing
Plug
7. C y l i n d e r
8. R o d
9. 0 - r i n g
10. D a m p e r r i n g
23.
Backup
24.
25.
Backup ring
Plain bearing
cover
ring
3.
4.
5.
6.
7.
9.
10.
8.
11.
12.
13.
14.
15.
22.
23.
24.
25.
. . " " .
"".
D IS A S S E M B LY A N D
R E A S S E M B LY
W A R N IN G
DO N O T USE CO M PRESSED A IR TO
E X T E N D T H E PISTO N R O D .
C A U T IO N
W H EN D IS A S S E M B LIN G A N D
R EASSEM
B L IN G , W O R K IN C O R RECT W A Y B Y
O B S E R V IN G T H E 'G E N E R A L C A U T IO N S
(H Y D R A U L IC U N IT S )'G IV E N
IN
C HAPTER A .
W H E N D IS A S S E M B LIN G A N D R EASSEM
B L IN G , T A K E C A R E N O T T O D A M A G E
T H E T H R E A D S , T H E F IN IS H E D SUR FAC ES
A N D T H E S E A LIN G P A R T S , A N D BE
SURE T O USE T H E S PE C IFIE D S P E C IA L
TO O LS .
W H EN R E M O V IN G T H E RO D C O V E R ,
E X T E N D T H E PISTO N R O D N E A R L Y T O
T H E S TR O K E E N D T O P R E V E N T S E I
ZUR E IN T H E T H R E A D , T H E N A L IG N
T H E R O D C O V E R A N D T H E C Y L IN D E R
TU B E , A N D R EM O VE TH E ROD CO VER
A V O ID IN G U N D U E P R Y IN G FO RCE TO
T H E T H R E A D E D P O R TIO N .
W ASH T H E D IS AS S E M B LED P A R T S IN
K E R O S IN E , A N D C H EC K T H E IR S LID IN G
S U R FA C E S , S E A L M O U N T IN G A R E A S ,
A N D T H E T H R E A D S . C O R R EC T M IN O R
D E N TS , D A M A G E , RUST A N D B U R R S
W IT H F IN E A B R A S IV E C LO TH O R O IL
S TO N E . IF THESE DEFECTS A R E S E R I
O U S, R E P LA C E T H E P AR TS W IT H N EW
P A R TS .
IN P R IN C IP L E , R EP LA C E A L L T H E S E A L
IN G P A R T S . IN S T A L L T H E R E P LA C IN G
S E A LIN G P A R TS B Y O BSER VIN G T H E
'G E N E R A L C A U T IO N S ( S E A LIN G P A R T S )"
IN C H A P T E R A , P A Y IN G A T T E N T IO N
T O T H E IR O R IE N T A T IO N .
W H EN R E A S S E M B LIN G ,T A K E C A R E TO
A V O ID T H E E N T R Y O F D U ST A N D O TH E R
FO R E IG N M A T T E R , A N D A P P L Y H Y
D R A U L IC O IL FO R LU B R IC A T IO N TO
T H E S L ID IN G S U R FA C E S
" " (
) ,
.
,
,
.
,
, 1
,
,
.
,
.
, ,
.
,
.
,
, .
"
" ( )
,
,
.
,
.
.
COUNTERBALANCE VALVE
(
,
,
).
PRINCIPLE OF OPERATION
1. When control valve is at the neu
tral position
The actuator holding pressure is
sealed by seat "a" of the main spool
and seat "b" of the check valve.
2. While actuator is being pushed up
The pressurized oil entering through
port A of the control valve enters
chamber C, flows out through port
by opening the check valve, and
enters the holding side of the actu
ator.
At this time, since port PP is con
nected to the tank circuit, the main
spool is kept forced to the valve
body by the spring, and remains
inactive.
3. While actuator descends
The hydraulic oil directly flowing
from the control valve to the actua
tor also enters through port PP to
exert force to the pilot spool to
move the main spool. Consequently,
the holding hydraulic pressure in
port P is vented to port A.
At this time, the main spool motion
is smoothened by orifices.
Hydraulic symbol
1.
, ,
"
"b ,
2.
,
,
,
,
,
.
,
,
,
.
3.
, ,
PP.
,
.
.
Cover
Fig. 1
. 1
1.
Valve
body
2.
0-ring
3.
Backup
4.
Main
5.
Check
6.
Spring
ring
spool
valve
7.
Pilot
8.
Orifice
spool
9.
0-ring
10. O r i f i c e
D IS M O U N T IN G
11.
0-ring
12.
Spring
guide
13.
Spring
(A)
14 .
Spring
(B)
15 .
Plug
16 .
0-ring
17 .
0-ring
18 .
Plug
19 .
0-ring
20.
0-ring
AND
1.
2. -
3.
4.
5.
6.
7.
8.
9. -
10.
11. -
R E M O U N T IN G
THE
COVER
PRESSURE
PORT
O FF.
PP,
TO
PENT
IS
THE
VALVE
PRESSURE
CONTROL
W IT H
PENT
PREVENT
LEVER
THE
THE
M AY
.,
SHOT
THE
and
BEFO RE
to
m ake
f a u lt y
u n it s ,
su re
of
b le e d
and
c o n d it io n s .
COVER.
r e m o u n t in g ,
th e
NOTE
A fte r
20.
THE
T IM E S
STOPPED,
IN
BE
M O V IN G
SEVERAL
ENQ NE
R E M O V IN G
W H IL E
UP
T H IS , V E N T
BY
18.
19.
REM O VED
IS S T I L L
17.
(A)
()
-
-
-
-
W A R N IN G
IF
12.
13.
14.
15.
16.
te st
th e
th e
c ir c u it
th e
absence
o p e r a t io n
of
D IS A S S E M B LY A N D R E A S S E M B LY
C A U T IO N
W H EN D IS A S S E M B LIN G A N D R EASSEM
B L IN G , A LS O O B S E R V E 'G E N E R A L C A U
TIO N S ( H Y D R A U L IC U N IT S )4 N
A T O W O R K C O R R E C T LY .
C H APTER
W H EN D IS A S S E M B LIN G A N D R EASSEM
B LIN G T H E V A L V E , T A K E C A R E T O
PREVENT D AM AG E TO THE TH R EAD S,
F IN IS H E D SUR FAC ES A N D S E A LIN G
P A R T S , A N D A V O ID IM P R O P E R H A N
D LIN G . W H IL E D IS AS S E M B LIN G , T A K E
N ECESSARY M EASU R ES T O ASSU RE
T H A T A L L T H E P AR TS W IL L BE R E
AS S E M B LE D IN T H E IR O R IG IN A L
P O S ITIO N S
"
" ()
,
.
,
.
,
.
,
.
, ,
.
,
.
.
,
, .
" "
( ) ,
,
.
W ASH T H E D IS AS S E M B LED P A R TS IN
K E R O S IN E , A N D C H E C K T H E IR S L ID IN G
S U R FAC E S, S E A LIN G P A R T M O U N T IN G
S EA TS , A N D TH R E A D S . C O R R EC T M IN O R
D E N TS , S C U F F , RUST O R B U R R W IT H
F IN E A B R A S IV E C LO TH O R O ILS TO N E .
W H EN T H E SUR FAC ES A R E N IC K E D ,
W O R N O R O TH ER W IS E D A M A G E D SUB
S T A N T IA L L Y , R EP LA C E T H E P AR TS.
C H E C K T H E C O N TA C T SU R FAC ES O F
TH E V A LV E A N D V A LV E S EAT, A N D
R EP LA C E T H E M IF T H E C O N TA C T
P A T T E R N IS N O T E V E N , O R EXCESSIVE
W E A R IS O BSER VED .
IN P R IN C IP L E , R EP LA C E A L L T H E S E A L
IN G P A R TS . O B S E R V E 'G E N E R A L C A U
TIO N S ( S E A LIN G P A R T S )' IN C H A P T E R
A IN IN S T A L L IN G T H E M , T A K IN G
C AR E T O IN S T A L L IN T H E C O R R E C T
O R IE N T A T IO N .
W H EN R E A S S E M B LIN G , T A K E E X T R E M E
C ARE NO T TO A LLO W TH E E N TR Y OF
DUST A N D O T H E R FO R E IG N M A T T E R ,
A N D A P P L Y H Y D R A U L IC O IL FO R L U B R IC A TO N T O T H E S LID IN G SU R FAC ES.
IN SER T T H E V A L V E A N D SPOOLS
S T R A IG H T , T A K IN G C A R E N O T
TO P R Y , A N D C H EC K T H E IR SM O O TH
M O V E M E N T A F T E R IN S E R T IO N .
162-651-53000/4, 160-251-61000
,
.
.
,
,
.
,
.
HOSE REEL
CONSTRUCTION
A-A
Fig.
.
13.
Ball
bearing
2. H o u s i n g
14.
Ball
bearing
3. S h a f t
4. D r u m p l a t e
5. D r u m p l a t e
6. S p r i n g
15.
16.
17.
18.
D u s t seal
0-ring
Set s c r e w
Set s c r e w
19.
20.
21.
22.
23.
24.
Bolt
Spring washer
Nut
Bolt
Spring washer
Retaining ring
1.
Stand
7.
8.
9.
10.
Pipe
Snap ring
Pin
Spring
11.
RL-ring
12.
Backup ring
1
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
RL
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
D IS M O U N T IN G
W A R N IN G
,
,
.
W H E N T H E C IR C U IT IS SUSPECTED TO
R E T A IN H IG H PRESSURE O IL , BE SURE
T O V E N T PRESSURE B EFO R E D IS M O U N T
IN G T H E HOSE R E E L.
,
,
.
SIN CE T H E S PR IN G FO R CE FO R E X T R A
W IN D IN G T U R N S IS A P P L IE D T O T H E
H O SE, H O L D T H E D R U M W H EN
D IS C O N N E C TIN G T H E HO SE.
R E M O U N T IN G
C A U T IO N
IN S T A L L T H E HOSE R EE L SO T H A T
W H EN T H E HOSE E N D IS C O N N EC TED
TO T H E TE LE S C O P IN G C Y L IN D E R , T H E
HOSE R E E L H AS T H E E X T R A W IN D IN G
TU R N S LIS T E D BELO W .
Model
,
,
,
.
No. of e x t r a w i n d i n g t u r n s
,
TG-500ERG-2
4.5 -
TG-700EG-1
DISASSEMBLY
Fig. 2
. 2
5.5
1. R e m o v e
2.
the h o s e
f r o m the h o s e
reel.
1.
2.
(. 3).
,
,
.
( ,
.)
.
3.
@
(1 .)
@
(2 . ) ,
,
. ,
..
,
(. 4).
P l a c e t he h o s e r ee l on a fla t
s u r f a c e w i t h the d r u m p l a t e s i d e
down. (Fig. 3)
D i s e n g a g e p i n @ f r o m the h o l e in
s p r i n g (D b y t u r n i n g s t a n d c l o c k w i s e
un t i l s p r i n g p r o d u c e s an e c h o i c
sou nd s. (The s o u n d i n d i c a t e s d i s
3.
engagement
of t he pi n.)
S ha ft (D is
n e x t step.
to be e x t r a c t e d
Remove
screw
set
a nd
i n th e
two set
s c r e w s l o c k i n g s h a f t to s t a n d
(D ; and e x t r a c t s h a f t f r o m s t a n d
, by i n s t a l l i n g a t h r e a d e d ro d
i n t o t he t h r e a d e d h o l e in the s h a f t
end
and
tapping
the rod w i t h
plastic hammer,
with
slightly.
