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REPAIR

MANUAL

TELESCOPING SYSTEM

REPAIR

MANUAL

CRANE CONTROLS

L01-0030R.

LOCATIONS OF COMPONENTS

L01-0030R.

GENERAL

FUNCTIONS OF UNITS

1. Master cylinder

1.




.


,
,

.

2.



,
,

.

The master cylinder is linked to the


accelerator pedal. The press^jre gen
erated in it actuates the control
cylinder on the lower structure to
accelerate the engine when the crane
is operated.
2. Control cylinder
The control cylinder, actuated by the
pressure from the master cylinder,
accelerates the engine during crane
operation.

MASTER CYLINDER

CONSTRUCTION AND FUNCTION

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

7-7. Valve spring


7-8. Retainer
7-9. Spring
8. Spacer
9. Gasket
10. Stopper bolt
11. Spring
12. Check valve
13. Gasket
14. Plug
15. Band
16. Nipple

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

When push rod


recedes, the oil in
the actuator cylinder is pushed back
by the actuator return spring and
spring < 0 5 If push rod
recedes
quickly and piston <7^^ moves faster
than the speed of returning oil,
the pressure in the master cylinder
tends to become negative. If this
occurs, valve cup
is unseated,
allowing oil to flow from chamber
into the master cylinder.
As p i s t o n m o v e s toward the
stroke end, stopper (6) pushes valve
rod<J3^9 to open valve cupCT^^ >
thereby allowing excess oil in the
cylinder to return to chamber
via the passage in valve rod <7^^ .
Check valve serves to leave a
0.2 0.5kg/cm^residual pressure in
the actuator cylinder and piping,
even when piston<7^i> is fully
returned. This pressure allows the
cylinder cup to remain in contact
with the cylinder wall, to prevent
leakage; the pressure also pro
tects the system from air entry
through connections.

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.

2. Unscrew stopper b o l t , and remove


g a s k e t and spacer together.
3. Remove b o o t , and remove stop
ring with a small screwdriver
or the like.
4. Remove s t o p p e r and piston a s s y
from cylinder body .

CAUTION

5.

5 ,
U

.

WHEN CLAMPING THE BODY IN A


VISE, TAKE CARE NOT TO
OVERTIGHTEN.

5. Clamp cylinder body (5) in a vise; un


screw plug
and remove valve .

CLENING

CAUTION

NEVER USE SUCH MINERAL OILS AS


KEROSENE AND GASOLINE, SINCE THEY
WILL CAUSE SWELLING AND IMPAIR
THE FUNCTIONING OF RUBBER PARTa

1) Metal parts


, , ,
.,
,
.
1)


,
.

2)



,
.
,



30 .

Wash in trichloroethylene, and dry


by blowing compressea air on them.
2) Rubber parts
Wash in ethyl alcohol or brake
fluid, and dry by blowing compressed
air on them. When washing in ethyl
alcohol, do not leave parts more than
30 seconds in the alcohol.

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
, ,
-
.

.



,

.

1. Apply fresh brake fluid to the


cylinder bore and the cups; and
apply rubber grease to the outside
diameter and the push rod
contact
area of p i s t o n C j ^ ; insert piston
a s s into cylinder body .

2.

3.

3. Install push rod


and s t o p p e r ,
and install stop ring into the
groove in cylinder body . After
installation, check to ensure piston
a s s y moves smoothly.

@
,


.
,
@
.

4.

4. Install boot

5.

12. ,

.

2. With piston a s s y installed,


install stopper bolt @ together with
gasket (9) and spacer

5. Install valve and plug

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

CONSTRUCTION AND FUNCTION

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
.

Wash in trichloroethylene, and dry


by blowing compressed air on them.
2) Rubber parts
Wash in ethyl alcohol or brake
fluid, and dry by blowing compressed
air on them. When washing in ethyl
alcohol, do not leave parts more than
30 seconds in the alcohol.

CHECKING

1)

,

,
.

2)


,
,
.
,
1 ,
,
.

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.

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

Max. speed (MAX.)

: 2150 "^^0 rpm

:
600

2) Discharge rate

2150

104.0 cc/rev

83.2 cc/rev

36.4 cc/rev

2. Hydraulic motor (winch)


. Oil intake rate : 535 cc/rev
3. Swing driving unit
1) Oil intake rate : 210 cc/rev
2) Reduction ratio : 16

2)

PI

104,0 3 /

83,2 3/

36,4 3/

2.

()

535 3/

3.

1) : 210 3/
2) : 16

WEIGHT TABLE

In the weight table below, the weights


of major components are given in terms
of weight codes A through T by crane
spec. Nos. When dismounting and remount
ing these components, find their appro
ximate weight given in the table under
the applicable Spec. No. and select pro
per slinging tools on the basis of the
given weight.

TG-500E-2-90101


.


,
,

.

ADJUSTMENT (Pressure)
()

HYDRAULIC CIRCUIT
PRESSURE SETTING TABLE

PRESSURE ADJUSTMENT


:
30 50
(
"DAPHNY Hydrau
lic Fluid WR22";
:
305)

Oil viscosity: 30 50 cSt


(When DAPHNY Hydraulic Fluid WR22 is
used: oil temperature: 30 5C)

1.

Location : Behind the crane cab


:

1)

1) Pump PI main circuit


(relief valve RVl)
Disconnect the wiring for the main
winch brake solenoid valve (SL8;
see circuit diagram), bringing the
winch brake in the engaged state.
Set the main winch lever to the
position for winding speed 1, and
measure the pressure.

1 (
RV1)

(SL8: . )
,
.


, .
:
2150

/ (.)

Pump speed: 2 1 5 0 rpm (MAX.)


2)

2) Pump P2 main circuit


(Relief valve RV2)
Fully retract the boom.
Move the boom telescoping lever to
the boom retraction position, and
measure the pressure.
Pump speed: 2150

rpm (MAX.)

3) Main winch unwinding circuit


. (port relief valve PRl)
'H^sconnect the wiring for the main
winch brake solenoid valve (SL8;
see, circuit diagram), bringing the
winctf brake in the engaged state.
Set m e main winch lever to the
position for unwinding speed 1, and
measure ttfe pressure.
Pump speed:

rpm^tlDL. )

2 (
RV2)
.

,
.
:
2150 / (.)

3)


( PR1)
.
(SL8: . )
,
.


, .
( ):

4) Auxiliary winch unwinding circuit


(port relief valve PR2)

4)

Disconnect the wiring for the


auxiliary winch brake solenoid valve
(SL9; see circuit diagram), bringing
the winch brake in the engaged
state.
Set the auxiliary winch lever to the
position for unwinding, and measure
the pressure.
Pump speed:

rpm (IDL.)
5)

5) Boom lowering circuit


(port relief valve PR3)
Fully retract the elevation cylinder
piston rods.
Move the boom elevation control
lever to the position for lowering
the boom, and measure the pressure.
Pump speed: 2150


(
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 )

Apply screw locking


Compound._______

Spool moves leftwards when performing


such operations as winch winding, boom
elevating and boom retracting.

,
,
.

.
Z,

S1 (

)
S2 (

)
S3 (

)
S4 (

)
S6 (
)
S7 (
)
S8 (
)

S1, S3, S7

Spool

Spool moves rightwards when


performing such operations as
winch unwinding, boom lowering
and boom extending.


,
,
.

S2, S4, S6, S8

Adjust these switches so that, when


the respective control levers are
positioned in neutral, they are
turned on (closed) and, when the
respective spools are moved 1.0 to
2.0 mm toward the detection side
from the neutral position, they are
turned off (open).

,
(
)
,


1,0 2,0 -
( ).

2.

Switch S12 ( F o r detecting over-unwinding


of main winch)
Switch S13 ( For detecting over-unwinding
of aux. w in ch )

Adjust clearance between the


winch drum and the roller to 5 mm
with the adjusting bolt .
Then turn the adjusting bolt to
bring the switch plunger into the
trip position (contacts COM-NC
open); further push in the plunger
by turning the bolt one full turn;
lock with the lock nut.

3. Switch S18( 3ril and top boom full


retraction detection )

Adjust the switches so that they


are tripped five to eight mm before
the full retraction of the 3rd and
top boo m sections, respectively.

S12 (

)
S13 (


)

A

@
,
5 .

,

( COM-NC
) , ,

, .

3.

S18 (


)

,


5 8 .

ADJUSTMENT AND CHECKS


in this section, the adjustment and


check procedure for areas other than
the pressure and electric areas, as
described in the preceding section,
is described.

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

3) Turn the adjust nuts until the mov


ing range of the swing brake lever
becomes approx. 75% of the maxi
mum stroke.

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 . S w in g d riv in g u n it bleeding procedure

2.

1) Pull up the swing brake lever.


2) With the bleeder screw open, operat
e
the swing control lever, to a l low
th e air in the unit escape r o ugh
the b l eeder screw. When t
s
r
i
a
e
h
all g o n e close the bleeder is
while oil is flowing

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)

3) Boom angle detector


The boom angle detector is installed
on the boom side, and converts, by
means of a potentiometer actuated
by a pendulum, the angle of the boom
relative to the ground into an
electric signal that is transmitted
to the moment limiter main body.



,
,
,

,
.
4)

4) Other detectors and switches


The outer detectors and switches
convert the crane operation modes
and working conditions into an
electric signal that is transmitted
to the moment limiter main body.
5) Moment limiter main body
The moment limiter main body makes
the calculation of the moment being
generated on the crane, using the
signals from the moment detector,
boom length detector and boom angle
detector.
The calculation result is compared
with the rated moment and, when it
reaches 90% and 100% of the rating,
the moment limiter sends an alarm
and auto, stop signals, respective
ly, to prevent the crane from being
over-loaded.



,
.
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

CONSTRUCTION AND FUNCTION

1. GENERAL

1.

The Moment Limiter system comprises


seven units as noted below. Functions
of each unit are described in the next
section.


()
.


.

Moment limiter main body


Moment detector
Boom angle detector
Boom length detector
Operating condition selector unit
Lever manipulation detector
Alarm and automatic stop circuit


Fig. 1 STRUCTURAL DRAWING

Moment detector

M o m e n t limiter
main body

@ Boom angle
detector

--------- U

Boom length detector


(6) Lever manipulation


detector

(D Operating condition
selector unit
^ '
-

^^

A l a r m and automatic
stop circuit

Fig. 2 SYSTEM BLOCK DIAGRAM


Boom angle
detector

Boom length
detector

. 2

-
AML MAIN BODY

Analog detecto
power source

Moment detector

.

Operating condition
selector sw. signal
input


Alarm signal output


Crane operation detector


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

LCD bar indicator



CPU sup erv i si o n


;nt
3M.

circuit L

Latch
driver
La t c h
driver

bar indica

LED for|
1 luraination

3ut

777

interface

Latch
driver

Jib angle display

III II I

Boom length display

. .

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

Total rated load


display

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


. .

Boom angle display


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

The schematic at left shows


the wiring connected to
connectors CNl and CN2.
The connector numbers G N ,
CN5, CN 6 , and CN7 cor
respond to the numbers
given in the wiring dia
gram for the crane. (This
is for Model TG-1200MG-1)

[]
Ha
,
(
) CN1 CN2.
() C N , CN5,
CN 6 CN7 ,


.
(
. TG-1200MG-1.)

CN5

[]||

CN@

CN6
DBA
DB5
DB6
DB7

CN7

2. CONSTRUCTION AND FUNCTION

2.
(1)

(1)

Moment detector

The moment detector is built in the


end of the piston rod of the elevating
cylinder. The detector is a strain
gauge which converts the total moment
caused by the load plus the weight of
the boom into an electrical signal.
This unit is completely shock-and
water-proof with the outlet and connec
tor of the signal cable made waterproof.



.
,

^.

-
,

(2)

Boom length detector

The boom length detector is fitted on


the side of the base boom section and
comprises a cord reel and a detector.
The detector, which converts the boom
length to resistance, comprises reduc
tion gears, which convert the length of
the wire extended out from the cord
reel into angle of rotation, and a
potentiometer.
This unit is vibration-and drip-proof.

(2)



.




(),

, .
- ; .

(3) Boom angle detector

(3)

The boom angle detector which is fitted


on the side of the base boom section
comprises a potentiometer driven by a
pendulum to convert the boom angle into
resistance.
The pendulum is damped by silicone oil.
This unit is also vibration-and water
proof.



,


.
.
-
.

(4) Operating condition selector unit

(4)
-

This system comprises the selector


switches on the side console in the cab,
and the limit switches located at the
boom side, swing table, etc., and func
tions to register (either manually or
automatically) the states of the boom,
jib, counterweight, etc., as well as
such operating conditions as the boom
swing area, into the AML main unit. The
numbers and the functions of the
switches and indicator lamps vary with
the crane model.
Take note of the switches and lamps used
on your machine by referring to the in
struction and maintenance manual.

*
,
,
, .

, .
,

,


.

(5) Lever manipulation detectors


Each of the manipulation detectors
(limit switches) detects the movement
of the applicable crane control lever,
and sends a signal to the AML main
unit, to prevent the machine from
being operated in an unsafe direction.

(5)

(
)


,

,

.

(6) Moment lim iter main unit


The moment limiter main unit is lo
cated in the front of the cab interior.
It incorporates a display board carry
ing various display elements and a
display circuit; a LCD illumination
board; a CPU board mainly carrying a
CPU and a memory; a power supply board
for supplying stabilized power to the
electronic circuit; a preamplifier for
amplifying moment signals; an I/O board
carrying connectors and fuse holders;
and a connector board carrying relays
to relay signals between the foregoing
boards. All these boards are easily
dismountable for replacement.
The functions of each AML main unit
component are common to all crane
models; they are described in the
following paragraphs.

