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REPAIR

MANUAL

TELESCOPING SYSTEM



REPAIR
MANUAL

CRANE CONTROLS


L01-0030R. L01-0030R.
LOCATIONS OF COMPONENTS

GENERAL

FUNCTIONS OF UNITS

1. Master cylinder 1.

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 2.

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 7-7. Valve spring 1. 7-7
2. Push rod 7-8. Retainer 2. 7-8
3. 7-9
3. Boot 7-9. Spring 4. 8.
4. Stop ring 8. Spacer 9.
5. Cylinder body 9. Gasket 5. 10.
6. Stopper 10. Stopper bolt 6. 11.
7. 12.
7. Piston ass' 11. Spring 13.
7-1
7-1. Piston 12. Check valve 7-2 14.
7-2. Cup 13. Gasket 7-3 15.
7-3. Cup 14. Plug 7-4 16.
7-5
7-4. Backup ring 15. Band 7-6
7-5. Valve rod 16. Nipple
7-6. Valve cup


PRINCIPLE OF OPERATION

1. During actuation
(2)
,
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.
2. When releasing 2.
(2)

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 , <7^
tends to become negative. If this ,
occurs, valve cup is unseated,
.
allowing oil to flow from chamber
< 53 ^
into the master cylinder. , ClzE)
As p i s t o n m o v e s toward the (6) ,
stroke end, stopper (6) pushes valve (J-^ ,

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 0,5 /2

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

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. Y.

DISASSEMBLY

1.
1. Discharge the brake fluid from the .
oil tank.
2. ,

2. Unscrew stopper b o l t , and remove .
g a s k e t and spacer together.
3. ,
@
3. Remove b o o t , and remove stop
ring with a small screwdriver ..
or the like.
4.
.
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)
,
Wash in trichloroethylene, and dry .
by blowing compressea air on them.
2)

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 .
30 seconds in the alcohol.

CHECKING
1) ,
1) Cylinder body, piston

Inspect sliding surfaces, and replace ,
parts showing scratches, rust, or .
excessive wear. 2)
,
2) Rubber parts ,
. ,
Replace the rubber parts when they

are damaged or aged. In addition, 1 , ,
even without any defects, replace .
all the rubber parts used more than
1 year.
REASSEMBLY

NOTE 1.
,
7-1
Take care not to damage the sliding , ,
surfaces of the cylinder and the -
piston and the seal areas of the .
cups, when inserting. .


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.
2. With piston a s s y installed,

install stopper bolt @ together with .
gasket (9) and spacer
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. ,
.
5. Install valve and plug .

TEST
1.
1. Function test

With a small amount of brake fluid , 0,5 1,0 /2
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 3
port, and make sure that when the .
piston is advanced approximately
2.
3 mm, (0.12 in.), the air flow to

the oil tank is stopped. ,
-
2. Operational test ( , 30 ) ,
,

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 of m a s t e r cylinder, brake fluid


level, a nd leak.

1 0 0 0 hr or 6 - m o n t h Master cylinder function test.


check

2000-hr or 1-year 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


check 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.
,

.

1000 .
6
, .
2000 .
. " .
CONTROL CYLINDER

CONSTRUCTION AND FUNCTION

Fig. 1
. 1

1. Piston 5. Boot 1. 5.
2. Cup 6. Cap 2. 6.
3. 7.
3. Cylinder body 7. Bleeder screw
4.
4. Push rod

REMOUNTING


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. Y.

CLEANING


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

CHECKING
1) ,
1) Cylinder body, piston
Inspect sliding surfaces, and replace ,
parts showing scratches, rust, or .
excessive wear. 2)
,
2) Rubber parts ,
. ,
Replace the rubber parts when they 1 ,
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

Item Maintenance standards


Routine check Operation conditions of c o n t r o l cylinder, a nd leak.

2000-hr or 1 -y e a r Disassemble control cylinder and c h e c k all parts. Re


check p l a c e all r u b b e r p a rts.


,
2000 .
.
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 /

1 104.0 cc/rev
2)
2 83.2 cc/rev

36.4 cc/rev PI 104,0 3 /


2 83,2 3/

2. Hydraulic motor (winch) 3 36,4 3/

. Oil intake rate : 535 cc/rev 2. ()

3. Swing driving unit : 535 3/

1) Oil intake rate : 210 cc/rev 3.


2) Reduction ratio : 16

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

Oil viscosity: 30 50 cSt : 30 50
(
(When DAPHNY Hydraulic Fluid WR22 is "DAPHNY Hydrau
used: oil temperature: 30 5C) lic Fluid WR22";
:
305)

1.

Location : Behind the crane cab


:

1) 1 (
1) Pump PI main circuit
RV1)
(relief valve RVl)

Disconnect the wiring for the main (SL8: . )
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.
2150 / (.)
Pump speed: 2 1 5 0 rpm (MAX.)
2) 2 (
2) Pump P2 main circuit RV2)
.
(Relief valve RV2)

Fully retract the boom. ,
Move the boom telescoping lever to .
the boom retraction position, and :
measure the pressure. 2150 / (.)
Pump speed: 2150 rpm (MAX.) 3)
( PR1)
3) Main winch unwinding circuit .
. (port relief valve PRl) (SL8: . )
,
'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: 6 0 0 rpm^tlDL. )
4) Auxiliary winch unwinding circuit 4)
(port relief valve PR2) (
PR2)
Disconnect the wiring for the
auxiliary winch brake solenoid valve (SL9: . )
(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: 6 0 0 rpm (IDL.) /


5) (
5) Boom lowering circuit PR3)
(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.
2150 / (.)
Pump speed: 2150 rpm (MAX.)
ADJUSTMENT (Electric)
, ()

SWITCH ADJUSTMENT

NOTE

For the locations of the switches, -


refer to Chapter Z ELECTRIC .
Z,
CIRCUIT ( Location of electrical p a rts).

1. Switch S 1(M ain winch winding detection) S1 (


Switch S 2(M ain winch unwinding detection)
Switch S3 (A u x ilia ry winch winding )
detection ) S2 (
Switch S4( A u xilia ry winch unwinding
detection ) )
Switch S6(Boom extending detection) S3 (
Switch S7 ( Boom elevating detection )
Switch S8 ( Boom lowering detection ) )
S4 (

)
S6 (
)
S7 (
)
S8 (
)

Apply screw locking


S1, S3, S7
Compound._______


Spool moves rightwards when
Spool moves leftwards when performing performing such operations as
such operations as winch winding, boom winch unwinding, boom lowering
elevating and boom retracting. and boom extending.

,
, ,
. Spool ,
.

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
1,0 2,0 -
from the neutral position, they are ( ).
turned off (open).
2. Switch S12 ( F o r detecting over-unwinding 2 . S12 (
of main winch)
Switch S13 ( For detecting over-unwinding )
S13 (
of aux. w in ch )


)

Adjust clearance between the A


winch drum and the roller to 5 mm
with the adjusting bolt . @ ,
Then turn the adjusting bolt to 5 .
bring the switch plunger into the ,
trip position (contacts COM-NC
( 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 3. S18 (


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. 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

S w i n g brake adjustment 1.

1)
1) Completely release the swing brake

lever. .
2) Remove the brake cover of the swing 2)
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 6 7 , -
0.2 to 0.3 mm (0.008 to 0.012 in.) 0,2 0 , 3
is obtained. (0,008 0,012 ).
Adjuster Brake drum hole

3)

3) Turn the adjust nuts until the mov ,
ing range of the swing brake lever
becomes approx. 75% of the maxi 75% ( )
mum stroke. .

[ ]
[Reference]
: 12
Max. stroke: 12 notches
75% : -
75% stroke: Approx. 9 notches 9
. stroke

75% s t r o k e
75%

2.
2 . S w in g d riv in g u n it bleeding procedure

1) Pull up the swing brake lever. 1



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



, ,
.
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 2)
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.
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)
-
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.
90% 100%
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.

2. Solenoid valve 2.

If the AML gets out of order on when ,


the actual moment reaches 100% of ,
the rating or the hook block is over 100% ,
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.
3.
3. Check valve


The vent circuits for relief valves
(RV1
RVl and RV2 incorporated in the
RV2),
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.
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 . 1

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 . 2 -
Boom angle Boom length
detector detector
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 S
--------r

f-12V , :
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
I

-
,
Jib angle display
Latch
driver III II I

LED for|

1 luraination


777
Boom length display

. .

3ut interface L E D for I
\c, i 1 l u m i n a t io n ,

Actual load display


Latch |
driveer
1-1. .
^ o L E D for I
^ g<5 1 1 l u m i n a tion
> IllnJ


Total rated load

cj
display

Or I
ctJvD LE D for I
41 1<:

illumination

Latch
Boom angle display
. . 1
LCD ILLUMI driver
L E D for 1
NATION BOARD I- i
11] 1 umi n_^t :
\-
OCl Working radius .
-
_______ /1 display
O.U.U
Il E D for '

1lumina
LATCH Ji.i

^ D R I V E R MAIN J3 J2 C/W

Output gate ->


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 I ;
point adjuster
^1 \ / indicator lamp - Height limit
1ZV.+SV ^ "'
Upper angle 1imit )

Lower angle limit.

W o r k i n g radius limit.

Bo o m state

Right outrigger

Left outrigger !

Input gate

Check switch
^'"
[NOTE]

The schematic at left shows


^ Angle detector
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
Moment detector
is for Model TG-1200MG-1)

[]
CN5
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 (2)

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. - -
; .
(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)

(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.
.

(6) Moment lim iter main unit


(6 )
The moment limiter main unit is lo
(A T)
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.

.

.
Fig. 3 A M L main unit . 3

Connector terminals No. Adjuster indication


indication plate plate

(
No. CONNECTION CN1 No. CONNECTION
1 POWER 23 ALARM(FAIL) SPAN BOOM
No. CONNECTION
2 SOURCE 24 ALARM (90) ZERO LENGTH
13 POWER
3 ANGLE OUT (-) 25 ALARM (100) SPAN BOOM
14 SOURCE
4 ANGLE OUT (+) 76 OVERWIND RZ ZERO ANGLE
15 Dil C.W.E/N
5 BOOM ANG. IN 27 ALARM (BACK) _ SPAN SLEW
16 DI2 F/JACK
6 LENGTH IN 78 AUTO STOP ZERO ANGLE
17 D13 R/F
7 lANG. SHIELD 29 OVERWIND C/0 SPAN JIB
18 DI4 JIB
8 '. SHIELD 30 AML C/0 ZERO ANGLE
19 DI5 B/RET. 1
9 !0. OUT (+) 31 EMERGENCY C/O CAL, RADIUS
20 DI6 RET. 2
10 MO. OUT (-) : 32 BUZZER CAL, LOAD
21 DI7 SLEW
11 MO. IN (+) 33 LENGTH SW. 1 ADJUST, 1
22 DI8 OVER W.
12 MO. IN (-) 34 LENGTH SW. 2 ADJUST, 2
SPAN
N o. CONNECTION
MOMENT
No. CONNECTION . CN2 ZERO
1 EXT. 19 DBO
No. CONNECTION Power supply lamp (LED)
2 POWER 20 DBl
11
3 SLEW OUT (-) 21 DB2 indication plate
12 POWER
4 SLEW OUT (+) 22 DB3
13 ABO
5 SLEW ANG. IN ?3 DR4
14 ABl
6 JIB ANG. IN 24 DB5 ()
15 AB2
7 SLEW SHIELD 25 DB6
16 I/O READ
8 POWER +24V ?6 DB7
17 I/O WRITE 5^
9 SOURCE (EXT.) 27
18 RESET + 12V
view 10 --
2o

+24V
112, +5
FAIL

Side view

Front view

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 (%) Buzzer Crane motions


-
, % .-. ,.. .______________ _______ _______________

N
[ i*i

Up to 89.9%
Moment (X)

I
1 1!1
10 2)56'09955 Do not stop.
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 ratio (%)


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.
(%)
.___________ ____________________________________________

- -

90.0 - 9 9 . 9 % ?7^^ ^
i1!11
2 0 X ^ 5 0 60 70 809515 |\\\ Do not st.c>p.
90,0 99,9 ^ 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 ratio (%) interm ittent

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.
(%) -
.________________________________________________ 1_____________

1
10 0 % and liPii 1 Red LEDs S top.
Moment (Z)
over 257099551
, %
100 Green LEDs L .Orange LEDs

continuous
Red LEDs illuminate all at the same time, time,

illuminating the entire length of the band .
! (
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 3 ,
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.
.
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 Height
Height
limit limit
limit Buzzer Auto, stop Height Note
input indicator
data
switch lamp
No.

-1
"
- -
___
=
Boom rising \ : Displayed
and extendingj height

are stopped. / : Stored
store Push Flickers height

data ^ limit /
=
-
;
-

State of boom:
Lowered or re
tracted after
a limit is
ON No auto. stop. < stored as in
No. 1.

;

Data
stored 1.

Silent State of boom;


/Boom rising \ Raised or ex

and extending tended to stored

\are stopped. J limit (After
Flickers assuming state
iHe
; = No. 2)
'
:
-

2.


Push
erase OFF
again
data



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. @
.. ______________
Boom angle Boom angle
Boom angle
upper limit upper limit
upper Buzzer Auto. Stop Boom angle Note
input indicator
No. limit data
switch lamp
BGDXHfrC
'



*

/Boom ris
ing is
\stopped.
store ^
Push Flickers
data 3

!

:^ -

;
-

State of boom:
Lowered after
a limit is
Silent stored as in
ON No auto. No. 1.
S t o p
:


1.
Data
stored
State of boom;
fBoom ris- \ Raised to

ing is stored limit
^topped. / (after assuming
Flickers state No. 2)
:

2.

erase Push
OFF
data again

"
"
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 Boom angle
Boom angle
lower limit lower limit
1ower
input indicator Buzzer. Auto, stop Boom angle Note
No. limit data
switch (g) lamp 1)
. .
",
- -

*

/ Boom Ox -
lowe: \ : Dis
I ing IS j played
^ S t o p p e d ./ angle
: Stored
store
Push Flickers angle
data
limit/
0x = 0

X -



-

State of boom:
Raised after
Silent a limit is
stored as in
ON No auto, >
No. 1.

stop
:
^
Data
1.
stored
State of boom:

/Boom Lowered to
/ lowering stored limit
I is - (after assuming
Flickers state No. 2)
\ s t o p p e d ./
^! :

^ 2.

erase Push
data again OFF
-
________
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. .

Working Working Working


radius radius radius limit
Working
limit limit input indicator Buzzer Auto, stop Note
No. radius
data switch @) lamp
or

"
-
"______
Rx ^ R
/Boom 1- \ /Rx: Dis-
wering a^nd played\
extending value
store Push. are R Stored
Flickers radius/
data
^stopped. . \ limit '

( CRx = R
Rx -

;
R -
____
State of boom:
Raised or re
tracted after
a limit is
ON Silent No auto, Rx < R stored as in
No. 1.
He stop
He . :


1.
Data
stored State of boom:
Boom lo \ Lowered or ex
wering and^ tended to
extending stored limit
Flickers are (After assuming
Vstopped. Rx state No. 2)

:


2.