4)
(Fig.
-7/77 /
the reel
lifted
^/ / / / / / / /7 / / / / /
Fig. 4
. 4
Fig.
.
4.
Remove 0-ring
from shaft
0-
@
.
5. R e m o v e b o l t () m o u n t i n g p i p e @ to
dr u m p l a t e , and remove bolts
clamping
together;
6.
drum plates
and
Drum plate
together with
an d h o u s i n g
sealant.
are
stuck
Taking great
c a r e to p r e v e n t s p r i n g f r o m d i s
l o d g i n g f r o m the h o u s i n g , s e p a r a t e
the p l a t e a nd t he h o u s i n g b y p r y i n g
the h o u s i n g e v e n l y a r o u n d the c i r
cumference with
a screwdriver
or
the like.
After separation, carefully holding
the d r u m p l a t e a g a i n s t the h o u s i n g
to a v o i d
spring dislodgment,
turn
@
, @
,
,
, .
@
.
,
..
.
,
,
(
).
,
(. 5 6).
Drum p l a t e
Vise
Protective plate
Fig. 6
. 6
Fig. 5
. 5
7. Place plate on the housing to
contain s p r i n g ; set the reel on
an appropriate support with the
spring-containing plate side down;
and drive out shaft with a plastic
hammer.
7.
(3)
.
Spring-containing plate
Fig.
7
. 7
Remove RL-rings
from shaft
8.
RL
~
9.
9. Further disassembly.
WARNING
NEVER ATTEMPT TO REMOVE SPRING
IT IS VERY DANGEROUS.
If necessary, remove dust s e a l and
ball bearing from h o u s i n g , and
remove pin @ , spring @ and ball
bearing from shaft @ .
@
,
@
ASSEMBLY
NOTE
-
, RL
.
into
(13)
1.
(2' .
2.
(15)
(D .
(
'*Low Temp Grease
2" )
,
RL.
Fig. 8
. 8
3. Install spring
and p i n ,
retain them with snap ring
(See Fig. 1)
and
.
3.
@
(8) (. . 1).
4.
RL ,
RL
.
.
RL
Orientation of RL-ring
RL
RL
Fig. 9
. 9
,
,
RL
6.
Force-fit
ball bearing
onto drum
6.
.
(
" 45 " " )
(
,
),
.
(. . 10).
Fig- 10
. 10
7.
P l a c e d r u m p l a t e on h o u s i n g ,
a nd c l a m p the d r u m p l a t e h o u s i n g
a nd d r u m p l a t e w i t h b o l t s .
M o u n t p i p e on d r u m p l a t e w i t h
b o l t s () .
8.
Install
shaft;
0-ring
an d
in
install
the g r o o v e
the
shaft
7.
8.
@
.
,
.
@
9.
(
45" " " )
,
@
@
.
of
and
h o u s i n g a s s in s t a n d , a l i g n i n g
the set s c r e w hol es . I n s t a l l set
screws @ and .
9. A p p l y s e a l a n t ( S h i n - e t s u K a g a k u s
S i l i c o n e S e a l a n t K E 4 5 ) to the
ring-shaped area between s t a n d
a nd s h a f t , and to set s c r e w s and
Fig.
.
11
11
HYDRAULIC VALVE
,
.
.
Electric symbol
Hydraulic symbol
Fig.
.
1
1
1.
2. H y d r a u l i c v a l v e
body
3. C o v e r
4. Sp o o l
5. S p r i n g
6. F i l t e r
7. Hex. s o c k e t
h e a d bolt
8. Hex.
socket
h e a d b olt
9. P l u g
10.
11.
12.
13.
14.
15.
Plug
0-ring
0-ring
Hex socket
h e a d bolt
Solenoid body
Spool
D IS M O U N T IN G A N D
16.
17.
Sleeve
Stopper
18.
19.
20.
21.
22.
Plunger
Rod
Pin
Spring
S o l e n o i d coil
23.
24.
Rubber.cap
N ut
25.
0-ring
26.
27.
28.
29.
30.
31.
32.
0-ring
0-ring
0-ring
0-ring
0-ring
Spacer
Connector
33.
34.
Cap
Washer
R E M O U N T IN G
W H EN T H E C IR C U IT IS SUSPECTED TO
R E T A IN H IG H PRESSURE O IL , BE SURE
T O V E N T PRESSURE BEFO RE D IS M O U N T
IN G T H E V A L V E .
N OTE
re m o u n tin g , b le e d
th e
c ir c u it
R E A S S E M B LY
12.
13.
14.
15.
16.
17.
18.
19.
26.
27.
28.
29.
30.
31.
32.
33.
34.
-
-
-
-
-
-
,
,
.
W H EN D IS A S S E M B LIN G A N D
,
,
.
C A U T IO N
R EASSEM
B L IN G , A LS O O B S E R V E 'G E N E R A L C A U
TIO N S ( H Y D R A U L IC U N IT S )4 N C H A P TE R
A T O W O R K C O R R E C T LY .
W H E N D IS A S S E M B LIN G A N D R EASSEM
B LIN G T H E V A L V E , T A K E C A R E T O
PREVENT D AM AG E TO TH E TH R EAD S,
F IN IS H E D SUR FAC ES A N D S E A LIN G
P A R TS , A N D A V O ID IM P R O P E R H A N
D LIN G . W H IL E D IS AS S E M B LIN G , T A K E
N ECESSARY M E A SU R ES T O ASSU RE
T H A T A L L T H E P AR TS W IL L BE R E
AS S E M B LE D IN T H E IR O R IG IN A L
PO SITIONS.
9.
10.
11.
20.
21.
22.
23.
24.
25.
a n d th e u n its , a n d te s t th e o p e ra tio n
to m a k e s u re o f th e a b s e n c e o f
fa u lty c o n d itio n s .
D IS A S S E M B LY A N D
8.
-
-
W A R N IN G
A ft e r
1.
2.
3.
4.
5.
6.
7.
"
" ()
,
.
,
.
,
. '
,
.
, ,
.
,
.
,
, .
" "
( ) ,
,
.
,
.
.
, ,
.
,
.
LOCATIONS OF COMPONENTS
GENERAL
FUNCTIONS OF UNITS
1 . E le v a t io n c y l in d e r
1.
The e l e v a t i o n c y li n d e r s s e r v e to e l e
v a te th e boom.
2 . C o u n te rb a la n ce v a lv e
T h is v a lv e s e r v e s to p re v e n t the
c y l i n d e r p i s t o n rod from pushed in
by th e lo a d d u rin g boom lo w e r in g to
m a in ta in th e lo w e rin g speed a t a l e v
e l determ in ed by th e o i l e n tr y flo w
r a t e to th e c y l i n d e r . I t a l s o p re v e n t
th e r e t r a c t i o n o f th e p i s t o n rod when
th e p ip in g betw een i t and th e manual
c o n t r o l v a lv e i s b ro k e n .
.
2.
,
,
.
.
DESCRIPTION OF SYSTEM
(Refer to the circuit diagram in Chapter Z .)
(, Z .)
The p r e s s u r iz e d o i l d e l i v e r e d th rough
th e manual c o n t r o l v a lv e ( e l e v a t i n g
b lo c k ) i s se n t to th e c y l in d e r v i a th e
c o u n te r b a la n c e v a lv e d u rin g r i s i n g ;
d u rin g lo w e r in g , i t i s d i r e c t l y sen t to
th e rod s id e o f th e c y l i n d e r , s e r v in g
s im u lta n e o u s ly as th e p i l o t p r e s s u r e o f
th e c o u n te r b a la n c e v a lv e to c o n t r o l i t s
o p e n in g a l a l e v e l p r o p o r t i o n a l to th e
su p p ly r a t e o f o i l .
The c i r c u i t p r e s s u r e i s c o n t r o l l e d by
th e p o r t r e l i e f v a lv e (PR4) o f th e man
u a l c o n t r o l v a lv e d u rin g r i s i n g , but by
p o r t r e l i e f v a lv e (PR3) d u rin g lo w e rin g
to cu t th e i n i t i a l su rg e to p re v e n t the
boom from h u n tin g .
,
(
),
.
,
.
(PR4)
.
(P R 3).
,
.
ELEVATING CYLINDER
1.
Cylinder
14.
Damper
2.
Piston
15.
16.
17.
Packing
Backup ring
Head cover
3. R o d
4. R o d c o v e r
5. S h i m
6. S h i m
7. R o d end
8. P l a i n b e a r i n g
9. P a c k i n g
10. B a c k u p r i n g
11. 0 - r i n g
12. S p r i n g p i n
13. 0 - r i n g
18.
19.
20.
21.
22.
23.
ring
0-ring
D u s t seal
Retainer
-------0-ring
24.
Set
screw
25.
Plate
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
-
-
14.
15.
16.
17.
18.
19.
20.
21 .22.23.
24.
25.
D IS M O U N T IN G
A N D
R E M O U N T IN G
W A R N IN G
W HERE
TH E
C IR C U IT
C O N T A IN
H IG H
SURE
VEN T
TO
TO
IS
PENT
IT
D IS M O U N T
SUSPECTED
UP
THE
TO
PR E S SU R E, BE
BEFORE
S T A R T IN G
C Y L IN D E R S .
NOTE
A fte r
c u it
th e
r e m o u n tin g ,
and
' s y s te m
th e
u n its ,
fo r
b le e d
and
fa u lt-fr e e
th e
te s t
c ir
th e
o p e r a tio n .
D IS A S S E M B L Y
A N D
DO
USE
COMPRESSED
EXTEND
THE
P IS T O N
B L IN G , W O R K
IN
A IR
TO
A N D
REASSEM
CORRECT W A Y
T H E 'G E N E R A L
(H Y D R A U L IC
CHAPTER
ROD.
D IS A S S E M B L IN G
O B S E R V IN G
NOT
W HEN
REASSEM BLY
C A U T IO N
. .
W A R N IN G
rv T rT R H H
BY
()
C A U T IO N S
U N IT S ) 'G IV E N
" "
,
IN
A .
W HEN
D IS A S S E M B L IN G
B L IN G , T A K E
CARE
THE
THREADS, THE
A N D
THE
SURE
TO
A ND
NOT
REASSEM
TO
F IN IS H E D
PARTS, A N D
USE
S P E C IF IE D
W ASH
S P E C IA L
TH E
D IS A S S E M B L E D
K E R O S IN E , A N D
CHECK
SURFACES, SEAL
A N D
THE
PARTS
T H E IR
M O U N T IN G
DENTS, D A M A G E, RUST
W IT H
F IN E
s t o n e
IF
b r a s iv e
THESE
OUS, REPLACE
A ND
S L ID IN G
THE
PARTS
.
,
M IN O R
o r
ARE
d e f e c t s
S E R I
NEW
IN
PARTS.
S E A L IN G
BY
A LL
THE
SEAL
T H E IR
A ,
P A Y IN G
TH E
M A TTER , A ND
D R A U L IC
O IL
S L ID IN G
FOR
DUST
CARE
A N D
APPLY
L U B R IC A T IO N
SURFACES.
A V O ID
F O R E IG N
(-
, '
A T T E N T IO N
R E A S S E M B L IN G ,T A K E
OF
" "
TH E
O R IE N T A T IO N .
ENTRY
,
.