(6 )
(A T)

.

,
,
,
,
,

,
,
, -,

,

.

.


.

.

Fig. 3 A M L main unit

. 3

Connector terminals No.


indication plate

(
No.
CONNECTION
CONNECTION
CN1

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

Power supply lamp (LED)


indication plate


()
5^
+ 12V
+24V
112, +5
FAIL

Side view

Front view

Adjuster indication
plate

Fuse ()

()


.

This protects the electronic


circuits of the main body from
shorting.
@

@ Fuse (5)

(5 A)



,
.

This fuse protects the buzzer and


the auto, stop circuits from short
ing. The fuse is irrelevant to the
internal circuits of the main unit.
(3) Pre-amplifier

Input/Output board

(D Connector board

Power supply board

CPU board

LCD illumination board

Display board

Bar-type moment ratio indicator




(%)

.
,


.

The segments of the band on the in


dicator illuminate incrementally as
the moment ratio (%) increases.
The relationship among the state of
the indicator, auto, stop signal
output, and buzzer signal output
is as shown in the chart below:
Moment (%)

, %

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

Or a nge 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 ge a r e on.

Do not st.c>p.

ratio

(%)

interm ittent

(%) .________________________________________________ 1_____________

10 0 % and
over
100

Moment (Z)

, %


liPii

1
1

257099551
Green LEDs

.Orange LEDs

Red LEDs illuminate all at the same time, time,


illuminating the entire length of the band .
!

S top.

Red LEDs

continuous

Jib angle display screen


This screen displays the angular
offset of the jib when boom state
register switch is set to iib".

Boom length display screen


This screen usually displays the
current boom length, and when lift
request s w i t c h is pushed, displays
the current lift above the ground.

Boom angle display screen


This screen usually displays the
current boom angle, and when boom
angle upper limit input s w i t c h
and boom angle lower limit input
switch are pushed and held simul
taneously for more than 3 seconds,
displays the current moment ratio
(%).

Actual load display screen


This screen usually displays the
actual load value, and when abnor
mality occurs in the system, dis
plays an error code number.
Total rated load display screen
This screen usually displays the
total rated load, and when abnor
mality occurs in the system, dis
plays an error message.




"".

.

@


.


.

@

@

3 ,
(
%).


.

-

.


.

-

.

.

Working radius display screen


This screen displays the current
working radius.
Height limit indicator lamp
This indicator illuminates while a
height limit (input by height limit
input switch ) is stored in the
system. When the stored limit is
reached, the indicator begins to
flicker, and at the same time, an
auto, stop signal is output to stop
boom rising and extending movements.

"
"


.



,
.

,
,
.

Height limit input switch

Pushing this switch stores in the


system a maximum operational height
(height limit) for the boom. To
erase a stored height limit, the
switch is pushed again.
The chart below shows relationship
among the state of in d i c a t o r ,
s w i t c h , and auto. stop.

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

Boom angle upper limit indicator


lamp
This indicator i lluminates while a
boom angle upper limit (input by
boom angle upper limit input switch
@ ) is stored in the system. When
the stored limit is reached, the
indicator begins to flicker, and
at the same time
an auto, stop
signal is output to stop boom
rising movement.
Boom angle upper limit input switch
Pushing this switch stores in the
system a maximum angle for the
boom. To erase a stored angle limit,
the switch is pushed again.
The chart below shows relationship
among the state of i n d i c a t o r,
s w i t c h , and auto. stop.

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.

Boom angle lower limit indicator


lamp
This indicator illuminates while a
boom angle lower limit (input by
boom angle lower limit input switch
) is stored in the system.
When the stored limit is reached,
the indicator begins to flicker,
and at the same time, an auto,
stop signal is output to stop boom
lowering movement.
Boom angle lower limit input switch
Pushing this switch stores in the
system a minimum angle for the
boom. To erase a stored angle
limit, the switch is pushed again.
The chart below shows relationship
among the state of i n d i c a t o r ,
s w i t c h , and auto. stop.
Boom angle
1ower

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.

Working radius limit indicator lamp


This indicator illuminates while
working radius limit data (input
by working radius limit input switch
@ ) is stored in the system. When
the stored limit is reached, the
indicator begins to flicker, and at
the same time, an auto, stop signal
is output to stop boom lowering and
extending movements.
Working radius limit input switch
Pushing this switch stores a work
ing radius limit in the system. To
erase a stored radius limit, the
switch is pushed again.
The chart below shows relationship
among the state of indicator),
s w i t c h , and auto. stop.

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 .

^ Boom indicator lamp


This lamp illuminates when boom state
register switch is pushed. (The
lamp also illuminates when the main
switch is turned on.)

""

. (

.)

D Single top indicator lamp


This lamp illuminates when boom state
register switch is pushed while
boom indicator lamp is on.

"
"

@

""
@ .

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.

' ""



"
" . (

.)

,
,
;
,
, ,
;

, ,
, .


.
,
,
, ,
,
, .

Fault indicator lamp


When some abnormality occurs in the
AML system, this indicator illumi
nates, or flickers, the auto, stop
circuit is activated, and actual
load display screen and total
rated load display screen @ display
an error code number and an error
message, respectively.
This indicator also illuminates when
check switch ) is pushed, and mo
mentarily after power supply is
turned on.

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 adjuster


...... LENGTH SPAN


("BOOM LENGTH SPAN")

Screw turn range


(number of rotations)

:
15

Boom length zero adjuster


...... BOOM LENGTH ZERO
Screw turn range
(number of rotations)
Adjusters and
length display.

15

adjust the boom

15


("BOOM ZERO")
:

15

Boom angle span adjuster


...... "BOOM ANGLE SPAN"
Screw turn range
(number of rotations)

: 15

Adjusters and adjust the boom


angle display.

NOTE

With models TG-1200MG, T G 700EG, and TG-500ERG adjusters


and @ are not used.
Swing angle span adjuster
...... "SLEW ANGLE SPAN
Screw turn range
(number of rotations)

: 15

@ Swing angle zero adjuster


...... "SLEW ANGLE ZERO"
Screw turn range
(number of rotations)


("BOOM ANGLE ZERO")
:

15


.


("SLEW ANGLE SPAN")
:

15


("SLEW ANGLE
ZERO")
:

15


("JIB ANGLE SPAN")
:

15


( " ANGLE ZERO")
: 15

Jib angle span adjuster


...... "JIB ANGLE SPAN"
Screw turn range
(number of rotations)

15

; 15

Boom angle zero adjuster


...... "BOOM ANGLE ZERO"
Screw turn range
(number of rotations)


("BOOM ANGLE SPAN")

: 15

15

ik
@


. TG-1200MG, TG-700EG TG-500ERG.

@ Jib angle zero adjuster


...... "JIB ANGLE ZERO"
Screw turn range
(number of rotations)

: 15

Working radius display adjuster


..... "GAL, RADIUS"
Used to adjust the display of work
ing radius (and max. lift).
Screw turn range
(number of rotations)

: 15

Load display adjuster


...... "GAL, LOAD"


("CAL, RADIUS")

(
).
:


("CAL, LOAD")

(
).
:

Used to adjust the display of


actual load (and total rated load).
Screw turn range
(number of rotations)

: 15

15

15

NOTE

With models TG-1200MG, and TG-700EG,


adjusters and @ are not used.

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")

This adjusts the output voltage of


the moment detector.

Screw turn range


(number of rotations):

@) Moment zero pr e-ad j us ter* -"MOMENT ZERO"


This adjuster and moment zero fine
adjuster are for zeroing the
moment detector.
Screw turn range
(number of rotations):

15

15

15


("MOMENT ZERO")
,

,

:




.
15

Indicator lamp for +5V power supply


+5
An LED (Light Emitting Diode) for
indicating +5V power supply, turn
ing on when power is on.


+5
.

@ Indicator lamp for +12v power supply


An LED (Light Emitting Diode) for
indicating +12V power supply, turn
ing on when power is on.

+12

+12
.

@ Indicator lamp for -12V power supply


-12
An LED (Light Emitting Diode) for
indicating -12V power supply, turn
ing on when power is on.
@ Indicator lamp for +24V power supply
An LED (Light Emitting Diode) for
indicating +24V power supply, turn
ing on when power is supplied from
battery to AML.
@ Indicator lamp for 12V and +5V
power supply fault
An LED (Light Emitting Diode) for
checking 12V and 5V power supply,
turning off when power supply is in
order, and turning on when it is
not in order.


-12
.
+24

+24

.

12 +5

12 +5 ,

,

.

NOTE

For Models TG-1200MG, the over


fro n t indicator lamp does not
illuminate.

Over-front indicator lamp


This lamp illuminates when an over
front signal is received from the
detector.

(7) Alarm and automatic stop circuits


Alarm circuit
this circuit is for sounding the
buzzer when the actual value exceeds
90% of the rated value, or when the
load limit function or the angle
limit function is tripped, or when
with the hookblock overhoisted the
crane controls are operated in the
condition-aggravating direction.

" "


.

. 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

Boom ext./ret. detection


-

DB 3

CN2

DB 4

Boom-up detection

(8 ) ,

---------^
------------ ---------- ,
,
.

./X Boom-down detection


DB 5

(8) Other functions

(>

The Moment Limiter system is provided


with four other functions, in addition
to those described above.

(D Angle limiting function


The system stores certain elevation
angles of the boom with the main
boom, single top or jib in the work
ing position, and when the boom
lowers below those angles, the
following elements assume the states
given.
Bar-type moment ratio indicator...
illuminates all band segments.
Boom angle display screen
displays detected value on and off.
Buzzer ... sounds continusouly.
Auto, stop circuit........operates
Stop angles vary with the crane
model. Refer to the limit angle
table at the end of this section.

NOTE

----i

Boom length shown in


total rated load table

Even when the boom is in lengthes


not listed in the table (e.g., between
and 2 ), the angle lim iting
function is effective.



,

.
,


.


...........


........


.......

....

,

,
.

.
.

ill , ^ 2 -^10
: ,

.


, (,
i 2 )

Load limiting function


The system stores certain limits
for lifted loads, and when the
actual load (detected and dis
played) exceeds the applicable
stored limit, the elements shown
below assume the states given.
With the single top and the jib,
the load limit is determined by
the strength of the wire rope
(or the strength of the jib).
With the main boom, the load limit
ing function may operate when the
boom is extended slightly longer
than the boom length given in the
table of total rated loads
Bar-type moment ratio indicator
...illuminates all band segments.
Actual load display screen
...displays detected value on
and off.
Total rated load display screen
...displays limit load.
Buzzer.... sounds continuously.
Auto, stop c i r c u i t ... operates.
The limit load setting and the load
value vary with the crane model, as
given in the limit load table at the
end of this section. In the table,
the limit load codes Wsi , W s 2 , etc.
denote loads under the following
conditions.

NOTE

^1 , ^ 2,
: boom length given in
the table of to ta l rated loads.

Wsi
WS 2
WS3

Boom length \ (full ret.)


.^i<Boom length ^ 2
^2 < Boom length ^ 3

Rear stability control function


This system processes signals re
ceived from the boom angle detec
tor, and when the boom is raised
to a certain angle, outputs a signal
to drive the boom elevation stopping
relay (RL4). When this function is
tripped and boom elevating motion
is halted, the system elements
assume the following states:




,
,
,
,

.



( ) .

,
,
,
.

...........


...............................



.........................

...................

.........



.
.

.
W s i , Ws z .

:

Wsi: i (
)
Ws 2 :
< ^ 9.2
Wss: 2 < 3

ill, ^ 2 ^iQ ,

.



,

( R L 4 ) .

.

Bar-type moment ratio indicator


displayed as usual.
Boom angle display screen
displays detected value on
and off.
B u z z e r ...... remains silent.
Auto, stop circuit.... operates.
Stop angle varies with the crane
model. Refer to the limit angle
table at the end of this section.
Telescoping control signal output
ting function

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

The seven units of the Moment Limiter


system, described in the chapter Construction and fucntions", are connected
together by cables and wires.
Each unit is made up of many parts.
When the AML malfunctions or is sus
pected of malfunctioning, trace down
the source of the malfunction among
the units and the parts by following
the procedure given below.

Follow the troubleshooting charts


for locating the fault.

1.
,
. " ",
,
.

.
, ,

,
,
.


.

Refer to the troubleshooting charts.

NOTE
i^W hen disconnecting or connecting the
connectors of the A M L system, keep
the battery switch turned OFF.

The conditions of the crane and the


power on or o ff condition are given
in the charts at each step as
necessary.

1) Determine the unit which fails to


operate properly.
2) If the AML main body is faulty,
locate the origin of trouble fur
ther within the main body.

2.

Repair procedures

When the crane develops fault, check


the crane systematically following the
steps described in the troubleshooting
charts, and when the cause of the fault
has been located in a certain unit,
repair that unit by following the repair
procedures given below.
(1) To repair defects in the following
blocks or parts, refer to "Disassem
bly and Reassembly" given later in
this section.

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

Booo length detector


Operating condition selector unit
Lever manipulation detector
Alarm, auto, stop circuit

(3) When some blocks or parts are re


placed, adjustments are required to
make the crane in proper operating
conditions. For the necessary adjustment, refer to **Test Procedures
and Maintenance Standards given at
the end of this section.
(4) Handle the units carefully, apying
attention to the following.

When mounting and dismounting


units, switch off the battery in
advance.
Take care to keep the AML main body,
connectors, etc. free from oil,
water, dust and other foreign matter,

(2)
,



.

(D
-
@



(3 ) ,

,
. "
"
.
(4)
, .


,

.


, .
, ,
.

,
..