Push OFF
erase again.
data



^ 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, exting-
guishing 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 . TG-1200MG, TG-700EG
illuminate. 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 two-
stage 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 two- .)
stage 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 "" (g)
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. . . "~
".
NOTE

jV
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.
.
$ Check switch ""

This switch is pushed in preoperatio-


nal 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 : 15


(number of rotations) 15

("BOOM ZERO")
Boom length zero adjuster
...... BOOM LENGTH ZERO : 15

Screw turn range


(number of rotations) 15
.
Adjusters and adjust the boom
length display.
Boom angle span adjuster
...... "BOOM ANGLE SPAN" ("BOOM ANGLE SPAN")

Screw turn range : 15


(number of rotations) ; 15

Boom angle zero adjuster ("BOOM ANGLE ZERO")
...... "BOOM ANGLE ZERO" : 15
Screw turn range
(number of rotations) : 15
.
Adjusters and adjust the boom
angle display.

NOTE ("SLEW ANGLE SPAN")

With models TG-1200MG, T G - : 15


700EG, and TG-500ERG adjusters

and @ are not used.
("SLEW ANGLE
ZERO")
Swing angle span adjuster
...... "SLEW ANGLE SPAN : 15

Screw turn range


(number of rotations) : 15 ("JIB ANGLE SPAN")

@ Swing angle zero adjuster : 15


...... "SLEW ANGLE ZERO"

Screw turn range ( " ANGLE ZERO")
(number of rotations) : 15
: 15

Jib angle span adjuster


...... "JIB ANGLE SPAN"

Screw turn range ik


(number of rotations) : 15 @
. TG-1200MG, TG-700EG TG-500ERG.
@ Jib angle zero adjuster
...... "JIB ANGLE ZERO"

Screw turn range
("CAL, RADIUS")
(number of rotations) : 15

(
Working radius display adjuster
).
..... "GAL, RADIUS"
: 15
Used to adjust the display of work
ing radius (and max. lift).
Screw turn range ("CAL, LOAD")
(number of rotations) : 15
(
Load display adjuster ).
...... "GAL, LOAD"
: 15
Used to adjust the display of
actual load (and total rated load).

Screw turn range


(number of rotations) : 15
NOTE g) "ADJUST, 1"
: 15
With models TG-1200MG, and TG-700EG,
adjusters and @ are not used. "ADJUST, 2"
: 15
"ADJUST, 1"
Screw turn range
(number of rotations): 15

@ "ADJUST, 2" . TG-
1200MG TG-700EG.
Screw turn range
(number of rotations): 15
Moment span adjuster "MOMENT SPAN" ("MOMENT SPAN")

This adjusts the output voltage of

the moment detector.
.
Screw turn range : 15
(number of rotations): 15

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


("MOMENT ZERO")
This adjuster and moment zero fine
,
adjuster are for zeroing the

moment detector.
,
Screw turn range .
(number of rotations): 15
: 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
+12
An LED (Light Emitting Diode) for
indicating +12V power supply, turn
ing on when power is on. +12
.
@ Indicator lamp for -12V power supply
-12
An LED (Light Emitting Diode) for
indicating -12V power supply, turn
-12
ing on when power is on.
.
@ Indicator lamp for +24V power supply
+24
An LED (Light Emitting Diode) for
indicating +24V power supply, turn +24
ing on when power is supplied from
battery to AML. .

@ Indicator lamp for 12V and +5V


power supply fault 12 +5
An LED (Light Emitting Diode) for
checking 12V and 5V power supply, 12 +5 ,
turning off when power supply is in
order, and turning on when it is ,
not in order.
.
NOTE @ " "

For Models TG-1200MG, the over
.
fro n t indicator lamp does not

illuminate. . TG-1200MG
.
Over-front indicator lamp
This lamp illuminates when an over (7)
front signal is received from the
detector.

(7) Alarm and automatic stop circuits ,
90%
Alarm circuit ,
this circuit is for sounding the ,
buzzer when the actual value exceeds
90% of the rated value, or when the ort^-
load limit function or the angle ,
limit function is tripped, or when .
with the hookblock overhoisted the (2)
crane controls are operated in the
condition-aggravating direction. , : (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 ,
ing functions (height limit, boom ) , (3)
angle upper and lower limits, and
working radius limit) is tripped, (4)
.
(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
used. When an automatic stop signal @) , @) CN1.
,
is output, the output states of these

terminals becomes as shown below.
.

When overhoist When overload


auto, stop signal is auto, stop signal
Terminal No. Normal operation output. is output
,
-
,
@) OFF ON OFF
OFF OFF ON
ON OFF OFF

NOTE

''^W h e n the working range lim iting "M"


functions or the rear sta b ility control

function is tripped, an auto, stop
signal is output, but the buzzer does ,
not sound. .
[Reference circuit] [ ]

TG-1200MG-1 circuit . TG-1200MG-1

AML - Ml

OVER WIND BZ
Solenoid valve

- AAAA , Buzzer
CN1 AUTO STOP

BUZZER

Winch-up detection

DB 0
Boom ext./ret. detection
-
CN2 DB 3
Boom-up detection ----i

DB 4 (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 .
.
Boom length shown in .
total rated load table

Even when the boom is in lengthes
ill , ^ 2 -^10
not listed in the table (e.g., between : ,
and 2 ), the angle lim iting
function is effective. .


, (,
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,
. W s i , Ws z .
the limit load codes Wsi , W s 2 , etc.
denote loads under the following :
conditions.

Wsi: i (
NOTE
)
Ws 2 : < ^ 9.2
^1 , ^ 2, : boom length given in
Wss: 2 < 3
the table of to ta l rated loads.

Wsi Boom length \ (full ret.)


WS 2 .^i<Boom length ^ 2
WS3 ^2 < Boom length ^ 3 ill, ^ 2 ^iQ ,

.

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 ( R L 4 ) .
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:
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 (4)
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 [, . TG-1200MG-1
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 35,0 (
), 35,0
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).

. .

.
TROUBLESHOOTING

1. Checking procedures 1.

The seven units of the Moment Limiter ,


system, described in the chapter Con- . " ",
,
struction 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.

-
.
Refer to the troubleshooting charts.

NOTE :

1) ,
i^W hen disconnecting or connecting the
.
connectors of the A M L system, keep
the battery switch turned OFF. 2) ,

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
2.
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 (1)
procedures given below. ,
. "
(1) To repair defects in the following " .
blocks or parts, refer to "Disassem

bly and Reassembly" given later in
(D
this section.
@
Moment detector
d) Boom angle detector
AML main body
(2) When the blocks or parts named be- (2)
low become faulty, repair them by ,
referring to the applicable sec
tions in this manual or crane elec
tric circuit diagram.
.
Booo length detector

(D Operating condition selector unit
Lever manipulation detector (D
-
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 ad- (3 ) ,
justment, refer to **Test Procedures
and Maintenance Standards given at ,
the end of this section. . "
"
(4) Handle the units carefully, apying .
attention to the following.
(4)
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,

, .
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 Note

W i r e or sw. be Unplug CNl after turning off Repair wiring and


tween battery POWER. Then, turn on POWER, switch according
& AML main body and measure voltage across to wiring dia
is faulty; no CNl connector side terminals gram, if voltage
power to AML (13 or U : + ) and (1 or 2:-) is wrong.
(+24V indicator with a multimeter. (Should
lamp on power be 22 - 32V).
supply board
is off).
........................................ - --------- -

(D Fuse for power Take fuse off the bracket, Replace fuse.
supply board and check it for continuity (If blown, again,
is blown. with a multimeter. replace power
(should read Oil ). supply board.)

F a u l t y power Above checks indicate no Replace power


supply board. fault, but following con supply board.
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.

Fault 2. All the lamps light correctly in the check mode, but LCDs remain
totally off, partly off, flicker, or weak.

Cause Check procedure Correction Note

F a u l t y display Replace display


board. board.

Fault 3. All the LCDs display correctly, but one or more lamps remain off.

Cause Check procedure Correction Note

F a u l t y LCD Replace LCD


illumination illumination
board. board.
1.
.
(
" ,)

1.
.



CN1
,
. ,
,


.
(13 14: +) (1 2 : -)
CN1,
, (
: 22 32
+24

,)

(2) 3
, ,
(
. ( . ,

+24 :
,)
.)

(3) ,
. ,
,
:

+12 , -12
+5 ,
"12
, +5" .

2, ,
, ,
.



. .

3, ,
, .




^ .
.
Fault 4. The LCDs display correctly, but one of the lamps remains off.

Cause Check procedure , Correction Note

F a u l t y display Replace display


board. board.

Fault 5. The LCD illumination lamps (for night operation) remain off.

Cause Check procedure Correction Note


i

F a u l t y LCD Replace LCD


illumination illumination
board. board.

Fault 6. Only the fault indicator lamp is on; the other lamps and the
LCDs remain off.

Cause Check procedure Correction Note

F a u l t y CPU Replace CPU


board. board.
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 " are displayed.

Cause Check procedure Correction Note

F a u l t y power Replace power


supply board. supply board.

Fault 2. Error code no. " 2 " and error message " E r r " are displayed.

Cause Check procedure Correction Note

F a u l t y CPU Replace GPU


board(ROM). board.

Fault 3. Error code no. "3" and error message " E r r " are displayed.

Cause Check procedure Correction Note

F a u l t y CPU Replace CPU


board(RAM). board.

Fault 4. Error code no. "4" and error message " E r r " are displayed.

Cause Check procedure Correction Note

F a u l t y CPU Replace CPU


board(A/D board.
converter)
2. "" ,
.
(

.)

1. "1" ^trr'





. .

2. "2" ^ ^




() .
.

3. "3" ^ '




() .
.

4. "4" ^




(D ( .
-
)
.
M o m e n t detector Turn off power, and unplug Check which is With CN un
or cable is CNl. Measure resistance across fault, detector plugged, if
faulty. terminals and and a c r o s s or cable; replace resistance
and of CNl on connector faulty one. (See across defec
side with a multimeter. Note) tor side ter
minals A and
Correct reading: Both 240(12)
and resist
ance across
and D are
24012 , detec
tor is OK.

Faulty CPU When above checks indicate Replace CPU


board. no fault. board.

Fault 6. Error code no. 7 and error message are displayed.

Cause Check procedure Correction Note

Faulty Check that error code and Perform length


adjustment. message are displayed when zero and span
the boom length is near the adjustments.
full extension or full retrac
tion length.

B o o m length Turn off power, unplug CNl, Check which is With C N u n


detector, its and unplug C N from boom faulty, detector plugged, if
cable, or boom length detector. With boom or cable; replace resistance
angle detector fully retracted, measure faulty one. across de
cable is resistance across terminals (See Note) tector side
faulty. (3) and (4) and across (3) terminals
and (6 ) of CNl on connector and D is 5000
si d e . 30012 and
resistance
Correct reading:.
across and
(3) - (4): 5000 30 0
D is 500
(3) - (6 ): 500 10012
10012 , de
tector is OK.

Faulty boom On detector side C N , un Replace boom


angle detec plugged in @ above, measure angle detec
tor. resistance across terminals tor .
A and D and across and D.

Correct reading:
(A) - (D): 1000 2 0 0
(C) - (D): 150 to 20000

F a u l t y CPU When above checks indicate Replace CPU


board. no fault. board.
,
, CN (3),
CN1, ,
.
(, ,
(9) ()> ). D
(1 1 ) ( 12 ) .
.
240 ,
: 240
.

,
. .
.

6 . "7 b~L




,

,

. .

,
, , CN(5),
CN1, ,
CN
. (, D,
). D
.
.
(3)
(4), (3) (6 ) 5000 300
CN1. 500 100
,
:
(3) (4) .
5000 300
(3) (6 )
500 100

(3)
D,
. D .
CN @ .

;
() (D)
1000 200
() (D)
150 20000

,
. .
.
Faulty Check that error code and Perform boom
adjustment. message are displayed when angle zero and
the boom angle approaches span adjustment,
the upper and lower stroke
ends.

Boom angle de Turn off power, unplug C N l , Check which is With C N


tector, its and unplug C N from length faulty, detector unplugged.
cable, or boom detector. With boom in hori or cable; replace if resis
length detectar zontal position, measure re faulty one. tance
cable is faulty. sistance across terminals (3) (See Note) across de
and (4), and across (3) and tector
(5), of Cnl on connector side side ter
with a multimeter. minals A
and D is
Correct reading:
(3 ) _ (4 ): 1000 2 0 0 ^i 1 0 0 0 + 20012 ,
(3 ) _ ( 5 ): 150 to 20000^i and resis
tance across
and D is
150 to
2000012 , de
tector is
OK.

)Faulty CPU When above checks indicate Replace CPU


board. no fault. board.
,

,

.
.

(2) ,
, , CN @ ,
CN1, ,
CN (5)
. (. D,
. ). D

.

(3) (4), 1000 200
(3) (5) 150 20000
CN1.
,
:
(3) (4) .
1000 200
(3) (5)
150 20000

- ,
,. .

C o m b i n a t i o n of Data table at end of this sec Make correct See **Input
boom status tion gives input patterns (in setting. patterns that
setting, work put signal combinations) which cause error
status setting canse display of this error code 12 and
and boom length code. If actual input pattern message l_,jE
is wrong. conforms to none of tabulated to be dis
patterns, and yet this error played** in
code is displayed, f a u l t data table at
below is present. end of this
section.

)Boom status or Turn off power and unplug C N l . If incorrect, With some
work status Check continuity across CNl correct wiring, models,
setting unit connector side terminals ( 1 or s w., etc. ac status input
is faulty. 2) and (15 through 19), and cording to can be made
identify input pattern (com crane electric to some ter
bination of input signals). circuit minals only
Compare this pattern with cor diagram. when power
rect pattern for current status is on.(Such
settings given in data table terminals
at end of this section. Dif are relay
fering terminal input is terminals)
faulty input. Refer to
crane elec
Correct:
tric circuit
Actual input pattern should
diagram.
conform to tabulated
pattern. See **Combi-
nation of
operating
condition
signals**
in data
table at end
of this
section.

F a u l t y power When above checks indicate no Replace power


supply board. fault. supply board.
. "
.
,
(
). " 12 "
, Luf
,
. .
,
,
,
,
,
. @ .


,
CN1.
(1 2 ) ,
(15 19) ,
. CN1
. ,
.

,
. .

,
.
:
. (

.
.)
.
-
.
. "



"

.

(3) ,
. .

See Boom
B o o m telescop When boom retraction detector Reset correctly.
lengths and
ing sequence is switch remains off with boom
input pat
incorrect. length less than length given
terns that
in data table at end of this
cause error
section, this error code is
code 13 and
displayed. If condition is OK,
message i i_[ to
and yet this code is given,
be displayed
fault (D below is present.
at end of
this section

Faulty boom Turn off power, and unplug If incorrect, With some
retraction C N l . Check continuity across correct wiring, models, input
detector CNl connector side terminals sw., etc. accord can be made
switch. ( 1 or 2 ) and terminals given ing to crane to some ter
in data table at end of this electric circuit minals only
section, and compare input diagram. when power is
pattern with tabulated on. (Such ter
pattern. If they are in con minals are re
formity, conforming terminal lay terminals
input is faulty input. See "boom
lengths and
Correct:
input patterns
Actual input pattern
that cause
should not conform
error code 13
to tabulated pattern.
and message
l l E to be
displayed at
end of this
section.