R E P L A C IN G
O B S E R V IN G
W HEN
TH E
THE
C A U T IO N S ( S E A L IN G P A R T S ) '
C H A PTER
TO
IN S T A L L
PARTS
'G E N E R A L
IN
P R IN C IP L E . R E P L A C E
IN G
PARTS.
o il
W IT H
BURRS
c l o t h
IN
AREAS,
THREADS. CORRECT
- .
,
BE
TO O LS.
SURFACES
S E A L IN G
THE
DAM AG E
TO
OTHER
H Y
TO
REPAIR
MANUAL
SWING SYSTEM
LOCATIONS OF COMPONENTS
D02-0040R.
D02-0040R.
GENERAL
FUNCTIONS OF UNITS
1.
DESCRIPTION OF SYSTEM
(R efer to the circuit diagram in Chapter Z.)
, , ,
,
-
.
(. Z.)
,
,
, ,
.
- ,
.
T h e s w i n g d r i v i n g u n i t c o n s i s t s of the
c o n t r o l v a l v e , t he h y d r a u l i c m o t o r , the
b r a k e and t he r e d u c e r , the f u n c t i o n s of
w h i c h a r e as f o ll ow s.
, ,
,
:
CONTROL VALVE
(Fig.
3)
of
these component
valves
ar e
as
follows.
1)
Spo ol
As the s p oo l is s h i f t e d , the oil
e n t e r i n g t h r o u g h p o rt P is s w i t c h e d ,
and the f l o w r a t e is a l s o a d j u s t e d
by t he s p o ol p o s i t i o n .
2) R e l i e f
valves
(R a , R b )
W h e n the h y d r a u l i c p r e s s u r e in the
hydraulic motor feed/discharge
p a s s a g e r i s e s to t he set level,
t h e s e v a l v e s o p e n to b y p a s s the oil
to the lo w e r p r e s s u r e p a s s a g e to
r e g u l a t e the p r e s s u r e a p p l i e d to
the h y d r a u l i c m o t o r and to s e r v e as
c i r c u i t s a f e t y v al v e s .
W h i l e t he s o l e n o i d v a l v e is d e e n
e r g i z e d , t h e r e b y c l o s i n g the v e n t
p a s s a g e , the p r e s s u r e s e t t i n g (high)
of r e l i e f v a l v e R a is e f f e c t i v e ,
a nd w h i l e the s o l e n o i d v a l v e is
e n e r g i z e d , t h e r e b y c o n n e c t i n g the
v e n t p a s s a g e to r e l i e f v a l v e R b ,
a nd po r t P is c o n n e c t e d to t he r e t u r n
c i r c u i t , the p r e s s u r e s e t t i n g (low)
of r e l i e f v a l v e R b p r e v a i l s .
3)
Solenoid valve
The
solenoid valve
opens
and c l o s e s
selectively
the v e n t
passage
of r e l i e f v a l v e R a to s w i t c h o v e r
the p r e s s u r e s e t t i n g b e t w e e n the
high
4)
and
the
Check valves
l o w levels.
(C a , C b )
W h i l e t he h y d r a u l i c m o t o r is d r i v e n
by the i n e r t i a of t he load to act
as a p um p,
these valves
to f l o w f r o m the b y p a s s
s u c t i o n line to p r e v e n t
a l l o w oil
to the
cavitation.
( .3
.
.
1)
,
,
.
.
2)
,
,
, , ,
, ,
.
,
,
( )
RA
.
,
R B ,
,
( )
RB
.
3)
RA
.
4) (A , CB )
,
.
5) B a c k p r e s s u r e v a l v e
5) ()
.
()
T h i s v a l v e s e c u r e s oil s u p p l y to the
s u c t i o n s i d e w h i l e the h y d r a u l i c
m o t o r ac t s as a pump.
(Fig.
HYDRAULIC MOTOR
4)
T h i s m o t o r is a s w a s h p l a t e t y p e p l u n g
er m o t o r , and s e r v e s to c o n v e r t h y d r a u
lic p r e s s u r e i n t o r o t a t i o n a l d r i v i n g
f o r c e to be t r a n s m i t t e d to the r e d u c e r .
REDUCER
This
reducer
(Fig.
(.
(.
ty p e
2 - s t a g e r e d u c e r . T h e r o t a t i o n of the
h y d r a u l i c m o t o r o u t p u t s h a f t is t r a n s
m i t t e d to s u n g e a r t h r o u g h the s p l i n e ,
and the su n g e a r d r i v e s the o u t p u t s h a f t
at a r e d u c e d s p e e d t h r o u g h the g e a r i n g
4)
.
,
.
4)
is a p l a n e t a r y g e a r
4)
.
,
,
.
s h o w n below.
Planetary gear
Ring gear
Sun gear
(input shaft)
( -)
Output shaft
Fig.
.
BRAKE
T h i s b r a k e is an i n t e r n a l e x p a n d i n g
t y p e m e c h a n i c a l b r a k e , in w h i c h t h e
b r a k e s h o e s a r e f o r c e d o n t o t h e b o r e of
the b r a k e d r u m b y a l i n k m e c h a n i s m .
1
1
.
.
Oil f i l l e r
Hydraulic c i r c u it
Dowel pin
Fig.
. 2
Control valve
()
Reducer assembly
CONSTRUCTION
1. Reducer un it
1.
Fig. 5
. 5
1. H o u s i n g
21.
Spring washer
2. S h a f t
3. R o l l e r b e a r i n g
22.
Spring pin
4. Oil seal
5. Ball b e a r i n g
23.
24.
25.
King pin
Gear
Needle bearing
6. K i n g p i n
7. T h r u s t b e a r i n g
26.
27.
Washer
Retaining
8. G e a r
9. N e e d l e b e a r i n g
10. L o c k w a s h e r
28.
29.
30.
31.
Gear
Pin
Bolt
Spring washer
32.
33.
Gear
Retaining ring
34.
Plug
11.
Bo l t
12.
Pin
13.
14.
Spider
Pin
15.
0-ring
16.
Ring gear
17.
18.
19.
Ball b e a r i n g
Gear
End cover
20.
Bo l t
35. P l u g
36. 0 - r i n g
37. B o l t
38. W a s h e r
39. W a s h e r
40. M a c h i n e
ring
1.
2.
3.
4.
5.
6.
7.
8.
9.
10 .
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
screw
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
- 35.
36.
37.
38.
-
39.
1
40.
2.
2.
Fig. 6
. 6
1. S h a f t
2. B a l l b e a r i n g
3. R e t a i n i n g r i n g
4.
5.
6.
7.
8.
Cam plate
Oil seal
0-ring
Oil seal c o v e r
Retaining ring
9.
Cylinder barrel
assembly
9-1 C y l i n d e r b a r r e l
9 -2 P l u n g e r b e a r i n g
9-3
9-4
9- 6
9-7
9-8
Plunger
Plunger spring
S p r i n g sea t
Center spring
Retaining ring
9-9
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Spring seat
Spring pin
Case
0-ring
Needle bearing
Bottom cover
Bolt
Bolt
Spring washer
Oil seal
Retaining ring
Plug
0-ring
Plug
Plug
Plug
Retaining ring
1.
2,
3.
.
5.
6.
-
7.
8 .
9.
9-1
9-2
9-3
9-4
9-6
9-7
9-8
9-9
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
3.
3.
. 7
1. M e c h a n i c a l
assembly
brake
1-1 B a c k p l a t e
1-2 B r a k e s h o e
1-3 A n c h o r p i n
1-4 N u t
1-5 S p r i n g w a s h e r
1-6 G u i d e p l a t e
1-7 R e t u r n s p r i n g
1-8 A d j u s t e r
1-9 S p r i n g
1-10 Pin
1-11 S p r i n g
1 -12 B r a k e l e v e r
1-16 P l u g
1-17 C a b l e
1-18 D r u m
4. 0 - r i n g
5. F l a n g e
6. H o l d e r
7. B o l t
8. L o c k w a s h e r
9. L o c k w a s h e r
10. R e a m e r bo l t
11. H e x a g o n s o c k e t
head bolt
1 -13 L i n k
13.
14.
15.
Eye bolt
Cover
Spring washer
1-14 P i n
16.
Retaining ring
1 -15 U - r e t a i n e r
1.
1-1
1 2
1-3
1-4
1-5
1-6
1-7
1 - 8
1-9
1-10
1-11
1-12
1-13
1-14
1-15 U-
1-16
1-17
1-18
4. -
5.
6 .
7.
8 .
9.
10.
11.
13.
14.
15.
16.
4.
26.
0-ring
27.
0-ring
29.
Plate
Spring
30.
Seat
Seal
31.
Poppet
0-ring
32.
Spring
Oil
33.
Cap
Plate
34.
0-ring
1.
Body
2.
Control
3.
Steel
4.
5.
6.
7.
8.
9.
spool
ball
cap
seal
Seat
35.
Adjust
10.
Spring
36.
0-ring
11.
Collar
37.
Nut
Cap
12.
Spool
38.
13.
Cap
40. S l e e v e
14.
Valve
seat
valve
15.
Check
16.
Retaining
17.
Spring
20.
Cover
21.
Spring
washer
nut
44.
Spring
45.
Spool
46.
Stopper
47.
Spring
48.
Push
49.
0-ring
rod
Solenoid
socket
50.
bolt
51.
Spring
Over-load
52.
Machine
53.
Check
54.
Spring-
2 2 . Hex.
head
23.
ring
screw
relief
23-1
valve
Spool
washer
screw
valve
23-2
Steel
ball
55.
Seat
23-3
Valve
seat
56.
0-ring
23-4
Sleeve
57.
Bleeder
23-5
0-ring
58.
Plug
23-6
Pilot
59.
Spring
60.
Hex.
socket
head
bolt
seat
23-7
0-ring
23-8
Spring
23-9
0-ring
23-10
Poppet
23-11
Spring
23-12
Adjust
23-13
Nut
23-14
Cap
23-15
Tube
nut
screw
61.
Plug
62.
Cap
screw
washer
63.
Terminal
7 0.
Manifold
7 1.
Plug
72.
Hex.
socket
head
bolt
24.
Cap
73.
Spring
25.
Choke
74.
Plug
washer
1.
2 .
3 .
4 .
5 . 1
6 . -
7 .
8 .
9 .
10 .
1 1 .
1 2 .
1 3 .
1 4 .
1 5 .
16.
1 7 .
2 0 .
2 1 .
2 2 .
2 3 . -
2 3-1
2 3 - 2
2 3 - 3
2 3-4
2 3 -5 -
2 3 - 6
2 3 -7 -
2 3 - 8
2 3 -9 -
2 3 -1 0 -
2 3 - 1 1
2 3 -1 2
.
2 3 -1 3
2 3 -1 4
23-15
2 4 .
2 5 .
26.
73.
-
-
- ;
-
-
-
-
74.
27.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
40.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
70.
71.
72.
DISMOUNTING
WARNING
WHEN THIS UNIT IS REM OVED, THE
SWING TABLE M AY ROTATE LOOSE.
TO PREVENT THIS DANGER, ARREST
THE SWING TABLE BEFORE REMOVING
THIS U NIT.
WHEN THE GIRICUIT IS SUSPECTED TO
RETAIN HIGH PRESSURE O IL , BE SURE
TO VENT PRESSURE BEFORE DISMOUNT
ING THE UNIT.
REMOUNTING
,
.
.
,
,
.