,
,
.

Install connectors etc. securely,


taking care to avoid imperfect
contact and moisture.

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.

Length display value is incorrect.


5.

Boom angle display value is incorrect.


6.

Moment % display value is incorrect.


(%)

7.

W orking radius and lift display values are incorrect.


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.

Both LCDs and lamps remain off.

Cause

Check procedure

Correction

Unplug CNl after turning off


POWER. Then, turn on POWER,
and measure voltage across
CNl connector side terminals
(13 or U : + ) and (1 or 2:-)
with a multimeter. (Should
be 22 - 32V).

Repair wiring and


switch according
to wiring dia
gram, if voltage
is wrong.

(D Fuse for power


supply board
is blown.

Take fuse off the bracket,


and check it for continuity
with a multimeter.
(should read Oil ).

Replace fuse.
(If blown, again,
replace power
supply board.)

F a u l t y power
supply board.

Above checks indicate no


fault, but following con
ditions are present.
Out of three power supply
indicator lamps(+ 1 2 V,
-12V, +5V), one or more
lamps are off; or 12V,
+5V FAIL lamp is on.

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.

The LCD illumination lamps (for night operation) remain off.

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.

Error code no. "1" and error message " E r r "

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

Error code no. "3" and error message " E r r "

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.

Error code no. "4" and error message " E r r "

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.

Turn off power, and unplug


CNl. Measure resistance across
terminals and and a c r o s s
and of CNl on connector
side with a multimeter.
Correct reading:

Fault

6.

Both 240(12)

When above checks indicate


no fault.

Faulty CPU
board.

Error code no. 7 and error message

Cause

Check which is
fault, detector
or cable; replace
faulty one. (See
Note)

Check procedure

Replace CPU
board.

are displayed.

Correction

Faulty
adjustment.

Check that error code and


message are displayed when
the boom length is near the
full extension or full retrac
tion length.

Perform length
zero and span
adjustments.

B o o m length
detector, its
cable, or boom
angle detector
cable is
faulty.

Turn off power, unplug CNl,


and unplug C N from boom
length detector. With boom
fully retracted, measure
resistance across terminals
(3) and (4) and across (3)
and (6 ) of CNl on connector
si d e .

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.

When above checks indicate


no fault.

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.

Check that error code and


message are displayed when
the boom angle approaches
the upper and lower stroke
ends.

Perform boom
angle zero and
span adjustment,

Turn off power, unplug C N l ,


and unplug C N from length
detector. With boom in hori
zontal position, measure re
sistance across terminals (3)
and (4), and across (3) and
(5), of Cnl on connector side
with a multimeter.

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.

When above checks indicate


no fault.

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.

Data table at end of this sec


tion gives input patterns (in
put signal combinations) which
canse display of this error
code. If actual input pattern
conforms to none of tabulated
patterns, and yet this error
code is displayed, f a u l t
below is present.

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.

Turn off power and unplug C N l .


Check continuity across CNl
connector side terminals ( 1 or
2) and (15 through 19), and
identify input pattern (com
bination of input signals).
Compare this pattern with cor
rect pattern for current status
settings given in data table
at end of this section. Dif
fering terminal input is
faulty input.

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.

When above checks indicate no


fault.

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.

When boom retraction detector


switch remains off with boom
length less than length given
in data table at end of this
section, this error code is
displayed. If condition is OK,
and yet this code is given,
fault (D below is present.

Reset correctly.

Turn off power, and unplug


C N l . Check continuity across
CNl connector side terminals
( 1 or 2 ) and terminals given
in data table at end of this
section, and compare input
pattern with tabulated
pattern. If they are in con
formity, conforming terminal
input is faulty input.

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.

When above checks indicate


no fault.

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.

Data table at end of this


section gives correct status
setting patterns. If actual
setting pattern conforms to
one of patterns given in
table, and still this error
code is displayed, fault (D
below is present.

Set correctly.

See "Combinatioti of
operating
condition
signals** in
data table.

Turn off power and unplug C N l .


Check continuity across CNl
connector side terminals ( 1
or 2) and (15 through 19), and
identify input pattern (com
bination of input signals).
Compare this pattern with cor
rect pattern for current status
settings given in data table
at end of this section. Dif
fering terminal input is
faulty input.

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.

When above checks indicate no


fault.

-See **Combination of operat


ing condition
signals** in
data table.
Replace power
supply 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.

Check mode cannot be turned on, or cannot be canceled.

Cause

Check procedure

Faulty display
board.

Fault

2.

Check procedure

F a u l t y display
board.

3.

Replace display
board.

Note

Pushing the state register switches cannot switch the lamp


illumination modes.

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.

Length display value is incorrect.


Fault

1.

Error is large, but the displayed value changes smoothly as the


boom telescopes.

Cause
Incorrect
adjustment

Fault

2.

Check procedure

Correction

Check by telescoping the boom


slowly over the full range.

Adjust according
to the adjustment
procedure.

The reading fluctuates, error is large at specific values, change


is not smooth, or error increases over several days.

Cause

Check procedure

L e n g t h detec
tor, its cable,
or boom angle
detector cable
is faulty.

Turn off power, unplug CNl,


and unplug C N from boom
angle detector. With boom
fully retracted, measure
resistance across CNl con
nector side terminals (3) and
(4) and across (3) and (6)
with a multimeter.

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

When above checks indicate


no fault.

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.

Boom angle display value is incorrect.


Fault

1.

Error is large, but the value changes smoothly as the boom rises
and lowers.

Check procedure

Cause

Check the fault condition by


raising or lowering the boom
slowly over entire angular
range.

Incorrect
adjustment

Fault

2.

Correction
Adjust according
to adjustment
procedure.

The reading fluctuates, error increases at specific values, change


is not smooth, or error increases over several days.

Cause

Check procedure

Correction

Boom angle de
tector, its
cable, or
length detec
tor cable is
faulty.

Turn off power, and unplug


CNl, and unplug CN (5) from
length detector.
With boom in horizontal
position, measure resistance
across CNl connector side
terminals and and across
(3) and (5) with a multimeter.

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

When above checks indicate


no fault.

Replace CPU board.

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.

Moment % display value Is incorrect.


Fault

1.

Error is large. The error is generally either negative or positive,


irrespective of the boom, jib or other conditions.

Cause

Check procedure

Faulty
adjustment

1) Check the length reading,


and the boom angle reading,
then, check the moment %
with the boom on the boom
rest, according to the
adjustment procedure.

Correction

Note

1) Perform zero
adjustment ac
cording to ad
justment
procedure.

Correct: 0.0 0.5(%)


2) Then, check the moment
values at boom angles
10 and 50 against
the values on preoperational check indication
plate.

2) Adjust the
span acording to adjust
ment pro
cedure .

Correct value:
given on indication
plate in crane cab.

Fault

2.

Error increases at specific boom status and work status.

Cause

Check procedure

Correction

status and
work status are
set incorrect
ly, or setting
units are
faulty.

Check that status settings are


correct and that input pattern
is correct, by referring to
Faults 8 and 10 in **2 Fault
indicator lamp lights, and..."

If incorrect, set
correctly or re
pair wiring and
switches accord
ing to crane elec
tric circuit
diagram.

Faulty power
supply board.

When above checks indicate no


fault.

Replace power
supply board.

Note

6.

(%) .
1,

. ,
, .


1) 1)


. ,
,
(%)

.
:
0,0 0,5%

2) 2)





10 50,

,
.
.
:


.
2.


- .

8 10
"2. "
" ,

", ,

(
).



,

,

, .


.

Fault

3.

The reading fluctuates, error increases at specific values, change


is not smooth, or error increases over several days.

Cause

Check procedure

Correction

Note

L e n g t h value,
boom angle
value are
faulty.

Check by referring to "4


Length display value is
incorrect** and **5 Boom
angle. ..**

Repair or
replace.

(2) Poor insula


tion in moment
detector and,
detector cable
(connector)

First, check moment system in


same manner as in Fault 5 for
**2 Fault indicator lamp lights,
and...**; then measure insula
tion resistance between CNl
connector side terminals (8)
and (9 through 12) with a
multimeter with a capacity
above 500Mil .

Replace detector With C N un


or cable, which plugged, if
resistance
ever is faulty.
across detec
(See Note)
tor side ter
minals (A
through D)
and chassis
is over
100M12 , de
tector is OK.

Correct value : 100(Mil)min.


Faulty

preamplifier.

When above checks indicate


no fault.

Replace pre
amplifier.

3.

;
; ;
(
).

, "4,
.


" "5.

.

1



()



, 5
"2.
" ,

",

(8) (9
12) CN1
;


500 .
:
. 100

,

,

(,
).


CN (3),


(
D)

.

100
,

.

7.

W orking radius and lift display values are incorrect.


Fault

1.

Error is large.

Cause

Check procedure

Correction

Note

Large boom
length display
value error.

See **4 Length display value


is incorrect".

(D Large boom
angle display
value error.

See 5" Boom angle display


value is incorrect".

B o o m status
is set
incorrectly.

Check that status is set cor


rectly, by referring to Fault
8 in "2 Fault indicator lamp
lights, and..."

Set correctly.

In this
case, moment% dis
play is
also in
correct.

F a u l t y boom
status setting
unit.

Check that status input


pattern is in conformity with
current status setting, by
referring to Fault 8 in "2
Fault indicator lamp lights,
and..."

If incorrect,
repair accord
ing to crane
electric cir
cuit diagram.

In this
case, moment% dis
play is
also in
correct.

(5)Faulty
adjustment

The longer the boom, and the


larger the boom angle, the
easier the 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.

See "6 Moment % display


value is incorrect*...

Large error in
working radius
display value.

See 7 Working radius and


lift display values are
incorrect**.

Check that statuses are set


B o o m status or
correctly, by referring to
work status is
set incorrectly. Faults 8, 9, 10 in **2 Fault
indicator lamp lights, and..**
B o o m status or
work status
setting unit
is faulty.

Faulty
adjustment

Check that status input


pattern is in conformity with
current status settings, by
referring to Faults 8, 9, 10
in **2 Fault indicator lamp
lights , and. . . **
Except for the rated load for
jib, all displays can be ad
justed upward and downward in
the same ratios.

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.

Crane motions stay auto, stopped.


(This occurs even when moment display is below 100%.)

Cause

Check procedure

Correction

B l o w n fuse
(for relay)

Take fuse off bracket, and


check it for continuity with
a multimeter.
Correct reading : 0 )

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.

With power turned off, unplug


CNl. After shorting CNl con
nector side terminals (13 or
14) and (28) with a wire,
turn on power.
Correct : Auto stop state
is cleared.

If incorrect,
correct according
to crane electric
circuit diagram.

F a u l t y lever
manipluation
detector
switch.

With power turned off, unplug * If incorrect,


correct according
CN2. With control lever in
to crane electric
neutral, check continuity
circuit
diagram.
across CN2 connector side ter
minals (19 through 26) and CNl
connector side terminal(1 or
2.)
Correct :
0(12)
For terminals without
switch (or relay), it
is infinite ( ^
12 ).

F a u l t y over
wind detector
switch.

With power turned off, unplug


CNl. Under non-overhoist con
dition, check continuity
across CNl connector side
terminals (1 or 2) and (22).

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.

Check to see workig range


limit indicator lamps are
off.

Erase limit
data.

F a u l t y power
supply board.

When above checks through


indicate no fault.

Replace power
supply board.

R e l a y (in AML
main unit)

When above checks through


indicate no fault.

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,

Turn off power, unplug CNl,


and then turn on power again.
Correct operation:
Auto, stop occurs.

)Faulty lever
manipulation
detector
switch.

Turn off power and unplug


CN2. With control lever moved
to danger side (boom lowering,
boom extension, hoist-up),
measure resistance across
each of CN2 connector side
terminals (19 through 26)
and CNl connector side ter
minal (1 or 2).

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.

Turn off power and unplug CNl,


Under overhoist condition,
check continuity across CNl
connector side terminals (1
or 2) and (22).
Correct: oo
When above checks through
reveal no fault.

Replace power
supply board.

R e l a y (in AML
main unit)

When above checks through


reveals no fault.

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

Buzzer keeps sounding without stopping.

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.

When above checks indicate no


fault.

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.

Buzzer will not sound.

Cause
buzzer
circuit is
faulty.

Check procedure

Correction

Turn off power, and unplug


CNl. Short across CNl connec
tor side terminals (13 or 14)
& (32) with a wire, and turn
on power.

If incorrect,
repair according
to crane electric
circuit diagram.

Note

Correct : Buzzer sounds.


P o w e r supply
board is
faulty.

Fault

5.

When above checks indicate


no fault.

Replace power
supply board.

No telescoping control signal is output.

Cause
Length display
adjustment is
faulty.

Check procedure
Check boom length display
value around telescoping
control output length.

Correction
Adjust.

Correct : See data table at


of this section.
Telescoping
control output
circuit is
faulty.

Turn off power and unplug


CNl. Short across CNl con
nector side terminals (13 or
14) & (33, 34) with a wire,
and turn on power.

If incorrect,
repair according
to crane electric
circuit diagram.

Correct : Boom telescopes.


Power supply
board is
faulty.

When above checks indicate


no fault.

Replace power
supply board.

Note


,
CN1.
(13 14) (32)
CN1 ,
.
:

.-

(2)
.

5.


,



.


.

,


.
:
.

.

(2)


,
CN1.
(13 14) (33, 34)
CN1 ,
.
:

.



,



.

(3)
.

npoBepotj

Fault

6.

Telescoping control signal keeps being output.

Cause

Check procedure

L e n g t h display
value adjust
ment is
faulty.

Check length display value


around telescoping control
signal output length.