F a u l t y power When above checks indicate Replace power


supply board. no fault. supply board.
. "
.
,
.
"13"
L l E
,
, .

.
,
,
,
, .

(D
,
CN1.
. (1 2 ) , ,
CN1
, ,
, .
,
, ,
. .
,
, .
. (
:

.)
. .

.
. "


,

"13"
L l E

(3) ,
. .

C o m b i n a t i o n of Data table at end of this Set correctly. See "Combi-
boom status and section gives correct status natioti of
work status setting patterns. If actual operating
settings is setting pattern conforms to condition
wrong. one of patterns given in signals** in
table, and still this error data table.
code is displayed, fault (D
below is present.

'Boom status Turn off power and unplug C N l . If incorrect, With some
or work status Check continuity across CNl correct wiring, models,
setting unit connector side terminals ( 1 s w . , etc. ac status input
is faulty. or 2) and (15 through 19), and cording to crane can be made
identify input pattern (com electric circuit to some ter
bination of input signals). diagram. minals only
Compare this pattern with cor when power
rect pattern for current status is on. (Such
settings given in data table terminals are
at end of this section. Dif relay ter
fering terminal input is minals) Refer
faulty input. to crane ele
ctric circuit
Correct:
diagram.
Actual input pattern
should conform to -See **Combina-
tabulated pattern. tion of operat
ing condition
signals** in
data table.

F a u l t y power When above checks indicate no Replace power


supply board. fault. supply board.

Fault 11. Displays given are other from those given for Faults 1 through 10;
fault indicator lamp illuminates, and auto, stop occurs.

Cause Check procedure Correction Note

F a u l t y CPU Check that check mode does not Replace CPU board.
board. come on when check switch is
pushed.
. "
.


- -
. "

.
,
,
,
,
,
. (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 Correction Note

Faulty display Replace display


board. board. ,

Fault 2. Pushing the state register switches cannot switch the lamp
illumination modes.

Cause Check procedure Correction Note

F a u l t y display Replace display


--------------
board. board.

Fault 3. Pushing the work range limit input switches cannot enter or cancel
the desired setting..

Cause Check procedure Correction Note

F a u l t y display
board.
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 Check procedure Correction Note

Incorrect Check by telescoping the boom Adjust according


adjustment slowly over the full range. to the adjustment
procedure.

Fault 2. The reading fluctuates, error is large at specific values, change


is not smooth, or error increases over several days.

Cause Check procedure Correction Note

L e n g t h detec Turn off power, unplug CNl, Check which is With C N


tor, its cable, and unplug C N from boom faulty, detector unplugged,
or boom angle angle detector. With boom or cable; replace if resist
detector cable fully retracted, measure faulty one. ance across
is faulty. resistance across CNl con (See Note) detector
nector side terminals (3) and side ter
(4) and across (3) and (6) minals
with a multimeter. and D is
5000300 0. ,
Correct reading:
and resist
(3) - (4) :5000 300i2
ance across
(3) - (6) : 500 lOOQ.
and D is
5001100
detector is
OK.

Faulty boom On C N , unplugged i n above, Replace boom


angle detector, measure resistance across de angle detector.
tector side terminals A and D,
and across and D.
Correct reading:
(A) - (D) : 1000 2 0 0 ^
(C) - (D) : 150 to 20000^2

Faulty CPU When above checks indicate Replace CPU


board. no fault. board.
4. .

1. ,
.




,
.
.

2. ;
; ;
(
).




(I) ,
, , CN (5),
CN1, ,
CN
. (, D,
. ). D

.
(3)
(4), (3) (6) 5000 300
CN1. 500 100

: ,
(3) (4)
5000 300 .
(3) (6)
500 100


D,
. D .
CN @ .

:
() (D)
1000 200
() (D)
150 20000

, 1
. .

5. Boom angle display value is incorrect.

Fault 1. Error is large, but the value changes smoothly as the boom rises
and lowers.

Cause Check procedure Correction Note

Incorrect Check the fault condition by Adjust according


adjustment raising or lowering the boom to adjustment
slowly over entire angular procedure.
range.

Fault 2. The reading fluctuates, error increases at specific values, change


is not smooth, or error increases over several days.

Cause Check procedure Correction Note

Boom angle de Turn off power, and unplug Check which is With C N
tector, its CNl, and unplug CN (5) from faulty, detector unplugged,
cable, or length detector. or cable: replace if resist
length detec With boom in horizontal faulty one. ance across
tor cable is position, measure resistance (See Note.) detector
faulty. across CNl connector side side termi
terminals and and across nals A and
(3) and (5) with a multimeter. D is 1000
200 Q. and
Correct value :
resistance
(D - ; 1000 200 ft
across
- : 150 to 20000
and D is
150 to
20000 ,
detector is
OK.

Faulty CPU When above checks indicate Replace CPU board.


board no fault.
5. .

1. ,
.




,

. ,

2. ;
; ;
(
).




,
, , CN @ ,
CN1, - ,
CN (5)
. ; (. D,
. ). D

.

(3) (4), 1000 200
(3) (5) CN1. 150 20000
,
:
(3) (4) .
1000 200
(3) (5)
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 Correction Note

Faulty 1) Check the length reading, 1) Perform zero


adjustment and the boom angle reading, adjustment ac
then, check the moment % cording to ad
with the boom on the boom justment
rest, according to the procedure.
adjustment procedure.
Correct: 0.0 0.5(%)

2) Then, check the moment 2) Adjust the


values at boom angles span acord-
10 and 50 against ing to adjust
the values on preopera- ment pro
tional check indication cedure .
plate.
Correct value:
given on indication
plate in crane cab.

Fault 2. Error increases at specific boom status and work status.

Cause Check procedure Correction Note

status and Check that status settings are If incorrect, set


work status are correct and that input pattern correctly or re
set incorrect is correct, by referring to pair wiring and
ly, or setting Faults 8 and 10 in **2 Fault switches accord
units are indicator lamp lights, and..." ing to crane elec
faulty. tric circuit
diagram.

Faulty power When above checks indicate no Replace power


supply board. fault. supply board.
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, Check by referring to "4 Repair or


boom angle Length display value is replace.
value are incorrect** and **5 Boom
faulty. angle. ..**

(2) Poor insula First, check moment system in Replace detector With C N un
tion in moment same manner as in Fault 5 for or cable, which plugged, if
detector and, **2 Fault indicator lamp lights, ever is faulty. resistance
detector cable and...**; then measure insula (See Note) across detec
(connector) tion resistance between CNl tor side ter
connector side terminals (8) minals (A
and (9 through 12) with a through D)
multimeter with a capacity and chassis
above 500Mil . is over
100M12 , de
Correct value : 100(Mil)min.
tector is OK.

Faulty When above checks indicate Replace pre


preamplifier. no fault. amplifier.
3. ;
; ;
(
).




, "4,
.

, " "5.

.

1 ,
CN (3),
, 5 ,
"2.
() " , (, (
). D)
",
.
(8) (9
12) CN1 100
; ,

.
500 .
:
. 100

,
. .

7. W orking radius and lift display values are incorrect.

Fault 1. Error is large.

Cause Check procedure Correction Note

Large boom See **4 Length display value


length display is incorrect". -
value error.

(D Large boom See 5" Boom angle display


angle display value is incorrect". -
value error.

B o o m status Check that status is set cor Set correctly. In this


is set rectly, by referring to Fault case, mo-
incorrectly. 8 in "2 Fault indicator lamp ment% dis
lights, and..." play is
also in
correct.

F a u l t y boom Check that status input If incorrect, In this


status setting pattern is in conformity with repair accord case, mo-
unit. current status setting, by ing to crane ment% dis
referring to Fault 8 in "2 electric cir play is
Fault indicator lamp lights, cuit diagram. also in
and..." correct.

(5)Faulty The longer the boom, and the Adjust.


adjustment larger the boom angle, the
easier the adjustment.
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 Correction Note

Large error in See "6 Moment % display


moment % dis value is incorrect*... -
play value.

Large error in See 7 Working radius and


working radius lift display values are <
display value. incorrect**.

B o o m status or Check that statuses are set Set correctly. In this case,
work status is correctly, by referring to moment% dis
set incorrectly. Faults 8, 9, 10 in **2 Fault play is also
indicator lamp lights, and..** incorrect.

B o o m status or Check that status input If incorrect, re In this case,


work status pattern is in conformity with pair according to moment% dis
setting unit current status settings, by crane electric play is also
is faulty. referring to Faults 8, 9, 10 circuit diagram. incorrect.
in **2 Fault indicator lamp
lights , and. . . **
Except for the rated load for
Faulty Adjust.
jib, all displays can be ad
adjustment
justed upward and downward in
the same ratios.
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 Note

B l o w n fuse Take fuse off bracket, and Replace fuse. 5A


(for relay) check it for continuity with (If it blows re
a multimeter. peatedly, check
Correct reading : 0 ) for short circuit
between CNl con
nector side ter
minals (23
through 34) and
chassis ground.
F a u l t y auto, With power turned off, unplug If incorrect,
stop circuit. CNl. After shorting CNl con correct according
nector side terminals (13 or to crane electric
14) and (28) with a wire, circuit diagram.
turn on power.
Correct : Auto stop state
is cleared.
F a u l t y lever With power turned off, unplug * If incorrect, With some
manipluation CN2. With control lever in correct according modeIs,lever
detector neutral, check continuity to crane electric manipulation
switch. across CN2 connector side ter circuit diagram. detector
minals (19 through 26) and CNl switch input
connector side terminal(1 or is made to
2.) some ter
Correct : 0(12) minals only
For terminals without when power
switch (or relay), it is on.(Such
is infinite ( ^ 12 ). input ter
minals are
relay ter
minals. )
F a u l t y over With power turned off, unplug If incorrect,
wind detector CNl. Under non-overhoist con correct according
switch. dition, check continuity to crane electric
across CNl connector side circuit diagram.
terminals (1 or 2) and (22).
Correct : 0 )
Wor k i n g range Check to see workig range Erase limit
limit has been limit indicator lamps are data.
stored by off.
mistake.
F a u l t y power When above checks through Replace power Check that
supply board. indicate no fault. supply board. angle limit,
load limit,
and rear
R e l a y (in AML When above checks through Replace case stability
main unit) indicate no fault. assy . 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) (
) (-^)) .


.
Cause Check procedure Correction Note

F a u l t y auto, Turn off power, unplug CNl, If incorrect, re


stop circuit, and then turn on power again. pair according to
crane electrical
Correct operation:
circuit diagram.
Auto, stop occurs.

)Faulty lever Turn off power and unplug If incorrect, re With some
manipulation CN2. With control lever moved pair according to models, lever
detector to danger side (boom lowering, crane electrical manipulation
switch. boom extension, hoist-up), circuit diagram. detector
measure resistance across switch input
each of CN2 connector side is made to
terminals (19 through 26) some ter
and CNl connector side ter minals only
minal (1 or 2). when power is
on.(Such in
Correct:
put terminals
With terminals without
are relay
switch (or relay), resist
terminals.)
ance should be infinite
Refer to
(^ ).
crane elec
trie circuit
diagram.
Turn off power and unplug CNl,
Faulty over If incorrect, re
Under overhoist condition,
wind detector pair according to
check continuity across CNl
switch. crane electrical
connector side terminals (1
circuit diagram.
or 2) and (22).
Correct: oo
Faulty power When above checks through Replace power
supply board. reveal no fault. supply board.

R e l a y (in AML When above checks through Replace case


main unit) reveals no fault. assy .

Fault 3. Buzzer keeps sounding without stopping.

Cause Check procedure Correction Note

C r a n e buzzer Turn off power, and unplug If incorrect, re


circuit is CNl. Turn on power with CNl pair according to
faulty. unplugged. crane electric
circuit diagram.
Correct : Buzzer stops

P o w e r supply When above checks indicate no Replace power


board is fault. supply board.
faulty.
!
,
. 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 Check procedure Correction Note

buzzer Turn off power, and unplug If incorrect,


circuit is CNl. Short across CNl connec repair according
faulty. tor side terminals (13 or 14) to crane electric
& (32) with a wire, and turn circuit diagram.
on power.
Correct : Buzzer sounds.

P o w e r supply When above checks indicate Replace power


board is no fault. supply board.
faulty.

Fault 5. No telescoping control signal is output.

Cause Check procedure Correction Note

Length display Check boom length display Adjust.


adjustment is value around telescoping
faulty. control output length.
Correct : See data table at
of this section.

Telescoping Turn off power and unplug If incorrect,


control output CNl. Short across CNl con repair according
circuit is nector side terminals (13 or to crane electric
faulty. 14) & (33, 34) with a wire, circuit diagram.
and turn on power.
Correct : Boom telescopes.

Power supply When above checks indicate Replace power


board is no fault. supply board.
faulty.

, -
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 Correction Note

L e n g t h display Check length display value Adjust.


value adjust around telescoping control
ment is signal output length.
faulty.
Correct : Data table at end
of this section.

(D Telescoping Turn off power, and unplug If incorrect, re


control signal CNl. Turn on power with CNl pair according to
output circuit unplugged. crane electric
is faulty. circuit diagram.
Correct : no telescoping.

Power supply When above checks indicate Replace power


board is faulty. no fault. supply board.

Fault 7. No rear stability control signal is output.

Cause Check procedure Correction Note

B o o m angle Check boom angle display Adjust.


display value value around rear stability
adjustment is control output angle.
faulty.
Correct : See data table at
end of this
section.

F a u l t y auto, Turn off power, unplug CNl, If incorrect,


stop circuit. and then turn on power again. repair according
to crane elec
Correct operation :
trical circuit
Auto, stop occurs.
diagram.

F a u l t y lever Turn off power and unplug If incorrect, With some


models,lever
manipulation CN2. With control lever moved repair according manipulation
detector switch. to danger side (boom raising), to crane elec detector
measure resistance across CN2 trical circuit switch input
is made to
connector side terminal (23) diagram. some ter
and CNl connector side minals only
when power
terminal (1 or 2). is on.(Such
Correct : oo(Q^) input ter
minals are
relay ter
minals. )Re
fer to crane
electric
circuit
diagram.

Faulty power When above checks through Replace power


supply board. reveal no fault. supply board.
Relay (in AML When above checks through Replace case
main unit.) reveal no fault. assy .
6. .




1)- .

,

.
;
.
.
(2) ,
CN1,
,
.
:
. .

(3)
. .
________________

7. .



- .

,


.
:
.
.
(2)
,
CN1, ,
. .
:
.
.
(3)
, ,
CN2. ,
(23)
CN2 (1
. 2) CN1,
.
( ,
). ,
: (
.)
.
.

(^(3)) .
.
(5) (
) (^(3)) .

Fault 8. Rear stability control signal keeps being output.

Cause Check procedure Correction Note

Boom angle dis Check angle display value Adjust.


play value ad around rear stability con
justment is trol signal output angle.
faulty.
Correct : Data table at end
of this section.

Faulty auto, Turn off power and unplug CNl. If incorrect,


stop circuit. Short across CNl connector repair according
side terminals (13 or 14) and to crane electric
(28) with a wire, and turn on circuit diagram.
power.
Correct operation : Auto,
stop state is cleared.