NOTE
When installing the pinion gear,
adjust the shims to provide a 0 .3 0.8 mm clearance between the shaft
and the upper surface of the pinion
gear.
0,3 0,8 .
,
,
.
(1)
(1)
BRAKE UNIT
Fig.
.
10
10
D IS A S S E M B LY
C A U T IO N
T H E B R A K E SHOES A N D T H E IN T E R N A L
S U R FAC E O F T H E B R A K E D R U M M U S T
BE FR EE F R O M O IL A N D G R E AS E .
P R IO R T O D IS A S S E M B LY O F T H E
B R A K E , T U R N A D JU S T E R <1 - 8 > T O
M A K E T H E B R A K E SHOE D IA M E T E R
.
<1 - 8 >.
.
S M A LLES T.
CHECKS
Measure
the
on brake
l ess
than
Use
limit
thickness
of
the
s h o e <1-2> a n d r e p l a c e
th e f o l l o w i n g u s e
: 1.5mm
(0.06 in.)
linings
if it is
limit.
<1-2> ,
,
.
:
1,5
R E A S S E M B LY
R e a s s e m b le in th e re v e rs e o r d e r o f
s a s s e m b ly , o b s e r v in g th e f o l l o w i n g :
d i
.
:
1) T h e b r a k e s h o e s a n d t h e i n t e r n a l
s u r f a c e of the b r a k e d r u m m u s t be
f r e e f r o m oil a n d g r e a s e .
1)
. .
2)
Install the a d j u s t e r
Fig. 12.
2)
,
. 12.
3)
I n s t a l l the d r u m so t h a t t h e d r u m
h o l e is in l i n e w i t h t h e a d j u s t e r .
(Fig.
as
s h o w n in
13)
Adjuster
Threaded portion
Fig. 12
.
12
3)
,
(. 13).
Adjuster
Fig.
.
13
13
4)
,
(. 4).
5)
.
,
,
6 7 .
0,2
0 ,3 .
(2)
(2)
Fig. 14
. 14
DISASSEMBLY
1.
.
NOTE
2. .
Match mark
Speed reducer
Fig. 15
Fig. 16
, 15
. 16
3.
.
NOTE
4. ,
.
,
.
.
Fig. 17
. 17
NOTE
5.
,
.
,
.
5. Unscrew bolts and remove bottom
cover @ from the case.
6. .
@
.
7.
.
CAUTION
TAKE CARE NOT TO DROP
PLUNGERS <9 -3 > OUT OF THE
CYLINDER BARREL <9 -1 >
IN CASE THEY DID, BE SURE TO
REINSERT THEM INTO THEIR
ORIGINAL BORES.
,
<9 -3 >
<9-1>
- ,
().
<9-1>,
.
from
Fig. 19
. 19
16
CAUTION
MARK THE BARREL LIGHTLY,
NEAR THE BARREL PERIPHERY,
AND NOT NEAR THE BORE. IF
THE BARREL IS PUNCHED NEAR
THE BORE, THE BORE MAY GET
DEFORMED.
8. Make punch mark on the cylinder
l <9-1> between any two plungers
CAUTION
REMOVE THE PLUNGERS IN EITHER
CLOCKWISE OR COUNTERCLOCKWISE
SEQUENCE STARTING FROM THE
PUNCH MARK ON THE CYLINDER
BARREL.
THE COMBINATIONS BETWEEN THE
CYLINDER BARREL BORES AND
PLUNGERS MUST NOT BE CHANGED.
NOTE
Center spring <9-7> can be removed
when retaining ring <9-8> is removed,
but do not remove the center spring
unless it is absolutely necessary,
as the setting load of the spring is
greato In case removal of the spring
is necessary, use a press or the
like, carefully avoiding violent
escape.
9. Pull the plungers <9-3>, plunger
springs <9-4>, out of the cylinder
barrel <9-1>.
8.
,
.
,
.
9. 9
>
1
<
<9-3> <9-4> .
,
.
<9-7>
<9-8>.
,
.
.. ,
.
Punch mark
Punch mark
Fig. 20
Fig. 21
. 20
. 21
CAUTION
USE PLASTIC HAMMER WHEN
10. .
.
,
.
10. Remove retaining r i n g , and tap
out shaft (D together with oil seal
cover and ball bearing @ .
Fig. 22
. 22
Fig. 23
. 23
NOTE
11 .
.
CAUTION
,
.
.
I2. .
@
,
.
12. Remove retaining r i n g , and remove
the ball bearing from the shaft
Bearing
Shaft
Fig. 24
. 24
13.
.
NOTE
Wash the disassembled parts in kerosine, and check their sliding surfaces,
sealing p a rt mounting surfaces and
threadeds. When there are apparent
damages o r when the follow ing
replacement standards are exceeded,
replace the parts.
1. S lid in g su rfa ce o f c y lin d e r b a rre l
< 9-1.>
Replace i f the depth o f the s cr a tc h
i s more than 0.1 mm (0 .0 0 4 i n . ) or
th ere i s d e p o s it o f fo r e ig n m atter.
(R eplace in c y lin d e r b a rre l assem
b ly ) .
2. Clearance between plunger
plunger bearin g ( 5 3 )
and
,
.
,
,
.
1.
,
0,1 (0,004 ),
,
(
.)
2. < 9 - 3
<
>
-2
9
,
: 0 ,3 (0,012 )
:
0 ,5 (0,020 )
(
.)
3. < 9 - 2 >
( )
F ig . 25
. 25
3. Wear o f plunger b e a rin g <9-2>
( Su rfa ce s on which camp la te @ moves)
Recommended replacem ent wear lim it :
0.1 mm (0 .0 0 4 i n . )
Use lim it : 0 .2 mm (0 .0 0 8 i n . )
(R eplace in c y lin d e r b a rre l assem
bly.)
4. P lu n ger
1) P lay
P u ll out th e p lu n g er 50 mm (1 .9 7 i n . )
and move i t up and down, r ig h t and
l e f t t o d eterm in e th e maximum p la y .
Recommended rep la cem en t p la y l i m i t :
0 .1 3 mm (0 .0 0 5 i n . )
Use l i m i t : 0 .1 6 mm (0 .0 0 6 i n . )
(R e p la ce in c y l i n d e r b a r r e l assem
b ly )
,
:
0,1 (0,004 )
:
0 ,2 (0,008 )
(
.)
4. <
>
-3
9
1)
50 (1,97 ),
.
,
: 0,13 (0,005 )
:
0,16 (0,006 )
(
.)
Cylinder barrel
2)
Fig. 26
. 26
2) Appearance
Replace if scored or otherwise
damaged.
(Replace in cylinder barrel assembly)
5. Wear of plunger spring
outside diameter
,
.
(
.)
5.
on the
,
:
0,2 (0,008 )
:
0,3 (0,012 )
(
.)
bly)
6. Partial wear of cam plate
sliding area
in the
6.
(4)
,
: 0,03 (0,0012 )
:
0,05 (,0020 )
7.
1 ,
0,1 (0,004
) ,
.
8.
1) ,
.
2) ,
.
Wear width:
Wear depth:
9. Ball b e a r i n g ,
needle b e a r i n g
:
0,5 (0,020 )
: 0,3 (0,012 )
9.
,
.
REASSEMBLY
.
:
CAUTION
1)
,
@ ,
,
.
Push
Fig. 27
. 27
,
,
.
2)
-
,
.
Fig. 28
. 28
CAUTION
3)
,
.
Projection of
bearing outer diameter
,
Bearing
Fig. 29
. 29
.Protection piece
4) <9-4> <9-4>
<9-1> ,
(. . 30).
,
. 31,
.
Fig. 31
. 31
Fig. 30
. 30
CAUTION
BE SURE REASSEMBLE THE PLUNGERS
IN THE ORIGINAL BORES.
5) < 9 - 3 >
,
,
.
,
.
,
<9-2>
,
,
, <9-3>
<9-1>.
Fig. 33
. 33
7) Whe n installing b ottom c o v e r , make
sure that there is no dirt, sc ratch
es, etc. on the lapped surfaces of
the bottom cover and cylinder
b a r r e l <9-1. Coat the lapped sur
faces wit h hydraulic oil.
8) Torque the bolts to the values given
in the structure d i agr am (Fig. 4).
7)
<9-1> ,
.
.
8) ,
( . 4) .
(3)
Fig. 34
. 34
DISASSEMBLY
NOTE
1.
@
.
,
.
Threaded hole
for disassembly
Match mark
Match mark
Fig. 36
. 36
Fig. 35
. 35
3. Remove gear from the hydraulic
motor shaft by removing retaining
ring
4. Remove gears
and gear
3.
(32) ,
4.
5.
6.
@)
#
,
@
.
together.
NOTE
Do not remove the king pins
unless gear
is faulty.
,
.
Fig. 37
. 37
NOTE
7.
@ ,
@ .
,
.
7. Flatten w a s h e r s , unscrew b o l t s
and remove ring gear @ from the
end cover @
Match mark
cna
Fig. 38
. 38
NOTE
Insert cylindrical support under
housing @ .
8.
Rem ove b o l t s
.
8.
@ .
Cylindrical support
Fig. 39
. 39
NOTE
9.
,
.
Fig. 40
. 40
10. Remove shaft (D and the associated
Parts together from housing .
NOTE
Punch match marks on the shaft
and the spider.
10.
11.
@
,
@ .
Match mark
Fig. 41
. 41
12.
NOTE
Wash the disassembled parts in kerosine, and check their sliding surfaces,
sealing part mounting surfaces and
threadeds. When there are apparent
damages or when the following
replacement standards are exceeded,
replace the parts.
1. Partial wear of gears
1) Gear (8), (g)
Recommended replacement wear limit:
0.2 mm (0.008 in.)
Use limit: 0.3 mm (0.012 in.)
2) Ring g e a r, (g)
Recommended replacement wear limit:
0.1 mm (0.004 in.)
Use limit: 0.2 mm (0.008 in.)
2. S h a f t
1) Replace the shaft if there is
partial wear in the splines.
2) Replace the shaft if wear in the
oil seal sliding area exceeds the
following:
Wear width: 0.5 mm (0.020 in.)
Wear depth: 0.3 mm (0.012 in.)
,
.
, ,
.
1.
1) ,
,
: 0,2
:
0,3
2)
@ , @)
,
: 0,1
:
0,2
2.
1) ,
.
2) ,
.
: 0,5
: 0,3
3. Ball bearings,
needle bearings
roller bearing, 3.
, ,
, ,
,
.
REASSEMBLY
, .
1) , .
2)
.
3)
0-
.
4) ,
.
Fig.4
2
.4
2
5) @
.
6)
,
(. 4).
(4)
Fig. 43
. 43
DISASSEMBLY
. 43, :
spool
1.
(2)
1)
..
.
2)
, . 44,
Fig. 44
. 44
3) He @ ,
.
.
2.
1)
.
2 )
,
,
,
.
3.
CAUTION
TOP THE SLEEVE AT THE PERIPHERY,
TAPPING NEAR THE BORE CAN DEFORM
THE SLEEVE AND CAUSE THE BINDING OF
SPOOL
1)
to the plate
,
. ,
,
,
4.
1) Remove c h o k e s by screwing in the
extraction bolt and pulling.
1) @
2) He -
,
.
-
.