(D Telescoping
control signal
output circuit
is faulty.

Turn off power, and unplug


CNl. Turn on power with CNl
unplugged.
Correct : no telescoping.

When above checks indicate


board is faulty. no fault.

7.

Adjust.

If incorrect, re
pair according to
crane electric
circuit diagram.
Replace power
supply board.

No rear stability control signal is output.

Cause

Check procedure

B o o m angle
display value
adjustment is
faulty.

Check boom angle display


value around rear stability
control output angle.

F a u l t y auto,
stop circuit.

Turn off power, unplug CNl,


and then turn on power again.

Correction

Note

Adjust.

Correct : See data table at


end of this
section.

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.

When above checks through


reveal no fault.

Replace power
supply board.

Relay (in AML


main unit.)

When above checks through


reveal no fault.

Replace case
assy .

Note

Correct : Data table at end


of this section.

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.

Rear stability control signal keeps being output.

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.

Correct : Data table at end


of this section.
Turn off power and unplug CNl.
Short across CNl connector
side terminals (13 or 14) and
(28) with a wire, and turn on
power.

If incorrect,
repair according
to crane electric
circuit diagram.

Correct operation : Auto,


stop state is cleared.
)Faulty lever
manipulation
detector
switch.

Turn off power and unplug CN2.


With controlllever in neutral,
check continuity across CN2
connector side terminal (23)
and CNl connector side ter
minal (1 or 2).

If incorrect,
repair according
to crane electric
circuit diagram.

Correct

F a u l t y power
supply board.
)Relay (in AML
main unit .)

When above checks through <


reveal no fault.

Replace power
supply board.

When above checks through'


reveal no fault.

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) ) .

> DISASSEMBLY AND REASSEMBLY

Mounting drawing

CN
CN

(Boom angle detector)


(

Boom angle detector


AML main body


(1)

(1)

MOMENT DETECTOR

DISASSEMBLY
1) Disconnect connector C N
the cable support.

and remove

2) Remove the elevating cylinder from


the crane.

1) CNC^
.

2)
.
3) (D. ,

3) Unscrew set screw d) .


4) Loosen moment detector, and remove
it from the piston rod.

4)
,
.

Moment detector

REASSEMBLY

Reassemble the moment detector by


reversing the disassembly procedure,
observing the following cautions.


,
.
1)
(, )
^

..

NOTE
The
are
Do
tely

moment detector and desiccant


delivered in vinyl bags.
not unpack them until immedia
before the installation.

The desiccant is packed in small


cellophane bags. Install them as
they are.



.
.

The desiccant contains blue grains.


If the color has changed into white,
this is the indication that the mois
ture absorbing power has been lost.
Replace desiccant.

iJr
.

.

1) For dehumidification, place desic


cant (e.g. silica gel) in small
pakages around the detector at
even intervals, and secure the
packages lightly with adhesive
tapes as shown below.

.
,
. ,
.

Adhesive tape

Moment detector
'

Desiccant

Piston rod

MOMENT LIMITER
on the moment

2) Install 0-rings
detector.

3) Install the moment detector in


the piston rod. Screw it in fully
until it bottoms.
4) Drill a hole for set screw of
6.0 mm in dia. and 3.0 mm in
depth in the piston rod. Screw
in the set screw lightly, re
lease it a half turn, and then
point-stake it at a position.

2) 0-
(3)
.
3)
.
4) 6
3
.
,

.

Set screw
-

...

__ 1 :

Punching

3 .0

(2) Boom angle detector

(2)

Replace the boom


angle detector as a com-
bo
.
plete assembly.

DISMOUNTING

TV
^
^
J _
1) Disconnect
Disconnec connector C N , and remove
the cable support.

1) CN ,
^
^
.

2) Remove the boom angle detector assem


bly from the boom.

2)
.

REMOUNTING
Remounting the angle detector by re
versing the disassembly procedures.

(3) A M L main body


Replace all components of the AML main
body in board units, except for the fuse
and P-ROM on the rear panel.

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 and reinstalling the boads


See Fig. 4 on page 75.
3^1. Display board

Removing
1) Unscrew screws, and remove the
side cover.

(3)


,
,
P-ROM
.



.
,
,
,
,
.

10 ,

.

,
.
,
,
.

,

,
,
.


. . 4 . 75.

3-1.

1) 0 ,
.

.2) Unscrew screws and remove the


escutcheon.

2) ,
.

3) Remove the front panel, display


board, and LCD illumination board
(D as an assembly from the main unit
case.

3) ,




.

4) Unplug connectors a n d f r o m the


LCD illumination board. (They come
off when the retaining levers are
pushed open.)

4) ()


.
(
.)

5) Unscrew s c r e w s and remove the


spacers.

5) ,

6) .
6) Replace the display board with
a new part.

"'
.

Remounting
Reverse the removing processes.

3-2.

3-2. LCD illumination board

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

6) Replace the LCD illumination board


with a new part.

Remounting
Reverse the removing processes.
3-3. CPU board

Removing
1) Unscrew screws, and remove the
side cover.

6)
.


.
3-3.

1) ,
.

2) Push the board retaining levers


open to let CPU board @ come out
approx. 10 mm; remove the board.
3) Replace the CPU board with a new
part.

2)
,
@

10 , .
3) .

Remounting
Reverse the removing processes.

3-4. Power supply board


3-4.

Removing

1) Unscrew screws, and remove the


side cover.
2) Push the board retaining levers
open to let power supply board
come out approx. 10 mm; remove
the board.
3) Replace the power supply board
with a new part.

Remounting

1)
,

0,

2)

,
10 ,
.
3) .

Reverse the removing processes.

3-5. Preamplifier
3-5.

Removing

1) Unscrew screws0 ,
side cover.

and remove the

2) Unscrew s c r e w s and remove


preamplifier (5) .
3) Replace the preamplifier with a
new part.

Remounting
Reverse the removing processes.

1) @ ,
.

2) ) ,
,
3) .

F ig.4
body

Disassembled view of AIVIL main

Connector

LCD illumination board



1
Display board ^
^
Front panel

Escutcheon

. 4

Fuse (5)
(5 )

TEST PFMXEDURES AND MAINTENANCE


STANDARDS

When blocks or parts related to the


AML system are replaced, adjust and
check the system as given below.

(1) Items requiring readjustment

(1) ,

When parts related to the AML system


have been replaced, make adjustments
according to the table below.

No,


Replaced part
_______________

Block

Part
Boom angle detector

_________

Boom length
detector

Required adjustment
_________

Boom angle display adjustment


Potentiometer or
length detector
assembly

Boom length display adjusttnent


Moment display adjustment


Moment zero adjustment
(D Moment span adjustment

Moment detector


1
2__ ____ __________________

Front panel

None

Display board

Moment zero adjustment

LCD illumination
Jboard

AML main body

CPU board

angle display adjustment


Boom length display adjustment
Moment display adjustment
Working radius display adjustment
Load display adjustment

!---1---------------

None

Pre-amplifier

Moment display adjustment


Power supply board

None

(
-
)

'

None

.
pa6oTM..TRg

Lever manipulation
detector




'

Main unit case(incl.


I/O board, connector
None
board)

Operating condition
selector unit

None

Alarm and auto, stop


circuit

None

(2)

(2) Adjusting procedures

,
:

Notes:

1)
.

Following conditions:
Crane is set up level on a firm,
uniformly supporting surface, with
outriggers fully extended.

Boom is fully retracted; jib is


stowed.

,
.

Boom state register switch is


set for boom" display.



'",

Outrigger state register switches


are set for max. extension
display.
Under the conditions above, check
that each of the actual load, total
rated load, boom length, boom angle,
working radius display screens gives
some display; then proceed to
adjustment.
In the following cases, however,
take specified measures, before
starting to adjust.

(a) When some abnormality is present:


Error code
No.(Actual load
display
screen)

(

)

Error
message
(Total rated
load display
screen)



,
.

,
,
,
,
- ,
,
,' ,

.
() :

Solution


(

(^ -

-[
-

Turn boom length zero adjuster clockwise


until corrected.

.

Turn boom angle zero adjuster clockwise


until corrected.

.

() When moment % display is a negative


(-) value, or if it is 110% or
above.
Turn the moment zero pre-adjuster
clockwise or counterclockwise
until the display comes into the
0 to 100% range.

3) AJJLadJust^
the sequence eiven in this
manual.

in

4) For the location of the adjusters,


refer to the drawing of the AML
main unit on page 8.

( 6) ,
(%)
(-) ,
"110% :
'^

, ,

100%.
2)
,
.
3)


.

, ,

.
4) .
. 8.

(3)

(3) Boom length display adjustment

:

: ****
(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%

Fully retract the boom

With connector C N unplugged, measure resistance


across plug terminals and and across and
. B-D : 5 0 0 + 1 0 0 ( ft), C-D : 5000 3 0 0 ( ft)
CN(5), 1 ^
() (J), 1^ () (
.
CormoTHBJ^ffle ) ( 500 100
, (U) 0
- 5000 JuO.

Turn the [LENGTH ZERO] adjuster slowly until the


boom length display becomes [C] m.
[LENGTH
ZEkO] ,
[] .

n o t e (D

Cranes with telescoping con


trol signal output function

Cranes without telescoping con


trol signal output function

Extend only the first-extending boom sections (e.g., 2nd


and 3rd boom sections with TG700EG-1) to the stroke end.
(Keep other boom sections fully
retracted.)

(,

. TG-700EG-1)
.
(
.)

Fully extend the boom.


.

NOTE (D ___

Turn the [LENGTH SPAN] adjuster


slowly until the boom length
display becomes [D] m.

[LENGTH
SPAN] ,

[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) Boom angle display adjustment


Measuring instrument :
Sprit level type angle meter
Conditions :
Boom state register switch: "boom**
(D Outrigger state register switches:
**max. extension**
(D Boom direction: any position
Boom length: full retraction
Moment display: between 0 and 100%

(4)
:

:

: "
(2)
:
" "
:
:

(5) :
100%

NOTE
^

() Angle display e rro r = Angle display value - s p rit level type angle meter reading

= -
.

(5) Moment zero adjustment


Prior to this adjustment,the boom
angle display and the boom length
display must be correctly adjusted.

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

The [] value varies with crane


model. Refer to the adjustment boom
length table at the end of this
section fo r this data.

[]
. , "
"
.

With those crane models which have


no boom rest (e.g. models T R ), sup
port the boom with a block in the
horizontal position where the ele
vation cylinder is not fu lly retracted,
to depressure the system.

(,
. TR),
,
(

) ,
.

(%)

,



'
3 .

Moment % display is given on the


boom angle display screen when the
boom angle upper lim it and lower
lim it input switches are pushed
simultaneously fo r more than 3 sec
onds.
If 0.0% is obtained w ith the pre
adjuster alone, the fine adjuster
need not be turned.

(D "0,0%"
,

.

(6)

(6) Moment span adjustment


Prior to this adjustment, the moment
zero adjustment must be made.

When moment span adjustment is


incorrect

Conditions
Same as for the moment zero
,
ad j ustment.________________ _
.
Elevate the boom until the angle display is 10'
,

Turn the moment zero fine adjuster on the front panel


of the AML main unit slowly until the moment display
"AML preoperational check" plate,
comes to display the yalue(for 10^") engraved on the

, ,
(10 ), .

Elevate the boom until the angle display is 50 .


,

50^______

______

____

Read the moment display value. It must be the value


(for 50) engraved on the "AML preoperational check"
plate.
,
(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

Check the values for 10 and 50 in the


same procedure as above.(For the value
for 10, readjustment will be neces
sary). Do the displayed values coincide
with the engraved values?

END


10 50
.
( 10
.)

, ? _____

N0

- 1

END

Proceed to the next chart "when parts


requiring moment span adjustment have
been replaced."

After performing moment zero


adjustment, check the values
for 10 and 50 again in the
same procedure as above.(For
the value for 10, readjust
ment will be necessary).



10
50 .
( 10

' .)

" ,

, .

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.

" "

.

When parts requiring moment span ad


justment have been replaced.
Conditions
Boom state register switch: **boom"
(D Outrigger state register switches:
max. extension**
Boom direction: Over rear or side.

Base jib section select switch:


**unused**
Counterweight select switch: **18.8t*

,

,
:

: ""
(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"

With the boom fully etracted, check the boom


length display; it muLst be [C] m.
, ,
[] .

Elevate the boom until the angle display is

.NOTE

(D

10.

,
10.

Read the moment display (X%).


(%).

Elevate the boom until the angle display

is 50.

.
5.

Read the moment display (Y%).


(Y%).

Check moment zero adj ustment


With the boom resting; on the boom rest, remove
hydraulic pressure fr om the elevating cylinder,
and see if the moment display is 0 . 0 0.5/o.
1
, : goep,

_NOTE d )

Out of 0.0 0.5% range

Within 0.0 0.5% range

0,0 0,5%

0,0 0 ,

readjustment starting with


moment zero adjustment.
,

.

Correct the values X and Y


engraved on preoperational
check plate
X Y,
^
__

END

NOTE

( l) With the models provided with the


telescoping control signal output
function, extend the boom to the
stroke end by manipulating the
emergency telescoping switch.
(D Refer to the'm om ent span adjustm ent'
at the end of this section fo r the
[J ] value and other conditions.
[K ] is the tota l rated load fo r w ork
ing radius [J ] m with the boom ex
tended fully, as given on the total
rated load table in the crane cab.
For example, with Model TG-1200MG
-1 , value [K ] is 2.6 ton because
value [J ] is 30.0m and the fu lly ex
tended boom length is 42.9 m.
* For crane models designed fo r the
Soviet Union, use 105% of value [K ]
when adjusting the moment span.