)Faulty lever Turn off power and unplug CN2. If incorrect, With some
manipulation With controlllever in neutral, repair according models,lever
detector check continuity across CN2 to crane electric manipulation
switch. connector side terminal (23) circuit diagram. detector
and CNl connector side ter switch input
minal (1 or 2). is made to
some ter
Correct
minals only
when power
is on.(Such
input ter
minals are
relay ter
minals.) Re
fer to crane
electric
circuit
diagram.

F a u l t y power When above checks through < Replace power


supply board. reveal no fault. supply board.

)Relay (in AML When above checks through' Replace case


main unit .) reveal no fault. assy.
8.
.

,

-. ,


.
:
.

.

()
,
. CN1. ,
(13 14) (28)
CN1 ,
.
: .

.

(3)
,
CN2. ,
,
.
(23) CN2
(1 2) .
CN1.
:


,


. (


.)
. -
.


. ( ) .

^ (
) ( ^(3) ) .

> DISASSEMBLY AND REASSEMBLY

Mounting drawing

CN (Boom angle detector) Boom angle detector


CN (

AML main body


(1) MOMENT DETECTOR (1)

DISASSEMBLY

1) Disconnect connector C N and remove 1) CNC^


the cable support. .

2)
2) Remove the elevating cylinder from
.
the crane.
3) (D. ,
3) Unscrew set screw d) .
4)
4) Loosen moment detector, and remove ,
it from the piston rod. .
Moment detector


REASSEMBLY

Reassemble the moment detector by


reversing the disassembly procedure, ,
observing the following cautions. .

1)
NOTE
(, )
^
The moment detector and desiccant

are delivered in vinyl bags. ..
Do not unpack them until immedia
tely 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, iJr
this is the indication that the mois .
ture absorbing power has been lost.
Replace desiccant. .
.
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. Piston rod
Adhesive tape


Moment detector
'

Desiccant

MOMENT LIMITER

2) Install 0-rings on the moment 2) 0-


detector. (3)
.
3) Install the moment detector in
the piston rod. Screw it in fully 3)
until it bottoms. .

4) Drill a hole for set screw of 4) 6


3
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.

Set screw Punching


-

... \

^

__ 1 :
3 .0

(2) Boom angle detector (2)

Replace the boom


bo angle detector as a com-
plete assembly. .


DISMOUNTING
TV ^ ^ J _ 1) CN ,
1) Disconnect
Disconnec connector C N , and remove ^ ^
.
the cable support.
2)
2) Remove the boom angle detector assem .
bly from the boom.


REMOUNTING

Remounting the angle detector by re .
versing the disassembly procedures.
(3) A M L main body (3)

Replace all components of the AML main


body in board units, except for the fuse
and P-ROM on the rear panel. ,
,
P-ROM
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 10 ,

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. . . 4 . 75.

3^1. Display board


3-1.
Removing
1) Unscrew screws, and remove the
1) 0 ,
side cover.
.
.2) Unscrew screws and remove the 2) ,
escutcheon. .

3) Remove the front panel, display 3) ,


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

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

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

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


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

Remounting "'
.
Reverse the removing processes.
3-2.

3-2. LCD illumination board

Removing
1) ,
1) Unscrew screws, and remove the .
side cover.
2) ,
.
2) Unscrew screws, and remove the
escutcheon.
3) ,

3) Remove the front panel, display
board, and LCD illumination .
board (2) as an assembly from the
main unit case. 4) ()

4) Unplug connectors @ and from . ( -
the LCD illumination board. (They
come off when the retaining levers .)
are pushed open.)
5) .
5) Unscrew screws .
6)
6) Replace the LCD illumination board .
with a new part.

Remounting

.
Reverse the removing processes.

3-3. CPU board 3-3.

Removing

1) Unscrew screws, and remove the 1) ,


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

Remounting

Reverse the removing processes.


.

3-4. Power supply board


3-4.
Removing

1) Unscrew screws, and remove the
side cover. 1) 0,
,
2) Push the board retaining levers
2)
open to let power supply board

come out approx. 10 mm; remove ,
the board. 10 ,
.
3) Replace the power supply board
with a new part. 3) .

Remounting

Reverse the removing processes.


.
3-5. Preamplifier
3-5.
Removing

1) Unscrew screws0 , and remove the
side cover. 1) @ ,
.
2) Unscrew s c r e w s and remove
preamplifier (5) . 2) ) ,
,
3) Replace the preamplifier with a
new part. 3) .


Remounting

Reverse the removing processes.
.
F ig.4 Disassembled view of AIVIL main . 4
body

Connector Fuse (5)


(5 )

LCD illumination board



1
Display board ^
^
Front panel

Escutcheon

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.


Replaced part _______________ Required adjustment
No, _________
Block Part
Boom angle detector Boom angle display adjustment

_________
Boom length Potentiometer or
detector length detector
Boom length display adjusttnent
assembly

Moment display adjustment


Moment zero adjustment
Moment detector (D Moment span adjustment

1
2__ -
____ __________________
Front panel None

Display board Moment zero adjustment


LCD illumination
None
Jboard

!---1---------------
angle display adjustment
Boom length display adjustment
Moment display adjustment
Working radius display adjustment
AML main body CPU board Load display adjustment




'

Pre-amplifier Moment display adjustment


Power supply board None



Main unit case(incl.
I/O board, connector
None
board)

(
-
)
Operating condition
None
selector unit
'
.
pa6oTM..TRg
Lever manipulation
None
detector



Alarm and auto, stop


7 None
circuit

(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 Error


No.- message
(Actual load (Total rated Solution
display load display
screen) screen)

( (

) (^ -
Turn boom length zero adjuster clockwise

( -[ until corrected.

.
Turn boom angle zero adjuster clockwise

8 - until corrected.

.
() When moment % display is a negative ( 6) ,
(-) value, or if it is 110% or (%)
above. (-) ,
Turn the moment zero pre-adjuster "110% :
clockwise or counterclockwise '^
until the display comes into the
0 to 100% range. , ,

100%.

2)
,
3) AJJLadJust^ in -
the sequence eiven in this .
manual.
3)

.

, ,

4) For the location of the adjusters, .
refer to the drawing of the AML
main unit on page 8. 4) .
. 8.
(3)
(3) Boom length display adjustment
:

Conditions : ****
Boom state register switch: **boom** (2)
(D Outrigger state register switches: :
**max. extension** " '*
Boom direction: over side or rear (3) :
Moment display: between 0 and 100%.
:
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
8, (U) 0 - 5000 JuO.

Turn the [LENGTH ZERO] adjuster slowly until the


boom length display becomes [C] m. n o t e (D
[LENGTH
ZEkO] ,
[] .

Cranes with telescoping con Cranes without telescoping con


trol signal output function trol signal output function
, ,
-

Extend only the first-extend- Fully extend the boom.


ing boom sections (e.g., 2nd .
and 3rd boom sections with TG-
700EG-1) to the stroke end.
(Keep other boom sections fully Turn the [LENGTH SPAN] adjuster
retracted.) slowly until the boom length

(,
NOTE (D ___ display becomes [D] m.

. TG-700EG-1) [LENGTH
. ( SPAN] ,
.)
[D] .
NOTE

When the length detector has only TOM ,


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
@ [], [D] []
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. .
(4)
(4) Boom angle display adjustment
:
Measuring instrument :
:
Sprit level type angle meter

Conditions :
: "
Boom state register switch: "boom**
(2)
(D Outrigger state register switches: :
**max. extension** " "
(D Boom direction: any position :
Boom length: full retraction :
Moment display: between 0 and 100%
(5) :
100%

NOTE
^

() Angle display e rro r = Angle display value - s p rit level type angle meter reading
= -
.
(5) Moment zero adjustment (5)

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: (2)
:
"max. extension" " "
Base jib section select switch"
(3) (3) :
"unused" " "
Counterweight select switch: "Ot" (4) : "Ot"
Boom direction: over front for (5) :
. TG-700EG,
TG-700EG, 500ERG; over rear for TG-500ERG; .
TG-1200MG 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 . TR),
port the boom with a block in the ,
(
horizontal position where the ele

vation cylinder is not fu lly retracted,
) ,
to depressure the system. .
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
3 .
adjuster alone, the fine adjuster
need not be turned. (D "0,0%"
,

.
(6) Moment span adjustment (6)

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 YES
If the moment display value is diffrent Check moment zero
from the value(for 50) engraved on the adjustment.
plate, make the angle display adjust Within specified tolerance?
ment again, and then make the moment
zero adjustment again. . (

?)_______
(50 ),

.
YES N0
_
Check the values for 10 and 50 in the END After performing moment zero
same procedure as above.(For the value adjustment, check the values
for 10, readjustment will be neces
sary). Do the displayed values coincide for 10 and 50 again in the
with the engraved values? same procedure as above.(For

10 50
the value for 10, readjust
. ( 10 ment will be necessary).
.)
, ? _____

- 1 N0
10
50 .
END Proceed to the next chart "when parts ( 10
requiring moment span adjustment have ' .)

been replaced."
" ,

, .

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** (2)
:
Boom direction: Over rear or side.
" "
Base jib section select switch: :
**unused**
Counterweight select switch: **18.8t* ' :
" "
(5) : "18,8t"
:
Conditions
Boom state register switch: boom* : '*
(D Outrigger state register switches: (D
:
"max. extension** "
Base jib section select switch: (3) :
**unused* " "
Boom direction: over front for :
TG-700EG, 500ERG; over rear for . TG-700EG,
TG-500ERG; .
TG-1200MG TG-1200MG
Counterweight select switch: **0t** (5) : **0t"
With the boom fully etracted, check the boom
length display; it muLst be [C] m. .NOTE
, ,
[] .
- (D

Elevate the boom until the angle display is 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,
_NOTE d )
and see if the moment display is 0 . 0 0.5/o.

1
, -
: goep, -

Out of 0.0 0.5% range Within 0.0 0.5% range


0,0 0,5% 0,0 0 ,

readjustment starting with Correct the values X and Y


engraved on preoperational
moment zero adjustment. 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
(2) [J] .
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.
[J] (.
[K ] is the tota l rated load fo r w ork
).
ing radius [J ] m with the boom ex , . TG-1200MG-1
tended fully, as given on the total [] 2,6 , [J]

rated load table in the crane cab. 30,0 42,9 .
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. , 105%
* For crane models designed fo r the
Soviet Union, use 105% of value [K ]
when adjusting the moment span.

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


= []
- .
Coimtenvei^t 18.8
TG-1200M TOTAL RATED LOADS ; 18,8
. TG-1200M X 1000 Kg
Outriggers extended fully Ha
Working Boom1 length (m) * 2 Boom Jib length (m) * 4 !Boom Jib length ( )*4
angle
12.5 18.2 23.9 29.6 35.3 42.9 *3 11.1 18.9 26.0 5J0+11.1 5.0+18.9 5.0+26.0
3.5 100.0 80 6.0 4.0 2.5 80 3.2 2.0 1.5
3.8 90.0 79 6.0 3.75 2.3 79 3.2 2.0 1.5
4.0 85.0 45.0 78 6.0 3.55 2.15 78 3.2 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 75 5.4 3.0 1.8 75 2.65 1.7 1.3
5.5 60.0 45.0 72 4.8 2.6 1.55 72 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
7.5 41.0 39.0 36.0 29.0 22.0 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
8.5 32.0 32.7 32.0 29.0 22.0 58 2.5 1.4 0.95 58 0.75
9.0 28.8 29.5 29.7 27.0 22.0 55 2.1 1.25 0.85 55 0.6
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
11.0 19.5 20.0 20.6 20.7 20.0 13.0 50 0.95 0.55 *2: c t d < .
12.0 17.0 17.6 17.7 17.8 13.0 48 0.6 *3 :
14.0 13.0 13.2 13.3 13.4 13.0 ,

. ly C b A c l,
16.0 9.9 10.2 10.3 10.4 11.0
18.0 8.0 8.1 8.1 9.0
20.0 6.2 6.4 6.4 7.0
22.0 4.8 5.0 5.0 6.0
24.0 4.0 4.0 5.0
26.0 3.0 3.0 4.0
28.0 2.0 2.0 3.2
< Jo ^ 1.7
32.0 1.1 2.0
34.0 1.5
36.0 1.1

When lowering the boom, run the


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

.
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 0 [] [D] . "


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

With those crane models which have (,


no boom rest (e.g. TR ). support , TR),
the boom in the horizontal position ,

with a block to prevent the cylinder

from retracting fu lly, and depressure

the system. .
(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** (D
@ Boom direction: over rear or side :
Base jib section select switch: * "
**unused** (3) :
Counterweight select switch: **18.8t**
:
'* *'
(D : '*18,8t"

Working radius
display ad
justment

Load display
adjustment


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 [D]
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, . TG-1200MG-1
the maximum boom length is 42.9 m, 42,9 , -
the maximum load fo r this boom -
length is 13.0 tons, and the maximum 13,0 .
rated working radius fo r this toad 14,0 .
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. 13,0 14,0.

[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. .
Counterweight 18.8
TG-1200M TOTAL RATED LOADS : 18,8
. TG-1200M X 1000 kg
Outriggers extended fully Ha

Working Boom length (m) *2 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
TXi 12.5 18.2 23.9 29.6 35.3 42.9 *3
3.5 100.0 80 6.0 4.0 2.5 80 3.2 2.0 1.5
3.8 90.0 79 6.0 3.75 2.3 79 3.2 2.0 1.5
4.0 85.0 45.0 78 6.0 3.55 2.15 78 3.2 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 75 5.4 3.0 1.8 75 2.65 1.7 1.3
5.5 ^0.0 45.0 72 4.8 2.6 1.55 72 2.15 1.35 1.05
6.0 '5 4 .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
7.5 41.0 39.0 36.0 29.0 22.0 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
8.5 32.0 32.7 32.0 29.0 22.0 58 2.5 1.4 0.95 58 0.75
9.0 28.8 29.5 29.7 27.0 22.0 55 2.1 1.25 0.85 55 0.6
10.0 23.6 24.3 24.5 24.6 22.0 52 1.35 0.85 0.6 *1 ; ,
11.0 19.5 20.0 20.6 20.7 20.0 13.0 50 0.95 0.55 *2: ,
*3:
12.0 17.0 17.6 17.7 17.8 13.0 48 0.6 ,
<> 13:0 13.2 13.3 13.4 Q3.(!) *4: ,
16.0 9.9 10.2 10.3 10.4 11.0
18.0 8.0 8.1 8.1 9.0
20.0 6.2 6.4 6.4 7.0
22.0 4.8 5.0 5.0 6.0
24.0 4.0 4.0 5.0
26.0 3.0 3.0 4.0
28.0 2.0 2.0 3.2
30.0 1.7 2.6
32.0 1.1 2.0
34.0 1.5
36.0 1.1
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 1/50 1/25 ,
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. 361-306-30000 (CR-3226LDRSY) 1. 3 6 1 -3 0 6 -3 0 0 0 0 (C R -3 2 2 6 L D R S Y )

2. 361-306-40000 (CR-3226LDRAS) 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


Term inal con n ection

Reducer Reduction ratio : 1/50 : 1/50

Resistance : 5000 250


Electrical turning angle : 355 2
Potentiometer Mechanical turning angle : 360, continuous rotation
: 5000250
: 3552
: 360
2. 361-306-60000 (CR-3233LDRS) 2. 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

Terminal connection Connector

Reducer Reduction ratio : 1/50 : 1/50

Resistance : 508020 Q.
Electrical turning angle : 355 2
Potentiometer Mechanical turning angle : 360, continuous rotation
: 508020
: 3552
: 360
1. Plate 1.
2. Case 2.
3.
3. Drum a s s 4.
4. Slip ring a s s y 5.
5. Contact a s s 6.
6. Contact a s s 7.
8.
7. Bearing case 9.
8. Bearing 10.
9. Retaining ring 11.
10. Retaining ring 12.
13.
11. Reducer 14.
12. Gear 15.
13. Gear 16.
14. Bracket 17.
18.
15. Potentiometer
19.
16. Spring 20.
17. Cover 21.
18. Clip 22.
23.
19. Clip
24.
20. Clamp 25.
21. Cord guide 26.
22. Bush 27.
28.
23. Packing
29.
24. Packing 30 .
25. Packing 31.
26. Connector 32.
33.
27. Connector
34.
28. Cord lock 35.
29. Holder plate 36.
30. Terminal 37.
38.
31. Terminal
39.
32. Nut 40.
33. Washer 41.
34. Machine screw 42.
43.
35. Bolt
44.
36. Bolt 45.
37. Machine screw 46.
38. Machine screw 47.
48.
39. Machine screw
49.
40. Machine screw 50.
41. Machine screw 51.
42. Machine screw 52.
43. Set screw 53.
54.
44. Washer 55.
45. Washer
46. Spring washer
47. Spring washer
48. Spring washer
49. Nut
50. Connector
51. Cable
52. Plug
53. Terminal
54. Terminal
55. Cord
DISASSEMBLY AND REASSEMBLY

The repair procedures are described ,


under three divisions, REPLACING CORD, : " " , "3
REPLACING RECOIL SPRING and REPLACING " "3
" .
POTENTIOMETER. Select the procedure

applicable to the faults.
.