Extraction bolt
Thread size : 5
; 5
Fig. 45
. 45
NOTE
Wash the disassembled parts in
kerosine, and check their sliding
surfaces, sealing part mounting seats,
and threads. Correct m inor dents,
scuff, rust or burr with fine abrasive
cloth or oilstone. When the surfaces
are nicked, worn or otherwise
damaged substantially, replace the
parts. Check the contact surfaces
of the valve and valve seat, and
replace them if the contact pattern
is not even, or excessive wear is
observed.
,
.
, ,
.
,
,
.
.
REASSEMBLY
s p o o l , solenoid
solenoid valve
,
.
1)
.
.
, ,
@ ,
@
-
(23-^ ,
<&>
poppet
@ -
, <^3^^
2)
(5?
.
3)
2'
, .
Seat surface
Fig. 46
. 46
4) Before installing overload relief
spool < 1 ^ into sleeve<|Q), shake the
spool as shown below to check free
m ot i o n of steel ball ($3^ by means
of rattling sound.
4) <^3-^
-
(|3^
, ,
( 2 3 ^ .
Fig. 47
. 47
5) <|^^
5) When driving the pilot seat <|> i^^to
-
overload relief sleeve (23^ , drive
(|^
it straight, as shown.
, .
Drive straight
.
No -ring
-
.
Fig. 48
. 48
6) - @
<~1) .
Spool
Fig. 49
. 49
7) After installing check v a l v e , move
it with the finger to checls for
smooth movement.
7)
@
.
8)
9)
.
,
.
Elongated recess
From this shape with a center punch
..
Fig. 50
. 50
NOTE
(D ,
( . 50)
3,3
.
3,3 .
,
,
2 ,
4 .
3.3 mm hole
Flush
3.3
.
Fig. 51
. 51
NOTE
Coat 0 - r in g s with grease to
prevent them from dropping.
11) When uniting the valve assemblies,
take care not to let 0-rings drop
off the grooves nor to let the
springs shift into an incorrect
position.
12) Torque the bolts, nut, and screws
to the values given in the str u c
ture d i a gram (Fig. 3).
13) After installing the control valve
unit to the hydraulic motor, adjust
the adjusting screw, referring to
the relevant items in TEST PR O
CEDURES AND MAINT E N A N C E STANDARDS".
10)
@
(10)
.
,
@
.
11)
-
,
.
-
.
12) ,
,
(. 3).
13)
"
" .
TEST
1.
1.
Test circuit
,
.
RBMSF-210T780-3
RBMSF-210T780-3
Relief valve
Control spool
Hydraulic pump
Suction filter
Flowmeter
Pressure gauge
Drain port
Fig. 52
. 52
REPAIR
MANUAL
WINCH SYSTEM
LOCATIONS OF COMPONENTS
GENERAL
1.
FU N C TIO N S O F U N ITS
1.
Hydraulic motor
T h i s is a h y d r a u l i c m o t o r i n c o r p o r a t
ing a wet m u l t i p l e disk brake. W h e n
t h e w i n c h c o n t r o l l e v e r is in n e u t r a l ,
t he
springs
in t he b r a k e
compresses
the f i x e d p l a t e s a n d the
p l a t e s t o g e t h e r to b r a k e
o u t p u t shaft.
During winch operation,
oi l
f r o m the m a i n
duced
through
the
friction
the m o t o r
hydraulic
circuit
is
intro
solenoid valve
to
o p e n the b r a k e , a l l o w i n g the p r e s
s u r i z e d o l d e l i v e r e d f r o m t he p u m p
to d r i v e
th e m o t o r
for
transmission
to the w i n c h .
2. W i n c h
2.
The rotational
s p e e d of
the h y d r a u
l ic m o t o r is r e d u c e d b y g e a r s to
d r i v e the w i n c h d r u m for w i n d i n g
and unwinding operations.
3.
Counterbalance valve
lowering phase,
,
.
3.
T h i s v a l v e p r e v e n t s the w i n c h f r o m
b e i n g d r i v e n b y t he l o a d in the
and m a i n t a i n s
the
w i n c h s p e e d at the l e v e l d e t e r m i n e d
b y the d i s c h a r g e f l o w r a t e of the
hydraulic motor.
4.
.
,
.
, ,
,
,
,
.
Check valve
,
,
.
4.
D u r i n g w i n c h o p eration, this v a l v e
p r e v e n t s th e r e l e a s i n g p r e s s u r e f or
the h y d r a u l i c m o t o r m u l t i p l e
disk
the w i n c h .
5.
Solenoid valve
When
the w i n c h c o n t r o l
5.
lever
is
m o v e d , the l i m i t s w i t c h m o u n t e d to
the m a n u a l c o n t r o l v a l v e e n e r g i z e s
th i s v a l v e to s e n d t h e h y d r a u l i c o i l
f r o m the m a i n c i r c u i t of t h e w i n c h
to the b r a k e of the h y d r a u l i c m o t o r
to r e l e a s e
the brake.
,
,
.
in C h a p te r Z . )
(. Z.)
1.
1. M a i n w i n c h
,
.
1 ,
2
.
1
,
2
, ,
.
(FC1),
.
.
.
,
,
,
,
.
,
.
Tw o s t e p s a r e p r o v i d e d f o r b o t h w i n d
ing a n d u n w i n d i n g o p e r a t i o n of the
winch. For i n d i v i d u a l 1st step o p e r a
tion,
PI
th e p r e s s u r i z e d o i l
is e m p l o y e d
and
th a t
from pump
from pump
is r e t u r n e d to t h e tank.
In the 2nd step, t he p r e s s u r i z e d
P2
oil
f r o m p u m p PI a n d th a t f r o m p u m p P 2 ,
w h i c h p a s s e s t h r o u g h the e l e v a t i n g
and
are
c o m b i n e d a n d s e n t to t h e w i n c h v a l v e
bl o c k . W h e n i n c h i n g the w i n c h , f l o w
c o n t r o l v a l v e (FCl) is u n d e r the
w i n c h m o t o r c i r c u i t p r e s s u r e , a n d is
m a i n t a i n e d in b a l a n c e w i t h the m a i n
circuit p r ess ur e always high er than
the w i n c h m o t o r c i r c u i t p r e s s u r e b y
a c o n s t a n t d i f f e r e n c e , a n d the e x
c e s s o i l is r e t u r n e d to the tank.
W i t h the pre ss ur e di ff e r e n c e b e t we en
the two c i r c u i t s k e p t c o n s t a n t , the
d e l i v e r y o i l f l o w r a t e to the w i n c h
motor
spool
is a l w a y s in p r o p o r t i o n to the
d i s p l a c e m e n t , i r r e s p e c t i v e of
t h e load, a l l o w i n g a c c u r a t e w i n c h
control. Since the exce s s oil r e
t u r n s to t h e t a n k at p r e s s u r e s b e l o w
th e r e l i e f v a l v e set l e v e l , h e a t
generation
is
small.
2. A u x i l i a r y w i n c h
2.
W h e n o p e r a t e d i n d i v i d u a l l y , the
p r e s s u r i z e d o i l f r o m p u m p PI a n d
that of p u m p P 2 , w h i c h p a s s e s t h r o u g h
the e l e v a t i n g a n d t e l e s c o p i n g v a l v e
blocks,
are
combined
and
supplied
to
the a u x i l i a r y w i n c h v a l v e b l o c k .
W h e n the a u x i l i a r y w i n c h v a l v e is
operated simultaneously with another
valve, o n l y p r e s s u r i z e d oil f rom pump
PI is s u p p l i e d to the a u x i l i a r y w i n c h
In i n c h i n g o p e r a t i o n s , the a c t i o n of
the f l o w c o n t r o l v a l v e (FC2) is the
s a m e as th a t of the m a i n w i n c h .
1
,
2
,
,
.
,
1 .
(FC2)
,
.
HYDRAULIC MOTOR
C O N STR U C TIO N A N D F U N C T IO N
T h i s h y d r a u l i c m o t o r is a f i x e d d i s
p l a c e m e n t ax i a l p i s t o n m o t o r , w h i c h
f e a t u r e s s h o e p l a t e l o c a t e d on the
s a m e s i d e w i t h t h e o u t p u t shaft.
P i s t o n s in c y l i n d e r b l o c k r e c e i v e
h y d r a u l i c p r e s s u r e a n d s l i d e o n the
s h o e pl a t e , c o n v e r t i n g h y d r a u l i c
p r e s s u r e i n t o r o t a t i o n a l force.
The m o t o r i n c o r p o r a t e s a n e g a t i v e type
mechanical
p i l o t p r e s s u r e is r e l i e v e d , a n d u n
b r a k e s w h e n p i l o t p r e s s u r e is a p p l i e d .
DESCRIPTION OF OPERATION
[Motor section]
Hydraulic
oil
the c y l i n d e r
under pressure
through inlet
enters
port
(a)
of the v a l v e p l a t e to e x e r t p r e s s u r e
on the p i s t o n s in the c y l i n d e r b l o c k ,
thereby generating rotational force
a r o u n d the o u t p u t shaft. A s f o u r (4)
of
the n i n e
(9)
,
,
.
,
, @ ,
,
.
" " -(
) ,
.
equally-spaced
pistons
r e c e i v e p r e s s u r e s u c c e s s i v e l y at the
i n l e t port, the o u t p u t s h a f t is d r i v e n
[]
()
, ,
,
.
9
,
.
,
.
,
.
Fig. 1
. 1
[Brake
section]
Wh en no pressure
is s u p p l i e d
through
p i l o t port (Pi), d i s k s p r i n g s p u s h
brake piston toward brake s p a c e r ,
p r e s s i n g s e p a r a t o r p l a t e s ) a n d
f r i c t i o n p l a t e s t o g e t h e r , a n d thus
c r e a t i n g f r i c t i o n a l force. T h i s f o r c e
brakes output shaft .
W h e n p i l o t p r e s s u r e is s u p p l i e d , b r a k e
p i s t o n @) is p u s h e d b a c k a n d b r a k e
released.
is
[]
(Pi)
( ) ,
@
, ()
@
()
@
.
@) ,
, ,
.
Hydraulic symbol
Fig. 2
. 2
Fig. 3
. 3
1. O u t p u t s haft
2. S p a c e r
3. C y l i n d e r b l o c k
4.
Spherical
5. D i s k
bush
spring
6.
7.
8.
Shim
Piston
Shoe
9.
Retainer
plate
24.
25.
26.
27.
28.
Needle bearing
Inner ring
Pin
Pin
Plug
29.
30.
31.
Plug
Plug
0-ring
32.
0-ring
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
10.
Shoe plate
33.
0-ring
11.
12.
Valve
Guide
plate
ring
34.
35.
36.
0-ring
0-ring
Oil seal
cover
37.
38.
39.
40.
41.
15.
O il seal
Brake cover
16.
Brake piston
S p l i n e d c o n n e c t o r 17.
Brake spacer
18.
Piston ring
13.
Casing
14.
Valve
15.
16.
Front cover
Hex. s o c k e t
h e a d bolt
17. Hex. s o c k e t
h e a d bolt
18- Hex. s o c k e t
h e a d bolt
19. Hex. s o c k e t
h e a d b olt
20.
21.
22.
23.
S t o p ri n g
Stop ring
Locking ring
Roller bearing
42.
43.
44.
45.
Piston ring
Brake shim
Disk spring
46.
Separator
47.
48.
49.
Friction
Plug
0-ring
19.
20.
plate
plate
21.
22.
23.
D IS M O U N T iN G
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
-
-
-
-
-
(.)
(.)