,
,

.
(2) [J] .
"
"
.
[]

[J] (.

).
, . TG-1200MG-1
[] 2,6 , [J]

30,0 42,9 .
,
,


, 105%

Load to be lifted = total rated load [K ] - hook weight


= []
- .
Coimtenvei^t

TG-1200M TOTAL RATED LOADS

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

When lowering the boom, run the


engine at idling speeds, and keep
the control valve half open.

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

Measured working ra d iu s -ra te d working radius [J]


= --------------------Rated working radius [J]------------------------- ^

(J)

- [J]
X 100%
[J]

Refer to the adjustment boom length


table at the end of this section fo r
the [C] and [D ] values.

0 [] [D] . "
"
.

With those crane models which have


no boom rest (e.g. TR ). support
the boom in the horizontal position
with a block to prevent the cylinder
from retracting fu lly, and depressure
the system.

(,
, TR),
,



.

(7) W orking radius display adjustment

(7) ,

Load display adjustment


Prior to this adjustment, the moment
span must be correctly adjusted.
Conditions
Boom state register switch: "boom**
(D Outrigger state register switches:
**max. extension**
@ Boom direction: over rear or side
Base jib section select switch:
**unused**
Counterweight select switch: **18.8t**

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.

[
]
,

,
.
,
.

TG-1200M TOTAL RATED LOADS


. TG-1200M

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

Outriggers extended fully


Boom length (m) *2
35.3
18.2
23.9
29.6
12.5
100.0
90.0
85.0 45.0
75.0 45.0
66.0 45.0
^0.0 45.0
29.0
45.0
36.0
'5 4 .0
29.0
50.0 45.0
36.0
29.0
22.0
36.0
45.0 42.0
22.0
29.0
36.0
41.0 39.0
29.0
22.0
34.0
36.0 36.7
29.0
22.0
32.0 32.7
32.0
27.0
22.0
29.7
28.8 29.5
24.6
22.0
24.5
23.6 24.3
20.7
20.0
20.6
19.5 20.0
17.7
17.8
17.0
17.6
13.3
13.4
13:0
13.2
10.4
10.3
9.9
10.2
8.1
8.0
8.1
6.4
6.4
6.2
5.0
5.0
4.8
4.0
4.0
3.0
3.0
2.0
2.0
1.7
1.1

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

Boom Jib length (m) *4 Boom


Jib length ( ) *4
angle 11.1 18.9 26.0 angk^ 5.0 + 11.1 5.0+18.9 5.0+26.0
*3
2.0
4.0 2.5
80
3.2
1.5
80 6.0
79
3.2
2.0
1.5
3.75 2.3
79 6.0
78
2.0
3.2
1.5
3.55 2.15
78 6.0
2.0
1.5
3.35 2.05
77
3.1
77 6.0
1.7
1.3
3.0 1.8
75
2.65
75 5.4
72
1.35
1.05
72 4.8
2.6 1.55
2.15
1.15
2.4 1.4
0.9
70
1.85
70 4.4
2.2 1.3
68
1.6
0.95
0.75
68 4.0
65
1.3
0.75
0.55
65 3.45 1.9 1.15
62
0.6
1.05
1.7 1.05
62 3.0
60
0.5
0.9
60 2.75 1.55 1.0
1.4 0.95
58
0.75
58 2.5
55
0.6
1.25 0.85
55 2.1
52 1.35 0.85 0.6
*1 ; ,
*2: ,
50 0.95 0.55
*3:
48 0.6
,
*4: ,

BOOM LENGTH DETECTOR


C O N S TR U C TIO N AND FU N C TIO N S

A boom length detector mainly consists


of a recoil spring, cord, reducer, and
a potentiometer. The cord is wound on a
drum, and is pulled out by the boom as
it extends, and is rewound by the recoil
spring. The accompanying rotation of the
drum is reduced to 1/50 or 1/25 by the
reducer, and drives the potentiometer
shaft. The electric resistance of the
potentiometer therefore changes in pro
portion to the boom length, and the AML
is supplied with the boom length signal
in the form of potentiometer resistance.



, ,
.



.

,
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

Term inal con n ection


Reduction ratio : 1/50

Resistance : 5000 250


Electrical turning angle : 355 2
Mechanical turning angle : 360, continuous rotation
:
5000250
:
3552
:
360

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

Reduction ratio : 1/50

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.

DISASSEMBLY AND REASSEMBLY

The repair procedures are described


under three divisions, REPLACING CORD,
REPLACING RECOIL SPRING and REPLACING
POTENTIOMETER. Select the procedure
applicable to the faults.

,
: " " , "3
" "3
" .

.

1.

1.

Replacing cord

(Refer to STRUCTURAL DRAWING)


1. After removing connector @ and cord
lock from the forward end of the
cord, tie a string of approximately
m to the end, and slowly let
the cord and string be wound on the
drum until the recoil spring
becomes free.
2. Remove the detector a s s from the
boom.
3. Loosen clamp @ and remove cover

(. .)
1.
@ @
,

,


.
2.

3.

@ ,
.

4.

@

(15) ,
.

5.

,
,

@
.

4. Disconnect cable from potentio


meter at the terminals, and
remove the cover and the cable
together.

NOTE

L ift the reducer straight upward,


taking care not to tilt it.

5* Loosen set screw and remove gear(


and then, unscrew machine s c r e w s
and remove reducer .

NOTE

6.

M ark an alignment line on case


and plate to record the subcord
installation direction.

,
(2) .

6. Remove retaining ring(9), unscrew


b o l t s , and take case (D off the
drum.


, ,

.

0 ) (2 )

()

7. Unscrew n u t , and separate drum


assembly from plate .

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. Remove the entire old cord from the


drum assembly.

9.

,
.

The
w ork
pages
length
given

values in the descriptions of


procedure given in the subsequent
diffe r w ith the models of the
detector. The concrete value are
in the table below.

10. Prepare new cord having length


of
m for the detector model on
hand. Install the 0-marker to the
cord at
m as shown firmly by
adhesive tape.
New cord

,
, (
) .

.

10.


.
'
[ ]
,
.

-marker
^

Drum e n d / ^
Co

NOTE
Core w ire :
Shield w ire :

Connect to slip ring


inner ring.
Connect to slip ring
outer ring.

Completely insulate the soldered joint.


11. Install the new cord by threading it
through the hole in the drum assem
bly and the holes in the holder
plate and following the dismounting
processes in the reverse sequence,
connect it to the slip ring assembly
by soldering.

11.



,

.

:
.

:

.

12. Install the slip ring assembly,


vinyl tube and holder plate on
the cord so that there will be no
slack in the cord when these parts
are installed on the drum assembly.

NOTE

12.

,

, ,

.

13.

,
,

.

,

,
,

..

Wind the cord clockwise, as viewed


from the slip ring side.
13. With an auxiliary string approxi
mately
m in length tied to the
end of a new cord, wind the new
cord around the drum assembly
without slack. From the 0-marker
at [b ] m, further wind the cord
[d ] times, and secure the cord
to the drum with a gummy adhesive
tape or the like.


,
.
Adhesive tape

. string

. string

14. Insert the shaft of drum a s s y


into the hole in p l a t e , and
install nut .
15. Apply sealant to p a c k i n g , and
install case on drum assembly
, threading the subcord through
the hole in b u s h , and threading
the aux. string through cord
guide .
16. Secure case @ and plate with
bolts and install retaining
ring .
17. Apply a thin coat of sealant to the
bottom surface of r e d u c e r , and
install the reducer to case .
18. Install gear @ on the shaft of
r e d u c e r , and loosen the set screw
o f gear on the potentiometer
side until both gears can turn.
Turn the gear on the potentiometer
side about 1/4 turn to make sure ^
that it returns to its original
position by the force of spring .
If not, loosen bolts and adjust
the position of bracket .

14.

Slip ring (Apply contact grease)


(

.)

15.


(23 ,
(2)
.


&
)
.

16.

(3^^ ,
@
.

17.


,
(2) .

18.

@

,
@

,
, ,
.

1/4
, ,
,

-) .
,

When the potentiometer itself is


faulty, replace it, referring to
the procedures described under RE
PLACING POTENTIOMETER.

-
,
. "
.
19.


()
& .
.
:
12 -.

20.



,
, .



, .

19. Secure gear to the shaft of re


ducer by tightening set screw
against the flat area on the shaft.
Apply screw locking compound to the
set screw.
Tightening torque : 12 kg.cm
20. Pull out the auxiliary string
through the guide window in the cord
reel, pull out the new cord to the
end, and then, slowly let it be
wound on the drum. When the 0-marker
has come to the center of the cord
guide, secure the cord in that posi
tion with adhesive tape as shown.

0-marker

21. Measure the resistance of the poten


tiometer. Make sure that the re
sistance across the terminals of
the red and black wires is [f ]
.
Turn the potentiometer shaft with a
screwdriver until the resistance
across the terminals of the red and
white wires comes to
.
At this position, secure gear
with set screw .
Apply screw locking compound to
the set screw.
Tightening torque : 12 kg.cm

21.

.


,
.

,


.


.

.
:
12 -.

Screwdriver

Gear

Black

White

Set screw
^

Bracket

Multimeter

22. Pull the cord slightly out of the


drum, and see if the resistance
increases smoothly.

22.

,
,
.

23.

.
(.
.)

24.

@

,
@)

,
.

@

25.

()

,

@
.

26.


(g)

@) ,

@
.
.

23. Connect cable terminals to po


tentiometer terminals . (See the
Terminal Connection diagram.)
24. Install c o v e r , positioning clamp
o p p o s i t e the potentiometer. Apply
sealant to packing @) .
25. Stretch cable
clamp @ ,

tight and tighten

26. Install cord lock to the forward


end of c o r d , and install the
wire and connector () to the cord
end. Fully insulate the soldered
pa r t .

insulating tape.

"HI-BOND ,
.

Cord

Lead wire

27. Check conductivity between the


subcord connector and cord con
nector, and absence of shorting.

27.

For the orientation of the


connector terminals and con
nector case, refer to the
structure drawing.
0
. .


,

.

Connector

2.

Replacing recoil spring

When the recoil spring is broken, re


place the entire drum assembly . For
this, disassemble and reassemble the
boom length detector in the same way as
in "REPLACING CORD".

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.


@
,
@ .

2. Disconnect the leads of the po


tentiometer from c a b l e , and remove
the potentiometer together with
bracket .

3. Remove g e a r and s p r i n g , and


remove the used potentiometer from
the bracket.
4. After removing connector and cord
lock from the forward end of the
cord, tie a string of approximately
m to the end, and slowly wind
up the cord and string on the drum
until the recoil string loses force.


(13)

,


,

,
.

NOTE

5.

Be sure to solder the leads to


the term inals quickly so that the
potentiometer w ill not be unduly
heated.



.
(.
.)


,
,
.

Secure the potentiometer term inal,


including the leads, with insulating
sealant to the bracket.



.
:
"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. Secure gear to the shaft of reducer


b y tightening set screw
against
the flat area on the shaft.
Apply screw locking compound to the
set screw.

7.





.
.
:
12 -.

8.




,
.

Tightening torque : 12 kg.cm


8. With the boom fully retracted, pull
out the cord, and adjust it with the
cord lock so that the 0-marker comes
to the center of the cord guide.

0-marker

9. Procede with the reassembly by


following the procedure 21 onward in
REASSEMBLY under "REPLACING CORD",
given above.

Cord lock

9.

,
. "
", . 21.

ADJUSTMENT

1.

1. With the boom fully retracted, adjust


the cord with the cord lock so that
the 0-marker comes to the center of
the cord guide.

Cord lock

0-marker

2. Adjust the length display of AML.


(Refer to the repair manual for the
AML.)



,

.

2.


.
(. .)

LINE ALAR M DEVICE


GENERAL

If the boom, wire rope, etc. touches,


or even approaches too closely to, an
electrical hot line, serious bodily
injury or death can be caused.
This alarm device is designed to
reduce the possibility of electrocu
tion and hot line breakage. When the
boom is moved into an unsafe distance
from an energized hot line, an alarm
lamp begins to flicker and a buzzer
sounds to warn the operator of the
impending danger.

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

The device incorporates cable breakage


detection circuit which checks the in
tegrity of the cable all while the device
is in service. If breakage occurs, the
device gives an alarm.

- ()


,
,
(
..).

, ,
,


.



,

.
, ,
,
.
[ ]

,
..
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. Check procedure when alarm main unit


is faulty.
Remove the rear cover of the alarm
main unit, and replace the fuse.
If the alarm does not stop after
the fuse is replaced, the internal
circuit is faulty.

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.

-
, ,


.
(

,
.)

1. Turn the voltage selection knob to


6.6 KV" and check that the power
supply lamp turns on.
2. With the voltage selection knob in
the "6.6 KV" position, unplug the 2P
connector of the sensor unit to
simulate wire breakage. Make sure
the alarm lamp flickers and the
buzzer sounds.
3. Travel the crane vehicle to move
the sensor probe toward a live hot
line. Make sure the alarm lamp,
flickers and the buzzer sounds.
(Set the voltage selection knob
properly according to the inten
sity of the voltage on the hot
line).

116-0020R

116-0020R

CHECK VALVE

CONSTRUCTION AND FUNCTION

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

DISMOUNTING AND REMOUNTING


WARNING
WHEN THE CIRCUIT IS SUSPECTED TO
RETAIN HIGH PRESSURE OIL, BE SURE
TO VENT PRESSURE BEFORE DISMOUNT
ING THE VALVE.
NOTE
After remounting, bleed the circuit
and the units, and test the operation
to make sure of the absence of
faulty conditions.