1. Replacing cord 1.

(Refer to STRUCTURAL DRAWING) (. .)


1. @ @
,
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
2.
becomes free.
.

2. Remove the detector a s s from the 3. @ ,


boom. .

4.


3. Loosen clamp @ and remove cover . @
(15) ,
4. Disconnect cable from potentio .
meter at the terminals, and
remove the cover and the cable
together.

NOTE 5. ,
,
@ .
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 (2) .
and plate to record the subcord
installation direction.

0 ) (2 )
6. Remove retaining ring(9), unscrew
b o l t s , and take case (D off the ()
drum. .

7. Unscrew n u t , and separate drum 7. ,


assembly from plate . .

8. Remove slip ring a s s e m b l y and hold- 8.


er plate (g) from the drum assembly, @)
and separate the cord from the slip () .
ring by unsoldering.

9. Remove the entire old cord from the 9.


drum assembly. .
The values in the descriptions of , -

w ork procedure given in the subsequent , (
pages diffe r w ith the models of the ) .
length detector. The concrete value are .
given in the table below.

10. Prepare new cord having length 10.


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

Drum e n d / ^
Co

NOTE 11.

Core w ire : Connect to slip ring ,
inner ring.
Shield w ire : 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.
12. Install the slip ring assembly, 12. ,
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. .

13.
NOTE ,
,
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

Slip ring (Apply contact grease)
(

.)
14. Insert the shaft of drum a s s y 14.
into the hole in p l a t e , and
install nut .
.
15. (23 ,
15. Apply sealant to p a c k i n g , and (2)
install case on drum assembly .

, threading the subcord through &
the hole in b u s h , and threading ) .
the aux. string through cord
16. @
guide . (3^^ ,
@ .
16. Secure case @ and plate with
17.
bolts and install retaining
,
ring . (2) .
18. @
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
1/4
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 .
When the potentiometer itself is -
faulty, replace it, referring to ,
the procedures described under RE . "
PLACING POTENTIOMETER. .

19.
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. 12 -.

Tightening torque : 12 kg.cm 20.



,
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 21. .


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 12 -.

Screwdriver

Gear Set screw ^




Bracket

Multimeter

Black

White

22. Pull the cord slightly out of the 22. ,
drum, and see if the resistance ,
.
increases smoothly.
23. )
23. Connect cable terminals to po
tentiometer terminals . (See the . (.
.)
Terminal Connection diagram.)
24. @
24. Install c o v e r , positioning clamp , @)
,
o p p o s i t e the potentiometer. Apply
. @
sealant to packing @) . .

25. ()
25. Stretch cable tight and tighten
,
clamp @ , @ .

26. (g)
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

For the orientation of the
Lead wire connector terminals and con
nector case, refer to the
structure drawing.
0
. .

27. Check conductivity between the 27.


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

Connector

2. Replacing recoil spring 2.


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".
3.
3. Replacing potentiometer

, ,
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 1. @ ,
@
assembly need not be removed.

1. Unscrew c l a m p , and remove b o l t s 2.


and cover @ . @ ,
@ .
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 (13) ,


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.
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. .

Recommended sealant:
SHINETSU SILICONE KE45RTV by
.
Shinetsu Chemical Co., Ltd. :
"SHINETSU SILI
5. Install a new potentiometer and con CONE KE45RTV" "
nect the leads. (Refer to the ter ., ." .
minal connection in the structure
drawing.)

Bracket

Potentiometer
Insulating sealant

6 .
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 1/4
position by the force of spring @ . , ,
If not, loosen bolts and adjust ,
.
the position of bracket .
,
.
Gear

7. Secure gear to the shaft of reducer 7.
b y tightening set screw against
the flat area on the shaft. .
Apply screw locking compound to the .
set screw. :
12 -.
Tightening torque : 12 kg.cm
8.

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 Cord lock


9. Procede with the reassembly by 9. ,


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


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. .

0-marker Cord lock


2. Adjust the length display of AML. 2.


(Refer to the repair manual for the .
AML.) (. .)
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 1

- ()
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] ..
,
6,6 3 10
10 3 10
Range D i s t a n c e at w h i c h
110 6 20
(AC-KV) 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.

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

. 2

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 2.


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. .

TESTS

After mounting the device and connect

ing the cables, perform operational ( . 2).
tests as follows: (See Fig. 2)
1.
1. Turn the voltage selection knob to "6,6 ",
,
6.6 KV" and check that the power
"" .
supply lamp turns on.
2.
,
2. With the voltage selection knob in "6,6 ", 2-
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. -
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. Body 6. 0-ring 1. 6 . -
2.
2. Plug 7. 0-ring
3. 7 . -
3. Plug 8. Plug 4.
4. Filter 9. Steel ball 5. 8 .
5. Spring 9 .

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.
.
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

Ite m M a in te n a n c e s t a n d a r d s

F ilte r R e p la c e at ev ery 24 m o n th s.

24 .

3 6 6 - 2 0 0 - 2 0 0 0 0 , 366 -2 0 3 -1 0 0 0 0
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. Valve body 7. 0-ring 1. 7. -
2.
2. Spool 8. Hex. socket head 8.
3.
3. Plug bolt 4.
4. Spring 10. Solenoid
5. -
10.
5. 0-ring 11. Hex. socket head 11.
6. -
6. 0-ring bolt

DISMOUNTING

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 , 4 0,5 . .
0.5kg.m (2.89-3.62ft-lb). ,

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) "" "",
(. 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. Y "
" .
After remounting, bleed the circuit ,
and the units, and test the operation
to make sure of the absence of ,
faulty conditions.
.
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 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 - .
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)



This valve controls the pressure in 1 ,

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) 2. (RV2)



This valve serves to determine the 2 ,

pressure in the pump P2 hydraulic
RV1.
circuit, and also to unload the
circuit similar to RVl.

3. Port relief valves 3.



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 . (PR1):
(PR2):
(PRl) : for m a i n w i nch (PR3):
(PR2) : for auxiliary w i nch :
(PR3) : for b o o m elevation (PR4):

For p rotecting cylinders:

(PR4) : for b o o m elevation


4. F l o w control valve 4.

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.
(FC1):
(FCl) : M ain win c h
(FC2):
(FC2) : A u x i liary w i n c h

5. Hydraulic valve (HV) 5. (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

. 1
2


Relief valve a s s '


(RV1, RV2)
Port relief valve ass o Port relief valve a s s


(PR1, PR2, PR4) (PR3)

1. Cover a s s 1.
2. Control valve a s s 2.
3.
3. Flow control valve a s s
4.
4. Control valve a s s y 5. (
5. Tundem plate )
6. Control valve a s s y 6.
7.
7. Control valve a s s y
8.
8. Cover a s s 9.
9. Tie rod 10.
10. Tie rod 11.
11. Nut 12.

12. Relief valve a s s y 13.
13. Port relief valve a s s y 14.
14. Port relief valve a s s y 15.
15. Port relief valve a s s y 16.

16. 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.

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.
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
2.
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 3.
tension circuit are damaged.

3. Hose reel
2.
The hose reel serves to let out and
take in the hose as the b o o m tele 4.
scopes to m a i n t a i n the hydrau lic

circuit to the No. 2 cylinder all ,
the time.
1 2.
4. Hydra ulic valve

The hydraul ic valve is electr ically



controlled, and serves to s e l e ct ive
(. Z.)
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 1,
boom section extends first, and .
then the third and top boom
sections extend simultaneously. ,
Hydraulic oil from the manual con CN1-33 ("LENGTH SW.
1" (". - 1") .
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.
(SN16),
W hen the second boom section ap (SL5)
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
extension s w i
t ch (SN16) is pushed, 1
hydraulic valve solenoid (SL5) is 2,
energized, switching the hydraulic

circuit from the No. 1 cylinder
2,
circuit to the No. 2 cylinder .
circuit, and thus sending hydraulic
oil to the No. 2 cylinder via the ,
hose reel and the counterbalance
(S18)
valve, to extend the third and top ,
b oom sections. (RL1)
W hen the third and top boom sections ,
are extended slightly, 3rd/top b o o m

full retraction detector switch (S18)
(SN16).
is freed, causing relay (RLl) to
hold the solenoid energizing circuit ,
in the energized state; therefore,
after the boom is extended to some ( 2).
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 1 2 , ,
wire ropes, and exactly follows
its movement. 1
,
2 .
2. Retraction circuit
2
The boom sections retract in the ,

reverse order of extension.
(S18) ,
Although hydraulic oil is sent (SL5.
from the manual control valve to
both No. 1 and No. 2 cylinders,
2
only the No. 2 cylinder is allowed
1 ,
to retract because the return line .
of the No. 1 cylinder is blocked
at the hydraulic valve.
When the No. 2 cylinder approaches 2 ,
2
the travel end, 3rd/top boom full ,
retraction switch (S18) is tripped, ,
causing solenoid (SL5) to break the 1 ,
solenoid energizing circuit. When 2
.
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.
BOOM

CONSTRUCTION
1. Top boom section 74. Retaining ring 1. 69.
2. Third boom 75. Bolt 70.
2. 71.
section 7 6. Slide plate
72.
3. Second boom 77. Shim 3. 73.
section 78. Shim 74.
4. Base boom 79. Pin 4.
75.
section 80. Retaining ring
5. 76.
5. Support 81. Pin 12. 77.
12. Hex. socket 82. Pin
head bolt 83. Plain bearing 78.
13.
13. Slide plate 84. Set screw
24. 79.
24. Spring washer 85. Slide plate 27. 80.
27. Bolt 86. Shim 28.
28. Pin 87. Shim 29. 81.
30. 82.
29. Plate 88. Nut
31. 83.
30. Bolt 89. Bolt 32. 84.
31. Spring washer 91. Bolt 33. 85.
32. Bolt 93. Plate 34. 86.
36.
33. Plate 94. Spring washer
87.
34. Guide 95. Plate
36. Hex. socket 96. Shim 37. 88.
head bolt 97. Shim 38. 89.
39. 91.
37. Sheave ass' 98. Slide plate
40. 93.
38. Pin 100. Slide plate 41. 94.
39. Spacer 101. Slide plate 95.
40. Wire rope 103. Slide plate 42. 96.
43.
41. Adjuster ass'y 108. Bolt
45. 97.
42. Nut 109. Hex. socket 46.
43. Nut head bolt 47. 98.
45. Guide 110. Bolt 48. 100.
49. 101.
46. Bolt 131. Slide plate
50. 103.
47. Wire rope a s s ' 51. 108.
48. Slide plate 141. Slide plate 52. 109.
49. Retainer ass'y 53.
54.
50. Retainer 154. Slide plate
56. 110.
51. Slide plate ass'y 57. 131.
52. Retainer 164. Slide plate 58.
53. Retainer 174. Slide plate 59. 141.

54. Slide plate ass'y
60. 154.
56. Bolt 184. Slide plate
57. Plain washer ass'y 61. 164.
58. Slide plate 191. Retainer
174.
59. Shim 192. Retainer
62.
60. Shim 204. Slide plate 63. 184.
61. Hex. socket ass'y 64.
head bolt 214. Slide plate 65. 191.
66. 192.
62. Pin ass'y
67. 204.
63. Bolt 221. Plug 68.
64. Spring washer 223. Grease nipple 214.
65. Bolt
221.
66. Spring washer
223. -
67. Plate
68. Slide plate
69. Pin
70. Spacer
71. Sheave ass'y
72. Bolt
73. Pin
D IS M O U N T IN G

1. Set up the crane level. 1.


.
2. Remove the main hook, and wind the 2. ,
wire rope on the winch drum. Similarly,
wind the aux. winch wire rope on the . ,
winch drum.
.
3. Bring the boom to 0, and stop the
3.
engine.
, .

4. Remove the jib with an overhead crane. 4.


.

5. Remove the end of the boom length 5.


detector cord from the top boom ,
section, let the cord reel take in ,
the cord, and fasten the end of the ()
cord to the detector case. Similarly, .

remove wind and fasten the cords of ,


(
the other cord reels (for anemometer

and 3rd/top boom full retraction
) ,
detector switch). Then, disconnect

the cables for the boom length
.
detector, the boom angle detector and

the moment detector, and other wires
,
at the connectors at the lower part ,
of the boom to separate them from ,
the swing table.
.
W A R N IN G
6.

,

M AKE SURE THAT THE CRANES AND
.
THE S L IN G S USED HAVE S U F F IC IE N T : 6500 .
STRENG TH TO SUPPO RT TH E BOOM
A S S 'Y .

6. Support the forward part of the boom


,
with a crane. ,

Boom a s s y weight: approx. 6,500 kg
.
7. Slightly lift the forward part of the
7.
boom with the crane, and free the
,
elevation cylinders from the boom

weight. Hold the elevation cylinders
.
as shown, and extract pins @) .
,

Weight of elevation cylinder ,


,
(one each): approx. 500 kg.
@).

: 500 .
Fig. 2
. 2

N O TE 8. ,


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 .

8 . S t ar t the e n g i n e , f u l l y r e t r a c t the ,
e l e v a t i o n c y l i n d e r p i s t o n rods, 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.
9. ,

W A R N IN G 1 ,
,
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 2. ,
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
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.
,
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.

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 (. 3).
above the boom pivot pin location.
(Fig. 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. ,
,
CAUTION .

CONNECT THE HOSE REEL HOSE TO 4.


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 (. 2).
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) .
6 . Similarly, insert the opposite pin 6. ,
and stop the engine. @)

.
7. Lower the cranes supporting the e le
vat ion cylinders and the forward
7. ,
part of the boom, and remove the

slings.