W A R N IN G
W H EN T H E C IR C U IT IS SUSPECTED T O
R E T A IN H IG H PRESSURE O IL , BE SURE
T O V E N T PRESSURE BEFO R E D IS M O U N T
IN G T H E M O TO R .
,
,
.
R E M O U N T IN G
(M20)
,
44 - .
C A U T IO N
T IG H T E N T H E M O TO R M O U N T IN G
( M 2 0 ) TO 4 4 K G -M .
AFTER
BO LTS
R E M O U N T IN G , BE SURE T O F IL L
T H E C AS IN G W IT H H Y D R A U L IC O IL B Y
P O U R IN G O IL TH R O U G H T H E D R A IN
PO R T. IF T H E U N IT IS O P E R A T E D W IT H
O U T O IL IN T H E C A S IN G , SEIZU R E T O
T H E S L ID IN G P AR TS A N D O T H E R
D AM AG E C AN
R ESU LT.
C O N NECT T H E B R A K E P IP IN G T O T H E
P IL O T P O R T IN T H E B R A K E U N IT
A F T E R B LE E D IN G A IR F R O M T H E P IP IN G .
,
.
,
,
.
.
TROUBLESHOOTING
FAILURE 1.
Pressure builds,
Probable
1.
Sliding
2.
Brake
parts
is n ot
cause
Remedy
a r e b r o k e n or s ei zed.
1.
released.
Brake releasing
supplied,
pressure
is n ot
Check hydraulic
Disassemble
Disassemble
B r a k e p i s t o n is stuck,
S e p a r a t e p l a t e s and f r i c t i o n p l a t e s
ar e s e i z i n g e a c h other.
F A IL U R E
2.
Braking
force
Probable
1.
F r i c t i o n p l a t e s and
p l a t e s a r e wo rn.
2.
Disk
3.
4.
5.
springs
D i s a s s e m b l e and c h e c k p i s t o n s ,
c y l i n d e r , v a l v e plat e, etc.
a re
and check,
and check.
is i n s u f f i c i e n t .
cause
Remedy
1.
separator
set,
lines.
a nd
a re not
f u n c t i o n i n g we ll .
B r a k e p i s t o n is stuck.
B r a k e r e l e a s i n g p r e s s u r e is n o t
relieved.
I n s u f f i c i e n t t h i c k n e s s of b r a k e
2.
D i s a s s e m b l e and ch ec k; a nd if w o r n
in e x c e s s of s t a n d a r d v a l u e , re pl a c e .
D i s a s s e m b l e and c he ck ; and if s p r i n g
3.
4.
is set, r e pl a c e .
D i s a s s e m b l e and check.
C h e c k h y d r a u l i c lines.
5. D i s a s s e m b l e
and r e a d j u s t .
shim.
6.
6.
S p l i n e s f r i c t i o n p l a t e s and
s e p a r a t o r p l a t e s are d a m a g e d .
1.
1.
2.
0
0
0
2.
D i s a s s e m b l e and ch ec k;
d a m a g e d , r e pl ac e.
2.
-
3.
4.
5.
6.
if
1. ,
,
.
2.
0
0
0
1.
a nd
1. .
2. .
3.
4.
5.
6. .
,
D IS A S S E M B LY
,
,
, .
NOTE
S in c e
a ll
th e
m o to r
p a rts
a re
p re
c is io n p a r t s , be s u re
d is a s s e m b le
a n d re a s s e m b le th e m o t o r in c le a n
e n v ir o n m e n t, a n d ta k e e x tr e m e c a re
in h a n d lin g th e p a r t s , a v o id in g
c o llis io n ,
d r o p p in g , e tc .
,
,
,
.
N e v e r a p p ly u n d u e b lo w o r fo r c e s o
a s n o t t o p ro d u c e m in u te s u r f a c e
d e f o r m a t io n w h ic h is c o n d u c iv e t o
d a m a g e , f a u l t y r e a s s e m b ly , lo s s o f
p e r f o r m a n c e , e tc .
1. A f t e r
sections
to
be d i s a s s e m b l e d ,
to
the
oil
the
1.
.
,
@
.
2.
,
@ ,
.
, .
".
"
3.
@
.
4.
@
,
@
@
.
5.
remove
in
R e m o v e hex. so ck et h e a d bol ts @
; remove brake cover , disk
and
s p r i n g s a n d b r a k e p i s t o n () . W h e n
b r a k e t o r q u e is b e i n g a d j u s t e d ,
m e a s u r e the d i m e n s i o n from the end
s u r f a c e of v a l v e c o v e r to s e p a r a t o r
p l a t e ) , a n d c o m p a r e it w i t h the
s tandard v a l u e in " CHECK"
later in this section.
3.
Remove
stop
splined
4.
ring(2l),
and
connector
given
remove
5.
Removal
of v a l v e
cover
c a k e t o p re v e n t v a lv e p la te 0
d r o p p in g o f f v a lve c o v e r O .
W hen
s e p a r a t in g
w it h
c a re
to
p a rts
s c r e w d r iv e r
a v o id
or
by
th e
d a m a g in g
p r y in g
lik e , ta k e
th e
m a t in g
s u r fa c e s .
Remove
hex.
socket
head
bolts,
.
@
. " " .
NOTE
Take
fro m
@
@
.
..
,
.
6.
.
, ,
@ ,
., ,
.
7.
,
(8) .
8.
@
@
,
@
.
9.
.
(
. 5.)
p l a t e , spherical b u s h , s h o e s ,
etc., t a k i n g c a r e to a v o i d d a m a g i n g
the s l i d i n g s u r f a c e s .
7. R e m o v e hex.
socket
and r e m o v e f r o n t
, by u t i l i z i n g
extraction holes
head b o l t s ;
8.
9.
Remove valve
cover @
from casing
f r o m the
side, u s i n g
from valve
p l a t e . (It m a y h a v e c o m e
d u r i n g S t e p 5.)
off
10.
LO.
P e r f o r m the
following
.
1)
,
@ .
only whe n
necessary:
1) R e m o v e g u i d e r i n g , n e e d l e
bea^ring @) a nd oil seal f r o m
valve
cover
2)
@
@
@ ,
@
.
3)
@
.
2) R e m o v e s t o p r i n g @ and s p a c e r
from output s h a f t ; remove roller
b e a r i n g (g) by l i g h t l y t a p p i n g t he
i n n e r ring.
3) R e m o v e oil seal @ f r o m f r o n t
c o v e r by l i g h t l y t a p p i n g the
b a c k s u r f a c e of the oil seal.
C H EC K
(1)
H y d r a u lic
1.
W ear
(1)
m o to r
p a rt
re p la c e m e n t
C h e c k the p a r t s , a n d r e p l a c e
use limits are exceeded.
1) C l e a r a n c e
cylinder
between
1.
s ta n d a rd s
piston
if
and
t he
1)
:
0,023
,
:
0,053
2)
^
(. 4)
:
0
,
:
0 ,3
bore.
Clearance between
shoe
^ (Fig.
piston
and
4)
S tandard value:
0 mm
Recom m e n d e d use
limit:
0.3 m m
3 ) S h o e t h i c k n e s s t (Fig.
4)
3)
t @
(.4)
:
8,8
,
:
8,6
4)
@
L - @
(. 5)
:
3,65
,
:
2,9
5)
@
H - h
(. 6)
:
29,1
,
:
28,5
S t a n d a r d v a l u e : 8.8 m m
R e c o m m e n d e d u s e limit: 8.6 m m
4) D e f l e c t i o n of d i s c
(Fig. 5)
springs
Standard value:
3.65 m m
Recommended
limit:
use
L-
2.9 m m
5) H e i g h t of r e t a i n e r p l a t e a b o v e
s p h e r i c a l b u s h i n g e nd s u r f a c e
H - h (Fig. 6)
2.
S t a ndard value:
29.1 m m
Recommended
limit:
28.5 m m
c o r r e c t io n
s ta n d a r d
S lid in g
use
s u rfa c e
2.
N OTE
,
,
.
L a p th e s u r fa c e s t o be c o r r e c te d
u n t il th e s t a n d a r d ro u g h n e s s g r a d e
is r e s t o r e d .
I f th e s p h e r ic a l s lid in g s u r f a c e o n
e ith e r th e c y lin d e r b lo c k o r th e
v a lv e p la te is w o rs e n e d in e x c e s s
of
th e
s p e c ifie d
ro u g h n e s s
lim it,
re p la c e b o th p a r t s in a m a tc h e d
s e t; i f th e s p h e r ic a l s lid in g s u r f a c e
o n e it h e r th e r e t a in e r p la te o r th e
s p h e r ic a l b u s h in g is w o rs e n e d in
Check
s e t.
the s l i d i n g
or r e p l a c e
if
surfaces,
the r o u g h n e s s
0,4 - Z
(Ra = 0,1)
()
3 - Z
(Ra = 0,8)
and correct
li m i t
given
0.4 -
b e l o w is e x c e e d e d .
Surface roughness
on s h o e , s h o e
plate @
, ,
.
e x c e s s o f th e s p e c ifie d ro u g h n e s s
l i m i t , re p la c e b o th p a r t s in a
m a tc h e d
Standard
(Ra= 0 . 1 )
(Lapping)
Roughness
l imit
3 - Z
(Ra= 0 . 8 )
,
,
.
(2)
B ra k e
(2)
s e c t io n
1.
1.
W ear
p a rt
r e p la c e m e n t
C h e c k the part s ,
use
limits
1) T o t a l
s ta n d a rd s
and r e place
if
the
are exceeded.
thickness
p l a t e s ) and
Free
1)
@
@
:
32,2
,
:
31,4
:
.
2)
@
:
36
(4
)
,
:
32
(4
)
3)
@
:
53,8
,
:
54,3
:
@
.
of s e p a r a t o r
friction p l a t e s
S t a n d a r d : 32. 2 m m
R e c o m m e n d e d r e p l a c e m e n t v alue:
31.4 m m
R e m e d y : R e p l a c e all p l a tes.
2)
l e n g t h of d i s k s p r i n g (45)
S t a n d a r d : 36 m m (set of 4 s p r i n g s )
R e c o m m e n d e d r e p l a c e m e n t val u e :
32 m m (set of 4 s p r i n g s )
3) D i m e n s i o n A f r o m the e n d s u r f a c e
of v a l v e c o v e r to s e p a r a t o r
plate
S t a n d a r d : 53 . 8 m m
R e c o m m e n d e d r e p l a c e m e n t valu e :
54. 3 m m
Remedy
: Readjust brake shim @
Fig. 7
. 7
A SSEM B LY
(1)
H y d r a u lic
(1)
m o to r
NOTE
W a s h th e p a r ts in kero sen e
d r y w ith c o m p re s s e d a ir .
L u b ric a te d th e
in g s , etc. w ith
b e fo re
and
, .
.
s lid in g p a r t s , b e a r
clean h y d r a u lic o il
0- ,
.
a s s e m b lin g .
I t is re c o m m e n d e d t h a t 0 - r i n g s ,
o il seals a n d o th e r s e a lin g p a r ts
be
re p la c e d
w ith
n ew
. 3.
p a r ts .
1.
F ig .3 .
1.
Set r o l l e r b e a r i n g on o u t p u t s h a f t
; i n s t a l l the s h a f t i n t o c a s i n g
by t a p p i n g the o u t e r r i n g of r o l l e r
b e a r i n g , and not tapping shaft .
2.
3.
( ,
.
4.