1.
2.
3.
4.
5.

6 . -

7 . -

8 .
9 .


.
,
,


.

,

,

.

116-0020R.

116-0020R.

DISASSEMBLY AND REASSEMBLY

CAUTION


"
" ()
,
.

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
POSITIONS



,

.

,

.

,

. .
, ,

.

,
.

WASH THE DISASSEMBLED PARTS IN


KEROSINE, AND CHECK THEIR SLIDING
SURFACES, SEALING PART MOUNTING
SEATS, AND THREAD& CORRECT MINOR
DENTS, SCUFF, RUST OR BURR WITH
FINE ABRASIVE CLOTH OR OILSTONE.
WHEN THE SURFACES ARE NICKED,
WORN OR OTHERWISE DAMAGED SUB
STANTIALLY, REPLACE THE PART&

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

CONSTRUCTION AND FUNCTION

This solenoid valve switches over the


hydraulic circuits by energizing the
solenoid which shifts the spool.
When the solenoid is energized, the
rod incorporated in the solenoid pushes
the spool to switch over the circuit.
When the solenoid is deenergized, the
spool is pushed back to the initial
position by the spring.
The spool can also be shifted with
the manual push pin in the solenoid.



.
,
, ,

.


.

,
.

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

Tighten the mounting bolts to 0 .4 0.5kg.m (2.89-3.62ft-lb).


- 0 , 4 0,5 . .

,

(
) ,

: -
-,
.


,
"
"
.

When the solenoid valve is used to


vent a relief valve (for automatic
stop), the mounting position differs
between normally energized type and
normally deenergized type, as shown
below. When mounting a solenoid
valve, first find out its type by
referring to the OUTLINE OF SPECIFI
CATION at the begining of this manual.

Check valve

Solenoid valve

Fig. 2

Fig. 3

. 2

. 3

[Normally deenergized type]

[- ]

So Install that only the engraved on the


check valve is visible. (Fig. 2)

,
"",
(. 2).

[Normally energized type]


So install that the and 0 engraved on
the check valve are visible. (Fig. 3)
W here the solenoid valve is used for
the winch brake, bleed the brake
cylinder on completion of remounting
of the valve by referring to Chapter
Y, ADJUSTMENT AND CHECKS.

After remounting, bleed the circuit


and the units, and test the operation
to make sure of the absence of
faulty conditions.

[- ]
,
"" "",
(. 3).
,
,

()
Y "
" .
,

,

.

121-0010R.

121-0010R.

DISASSEMBLY AND REASSEMBLY


CAUTION


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.

Z01-0210R ._____________ ___________________________________________________________________ Z01-0210R.


MANUAL CONTROL

VALVE

CONSTRUCTION AND FUNCTION


The manua l control valve is a q u a d
ruple flow d i rection control valve
consisting of four direction control
valve blocks; elevation, telescoping,
ma i n winch, and auxiliary winch; bolted
integrally.
In addition to the four blocks, the
valve also incorporates circuit control
elements; relief valves, flow control
valves, and port relief valves.
The functions of these units are as
follows.
1. Relief valve

(RVl)




, ,
, ,
: ,
,
.
,
:
,
.

.

1.

(RVl)

1 ,


,
,
.

2.

(RV2)

2 ,

RV1.

3.







.
(PR1):

(PR2):
(PR3):
:
(PR4):

This valve controls the pressure in


the pump PI circuit, and also vents
the hydraulic pressure to the tank
by opening the solenoid valve to
the vent circuit when the crane
safety devices such as the overwinding
cutout device are tripped.

2. Relief valve

(RV2)

This valve serves to determine the


pressure in the pump P2 hydraulic
circuit, and also to unload the
circuit similar to RVl.
3. Port relief valves
For smooth starting of the w i n c h
and the boom by cutting the initial
surge pressure when the w i n c h starts
to unwind and when the boo m starts
to l o w e r .
(PRl)
(PR2)
(PR3)

: for m a i n w i nch
: for auxiliary w i nch
: for b o o m elevation

For p rotecting cylinders:


(PR4)

: for b o o m elevation

4. F l o w control valve

4.



,
, ,


,
.

.
(FC1):
(FC2):

5.

(HV)




.

The win c h flow control valve is d e


signed to m a i n t a i n the flow rate of
the w i n c h motor drive oil at levels
determined by the amount of valve
spool displacement, irrespective of
the w i nch circuit pressure.
It serves to obtain smooth inching
control of the winch.
(FCl) : M ain win c h
(FC2) : A u x i liary w i n c h
5. Hydraulic valve

(HV)

This valve serves to vent the ex


cess oil to the tank while only a
small portion of the pump delivery
oil is supplied to the w i n c h circuit
for slow w i n ching operation.

Hydraulic symbol

Main winch

. winch


Telescoping.

Elevating

Relief valve a s s '




(RV1, RV2)

Port relief valve ass




(PR1,

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

PR2,

o Port relief valve a s s

(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

DISMOUNTING AND REMOUNTING


CAUTION
WHEN THE CIRCUIT IS SUSPECTED TO
RETAIN HIGH PRESSURE OIL, BE SURE
TO VENT PRESSURE BEFORE DISMOUNT
ING THE VALVE.
NOTE
After remounting, bleed the circuit
and the units, and test the operation
to make sure of the absence of
faulty conditions.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.





(
)




,
,


.

,

,
.

DISASSEMBLY AND REASSEMBLY


CAUTION
WHEN DISASSEMBLING AND REASSEM
BLING, ALSO OBSERVE 'GENERAL CAU
TIONS (HYDRAULIC UNITS)" IN CHAPTER
A TO WORK CORRECTLY.


" "
()
, .

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
POSITIONa
WASH THE DISASSEMBLED PARTS IN
KEROSINE, AND CHECK THEIR SLIDING
SURFACES, SEALING PART MOUNTING
SEATS, AND THREADa CORRECT MINOR
DENTS, SCUFF, RUST OR BURR WITH
FINE ABRASIVE CLOTH OR OILSTONE.
WHEN THE SURFACES ARE NICKED,
WORN OR OTHERWISE DAMAGED SUB
STANTIALLY, REPLACE THE PART&
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.
IN PRINCIPLE, REPLACE ALL THE SEAL
ING PARTS. OBSERVE'GENERAL CAU
TIONS ( SEALING PARTS)'IN CHAPTER
A IN INSTALLING THEM, TAKING AND
TAKE CARE TO INSTALL IN THE
ORIENTATION.
WHEN REASSEMBLING, TAKE EXTREME
CARE NOT TO ALLOW THE ENTRY OF
DUST AND OTHER FOREIGN MATTER,
AND APPLY HYDRAULIC OIL FOR L U BRICATON TO THE SLIDING SURFACES.
INSERT THE VALVES, PISTON, OR
SPOOLS STRAIGHT, AND CHECK THEIR
SMOOTH MOVEMENT AFTER INSERTION.



,


.

,

.

,

.

, ,

.

, ,
,
.




.

, ,
.

" "
( ) ,
,

.

-
,

.

.
, -'
,

.

, .

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.

1. T e l e scop ing cylinder


The t elescoping cylinders are incor
por ated in the boom, and serve to
telescope the b o o m to w hic h they are
connec ted by pins.
2. Counter balan ce valve
The counte rbalan ce valve is directly
con nected to the tel escoping c ylin
der, and serves to prevent the cyl
inder from r etracting while the con
trol lever is in NEUTRAL, to prevent
the cylinder from being d riven by
the load during retraction, and to
prevent its violent retra ction w h e n
the hoses and other parts of the e x
tension circuit are damaged.
3. Hose reel
The hose reel serves to let out and
take in the hose as the b o o m tele
scopes to m a i n t a i n the hydrau lic
circuit to the No. 2 cylinder all
the time.
4. Hydra ulic valve
The hydraul ic valve is electr ically
controlled, and serves to s e l e ct ive
ly send the pre ssurized oil fed from
the m a n u a l control valve to the No. 1
or the No. 2 cylinder circuit.

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

w i n d the o v e r h e a d c r a n e to res t the


e l e v a t i o n c y l i n d e r s on a p r e a r r a n g e d
s u p p o r t on the frame.
W A R N IN G
M O V E T H E TELESCO PIN G C O N TR O L
L E V E R S E V E R A L T IM E S O V E R T H E
F U L L S TR O K E T O V E N T T H E
PRESSURE IN T H E C Y LIN D E R S A N D
T H E P IP IN G BEFO RE D ISC O N N EC TIN G

,

,

,
.

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.

R e m o v e the p i p i n g and the h o s e reel


h o s e f r o m the No. 1 and No.2 t e l
escoping cylinders.
C o v e r the o p e n i n g s of the p ipes,
h o s e and

cylinders.



,


.


,

.

NOTE

10

A lign the pin holes in the boom


and in the swing table by
adjusting w ith the tw o cranes, in
advance.
10. Wit h the rear part of the bo om sup
ported w i th another overhead crane,
and the boom a s s weight supported
by the two cranes, extract the boom
pivot pin.
11. Lift up the boom a s s slowly, m a i n
taining the horizontal attitude, to
remove it from the swing table, and
lower it on prearranged rests.

,


.



,

.

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.

A pply grease to the pin and pin


holes beforehand.
2. Lower the boom a s s slowly, taking
care not to foul the cab, align the
pin holes in the boom and in the
swing table, and insert the boom
pivot pin through them with the pin
cutout aligned with the lock plate at
the swing table pin hole.

,

.


,

,

,

.


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)



,

.
(. "
".)

4. Reconnect the high pressure hoses


and pipes to the telescoping
cylinder.

CAUTION
5.

ALIGN THE ELEVATION CYLINDER


PISTON RODS AND THE SPHERICAL
BEARINGS WITH THE PIN MOUNTS ON
THE BOOM, BEFORE EXTENDING THE
ELEVATION CYLINDER PISTON ROD&
NOTE
Extend the elevation cylinder w ith
the A M L emergency switch ON.
A pply grease to the pin and the
pin holes in advance.

5. Wi th the two elevation cylinders


lifted up together, start the engine,
extend their piston rods by moving
the elevation control lever to ex
actly align either the right or
the left elevation cylinder upper
pivot pin holes, and insert pin @).
(Fig. 2)


, .







@)
(. 2).



,

.

6 . Similarly, insert the opposite pin


and stop the engine.
7. Lower the cranes supporting the e le
vat ion cylinders and the forward
part of the boom, and remove the
slings.
8. Reconnect the cords and the cables
to the boom length detector, the
b oom angle detector, and the moment
detector and other wires.
9. After remounting,
specified.

conduct the tests

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.

,

Slide plate ass'y^^jQ^



WARNING

3.

MAKE SURE THAT THE CRANES AND


THE SLINGS HAVE SUFFICIENT CAPACI
TIES TO SUPPORT THE BOOM ASS Y.
PREVENT THE SLINGS FROM BEING
BENT SHARPLY AT THE BOOM EDGES
BY COVERING THE EDGES WITH
APPROPRIATE PLATE&

(J41^ ,
''^74^

,

1 .


(. 6).

3. Remove slide plate ass*ies ,


and Cj84^ from the side plates
of the base boom section; then pull
the second boom section approx. Im
from the base boom section. With the
second boom section slightly lifted,
remove slide plate a s s i e s ^ J ^ and
from the b o tto m plate of the
base boo m section. (Fig. 6)

,
,


.

,
.
4.

4. W ith the second b oo m section pulled


out approx. 7 m, resupport it at two
points using two overhead cranes;
then pull it out completely. (Fig. 7)



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.

'^M easure and note the positions of


extension w ire rope adjust nuts @
and on th e ir respective bolts fo r
reference in reassembly.
Measure and note the position of
the nut of adjuster ass'y ) (fo r
retraction w ire rope adjustm ent) on
the adjust bolt fo r reference in
reassembly.
6.

7.




.
,


,
.



@




.

Remove top boom section extending


wire rope @ from the second boom
section and fasten it temporarily
to the top boom section. Then,
remove adjuster a s s f r o m the
second b oom section, and fasten it
temporarily to the third boom
section.



@ (

)
.

Remove slide plates @ from the side


plates of the second boom section.

7.


(@)

.

2nd boom section


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.

When w ithdraw ing the th ird boom


section, take care not to damage
boom re tra ctio n w ire rope @ located
on the upper surface.


,
. 3 4.


,
@

,
.

When w ithdraw ing the th ird boom


section, take care to prevent the
No. 1 cylinder from fouling the
second boom section. Remember the
rear p a rt of the cylinders has been
freed.



1
.

,
.

9, Remove the third b oom section from


the second boom section by proce ed
ing similar to processes 3 and 4.

10. Remove b o l t s , and remove support


from the rear end of the third
boom section. (Fig. 12)

10

11.

11. With the No. 2 cylinder supported


wit h a crane, extract p i n s , and
wit h d r a w the No. 1 and No. 2 cy lin
ders together from the boom.
(Fig.


,

(. 12).

2
, ,

( 1 2)
(. 13).

13)

Bolt

Fig. 12
. 12

Support

Fig. 13
. 13

12. Remove p i n s , and remove sheave


a s s ies @ from the rear end of the
third boom section. Extract pins
t h r o u g h the holes in the side
plates of the third boom section;
remove retraction wire rope
.

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)

Check the boom for twist,


warp, and cracks.

deformation,

2) Slide plate

, ,
.
2)

Check the slide plates for cracks


and wear, and replace whe n these
conditions are excessive.
3) Sheave


,
, .
3)

Check the sheaves for damage, defo r


mation and wear, and replace them
whe n these conditions are excessive.
4) Boom telescoping wire ropes
Whe n the wire rope is in any of the
following conditons, its further use
is strictly prohibited:
a. Deformed or corroded

,
,
, .
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) Adjust the lateral clearances of the


b oom boxes w ith shims. The sum of
the right and left clearances
(clearance between b oom side plate
and slide plate) should be 0 to 0.3mm
for all boo m sections.
3) In the locations shown below, use
slide plates thick enough to allow
a m i n i m u m embeded length of 5 m m
( a in sketch).