, .
8. Reconnect the cords and the cables
to the boom length detector, the 8.
b oom angle detector, and the moment ,
detector and other wires. , ,

9. After remounting, conduct the tests .
specified.
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 . 1.
1
, ,
@ , ,

.

Fig. 4
. 4 2.
2. Remove slide plate a s s iesC|o)
from the side plates of the base ,
boo m section.

Slide plate ass'y^^jQ^




WARNING 3. (J41^ ,
''^74^
MAKE SURE THAT THE CRANES AND ,
THE SLINGS HAVE SUFFICIENT CAPACI
1 .
TIES TO SUPPORT THE BOOM ASS Y.
,
PREVENT THE SLINGS FROM BEING

BENT SHARPLY AT THE BOOM EDGES
BY COVERING THE EDGES WITH (. 6).
APPROPRIATE PLATE&

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 7 , , ,
, ,
points using two overhead cranes;

then pull it out completely. (Fig. 7)
(. 7).

Fig. 6 Fig. 7
. 6 . 7
5. With the No. 1 cylinder supported 5. 1
with a crane, extract p i n s ; also , ,
extract pin connecting the No. 2 ,
cylinder and the second boom sec 2
, , ,
tion; then unscrew n u t s , and re
,
move anti-buckling bolts
.

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. 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. .

7. Remove slide plates @ from the side 7. (@)


plates of the second boom section.
.

2nd boom section


Fig. 9
. 9
During extraction of the third boom 8 .
section from the second boom sec
tion, the position of the No. 1 1
cylinder relative to the No. 2 2,
cylinder may shift, resulting in ,
possible damage to the hydraulic .

hose . To prevent this, fasten the
..
cylinders to each other with wires,
etc.

Hydraulic hose

NOTE 9.
,
When w ithdraw ing the th ird boom . 3 4.
section, take care not to damage

boom re tra ctio n w ire rope @ located

on the upper surface. ,
@
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 1
freed. .
,
.
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 10 . , ,


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

11. 2
11. With the No. 2 cylinder supported , ,

wit h a crane, extract p i n s , and
( 1 2)
wit h d r a w the No. 1 and No. 2 cy lin
(. 13).
ders together from the boom.
(Fig. 13)

Bolt
Support

Fig. 12 Fig. 13
. 12 . 13
12. Remove p i n s , and remove sheave 12. @ ,
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 .@ .

Fig. 14
. 14
13. Remove sheave a s s i e s , s p a c e r 13. ,
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 . 2 4.
4.

Fig. 15
. 15
CHECKS

1) Boo m 1)

Check the boom for twist, deformation, -


warp, and cracks. , ,
.

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 4)



Whe n the wire rope is in any of the
following conditons, its further use
is strictly prohibited:
,
a. Deformed or corroded
:
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. .
6 ,
d. For extension wire rope (nominal

dia.: 24mm) having a reduction in
3 ;
diameter exceeding 7 percent of the
nominal diameter. .
(
e. For retraction wire rope (nominal : 24 )
dia: 10mm) having a reduction in 7% ;
diameter exceeding 7 percent of the
.
nominal diameter.
(
f. Deteriorated by heat : 10 )
7% ;
. .

REASSEMBLY

NOTE

Reassemble by reversing the



disassembly processes, observing ,
the follow ing .

1)
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. .
2) Adjust the lateral clearances of the 2)
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
0 0,3 .
slide plates thick enough to allow
a m i n i m u m embeded length of 5 m m 3) ,
( a in sketch). ,

,
5 .

boom section

3rd boom section



Fig. 16 2nd boom section
. 16

Base boom section


4) Install extension wire r o p e so 4)


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. 5) @ ,
Install spacer @ on the inside.
. @
.
6) Whe n inserting the third boom
section into the second boom sec 6)
tion, take great care to prevent
the No. 1 cylinder from fouling
the second boom section. (If the 1
.
relative positions of the No. 1
(
and No. 2 cylinder change, the h y

draulic hose between them can be
1 2
d a m a g e d .)

.)

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 fixing 7) ^5)
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. 1/4 .

8) , 1
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 for
2 ,
th e No. 1 a nd 2 cylinders as
.
follows:
@
With the p i n i n s t a l l e d , and the b o l t
thread coated wit h screw locking c o m Y ,
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 is a d ju s tm e n t w ith o u t lo a d in g
th e c ra n e .
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 2 3
b e fo re d is a s s e m b ly . ,
.
1. A d ju s tin g e x te n s io n w ire ro p e
1.
1) R e t r a c t the b o o m a n d lower it to

the h o r i z o n t a l .
1) ,
.
N O TE

2)
D u rin g th e a d ju s tm e n t, te le s c o p e 1 ,
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 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
and . ,
-

-
.
Fig. 19
. 19

3) Retract the boom fully. 3) .

4) Tighten the right and left boom ex 4)


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

Fig. 20
. 20

5)
,
5) Extend the 3rd and top boom sec
( )
tions again, and check that (
10 .
) is approx. 10 mm.
2.
2. Adjusting retraction w ire rope

1) Retract the boom and lower it to 1) ,


the horizontal. .

2) Extend the 3rd and top boom sections 2)


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

( ).

Fig. 21
. 21


3) E x t e n d the 3rd an d top b o o m s e c 3)
1 .
tions a pp ro x. 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 adjust .
nu t t h r o u g h d i s t a n c e .
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 5)
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.
.

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 6)
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 .
.
When t he 3rd b o o m s e c t i o n stopper ,
is f a s t e r , tighten the a d j u s t n ut
fu r t h e r . , ,
When th e to p b o o m s e c t i o n stopper .
is f a s t e r , loosen the a d j u s t nut. ,

, ,
7) R e t r a c t 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
1.
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] 2.
Crane levelness 6 max.
Boom length Full e x t e n s i o n
Boom elevation Maximum [ ]
Boom direction Over-front, : 6
:
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
,

:

.

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 ) 1)
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.
,)
100 .
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
2)
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 than ,
t he s p e c i f i e d l imit, r e a d j u s t the
shim. 1 600 .


3. O th e r f u n c t io n a l te s t
.
C h e c k all the e l e c t r i c and e l e c
tronic parts (boom length d e t e c
3.
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. ( ,
.),

,
.
TELESCOPING CYLINDER

CONSTRUCTION

Fig. 1
. 1
1. Spring pin 11. Support 1. 11.
2. N u t 12. Rod cover 2. 12.
3. 13.
3. P a c k i n g 13. Packing 4. 14.
4. B a c k u p r i n g 14. D u s t seal 5. 15.
5. P i s t o n 15. Plain bearing 6. - 22.
6. 0 - r i n g 22. Plug 23.
7. 24.
7. C y l i n d e r 23. Backup ring
8. 25.
8. R o d 24. Backup ring 9. -
9. 0 - r i n g 25. Plain bearing

10. D a m p e r r i n g 10.

DISMOUNTING AND REMOUNTING


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

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 , 1
,
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 ,

.

.
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
1.
The actuator holding pressure is
sealed by seat "a" of the main spool
and seat "b" of the check valve. , ,
"
"b ,
2. While actuator is being pushed up

The pressurized oil entering through 2.


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 3.


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 PP.
port P is vented to port A.
At this time, the main spool motion ,
is smoothened by orifices.

.


.

Hydraulic symbol


Cover

Fig. 1
. 1
1. 12.
1. Valve body 11. 0-ring 2. - 13. (A)
2. 0-ring 12. Spring guide 14. ()
3. Backup ring 13. Spring (A) 3. 15.
4. 16. -
4. Main spool 14 . Spring (B)
5.
5. Check valve 15 . Plug 6. 17. -
6. Spring 16 . 0-ring 7.
7. Pilot spool 17 . 0-ring 18.
8. 19. -
8. Orifice 18 . Plug
9. -
9. 0-ring 19 . 0-ring 20. -
10. O r i f i c e 20. 0-ring 10.
11. - -

D IS M O U N T IN G AND R E M O U N T IN G

W A R N IN G

IF THE COVER IS REM O VED W H IL E


PRESSURE IS S T I L L PENT UP IN
PORT PP, THE VALVE M AY BE SHOT ., .

O FF. TO PREVENT T H IS , V E N T THE



PENT PRESSURE BY M O V IN G THE

CONTROL LEVER SEVERAL T IM E S

W IT H THE ENQ NE STOPPED, BEFO RE
.
R E M O V IN G THE COVER.


NOTE


A fte r r e m o u n t in g , b le e d th e c ir c u it
,
and th e u n it s , and te st th e o p e r a t io n
,
to m ake su re of th e absence of

f a u lt y c o n d it io 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 C H APTER
,
A T O W O R K C O R R E C T LY .
.
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. 1
. 1
1. Stand 13. Ball bearing 1. 13.
2. H o u s i n g 14. Ball bearing 2. 14.
3. 15.
3. S h a f t 15. D u s t seal 4. 16. -
4. D r u m p l a t e 16. 0-ring 5.
5. D r u m p l a t e 17. Set s c r e w 6. 17.
6. S p r i n g 18. Set s c r e w 7. 18.
8. 19.
7. Pipe 19. Bolt 20.
8. Snap ring 20. Spring washer 9. 21.
9. Pin 21. Nut 10. 22.
10. Spring 22. Bolt 11. RL 23.
12. 24.
11. RL-ring 23. Spring washer

12. Backup ring 24. Retaining ring
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 - 5.5
TG-700EG-1

DISASSEMBLY

Fig. 2
. 2
1. R e m o v e the h o s e f r o m the h o s e reel. 1. .

2.
2. P l a c e t he h o s e r ee l on a fla t (. 3).
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
engagement of t he pi n.) .
S ha ft (D is to be e x t r a c t e d i n th e 3. @ (1 .)
n e x t step. @ (2 . ) ,
,
. ,
3. Remove set screw a nd 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 (. 4).
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 a
plastic hammer, with the reel lifted
slightly. (Fig. 4)

-7/77 / ^/ / / / / / / /7 / / / / /

Fig. Fig. 4
. . 4
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 drum plates and
, .
together; remove drum plate .
@
6. Drum plate an d h o u s i n g are stuck .
,
together with sealant. 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. (. 5 6).
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)
Drum p l a t e

Vise
Protective plate

Fig. 5 Fig. 6
. 5 . 6
7. Place plate on the housing to 7.
contain s p r i n g ; set the reel on
an appropriate support with the
(3)
spring-containing plate side down; .
and drive out shaft with a plastic
hammer.

Spring-containing plate

Fig. 7
. 7
Remove RL-rings and backup rings 8. RL
from shaft . ~

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
-
Replace 0 -rin g , RL-rings, and backup , RL
rings w ith new parts. .

1. (13)
1. Force-fit ball bearing into
(2' .
housing (2) .
2. (15)
2. Force-fit dust seal
into housing (D .
(2). After fitting, apply grease (
(Low Temp Grease No. 2 or equivalent) '*Low Temp Grease
2" )
to the lip of the dust seal, the
,
bore of the ball bearing and the

housing surfaces on which the RL-rings
RL.
slide.

Fig. 8
. 8
3. Install spring
and p i n , and 3.
retain them with snap ring . @
(See Fig. 1) (8) (. . 1).

4.
4. Slide an RL-ring installation jig RL ,
onto the end of s h a f t , and with RL .
the jig and the shaft coated with
grease, install R L - r i n g s , and .
then backup rings . RL
.

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
RL .
to avoid damaging RL-rings .
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 " 45 " " )
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) ),
. (. . 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 , 7. ,
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. -
@ .
8. Install 0-ring in the g r o o v e of
shaft; an d install the shaft 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. (
45" " " )
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 move-

ing 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 16. Sleeve 1. 20.
2. H y d r a u l i c v a l v e 17. Stopper 2. 21.
3. 1 22.
body 18. Plunger
4. 23.
3. C o v e r 19. Rod 5. 24.
4. Sp o o l 20. Pin 6. 25. -
5. S p r i n g 21. Spring 7.
26. -
6. F i l t e r 22. S o l e n o i d coil
8.
7. Hex. s o c k e t 23. Rubber.cap 27. -
h e a d bolt 24. N ut 9.
8. Hex. socket 25. 0-ring 10. 28. -
11. -
h e a d b olt 26. 0-ring
29. -
9. P l u g 27. 0-ring 12. -
10. Plug 28. 0-ring 30. -
11. 0-ring 29. 0-ring 13.
31.
12. 0-ring 30. 0-ring 14. 32.
13. Hex socket 31. Spacer 15. 33.
h e a d bolt 32. Connector 16. 34.
14. Solenoid body 33. Cap 17.
18.
15. Spool 34. Washer 19.

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 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

A ft e r re m o u n tin g , b le e d th e c ir c u it ,
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 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 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.
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.
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 .
.

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 (PR4)
boom from h u n tin g . .

(P R 3).
,



.
ELEVATING CYLINDER

CONSTRUCTION AND FUNCTION

1. Cylinder 14. Damper ring 1. 14.


2. Piston 15. Packing 2. 15.
3. 16.
3. R o d 16. Backup ring
4. 17.
4. R o d c o v e r 17. Head cover 5. 18. -
5. S h i m 18. 0-ring 6.
6. S h i m 19. D u s t seal 7. 19.
8. 20.
7. R o d end 20. Retainer
9. 21 .-
8. P l a i n b e a r i n g 21. - 10. 22.-
9. P a c k i n g 22. -------- 11. - 23. -
10. B a c k u p r i n g 23. 0-ring
12. 24.
11. 0 - r i n g 24. Set screw
13. - 25.
12. S p r i n g p i n 25. Plate
13. 0 - r i n g


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 IS SUSPECTED TO

C O N T A IN H IG H PENT UP PR E S SU R E, BE

SURE TO VEN T IT BEFORE S T A R T IN G
.
TO D IS M O U N T THE C Y L IN D E R S .


NOTE

,
A fte r th e r e m o u n tin g , b le e d th e c ir -
c u it and th e u n its , and te s t th e ,
' s y s te m fo r fa u lt-fr e e o p e r a tio n . -
rv T rT R H H . .

D IS A S S E M B L Y A N D REASSEM BLY


W A R N IN G


DO NOT USE COMPRESSED A IR TO
.
EXTEND THE P IS T O N ROD.


C A U T IO N


W HEN D IS A S S E M B L IN G A N D REASSEM
" "
B L IN G , W O R K IN CORRECT W A Y BY
()
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

CHAPTER A .

W HEN D IS A S S E M B L IN G A ND REASSEM ,
B L IN G , T A K E CARE NOT TO DAM AG E
THE THREADS, THE F IN IS H E D SURFACES ,
A N D THE S E A L IN G PARTS, A N D BE - .
,
SURE TO USE THE S P E C IF IE D S P E C IA L
TO O LS.
,
W ASH TH E D IS A S S E M B L E D PARTS IN

K E R O S IN E , A N D CHECK T H E IR S L ID IN G
.
SURFACES, SEAL M O U N T IN G AREAS,
, ,
A N D THE THREADS. CORRECT M IN O R

DENTS, D A M A G E, RUST A ND BURRS .
W IT H F IN E A b r a s iv e c l o t h o r o il
s t o n e . IF THESE d e f e c t s ARE S E R I , ,
OUS, REPLACE THE PARTS W IT H NEW ,
PARTS. .