2. W i t h oil seal in f r o n t c o v e r
and the lip of the oil seal c o a t e d
with greased,
cover
3.
4.
install
on c a s i n g
the f r o n t
I n s e r t s h o e p l a t e , the l a r g e r
c h a m f e r s i d e first, in c a s i n g
Installing
the c y l i n d e r b l o c k a s s * y
NOTE
in s ta ll th e disc s p rin g s in c o r r e c t
o r ie n ta tio n . In s e r t sh im s b etw een
th e disc s p rin g an d th e s p h e ric a l
b u sh in g .
A s s e m b l e the c y l i n d e r b l o c k a s s
( p i s t o n , cylinder b l o c k , re
tainer p l a t e ,
disk s p r i n g s ,
the s p l i n e s
spherical b u s i n g ,
s h i m ) : aligning
in s p h e r i c a l
busing
and c y l i n d e r b l o c k , i n s t a l l the
c y l i n d e r b l o c k a s s e m b l y o v e r the
s p l i n e on the o u t p u t
into casing .
s h aft,
and
,
.
(
, ,
@ , ,
.
.
.
Fig. 8
. 8
5.
.
@ .
@
( ),
( L ) .
L -
(
) .
3,650,1 ,
.
,
.
Fig. 9
. 9
6.
Installing
the v a l v e
plate
NOTE
If
th e
th is
th e
va lv e
h ole
p la te
sh o u ld
has
com e
s m a ll
to
BDC
h o le ,
A p p l y g r e a s e l i g h t l y to the flat
s u r f a c e of v a l v e p l a t e , and i n
stall it on v a l v e c o v e r , a l i g n i n g
p i n (g) w i t h
,
,
of
p is to n s .
retainer
the p i n hole.
,
,
.
7.
8. M a k e
sure output
on c a s i n g ,
their relative
shaft
7.
,
.
8.
,
.
rotates
smoothly.
(2)
2.
shim;
then alter n a t e l y
separator
plates,
separator
spacer
Install
surface
2.
@
, .
insert
:
:
p l a t e s ) and f r i c t i o n
starting with a
plate.
dimension A
of v a l v e
3.
f r o m the end
cover
to
separator plate
.
If it is n o t w i t h i n the r a n g e of
53 .8 0.1 mm, c h a n g e b r a k e shimffl)
to b r i n g d i m e n s i o n A i n t o
specified
and b r a k e
[Quantity]
S e p a r a t o r pl at es : 9
Friction plates : 8
3. M e a s u r e
1.
9 .
8 .
,
53,80,1 .
,
,
.
the
range.
Fig.
.
11
11
4.
4.
,
,
@
@
.
5.
,
@
.
p i n of b r a k e c o v e r w i l l be i n
s e r t e d in the h o l e in the b r a k e
pis to n.
5.
Install disk s p r i n g s ,
brake cover .
an d
install
WINCH
Fig. 1
.
1. B r a c k e t
3. Hex. s o c k e t
h e a d bolt
4. S p r i n g w a s h e r
15.
16.
17.
Collar
Ball bearing
Ball b e a r i n g
18.
Gear
5. Oil seal
7. B e a r i n g r e t a i n e r
8. B all b e a r i n g
19.
Gear
9. Nut
10. W a s h e r
11. C o l l a r
12.
13.
14.
Bo l t
Spring washer
D r u m ge a r
case
20 Ball b e a r i n g
21. B e a r i n g r e t a i n e r
22. B e a r i n g r e t a i n e r
23.
24.
25.
26.
27.
Oil seal
Bo l t
Spring washer
Lock plate
D r u m boss
1.
3.
4.
5.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
28.
P in
29.
30.
Drum
D r u m shaft
31.
B a ll
32.
Bearing
33.
Hex.
head
34.
35.
36.
37.
38.
bearing
stand
socket
bol t
Spring washer
Plug
Elbow
Gear case cover
Plug
41. S l e e v e
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
41.
D IS M O U N T IN G
1. R e m o v e
drum.
2.
the w i r e
Disconnect
all
rope
1.
.
f r o m the w i n c h
the h o s e s
f r o m the
w i n c h m o t o r , a nd ca p the o p e n i n g s in
the m o t o r and o p e n en d s of the hoses.
2.
,
.
3. .
3.
Remove
the w i n c h
rope follower.
4. A p p l y s l i n g s to the w i n c h a s s y at
t he t h r e e p o s i t i o n s s hown, u n s c r e w
t he m o u n t i n g bo l t s , and h o i s t it up
a w a y f r o m the frame.
4.
,
,
,
.
Fig. 2
. 2
5.
Remove
winch
t he h y d r a u l i c m o t o r
a s s y.
f r o m the
5. .
R E M O U N T IN G
NOTE
R e m o u n t th e w in c h b y r e v e r s in g th e
d is m o u n t in g p ro c e s s e s , o b s e r v in g th e
f o llo w in g .
1) T i g h t e n
bolts
2)
t he w i n c h
to 45
to
a s s m o u n t i n g
50 k g . m .
I n s t a l l the w i r e r o p e in a c c o r d a n c e
w i t h " R e p l a c i n g w i r e r o p e in
"Operation
3) A f t e r i n s t a l l a t i o n , r e m o v e air f r o m
t he w i n c h c i r c u i t an d the b r a k e
c i r c u i t , a nd then, tes t the w i n c h
f or o p e r a t i o n to m a k e s u r e that it
is
free
f r o m faults.
D IS A S S E M B LY
a nd d i s c h a r g e
the g e a r
oil.
2. R e m o v e b e a r i n g
3.
1)
45 50 .
2)
. "
"
.
3) ,
,
.
1. U n p l u g p l u g ,
ba l l
,
.
bearing
Unscrew n u t ,
stand,
an d r e m o v e
.
and
remove
t he d r u m
1.
,
.
2 .
@ ,
@ .
3.
.
@ ,
4.
@ .
a s s y
4.
Unscrew b o l t s ,
retainer
a nd r e m o v e
bearing
NOTE
5.
th e m
6.
case
6.
,
,
% .
7. R e m o v e b r a c k e t a n d b e a r i n g r e t a i n e r
@ , and r e m o v e g e a r @ to the b r a c k e t
side.
@
.
.
u n le s s
,
5.
@ .
7.
- , - @
.
C LE A N IN G A N D CHECKS
1)
1) C l e a n i n g
C A U T IO N
W ASH T H E O IL SEALS IN T H E L U B R I
C A T IN G O IL IN USE. DO N O T W ASH
T H E M IN K E R O S IN E , AS K ER O S IN E
SPO ILS T H E O IL SEA LS B Y S W E L L IN G .
Wash
all
kerosine,
2)
the p a r t s
a nd d r y
thoroughly
in
them.
Checking
Oil
2)
seals
In p r i n c i p l e ,
,
.
,
,
.
replace
t h e m all.
, ,
.
Bearings
R e p l a c e bea r i n g s w i t h large abnormal
n o i s e , l a r g e p l ay, a nd e x c e s s i v e
coloring.
Gears,
d r u m shaft
and d r u m boss
C h e c k the t o o t h f a c e s a n d t h e s p l i n e s
for w e a r i n g a n d p i t t i n g , a n d r e p l a c e
w h e n these co n d i t i o n s are excessive.
C h e c k th e oil seal
the s h a f t for w e a r
,
,
,
.
c o n t a c t a r e a of
a nd s u r f a c e d e f e c t ,
and if t h e s e c o n d i t i o n s a r e t a n g i b l e
w i t h the f i n g e r tip, r e p l a c e .
,
,
.
,
, , ,
, .
R E A S S E M B LY
C A U T IO N
B E A R IN G S P R O P E R LY IN A C C O R D A N C E
" " (
) .
W IT H 'G E N E R A L C A U T IO N S (S E A L IN G
P A R T S A N D M A C H IN E E L E M E N T S )
IN C H A P T E R A .
"THREE-BOND 1215",
.
H A N D L E T H E O IL S EA LS A N D T H E
1. @
@
.
BEFO R E A P P L Y IN G 3 -B O N D 121 5 ,
D EG R E A SE D T H E S U R FAC E IN
ADVANCE.
1.
S h r i n k fit
@in
th is
fit
sleeve
sequence
bearing
on d r u m sh a f t
a nd
3.
,
-
@ .
on
Force
gear
3.
4.
I n s t a l l b r a c k e t i n c o r p o r a t i n g oil
se al to g e a r c a s e , a nd c l a m p w i t h
hexagon socket head bolts coated
with screw locking compound. Apply
apply
bearings
to the oil
3 ~ B 0 N D 1215
seal
a nd g e a r
case
6.
a nd
to t he m a t i n g
s u r f a c e s of b r a c k e t
i n ad v a n c e .
5.
lip,
I n s e r t d r u m g e a r in g e a r c a s e ,
and insert d r u m shaft w i t h collar
o n in t o d r u m g e a r a l i g n i n g the
s pl in e.
7.
8.
T u r n o v e r g e a r c a s e aga in, f o r c e
dr u m gear towards d r u m , install
c o l l a r , b a l l b e a r i n g , an d w a s h e r
on d r u m s h a f t ,
l o c k it w i t h w a s h e r
tighten n u t ,
2.
@ .
2.
grease
ba l l
an d b al l
and
4.
,
.
"THREE-BOND 1215"
.
5. ,
.
"THREE-BOND 1215"
,
,
.
6.
,
,
,
.
7.
.
"THREE-BOND 1215"
.
8.
) ,
@ ,
,
,
.
9.
Install
bearing
retainer @
to g e a r
c a s e an d c l a m p w i t h b o l t s . A p p l y
3 - B O N D 121 5 to t h e m a t i n g s u r f a c e s
of b e a r i n g r e t a i n e r a nd g e a r c a s e
10.
in ad v a n c e .
I n s t a l l g e a r c a s e c o v e r w i t h the
mating surfaces coated with 3-BOND
1215 to g e a r c a s e , a n d c l a m p w i t h
hexagon
11.
12.
head
bolts
I n s t a l l d r u m b o s s @ to d r u m , c l a m p
w i t h b o l t s , and f o l d l o c k p l a t e
M o u n t the d r u m a s s on d r u m sh a f t
w i t h the s p l i n e s a l i g n e d , s c r e w
nut (D w i t h w a s h e r , a nd l o c k n u t
with
13.
socket
Force
washer
fit
ball
.
bearing
onto drum
sh a f t
14.
Install
bearing
15.
R e m o v e p l u g , and a dd g e a r oil
u n t i l it s t a r t s to o v e r f l o w f r o m
the h o l e for oil level p l u g .
stand
Oil q u a n t i t y :
a ppro x . 4 l iters.
9.
.
"THREE-BOND 1215
.
10.
@
,
"THREEBOND 1215".
11.
@
.
12.
, ,
,
(9) @
.
13.
.
14.
@ .
15. ) ,
,
.
:
4
COUNTERBALANCE
D u r i n g h o i s t i n g do w n ,
the f o l l o w
this valve
s e l e c t i v e l y o p e n s a n d c l o s e s the
m o t o r o u t l e t p a s s a g e in a c c o r d a n c e
w i t h the p r e s s u r e level of the
m o t o r i n l e t p r e s s u r e to c o n t r o l
the s p e e d of t he lo a d a n d to p r e
v e n t the loa d f r o m f a l l i n g u n d e r
w e i g h t f a s t e r t h a n the h y d r a u l i c
is b e l o w
a c e r t a i n level, thi s v a l v e c l o s e s
the r e t u r n p a s s a g e to h o l d t he load
at a d e s i r e d p o s i t i o n .