2)

.


(


)
0 0,3 .
3) ,
,

,
5
.

boom section

3rd boom section

Fig.
.

16
16

2nd boom section



Base boom section

4) Install extension wire r o p e so


that the center m a rk on it comes to
the center.
5) Install sheave a s s i e s @ w i t h the
retaining ring towards the outside.
Install spacer @ on the inside.
6) Whe n inserting the third boom
section into the second boom sec
tion, take great care to prevent
the No. 1 cylinder from fouling
the second boom section. (If the
relative positions of the No. 1
and No. 2 cylinder change, the h y
draulic hose between them can be
d a m a g e d .)

4)

,

.
5) @ ,

.
@
.
6)


1
.
(

1 2


.)

2nd boom sec.


3rd boom sec

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 slide plates, w i t h scr e w lock


c o m p o u n d a p p l i e d , l i g h t l y , a n d then,
b a c k o f f 1/4 turn.
8) I n s t a l l

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

thread coated wit h screw locking c o m


p o u n d , t i g h t e n n u t (a) u n t i l the bo l t
h ea d comes into light c ontact w i t h
s u r f a c e Y;

l o c k w i t h nut

Nut

Fig. 18
. 18

A D JU S T IN G B O O M TELESC O PIN G W IR E ROPES


N O TE
M ake
th e

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) Retract the boom fully.

3) .

4) Tighten the right and left boom ex


tending adjusting nut s alternately
until difference ( ) becomes
approx. 10 mm.

4)


,
( )
10 .

Fig. 20
. 20

5) Extend the 3rd and top boom sec


tions again, and check that (

2.

) is approx.

5)
,
( )
10 .

10 mm.
2.

Adjusting retraction w ire rope


1) Retract the boom and lower it to
the horizontal.

1) ,
.

2) Extend the 3rd and top boom sections


approx. 1 m, then retract them. M e a
sure the still unretracted l e n g t h
of the top boom section.

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

tronic parts (boom length d e t e c


tor, a n g l e d e t e c t o r , et c . ) that a r e
i n f l u e n c e d by b o o m d i s m o u n t i n g , f o r
f u n c t i o n and accuracy.

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

DISMOUNTING AND REMOUNTING


Refer to DISASSEMBLY AND REASSEMBLY
in the chapter for the boom.

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

CONSTRUCTION AND FUNCTION

this counterbalance valve is for pre


venting the actuator from being driven
by the load and its own weight faster
than the speed corresponding to the
oil supply rate.



(
,
,
).

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

remove drum plate

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

the re el u p s i d e d o w n (so tha t d r u m


p l a t e is up). C l a m p s h a f t a n d
r e m o v e d r u m p l a t e . (Figs. 5, 6)


@
, @
,
,



, .

@
.

,
..

.
,
,
(

).

,

(. 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

and backup rings

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
.

Replace 0 -rin g , RL-rings, and backup


rings w ith new parts.
1. Force-fit ball bearing
housing (2) .

into

(13)

1.


(2' .

2.


(15)
(D .
(
'*Low Temp Grease
2" )
,

RL.

2. Force-fit dust seal


into housing
(2). After fitting, apply grease
(Low Temp Grease No. 2 or equivalent)
to the lip of the dust seal, the
bore of the ball bearing and the
housing surfaces on which the RL-rings
slide.

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

4. Slide an RL-ring installation jig


onto the end of s h a f t , and with
the jig and the shaft coated with
grease, install R L - r i n g s , and
then backup rings .

Orientation of RL-ring

RL

RL-ring installation jig

RL

Fig. 9
. 9

5. Apply grease to the inside surface


of spring and the outside
diameter of shaft ; and slide
shaft into h o u s i n g , taking care
to avoid damaging RL-rings .


,


,
RL

6.

Force-fit

ball bearing

onto drum

6.

plate . Apply sealant (Shin-etsu


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 th e f l a n g e of h o u s i n g (D (the
a r e a w h e r e the h o u s i n g m a t e s w i t h
d r u m p l a t e ) ; an d p l a c e d r u m
p l a t e o n th e h o u s i n g . (Fig. 10)

.
(
" 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

CONSTRUCTION AND FUNCTION

This hydraulic valve is for switching


over the hydraulic circuit from the
normal route from port P to port A
into one from port P to port by moveing the spool by applying pilot p r e s
sure through port PP by energizing the
solenoid.






,

.
.

Electric symbol

Hydraulic symbol

Apply adhesive (THREE-BOND 1327)


to the threaded portions_________
("THREE-BOND 1327")
.

Fig.
.

1
1

1.

Pilot valve body

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.


"
" ()
,
.


,

.

,

. '

WASH THE DISASSEMBLED PARTS IN


KEROSINE, AND CHECK THEIR SLIDING
SURFACES, SEALING PART MOUNTING
SEATS, AND THREADS. CORRBn* MINOR
DENTS, SCUFF, RUST OR BURR WITH
FINE ABRASIVE CLOTH OR OILSTONE.
WHEN THE SURFACES ARE NICKED,
WORN OR OTHERWISE DAMAGED SUB
STANTIALLY, 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 BRICATON TO THE SLIDING SURFACES.
INSERT THE SPOOLS STRAIGHT, TAKING
CARE NOT TO PRY, AND CHECK THEIR
SMOOTH MOVEMENT AFTER IN
SERTION.



,
.

, ,


.

,
.

,
, .
" "
( ) ,
,

.


,

.


.

, ,

.
,
.

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

CONSTRUCTION AND FUNCTION

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. Swing driving unit

1.

The swing driving unit comprises a


motor, a reducer, a brake, and a
control valve, and w h e n h y draulic oil
is supplied under pressure by the
pump, the unit develops rotational
force and transmits it to the inner
ring of the swing bearing by the
pinion.

DESCRIPTION OF SYSTEM
(R efer to the circuit diagram in Chapter Z.)

The p r e ssurized oil brought to the


swing driving unit is directed by the
control valve inside the unit to the
hydraulic motor, to produce either
c l o ckwise or counterclockwise rotation.
The m o t i o n of the hydraulic mot o r is
t ransmitted through the speed reducer
to the gear of the swing bearing, thus
rotating the swing table of the crane.



, , ,
,


-

.


(. Z.)
,

,
, ,

.


- ,
.

SWING DRIVING UNIT


C O N STR U C TIO N A N D FU N C TIO N

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)

The control valve comprises various


v a l v e s f or c o n t r o l l i n g the o p e r a t i o n
of t he h y d r a u l i c m o t o r , a nd the f u n c
tions

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

Back pressure 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.

Hydraulic m otor unit

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.

Mechanical brake unit

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. Control valve unit

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.

A fte r remounting, bleed the circuit


and the units, and test the operation
to make sure of the absence of
fa u lty conditions.




0,3 0,8 .

,
,

.

DISASSEMBLY AND REASSEMBLY

(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.
.

Brake drum hole


13
13

4) Torque the bolts and nuts to the


values given in the structure dia
gram (Fig. 4).

4)
,
(. 4).

5) Adjust the lining-to-drum clearance


as follows. Turn the adjuster with
a screw-driver until the linings
contact the drum, and then back off
6 to 7 notches.
The proper clearance is 0.2 to 0.3mm
(0.008-0.012 in.).

5)

.


,

,

6 7 .
0,2
0 ,3 .

(2)

HYDRAULIC MOTOR UNIT

(2)

Fig. 14
. 14

DISASSEMBLY

1. Dismount the control valve unit from


the hydraulic motor unit.

1.
.

NOTE

Punch match marks on the


hydraulic m otor and speed reducer
before separating them.

2. Separate the hydraulic motor unit


from the speed reducer.

2. .

Hydraulic motor unit


Match mark

Speed reducer

Fig. 15

Fig. 16

, 15

. 16

3. Dismount the mechanical brake unit


from the hydraulic motor unit.

3.
.

NOTE

4. ,

.

Do not remove the oil seal if


it is not damaged. The oil
seal cannot be reused if once
removed.

,
.
.

4. Remove retaining ring @ and remove


oil seal from bottom cover .

Fig. 17
. 17

NOTE

5.

When the bolts are removed,


the bottom cover w ill come out
halfway by itself.

,
.

,
.
5. Unscrew bolts and remove bottom
cover @ from the case.

6. Remove retaining r i n g , and remove


needle bearing f r o m the bottom
cover .

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>
- ,

().

PROTECT THE LAPPED SURFACE


OF THE CYLINDER BARREL <9-1> BY
PUTTING CLOTH OR SPONGE
BENEATH THE SURFACE.
7. Remove cylinder barrel a s s '
the case .


<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. .



.

DRIVING THE SHAFT OUT.

WHEN REMOVING THE RETAINING

RING, TAKE CARE NOT TO DAMAGE


THE INTERNAL SURFACE OF CASE

,
.


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 .
.

i!)rDo not remove the oil seal if


it is not damaged. The oil seal
can not be reused if once
removed.
11. Remove the oil seal cover from the
shaft and remove the oil seal.

CAUTION

BE SURE TO APPLY FORCE TO THE


INNER RACE WHEN REMOVING AND
MOUNTING THE BEARING.

,
.


.
I2. .
@
,
.


12. Remove retaining r i n g , and remove
the ball bearing from the shaft

Bearing

Shaft

13. Remove cam plate from the case.

Fig. 24
. 24

13.
.

CLEANING AND CHECKING

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

Recommended replacem ent c le a r a n c e :


0 .3 mm (0 .0 1 2 i n . )
Use lim it : 0 .5 mm (0 .0 2 0 i n . )
(R eplace in c y lin d e r b a rre l assem
b ly )



,
.
,
,

.
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

Recommended replacement wear limit:


0.2 m m (0.008 i n . )
Use limit: 0.3 m m (0.012 in.)
(Replace in cylinder barrel assem

,
:
0,2 (0,008 )

:
0,3 (0,012 )
(

.)

bly)
6. Partial wear of cam plate
sliding area

in the

R ecommended replacement wear limit:


0.03 m m (0.0012 in.)
Use limit: 0.05 m m (0.0020 in.)
7. Sliding surface of bottom c o v e r
Replace if the depth of the scratch
is more than 0.1 m m (0.004 in.) or
there is deposit of foreign matter.
8. Shaft

6.
(4)
,
: 0,03 (0,0012 )

:
0,05 (,0020 )
7.
1 ,
0,1 (0,004
) ,
.
8.

1) Replace the shaft if there is


partial wear in the splines.

1) ,
.

2) Replace the shaft if wear in the


oil seal sliding area exceeds the
following:

2) ,

.

Wear width:
Wear depth:

0.5 m m (0.020 in.)


0.3 mm (0.012 in.)

9. Ball b e a r i n g ,

needle b e a r i n g

Replace if bearing is in any of the


following conditions.
Unsmooth rotation
Excessive play
Abnormal noise

:
0,5 (0,020 )
: 0,3 (0,012 )
9.

,

.


REASSEMBLY

Reassemble in the reverse order of


disassembly, observing the following.


.

:

CAUTION

1)
,
@ ,

,
.

DO NOT DAMAGE THE SURFACE OF


THE CAM PLATE WHERE THE
PLUNGER BEARINGS SLIDE

1 ) Insert cam p l a t e into the c a s e ,


aligning pins installed in the
cam plate with the pin holes in
the case . Push in the cam plate
u n t i l it bottoms in the case .

Push

Fig. 27
. 27


,

,
.

2)

-


,
.

2) Apply grease to the lip of the oil


s e a l and to the 0 - r i n g s , and @
Install the oil seal in the oil
seal cover with the surface with
the model number down.
Oil seal

Fig. 28
. 28

CAUTION

3)
,
.

APPLY METAL PIECE THE


BEARING INNER RACE.

3) Install ball b e a r i n g @ o n the s h a f t


in the correct orientation.

Projection of
bearing outer diameter

,

Bearing

Fig. 29
. 29

.Protection piece

4) When installing springs <9-4> and


spring seat <9-4> into cylinder
barrel <9-1> , take care not to re
verse the orientation of the spring
seats. (See Fig. 30).
The installation will be facilitated
if a slim bar as shown in Fig. 31
is used as a guide.

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 >
,
,
.

APPLY HYDRAULIC OIL TO THE SLIDING


SURFACES ON THE PLUNGERS.

5) Install plungers <9-3> in the original


bores, and make sure they move
smoothly by pushing with the fingers.

Set the case on its control valve


mounting surface, insert the cylin
der barrel a s s y into the c a s e ,
taking care not to let the plungers
<9-3> slip out of the cylinder barrel
<9-1>, and bring <
>
2
9
plunger bearings
snug contact with the
inclined face camp late .


,
.


,
<9-2>

,
,
, <9-3>

<9-1>.

Control valve mounting face


(to face downward)

( )

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) SPEED REDUCER UNIT

(3)

Fig. 34
. 34

DISASSEMBLY

NOTE

1.

When separating the hydraulic m otor,


gear and its associated parts
may come out on the m otor shaft.
In this case, tap gear (@) from the
shaft, using a plastic hammer.

@

.


,
.

1. Separate the hydraulic motor unit


from the speed reducing u n i t .
2.

2. Punch match marks to the following


parts:
Housing (D and ring g e a r
Ring g e a r and end c o v e r
End c o v e r and ring gear @)

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.

5. Remove retaining rings @ and remove


gears (
g) and needle bearings from
gear .