IN P R IN C IP L E . R E P L A C E A LL THE SEAL , ,
IN G PARTS. IN S T A L L THE R E P L A C IN G .

S E A L IN G PARTS BY O B S E R V IN G TH E " " (-


) , '
'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 ) '
,
IN C H A PTER A , P A Y IN G A T T E N T IO N

TO T H E IR O R IE N T A T IO N .
.
W HEN R E A S S E M B L IN G ,T A K E CARE TO

A V O ID TH E ENTRY OF DUST A N D OTHER
,
F O R E IG N M A TTER , A ND APPLY H Y
D R A U L IC O IL FOR L U B R IC A T IO N TO .

TH E S L ID IN G SURFACES. ,
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.) (. 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.
.
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.
( .3 )

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 1)
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 2)


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 ( )
RA
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 .
R B ,
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)
RB
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 3)
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
RA
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 4) (A , CB )

The solenoid valve selectively
opens and c l o s e s 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 and the l o w levels. .

4) Check valves (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 a l l o w oil
to f l o w f r o m the b y p a s s to the
s u c t i o n line to p r e v e n t cavitation.

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.

(. 4)
HYDRAULIC MOTOR (Fig. 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 .

(. 4)
REDUCER (Fig. 4)

This reducer is a p l a n e t a r y g e a r 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
s h o w n below.

Planetary gear

Ring gear

Sun gear
(input shaft)

( -)

Output shaft

Fig. 1
. 1

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 .
Oil f i l l e r

Hydraulic c i r c u it

Dowel pin

Fig. 2
. 2

Back pressure valve ()


Control valve ()

Reducer assembly

CONSTRUCTION
1. Reducer un it 1.

Fig. 5
. 5
1. H o u s i n g 21. Spring washer 1. 21.
2. S h a f t 22. Spring pin 2. 22.
3. 23.
3. R o l l e r b e a r i n g 23. King pin
4. 24.
4. Oil seal 24. Gear 5. 25.
5. Ball b e a r i n g 25. Needle bearing 6. 26.
6. K i n g p i n 26. Washer 7. 27.
8. 28.
7. T h r u s t b e a r i n g 27. Retaining ring
9. 29.
8. G e a r 28. Gear 10 . 30.
9. N e e d l e b e a r i n g 29. Pin 11. 31.
10. L o c k w a s h e r 30. Bolt 12. 32.
13. 33.
11. Bo l t 31. Spring washer 34.
14.
12. Pin 32. Gear 15. - 35.
13. Spider 33. Retaining ring 36. -
34. Plug 16.
14. Pin
17. 37.
15. 0-ring 35. P l u g 18. - 38.
16. Ring gear 36. 0 - r i n g 19. 1 39.
17. Ball b e a r i n g 37. B o l t 20. 40.
18. Gear 38. W a s h e r
19. End cover 39. W a s h e r
20. Bo l t 40. M a c h i n e screw
2. Hydraulic m otor unit 2.

Fig. 6
. 6
1. S h a f t 9-9 Spring seat 1. 9-9
2, 10.
2. B a l l b e a r i n g 10. Spring pin
3. 11.
3. R e t a i n i n g r i n g 11. Case . 12. -
4. Cam plate 12. 0-ring 5.
5. Oil seal 13. Needle bearing 6. - 13.
14.
6. 0-ring 14. Bottom cover
7. 15.
7. Oil seal c o v e r 15. Bolt 8 . 16.
8. Retaining ring 16. Bolt 9. 17.
9. Cylinder barrel 17. Spring washer 9-1 18.
9-2 19.
assembly 18. Oil seal
9-3 20.
9-1 C y l i n d e r b a r r e l 19. Retaining ring 9-4 21. -
9 -2 P l u n g e r b e a r i n g 20. Plug 9-6
21. 0-ring 9-7 22.
9-3 Plunger
9-8 23.
9-4 Plunger spring 22. Plug 24.
9- 6 S p r i n g sea t 23. Plug 25.
9-7 Center spring 24. Plug
9-8 Retaining ring 25. Retaining ring
3. Mechanical brake unit 3.

. 7
1. M e c h a n i c a l brake 1. 1-16
1-16 P l u g
1-17
assembly 1-17 C a b l e
1-1 1-18
1-1 B a c k p l a t e 1-18 D r u m 1 2 4. -
1-2 B r a k e s h o e 4. 0 - r i n g 1-3
1-3 A n c h o r p i n 1-4 5.
5. F l a n g e
1-5 6 .
1-4 N u t 6. H o l d e r 7.
1-6
1-5 S p r i n g w a s h e r 7. B o l t 1-7 8 .
1-6 G u i d e p l a t e 8. L o c k w a s h e r 1 - 8 9.
1-7 R e t u r n s p r i n g 1-9 10.
9. L o c k w a s h e r
1-10 11.
1-8 A d j u s t e r 10. R e a m e r bo l t
1-11
1-9 S p r i n g 11. H e x a g o n s o c k e t 1-12 13.
1-10 Pin head bolt 1-13 14.
1-11 S p r i n g 1-14 15.
13. Eye bolt
1-15 U- 16.
1 -12 B r a k e l e v e r 14. Cover
1 -13 L i n k 15. Spring washer
1-14 P i n 16. Retaining ring
1 -15 U - r e t a i n e r
4. Control valve unit 4.
1. Body 26. 0-ring 1. 26. -
27. 0-ring 2 .
2. Control spool
3 . 27. -
3. Steel ball 29. Plate
4 .
4. Spring 30. Seat 5 . 1 29.
5. Seal cap 31. Poppet 6 . - 30.
31. - -
6. 0-ring 32. Spring
7 . ;
7. Oil seal 33. Cap 32.
8 .
8. Plate 34. 0-ring 9 . 33.
9. Seat 35. Adjust screw 10 . 34. -
1 1 .
10. Spring 36. 0-ring
1 2 . 35.
11. Collar 37. Nut
1 3 .
12. Spool 38. Cap nut 1 4 . 36. -
13. Cap 40. S l e e v e 1 5 .
16. 37.
14. Valve seat 44. Spring
1 7 . 38.
15. Check valve 45. Spool 40.
2 0 .
16. Retaining ring 46. Stopper 2 1 . 44.
17. Spring 47. Spring 2 2 . 45.
46.
20. Cover 48. Push rod
2 3 . - - 47.
21. Spring washer 49. 0-ring 48.
2 2 . Hex. socket 50. Solenoid 2 3-1 49. -
head bolt 51. Spring washer 2 3 - 2
2 3 - 3 50.
23. Over-load 52. Machine screw
2 3-4 51.
relief valve 53. Check valve 2 3 -5 - 52.
23-1 Spool 54. Spring- 53.
23-2 Steel ball 55. Seat 2 3 - 6 54.
55.
23-3 Valve seat 56. 0-ring
2 3 -7 - 56. -
23-4 Sleeve 57. Bleeder screw
23-5 0-ring 58. Plug 2 3 - 8 57.
23-6 Pilot seat 59. Spring washer 2 3 -9 - 58.
59.
23-7 0-ring 60. Hex. socket
2 3 -1 0 - - 60.
23-8 Spring head bolt
23-9 0-ring 61. Plug 2 3 - 1 1 61.
23-10 Poppet 62. Cap 2 3 -1 2 62.
. 63.
23-11 Spring 63. Terminal
2 3 -1 3 70.
23-12 Adjust screw 7 0. Manifold 2 3 -1 4 71.
23-13 Nut 7 1. Plug 23-15 72.
23-14 Cap nut 72. Hex. socket 2 4 .
2 5 . 73.
23-15 Tube head bolt
74.
24. Cap 73. Spring washer
25. Choke 74. Plug
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 0,3 0,8 .
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.
.
DISASSEMBLY AND REASSEMBLY

(1) BRAKE UNIT (1)

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 <1 - 8 >.
M A K E T H E B R A K E SHOE D IA M E T E R .
S M A LLES T.

CHECKS
<1-2> ,
Measure the thickness of the linings
on brake s h o e <1-2> a n d r e p l a c e if it is ,
l ess than th e f o l l o w i n g u s e limit. .

:
Use limit : 1.5mm (0.06 in.)
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 d i
. -
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 :
:

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 1)
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 .
. .

2) Install the a d j u s t e r as s h o w n in 2)
Fig. 12. ,
. 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 3)
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. 13) ,
(. 13).
Adjuster Brake drum hole
Adjuster Threaded portion

Fig. 12 Fig. 13
. 12 . 13
4) Torque the bolts and nuts to the 4)
values given in the structure dia ,
gram (Fig. 4). (. 4).

5)
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.).
6 7 .
0,2
0 ,3 .
(2) HYDRAULIC MOTOR UNIT (2)

Fig. 14
. 14
DISASSEMBLY

1. Dismount the control valve unit from 1.


the hydraulic motor unit. .

2. .
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.
Hydraulic motor unit

Match mark

Speed reducer

Fig. 15 Fig. 16
, 15 . 16
3. Dismount the mechanical brake unit 3.
from the hydraulic motor unit. .

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 6. .


needle bearing f r o m the bottom @
cover . .
7.
CAUTION .

TAKE CARE NOT TO DROP


PLUNGERS <9 -3 > OUT OF THE
CYLINDER BARREL <9 -1 > ,
IN CASE THEY DID, BE SURE TO <9 -3 >
REINSERT THEM INTO THEIR <9-1>
ORIGINAL BORES. - ,

PROTECT THE LAPPED SURFACE ().
OF THE CYLINDER BARREL <9-1> BY

PUTTING CLOTH OR SPONGE
<9-1>,
BENEATH THE SURFACE. .

7. Remove cylinder barrel a s s ' from


the case .

Fig. 19
. 19
16
CAUTION 8.

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 9. 9
>
1
-
<
<9-3> <9-4> .
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, <9-7> -
but do not remove the center spring
unless it is absolutely necessary, <9-8>.
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>.

Punch mark

Punch mark

Fig. 20 Fig. 21
. 20 . 21
CAUTION 10. .

USE PLASTIC HAMMER WHEN .
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 Fig. 23
. 22 . 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.
I2. .
CAUTION @ ,
.
BE SURE TO APPLY FORCE TO THE
INNER RACE WHEN REMOVING AND
MOUNTING THE BEARING.

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

Bearing

Fig. 24
Shaft

. 24

13. Remove cam plate from the case. 13.


.
CLEANING AND CHECKING
NOTE

Wash the disassembled parts in kero-
sine, 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.> 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 0,1 (0,004 ),
b ly ) . ,
(
2. Clearance between plunger and .)
plunger bearin g ( 5 3 )
2. < 9 - 3
<
>
-2
9
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 . ) : 0 ,3 (0,012 )
(R eplace in c y lin d e r b a rre l assem
b ly ) : 0 ,5 (0,020 )
(

.)
3. < 9 - 2 >
( )

,
: 0,1 (0,004 )
F ig . 25
. 25 : 0 ,2 (0,008 )
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 . ) 4. <
>
-3
9
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 1)
bly.)
50 (1,97 ),
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 . )
: 0,13 (0,005 )
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 . : 0,16 (0,006 )
(
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 )
Cylinder barrel

2)

Fig. 26 ,
. 26 .
2) Appearance (

Replace if scored or otherwise .)
damaged.
(Replace in cylinder barrel assembly) 5.

5. Wear of plunger spring on the
outside diameter ,
: 0,2 (0,008 )
Recommended replacement wear limit:
0.2 m m (0.008 i n . ) : 0,3 (0,012 )
(
Use limit: 0.3 m m (0.012 in.)

(Replace in cylinder barrel assem
.)
bly)
6.
6. Partial wear of cam plate in the (4)
sliding area
,
R ecommended replacement wear limit: : 0,03 (0,0012 )
0.03 m m (0.0012 in.)
Use limit: 0.05 m m (0.0020 in.) : 0,05 (,0020 )

7. Sliding surface of bottom c o v e r 7.

1 ,
Replace if the depth of the scratch
0,1 (0,004
is more than 0.1 m m (0.004 in.) or
) ,
there is deposit of foreign matter.
.

8. Shaft 8.

1) Replace the shaft if there is 1) ,


partial wear in the splines. .

2) Replace the shaft if wear in the 2) ,


oil seal sliding area exceeds the
following: .

Wear width: 0.5 m m (0.020 in.) : 0,5 (0,020 )


: 0,3 (0,012 )
Wear depth: 0.3 mm (0.012 in.)
9.
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

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 Push

,
u n t i l it bottoms in the case .

,
-
.

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

3)
CAUTION ,
.
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 Fig. 29
bearing outer diameter . 29
Bearing
,

.Protection piece

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

Fig. 30 Fig. 31
. 30 . 31
CAUTION 5) < 9 - 3 >
,
BE SURE REASSEMBLE THE PLUNGERS ,
IN THE ORIGINAL BORES. .

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 <9-2>
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 , <9-3>
snug contact with the
inclined face camp late . <9-1>.
Control valve mounting face
(to face downward)

( )

Fig. 33
. 33
7) Whe n installing b ottom c o v e r , make 7)
sure that there is no dirt, sc ratch ,
es, etc. on the lapped surfaces of
the bottom cover and cylinder <9-1> ,
.
b a r r e l <9-1. Coat the lapped sur
.
faces wit h hydraulic oil.
8) ,
8) Torque the bolts to the values given

in the structure d i agr am (Fig. 4).
( . 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. 35 Fig. 36
. 35 . 36
3. Remove gear from the hydraulic 3. (32) ,
motor shaft by removing retaining
ring 4.
.
4. Remove gears and gear together.
5.

5. Remove retaining rings @ and remove

gears (
g) and needle bearings from
gear . 6. @)
# ,
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 8. ,
@ .
Insert cylindrical support under
housing @ .
@ -
.

8. Rem ove b o l t s and remove end cover


.
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 10.
Parts together from housing . .

11. @
NOTE ,
@ .
Punch match marks on the shaft
and the spider.

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 12.
mounting side, and remove thrust ,
bearings, gears (8) and needle .
bearings .

CLEANING AND CHECKING

NOTE

Wash the disassembled parts in kero-
,
sine, 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.
1) Gear (8), (g)
1) ,
Recommended replacement wear limit: ,
0.2 mm (0.008 in.) : 0,2
Use limit: 0.3 mm (0.012 in.)
: 0,3
2) Ring g e a r, (g)
2) @ , @)
Recommended replacement wear limit: ,
0.1 mm (0.004 in.) : 0,1
Use limit: 0.2 mm (0.008 in.)
: 0,2
2. S h a f t 2.
1) ,
1) Replace the shaft if there is
.
partial wear in the splines. 2) ,

2) Replace the shaft if wear in the .
oil seal sliding area exceeds the : 0,5
following: : 0,3

Wear width: 0.5 mm (0.020 in.)


Wear depth: 0.3 mm (0.012 in.)
3. Ball bearings, roller bearing, 3. , ,
needle bearings , ,

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
2)

match marks made during disassembly.
.

2) Oil seal cannot be reused if once 3)


removed. 0-
.
3) Coat the lip of the oil seal and 4) ,
0-ring with grease. .

4) Install the oil seal as shown below.