2) O v e r l o a d
relief
.
1)
functions
m o t o r d r i v i n g speed.
W h e n the i n l e t p r e s s u r e
1) B a l a n c i n g
VALVE
, ,
.
,
,
.
function
2) -
W h e n the c i r c u i t p r e s s u r e r i s e s
a b o v e the p r e s e t o v e r l o a d r e l i e f
level, th i s v a l v e v e n t s it to
protect
-
,
.
the circuit.
(Fig. 1)
PRINCIPLE OF OPERATION
1. W h e n c o n t r o l
valve
is in n e u t r a l
of
t he h y d r a u l i c
m o t o r is l o c k e d by the sea t a r e a a
of the c h e c k v a l v e a n d the o v e r l o a d
2.
(. 1)
1.
relief valve.
"
Hoisting
- .
When
the c o n t r o l
p o r t A,
the oil
valve
pushes
sends
open
oil
to
c h e c k v a l v e and f l o w s to por t c o n
n e c t e d to the m o t o r . O n t he o t h e r
hand, the r e t u r n oil f o r m the m o t o r
port e n t e r s t h r o u g h por t D, and then,
is d i s c h a r g e d t h r o u g h por t to the
control
val v e .
3. H o i s t i n g d o w n
A s oil is sent to p o r t by the c o n
trol v a l v e , it f l o w s to the m o t o r
v i a p o r t D, a nd t he r e t u r n oil f r o m
the m o t o r is b l o c k e d at p o r t C, to
raise
the p r e s s u r e
at p o r t
2.
the
B.
,
, ,
.
, ,
D,
.
3.
,
D,
.
,
p u s h e s t he p l u n g e r to the r i g h t by
o v e r c o m i n g the s p r i n g f orce, and
o p e n s lan d d.
As a r e s u l t , the
r e t u r n oil f r o m the m o t o r is d i s
c h a r g e d to the c o n t r o l v a l v e v i a
land d to d r i v e the m o t o r .
W h e n the load t e n d s to pul l the
m o t o r f a s t e r t h a n the s p e e d c o r
r e s p o n d i n g to t he f l o w r a t e to po r t
B, the p r e s s u r e in c h a m b e r d r o p s ,
m a i n t a i n i n g b a l a n c e w i t h t he s p r i n g
f o r c e to a u t o m a t i c a l l y a d j u s t
the oil p a s s a g e a r e a in land d
to p r e v e n t the load f r o m f a l l i n g
at s p e e d s f a s t e r t h a n the m o r o r d r i v e
speed.
4.
in
land
d to h o l d
a desired height.
the
,
,
.
,
"b ",
"", ,
,
, "d".
, ,
,
" d "
,
.
,
,
,
,
, ,
"" ,
,
"d",
.
4.
""
, ..
"" ,
,
"d",
.
Fig. 1
. ]
1.
Valve
2.
Plug
body
16. H e x .
socket
head
bolt
3.
0-ring
17 . Spring
4.
0-ring
1 8.
Plunger
5.
0-ring
1 9.
Spring
6.
Hex.
socket
20.
Check
head
bolt
21.
Seat
22.
Spring
7.
Spring
washer
washer
Cover
23.
Plug
Cover
24.
0-ring
10.
Plug
25.
Orifice
11.
Plug
26.
Relief
12.
0-ring
valve
ass'y
13.
0-ring
27.
Spacer
14.
Hex.
socket
28.
Steel
head
bolt
29.
Spring
30.
Orifice
washer
5.
6.
9.
Spring
4.
valve
8.
15.
1.
2.
3.
ball
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
-
17.
- 18.
19.
- 20.
21.
22.
23.
24.
25.
1
26.
- 27.
28.
- 29.
30.
WARNING
W H EN T H E C IR IC U IT IS SUSPECTED TO
R E T A IN H IG H PRESSURE O IL , BE SURE
T O V E N T PRESSURE BEFO RE D IS M O U N T
IN G T H E V A L V E .
NO TE
A ft e r r e m o u n tin g , b le e d th e
a n d th e u n its , a n d te s t th e
to
m ai<e
fa u lty
s u re
of
th e
c ir c u it
o p e ra tio n
absence
of
c o n d itio n s .
D IS A S S E M B LY A N D
,
,
.
R E A S S E M B LY
C A U T IO N
W H EN D IS A S S E M B LIN G A N D R EASSEM
B L IN G , A LS O O B S E R V E 'G E N E R A L C A U
TIO N S ( H Y D R A U L IC U N IT S )4 N
A T O W O R K C O R R E C T LY .
,
,
C H A P TE R
W H EN D IS A S S E M B LIN G A N D R EASSEM
B LIN G T H E V A L V E , T A K E C A R E TO
PR EVEN T D A M A G E TO TH E TH R E A D S ,
F IN IS H E D SUR FAC ES A N D S E A LIN G
P A R T S , A N D A V O ID IM P R O P E R H A N
D L IN G . W H IL E D IS A S S E M B LIN G , T A K E
NECESSARY M EASU R ES T O ASSURE
T H A T A L L T H E P AR TS W IL L BE R E
A S S E M B LE D IN T H E IR O R IG IN A L
"
" ()
,
.
,
.
,
.
PO SITIONS.
W ASH T H E D IS AS S E M B LED P A R TS IN
K E R O S IN E , A N D C H E C K T H E IR S L ID IN G
S U R FAC E S, S E A LIN G P A R T M O U N T IN G
S EA TS , A N D THREADSw C O R R EC T M IN O R
D E N TS , S C U F F, RUST O R B U R R W IT H
F IN E A B R A S IV E C LO TH O R O ILS TO N E .
W H EN T H E SUR FAC ES A R E N IC K E D ,
W O R N O R O TH ER W IS E D A M A G E D SUB
S T A N T IA L L Y , R EP LA C E T H E PAR TS.
C H E C K T H E C O N TA C T SU R FAC ES O F
TH E V A L V E A N D V A LV E S E A T, A N D
R EP LA C E T H E M IF T H E C O N TA C T
P A T T E R N IS N O T E V E N , O R EXCESSIVE
W E A R IS O BSER VED .
IN P R IN C IP L E , R E P LA C E A L L T H E S E A L
IN G P A R TS . O B S E R V E 'G E N E R A L C A U
TIO N S ( S E A LIN G P A R T S )' IN C H A P T E R
A IN IN S T A L L IN G T H E M , T A K IN G
C AR E T O IN S T A L L IN T H E C O R R EC T
O R IE N T A T IO N .
,
.
, ,
.
,
, ,
.
, ,
.
.
,
, .
"
" ( )
,
,
.
W H E N R E A S S E M B LIN G , T A K E E X T R E M E
CARE NOT TO A LLO W THE EN TR Y OF
D U ST A N D O T H E R FO R EIG N M A T T E R ,
A N D A P P L Y H Y D R A U L IC O IL FO R L U B R IC A T O N T O T H E S L ID IN G S U R FA C E D
IN S E R T T H E V A L V E O R P LU N G E R
S T R A IG H T , T A K IN G C A R E N O T T O P R Y ,
A N D C H E C K T H E IR S M O O TH M O V E M E N T
AFTER
IN S E R T IO N .
.
,
ROTARY JOINT
Fig. 1
.
P ort
N o.
C ir c u it
PI
W in c h
P2
E l e v a t i o n , t e l e s c o p i n g , w in c h
,
,
P3
S w in g
13
D r a in
TO
Tank
Connector
()
View D
View
B r u s h No
.
Slip
ring
Wire
Wire
1.25
YR
YR
1.25
g
h
1.25
1.25
0.85
1.25
WL
1.25
RB
3.0
0.85
1.25
WL
1.25
RB k
3.0
Fig. 2
. 2
WIRE INDICATION
Color
Code
YR
Color of stripe
Ground color
Sectional area of conductor (mm2)
, 2
Yellow
Green
Red
WL
White
RB
Red
Red
w/red
w / b lue
w / b lack
Fig. 3
. 3
20.
Packing
2. S u p p o r t
3. P l u g
4. C a s e
5. F i t t i n g
21.
22.
23.
24.
Seal r i n g
Body
Core
Plain bearing
6. H o s e
7. Hex. s o c k e t
h e a d bo l t
8. S p r i n g w a s h e r
25.
26.
27.
28.
1.
Swivel
joint
9. Hex. s o c k e t
head bolt
10. S p r i n g w a s h e r
11. C l a m p
12. B r u s h a s s '
Grommet
Hose
Fitting flange
Hex. s o c k e t
h e a d bol t
29. S p r i n g w a s h e r
30. F i t t i n g
31. 0 - r i n g
32. 0 - r i n g
13. N u t
14. W a s h e r
15. S l i p r i n g a s s ' y
16. I n s u l a t o r
17. S p a c e r
33.
34.
35.
36.
0-ring
0-ring
0-ring
Hex. s o c k e t
18.
19.
37.
h e a d bol t
Plain washer
38.
Cover
Connector
Plain bearing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
-
-
-
-
-
DISMOUNTING
1.
,
60
.
2.
, ,
.
WARNING
^BE SURE TO DISCONNECT THE
BATTERY BEFOREHAND.
CAUTION
.
,
.
.
,
.
REMOUNTING
NOTE
After remounting, bleed the circuit
and the units, and test the operation
to make sure of the absence of
faulty conditionSo
Remove any dust, dirt and rust from
the mounting surfaces of the rotary
joint a s s y and the support. Mount
the rotary joint a s s y with the
engraved F m ark facing the front of
the carrier.
Rotary joint mounting b o l t ( M 1 0 X 2 5 )
T ightening torque : 235 15 kg. c m
,
.
, "F"
.
(10 X 25)
:
23515 .
,
,
.
DISASSEMBLY
CAUTION
WHEN DISASSEMBLING AND REASSEM
BLING, ALSO OBSERVE'GENERAL CAU
TIONS ( HYDRAULIC UNITS) 4N CHAFTER
A TO WORK CORRECTLY.
WHEN DISASSEMBLING AND REASSEM
BLING, TAKE CARE TO PREVENT
DAMAGE TO THE THREADS, FINISHED
SURFACES AND SEALING PARTS, AND
AVOID IMPROPER HANDLING. WHILE
DISASSEMBLING, TAKE NECESSARY
MEASURES TO ASSURE THAT ALL
THE PARTS WILL BE REASSEMBLED
IN THEIR ORIGINAL POSITION&
" " ("
") ,
.
,
.
,
,
.
, , .
.
REASSEMBLY
,
.
,
.
CAUTION
, ,
.
" " (
)
,
.
,
.
(6,
@
,
,
1-1/4 .
@ , @
, "F" .
116-0030R
1 1 6 -0 0 3 0 R
CHECK VALVE
1 1
Hydraulic
symbol
Fig. 1
. 1
1.
2.
3.
4.
5.
Body
Plug
Plug
Filter
Spring
6.
7.
8.
9.
10.
0-ring
0-ring
Plug
Steel ball
Plug
1.
2.
3.
4.
5.
6. -
7. 0-
8.
9.
10.
,
,
.
,
,
.
116-0030 R.
116 -0030R.
CAUTION
" "
()
, .
,
,
,
.
,
.
, ,
.
, ,
,
.
MAINTENANCE STANDARDS
Item
Maintenance standards
Filter
24 .