NOTE
Do not remove the king pins
unless gear
is faulty.

6. spring pins () into king pins@),


and tap out the king pins @) toward
the g e a r mounting end.

,
.

Fig. 37
. 37

NOTE

7.

Separation w ill be facilitated if bolts


are screwed into the threaded holes
fo r disassembly.

@ ,

@ .


,
.

7. Flatten w a s h e r s , unscrew b o l t s
and remove ring gear @ from the
end cover @

Threaded hole for dis


assembly, two symmetri
cal places.
:

.

Match mark
cna

Fig. 38
. 38

NOTE
Insert cylindrical support under
housing @ .

8.

Rem ove b o l t s
.

and remove end cover

8.

@ .

Cylindrical support

Fig. 39
. 39

NOTE

9.

Separation w ill be facilitated if bolts


are screwed into the threaded holes
fo r disassembly.


,
.

9. Remove ring gear from housing (D .

Threaded hole for dis


assembly, two symmetri
cal places.
:

.

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.


@

,
@ .

11. Flatten w a s h e r s , unscrew b o l t s


and remove spider @ from the shaft

Match mark

Fig. 41
. 41

12. out king pins from the shaft


mounting side, and remove thrust
bearings, gears (8) and needle
bearings .

CLEANING AND CHECKING

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.

, ,
, ,
,

.


Replace if bearing is in any of the


following conditions
Unsmooth rotation
Excessive play
Abnormal noise

REASSEMBLY



, .

Reassemble in the reverse order of


disassembly, observing the following :

1) , .

1) Reassemble the unit aligning the


match marks made during disassembly.

2)

.

2) Oil seal cannot be reused if once


removed.

3)
0-
.

3) Coat the lip of the oil seal and


0-ring with grease.

4) ,
.

4) Install the oil seal as shown below.

Fig.4
2
.4
2

5) When installing shaft, take care


not to damage the oil seal sliding
surface of the shaft.
6) Torque the bolts and nuts to the
values given in the structure
diagram (Fig. 4).

5) @

.
6)
,
(. 4).

(4) CONTROL VALVE UNIT

(4)

Fig. 43
. 43

DISASSEMBLY

Disassemble the unit as shown in Fig.43,


observing the follow ing:


. 43, :

1. Whe n disassembling control

spool

1) Before extracting the spool, mark it


wit h a marking pen or the link to
identify its head and tail.
2) Use a spool extraction jig as shown
in Fig. 44 when extracting the c o n
trol spool, to prevent damage to
the oil seal.
spool extraction jig'

1.
(2)
1)
..

.
2)

, . 44,

Spool extracting direction


3) Unless the oil seals are damaged,


do not remove them, and use them
further. If they are removed, re
place wit h new oil seals.
2. W hen disassembling overload relief
valve @)
1) W hen clamping sleeve (| ^ in a vise,
do not tighten excessively to
prevent its deformation.
2) Remove pilot seat < ^ 3 ^ from the
sleeve by pushing spool (| ^ in the
sleeve with a suitable rod, taking
care to prevent damage to the
sleeve bore.
3. Whe n disassembling solenoid v a l v e ~ ^

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)

1) Tap out sleeve


mounting side.

to the plate

4. W hen disassembling chokes


,
. ,
,
,

4.
1) Remove c h o k e s by screwing in the
extraction bolt and pulling.

1) @

2) He -

,
.

-
.

2) Unless -ring @ is damaged, do not


remove it, and use it further. If
it is removed, replace it w ith a
n ew 0-ring.

Extraction bolt

Thread size : 5
; 5

CLEANING AND CHECKING

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

Reassemble in the reverse order of


disassembly, observing the following :
1) The following parts are not repl a c e
able individually. When they require
replacement, replace them in subassemblies as listed under the
same number.
B o d y , control
valve s l e e v e ,
spool

s p o o l , solenoid
solenoid valve

Overload relief valve spool


(), sleeve (|^

Overload relief valve pilot seat


3^,


,
.
1)
.



.
, ,
@ ,
@
-
(23-^ ,

<&>

poppet
@ -

, <^3^^

2) Whe n installing seal cap (D and valve


seat<|33>5 degrease their threaded
portions as well as their mating
members, and apply screw locking
compound to the threads.
3) Before inserting control spool (D
into b o d y , check the smooth m o v e
ment of steel b a l l , and its proper
seating on the seat surface as
shown below.

2)
(5?



.
3)
2'



, .

Seat surface

Push with fine rod to


check smooth movement of
the steel ball.

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
.

After insertion, no gap


is permissible all around
the circumference

.

No -ring
-
.

Fig. 48
. 48

6) After installing overload relief


valve assembly @ into b o d y , check
spool<|53) for smooth movement.

6) - @


<~1) .

Approx. 4 kg (8.8 lb.)


4
(8,8 )

Spool

Check movement by pushing with 10 - 15 mm (0.4 - 0.6 in.) dia rod.



10 15 (0,4 0,6 ).

Fig. 49
. 49
7) After installing check v a l v e , move
it with the finger to checls for
smooth movement.

7)
@

.

8) Before' installing solenoid valve


sleeve into b o d y , check spool
f o r smooth movement in the sleeve.

8)

9) Install solenoid valve sleeve


into body as follows.

9)



.

To locate the sleeve, center punch


the sleeve as shown below.


,
.

Elongated recess

From this shape with a center punch

..

Fig. 50
. 50

NOTE

(D ,

( . 50)
3,3
.

Align the centers of the recess and


the 3.3 mm hole.
' that there is a 2 mm dia hole
drilled in a 4 mm dia. hole on the
opposite side of the elongated recess.
(D Insert the sleeve into the body until
the elongated recess (marked by i n
Fig. 50) is visible through the 3.3
mm did. hole in the body.
T o p the sleeve into the body until
the sleeve end is flush with the body
surface.



3,3 .
,
,
2 ,
4 .

3.3 mm hole

Flush
3.3

.

Fig. 51
. 51

10) Insert check valve into valve


seat for the back-pressure valve,
and install retaining ring @ c a r e
fully into the groove.
Then, shake the entire back - p r e s
sure valve to check for the free
movement of check valve @ by means
of rattling sound.

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

,
.

Prepare a hydraulic circuit for testing


as shown below.
A p p licable model:

RBMSF-210T780-3

RBMSF-210T780-3

Relief valve


Control spool

Flow control valve


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

brake from dropping caused by winch


o p e r a t i o n , to p r e v e n t c h a t t e r i n g of

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.



,
,




.

D ESC RIPTIO N O F S YSTEM


( R e fe r t o th e c i r c u it d ia g r a m

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

telescoping valve blocks,

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

brake which brakes when

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

but the motor does not operate.

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

giving match marks

sections

to

be d i s a s s e m b l e d ,

plug and di scharge


casing @ .
2.

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

Remove separator plates), friction


p l a t e s , brake s h i m , and brake
spacer .

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,

and remove valve cover .


W h e n the d e f l e c t i o n of d i s k s p r i n g
i s t o b e m e a s u r e d , m e a s u r e i t at
t his time, r e f e r r i n g to
CHECK
g i v e n later in this section.

.

@


. " " .

NOTE
Take
fro m



@

@
.


..
,
.

6. W i t h the m o t o r p l a c e d on its side,


withdraw cylinder b l o c k parallel
to o u t p u t s h a f t . At t h e s a m e
time, w i t h d r a w p i s t o n s , r e t a i n e r

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 ;

cover from casing


t he t h r e a d e d
(M8).

8.

Extract output shaft


b y t a p p i n g the s h a f t
valve cover @ mounting
a plastic hammer.

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.

Sta n d a r d value: 0.023 m m


R e c o m m e n d e d u s e limit: 0 . 0 5 3 m m
2)

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 .

W h en tig te n in g th e b o lts , use


th e to r q u e va lu e s sp e c ifie d in

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.

5. Adjusting the disc spring shim


Place the cylinder block and casing
assembly with the concave of cylinder
block @ up; place valve plate on it,
Measure dimension ^ from the valve
plate to the end surface of casing
; measure dimension L on valve
c o v e r ; then calculate L - (deflec
tion of pack of disc springs). If
the result is 3.65 0 . 1 mm, there
is no need for adjustment. If not,
adjust with shims .






.


@ .


@
( ),

( 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.

Install valve cover


p a y i n g a t t e n t i o n to
position.

8. M a k e

sure output

on c a s i n g ,
their relative

shaft

7.

,
.

8.

,
.

rotates

smoothly.
(2)

(2) Brake section


1.

2.

Slide splined connector @ onto


o u t p u t s h a f t , an d i n s t a l l s t o p
ring .
brake

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.

Insert brake p is t o n in va l v e cover


, an d r o t a t e the p i s t o n so that

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

CONSTRUCTION AND FUNCTION

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

& Maintenance Manual".

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

B all bearing a n d sle e ve @ ) a r e


s h r i n k - f i t t o th e d r u m s h a f t .
D o n o t re m o v e
n e c e s s a ry .

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 screw hexagon socket head b o l t s ,


remove gear case c o v e r , and take
out d r u m g e a r @ a n d c o l l a r f r o m
gear

u n le s s

Unscrew b o l t s , remove bearing re


t a i n e r , n u t a n d w a s h e r , a nd
w i t h d r a w d r u m shaft

,
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.

Temporarily install bearing retainer


@ o n g e a r c a s e , an d i n s e r t g e a r
in g e a r c a s e .

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

T u r n over gear c a s e , remove bearing


r e t a i n e r that w a s t e m p o r a r i l y i n
s t a l l e d , i n s t a l l it a g a i n o n g e ar
c a s e a f t e r a p p l y i n g 3 - B O N D 1215 to
its m a t i n g s u r f a c e , an d c l a m p w i t h
bolts

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.

Install bearing retainer @ containing


oil seal @ to g e a r c a s e a nd c l a m p
w i t h b o l t s . A p p l y g r e a s e to the
oil seal lip, and co a t the 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 @ and
g e a r c a s e w i t h 3 - B O N D 1215 in a d
v a nc e.

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

This cou nt e r b a l a n c e val ve has


in g f u n c t i o n s :
a nd h o l d i n g

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

C O N STR U C TIO N A N D FU N C TIO N S

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

The holding pressure

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,
.
,

This pressure flows through orifice


a nd e n t e r s c h a m b e r c, w h e r e it

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.

Stopping hoisting down motion


W h e n the c o n t r o l v a l v e is m o v e d f r o m
the D O W N p o s i t i o n to the n e u t r a l
p o s i t i o n , the p r e s s u r e in por t B,
i.e., th e p r e s s u r e in c h a m b e r d r o p s ,
c a u s i n g t h e p l u n g e r to r e t u r n to
n e u t r a l u n d e r s p r i n g f o r c e to c l o s e
the p a s s a g e
load at

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.

DISMOUNTING AND REMOUNTING

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 .


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,

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


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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 .



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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 .

366 - 028 - 2000

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ROTARY JOINT

CONSTRUCTION AND FUNCTION

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

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,

P3

S w in g

13

D r a in

TO

Tank

Details of electrical assembly


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. Set the outriggers, elevate the boom


to approximately 60, and stop the
engine.

1.

,
60
.

2.


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WARNING
^BE SURE TO DISCONNECT THE
BATTERY BEFOREHAND.

CAUTION


.

WHEN DISCONNECTING THE PIPING,


HOSING AND WIRING IN DISASSEMBLY
WORK, TAG THEM TO FACILITATE
REASSEMBLY.
CLOSE THE OPEN ENDS OF THE PIPES
AND HOSES WITH PLUGS AND CAPS

2. Disconnect the piping, hosing, w i r


ing and the locker from the rotary
joint.
3.
3. Unscrew the m ounting bolts, and hoist
off the rotary joint, using a proper
hoisting device.

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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


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.

, "F"
.

(10 X 25)
:
23515 .

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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&



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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 OIL
STONE. WHEN THE SURFACES ARE
NICKED, WORN OR OTHERWISE DAM
AGED SUBSTANTIALLY, REPLACE THE
PARTS.

REASSEMBLY



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CAUTION

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 EX
TREME CARE NOT TO ALLOW THE
ENTRY OF DUST AND OTHER FOREIGN
MATTER.
To connect hose (D to fittings and
insert the hose end fully into
the fitting body, tighten the nut
hand-tight, and then using a wrench,
further tighten the nut one and a
quarter (1 1/4) turns.
Reassemble b o d y , core) and c a s e
with "F" stamp marks matching.

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(6,

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1-1/4 .
@ , @

, "F" .

116-0030R

1 1 6 -0 0 3 0 R

CHECK VALVE

CONSTRUCTION AND FUNCTION

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

DISMOUNTING AND REMOUNTING


WARNING
WHEN THE CIRCUIT IS SUSPECTED TO
RETAIN HIGH PRESSURE OIL, BE SURE
TO VENT PRESSURE BEFORE DISMOUNT
ING THE VALVE.
NOTE
After remounting bleed the circuit
and the units, a n d tes t the operation
to make sure ofth
e
absence of
faulty conditions.

1.
2.
3.
4.
5.

6. -
7. 0-

8.
9.
10.

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116-0030 R.

116 -0030R.

DISASSEMBLY AND REASSEMBLY

CAUTION

WHEN DISASSEMBLING AND REASSEM


BLING, ALSO OBSERVE'GENERAL CAU
TIONS ( HYDRAULIC UNITS)MN 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
POSITIONS



,

,
,

.


,

.
, ,


.
, ,
,
.

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 SUB
STANTIALLY, REPLACE THE PARTS

MAINTENANCE STANDARDS

Item

Maintenance standards

Filter

Replace at every 24 months.

24 .

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