Fig.4
2
.4
2
5) When installing shaft, take care 5) @
not to damage the oil seal sliding
surface of the shaft. .
6)
6) Torque the bolts and nuts to the ,
values given in the structure (. 4).
diagram (Fig. 4).
(4) CONTROL VALVE UNIT (4)

Fig. 43
. 43
DISASSEMBLY

Disassemble the unit as shown in Fig.43,


observing the follow ing: . 43, :

1.
1. Whe n disassembling control spool
(2)

1) Before extracting the spool, mark it 1)


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 2)
trol spool, to prevent damage to
the oil seal. , . 44,
spool extraction jig'

Spool extracting direction Fig. 44


. 44

3) Unless the oil seals are damaged, 3) He @ ,


do not remove them, and use them .
further. If they are removed, re .
place wit h new oil seals.
2.
2. W hen disassembling overload relief
valve @)
1)

1) W hen clamping sleeve (| ^ in a vise,
.
do not tighten excessively to
prevent its deformation.
2 )
,
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 ~ ^ 3.



CAUTION
1)
TOP THE SLEEVE AT THE PERIPHERY,
TAPPING NEAR THE BORE CAN DEFORM
THE SLEEVE AND CAUSE THE BINDING OF
SPOOL

1) Tap out sleeve to the plate ,
mounting side. . ,
,
,
4. W hen disassembling chokes
4.
1) Remove c h o k e s by screwing in the
extraction bolt and pulling. 1) @

.
2) Unless -ring @ is damaged, do not 2) He -
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

Fig. 45
. 45

CLEANING AND CHECKING

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
1)
replacement, replace them in sub-
.
assemblies as listed under the
same number.
B o d y , control s p o o l , solenoid .
valve s l e e v e , solenoid valve , ,
spool @ ,
@
Overload relief valve spool
(), sleeve (|^ -
(23-^ ,
Overload relief valve pilot seat <&>
3^, poppet
@ -
, -
<^3^^
2) Whe n installing seal cap (D and valve 2)
seat<|33>5 degrease their threaded (5?
portions as well as their mating
members, and apply screw locking
compound to the threads. .

3)
3) Before inserting control spool (D 2'
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.
Seat surface

Push with fine rod to


check smooth movement of
.
the steel ball.

Fig. 46
. 46
4) Before installing overload relief 4) <^3-^
spool < 1 ^ into sleeve<|Q), shake the -
spool as shown below to check free (|3^
, ,
m ot i o n of steel ball ($3^ by means

of rattling sound.
( 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 No -ring
the circumference -
.
.

Fig. 48
. 48

6) After installing overload relief 6) --


valve assembly @ into b o d y , check @
spool<|53) for smooth movement.
<~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 7)
it with the finger to checls for @
smooth movement. .

8) Before' installing solenoid valve 8)



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

9) Install solenoid valve sleeve 9)


into body as follows.
.
To locate the sleeve, center punch
the sleeve as shown below.
,
.

Elongated recess

From this shape with a center punch

..

(D ,
Fig. 50
. 50 ( . 50)
NOTE 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. 3,3 .

(D Insert the sleeve into the body until ,


the elongated recess (marked by i n ,
Fig. 50) is visible through the 3.3 2 ,
mm did. hole in the body. 4 .

T o p the sleeve into the body until




the sleeve end is flush with the body
.
surface.
3.3 mm hole
Flush
3.3
.

Fig. 51
. 51

10) Insert check valve into valve 10)


seat for the back-pressure valve, @
and install retaining ring @ c a r e
fully into the groove. (10)
.
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 11)

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 12) ,
ture d i a gram (Fig. 3). ,
(. 3).
13) After installing the control valve
13)
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".

" .
TEST
1.
1. Test circuit
,
Prepare a hydraulic circuit for testing .
as shown below. : RBMSF-210T780-3

A p p licable model: RBMSF-210T780-3

Flow control valve


Relief valve


Control spool
Hydraulic pump

Suction filter

Pressure gauge Flowmeter


Drain port

Fig. 52
. 52
REPAIR
MANUAL

WINCH SYSTEM


LOCATIONS OF COMPONENTS

GENERAL

FU N C TIO N S O F U N ITS

1. Hydraulic motor 1.

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 friction
,
p l a t e s t o g e t h e r to b r a k e the m o t o r
.
o u t p u t shaft.

During winch operation, hydraulic

oi l f r o m the m a i n circuit is intro

duced through the 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 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
lowering phase, 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 5.

When the w i n c h c o n t r o l 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
(. Z.)
( 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 . )

1.
1. M a i n w i n c h

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, th e p r e s s u r i z e d o i l from pump 1 ,
PI is e m p l o y e d and th a t from pump P2 2
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 oil 1
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 2
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 (FC1),
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 is a l w a y s in p r o p o r t i o n to the ,
spool 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
1
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 2
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 1 .
s a m e as th a t of the m a i n w i n c h .
(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 under pressure enters , ,
the c y l i n d e r through inlet 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
. 9
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 .

Fig. 1
. 1

[Brake section] []
(Pi)
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 is .
released.
Hydraulic symbol

Fig. 2
. 2

Fig. 3
. 3
2
1. O u t p u t s haft 24. Needle bearing 1. 24.
2. S p a c e r 25. Inner ring 2. 25.
3. 26.
3. C y l i n d e r b l o c k 26. Pin
4. 27.
4. Spherical bush 27. Pin 5. 28.
5. D i s k spring 28. Plug 6. 29.
6. Shim 29. Plug 30.
7. 31. -
7. Piston 30. Plug
8.
8. Shoe 31. 0-ring 9. 32. -
9. Retainer plate 32. 0-ring 10.
10. Shoe plate 33. 0-ring 11. 33. -
34. 0-ring 12.
11. Valve plate
13. 34. -
12. Guide ring 35. 0-ring 14.
13. Casing 36. Oil seal 35. -
14. Valve cover 37. O il seal 15.
15. Front cover 38. Brake cover 36.
16. 37.
16. Hex. s o c k e t 39. Brake piston 38.
h e a d bolt 40. S p l i n e d c o n n e c t o r 17. 39.
17. Hex. s o c k e t 41. Brake spacer 40.
h e a d bolt 42. Piston ring 18. 41.
42.
18- Hex. s o c k e t 43. Piston ring 19. 43.
h e a d bolt 44. Brake shim 44.
19. Hex. s o c k e t 45. Disk spring 20. 45.
h e a d b olt 46. Separator plate 46. (.)
21. 47. (.)
20. S t o p ri n g 47. Friction plate 48.
21. Stop ring 48. Plug 22. 49. - -
22. Locking ring 49. 0-ring 23.
23. Roller bearing

D IS M O U N T iN G

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)
C A U T IO N
,
44 - .
T IG H T E N T H E M O TO R M O U N T IN G BO LTS

( M 2 0 ) TO 4 4 K G -M .

AFTER 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, but the motor does not operate.

Probable cause Remedy

1. Sliding parts a r e b r o k e n or s ei zed. 1. 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.

2. Brake is n ot released.

Brake releasing pressure is n ot Check hydraulic lines.


supplied,
B r a k e p i s t o n is stuck, Disassemble and check,
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 Disassemble and check.
ar e s e i z i n g e a c h other.

F A IL U R E 2. Braking force is i n s u f f i c i e n t .

Probable cause Remedy

1. F r i c t i o n p l a t e s and separator 1. D i s a s s e m b l e and ch ec k; a nd if w o r n


p l a t e s a r e wo rn. 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 .
2. Disk springs a re set, a nd a re not 2. D i s a s s e m b l e and c he ck ; and if s p r i n g
f u n c t i o n i n g we ll . is set, r e pl a c e .
3. B r a k e p i s t o n is stuck. 3. D i s a s s e m b l e and check.
4. 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 4. C h e c k h y d r a u l i c lines.
relieved.
5. 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 5. D i s a s s e m b l e and r e a d j u s t .
shim.
6. S p l i n e s f r i c t i o n p l a t e s and 6. D i s a s s e m b l e and ch ec k; a nd if
s e p a r a t o r p l a t e s are d a m a g e d . d a m a g e d , r e pl ac e.

1. , .


1. 1. ,
,
.
2. 2.
0 0

0 0
0 0

2. .


1. 1. .

2. 2. .
-

3. 3.
4. 4.
5. 5.

6. 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.
1. A f t e r giving match marks to the .
sections to be d i s a s s e m b l e d , remove ,
plug and di scharge the oil in @ .
casing @ .
2.
,
2. R e m o v e hex. so ck et h e a d bol ts @ and @ ,
; remove brake cover , disk .

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" given
later in this section. 3. ,
@ .
3. Remove stop ring(2l), and remove 4. ,
splined connector . @ ,
@ @ .
4. Remove separator plates), friction 5.
p l a t e s , brake s h i m , and brake
spacer .
,
5. Removal of v a l v e cover . .

@
NOTE
. " " .
Take c a k e t o p re v e n t v a lv e p la te 0
fro m 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 p a rts by p r y in g @
w it h a s c r e w d r iv e r or th e lik e , ta k e @ .
c a re to a v o id d a m a g in g 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.
6. W i t h the m o t o r p l a c e d on its side, 6.
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 , ,
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 head b o l t s ; 7.


and r e m o v e f r o n t cover from casing ,

, by u t i l i z i n g t he t h r e a d e d
,
extraction holes (M8). (8) .

8. @
8. Extract output shaft from casing
@ ,
b y t a p p i n g the s h a f t f r o m the
valve cover @ mounting side, u s i n g @
a plastic hammer. .

9. @
9. Remove valve cover @ from valve .
p l a t e . (It m a y h a v e c o m e off (
d u r i n g S t e p 5.) . 5.)

10.
LO. P e r f o r m the following only whe n .
necessary: 1)
,
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
2) @
valve cover . @
@ , @
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 3)
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 m o to r (1)

1. W ear p a rt re p la c e m e n t s ta n d a rd s 1.

C h e c k the p a r t s , a n d r e p l a c e if t he
use limits are exceeded. .

1)
1) C l e a r a n c e between piston and

cylinder bore.
: 0,023
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 : 0,053

2) ^
2) Clearance between piston and (. 4)
shoe ^ (Fig. 4) : 0
,
S tandard value: 0 mm : 0 ,3
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
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
: 8,6

4) D e f l e c t i o n of d i s c springs L- 4)
(Fig. 5) @ L - @ (. 5)
: 3,65
Standard value: 3.65 m m ,
Recommended use limit: 2.9 m m : 2,9

5) @
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 (. 6)
H - h (Fig. 6) : 29,1
S t a ndard value: 29.1 m m ,
: 28,5
Recommended use limit: 28.5 m m

2. S lid in g s u rfa c e c o r r e c t io n s ta n d a r d 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
0,4 - Z
e ith e r th e c y lin d e r b lo c k o r th e
(Ra = 0,1)
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 3 - Z
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 @ (Ra = 0,8)
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

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 s e t.
.
Check the s l i d i n g surfaces, and correct
or r e p l a c e if the r o u g h n e s s li m i t given

b e l o w is e x c e e d e d .
,

0.4 - Z
Standard (Ra= 0 . 1 ) ,
Surface roughness
(Lapping) .
on s h o e , s h o e
plate @ Roughness 3 - Z
l imit (Ra= 0 . 8 )

(2) B ra k e s e c t io n (2)

1.
1. W ear p a rt r e p la c e m e n t s ta n d a rd s

C h e c k the part s , and r e place if the .
use limits are exceeded.
1) @
@
1) T o t a l thickness of s e p a r a t o r
: 32,2
p l a t e s ) and friction p l a t e s
,
S t a n d a r d : 32. 2 m m : 31,4
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) @ -

2) Free l e n g t h of d i s k s p r i n g (45) : 36
(4
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 ) : 32
(4
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
3)
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 : 53,8
Remedy : Readjust brake shim @ . ,
: 54,3
:
-

@ .

Fig. 7
. 7
A SSEM B LY

(1) H y d r a u lic m o to r (1)


NOTE
.
W a s h th e p a r ts in kero sen e and
, .
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 s lid in g p a r t s , b e a r .
in g s , etc. w ith clean h y d r a u lic o il
0- ,
b e fo re 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 p a r ts . . 3.

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


1.
th e to r q u e va lu e s sp e c ifie d in , ,
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
2.
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. 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
3.
with greased, install the f r o n t
( ,
cover on c a s i n g .
.

3. I n s e r t s h o e p l a t e , the l a r g e r 4.
c h a m f e r s i d e first, in c a s i n g . (
, ,
4. 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 , spherical b u s i n g , .
disk s p r i n g s , s h i m ) : aligning
the s p l i n e s 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 s h aft, and
into casing .
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 ( L ) .
; measure dimension L on valve L -
c o v e r ; then calculate L - (deflec (
tion of pack of disc springs). If ) .
3,650,1 ,
the result is 3.65 0 . 1 mm, there
. ,
is no need for adjustment. If not,

adjust with shims .
.

Fig. 9
. 9

6.
Installing the v a l v e plate


NOTE
,
,
If th e va lv e p la te has a s m a ll h o le ,
.
th is h ole sh o u ld com e to BDC of
th e p is to n s .

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 .

retainer p i n (g) w i t h the p i n hole.


7. Install valve cover on c a s i n g , 7.
p a y i n g a t t e n t i o n to their relative ,
position. .

8. ,
8. M a k e sure output shaft rotates .
smoothly.
(2)

1.
(2) Brake section


1. 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 . 2.
,

2. Install brake spacer @ and b r a k e
@ , .
shim; then alter n a t e l y insert
separator p l a t e s ) and f r i c t i o n
plates, starting with a : 9 .
separator plate. : 8 .
[Quantity] 3.
S e p a r a t o r pl at es : 9
Friction plates : 8
,
3. M e a s u r e dimension A f r o m the end
53,80,1 .
surface of v a l v e 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 the
specified range.

Fig. 11
. 11
4. Insert brake p is t o n in va l v e cover 4.
, an d r o t a t e the p i s t o n so that ,
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 , an d install 5.
brake cover . , @
.
WINCH

CONSTRUCTION AND FUNCTION

Fig. 1
. 1

1. B r a c k e t 15. Collar 1. 16.


3. 17.
3. Hex. s o c k e t 16. Ball bearing
18.
h e a d bolt 17. Ball b e a r i n g 4. 19. -
4. S p r i n g w a s h e r 18. Gear case 5. 20.
5. Oil seal 19. Gear 7. 21.
8. 22.
7. B e a r i n g r e t a i n e r 20 Ball b e a r i n g
9. 23.
8. B all b e a r i n g 21. B e a r i n g r e t a i n e r 10. 24.
9. Nut 22. B e a r i n g r e t a i n e r 11. 25.
10. W a s h e r 23. Oil seal 12. 26.
13. 27.
11. C o l l a r 24. Bo l t
14. 28.
12. Bo l t 25. Spring washer 15.
13. Spring washer 26. Lock plate
14. D r u m ge a r 27. D r u m boss

28. P in 34. Spring washer 29. 34.


29. Drum 35. Plug 30. 35.
31. 36.
30. D r u m shaft 36. Elbow
32. 37.
31. B a ll bearing 37. Gear case cover 38.
32. Bearing stand 38. Plug 33. 41.
33. Hex. socket 41. S l e e v e
head bol t


D IS M O U N T IN G
1.
1. R e m o v e the w i r e rope f r o m the w i n c h .
drum.
2.
2. Disconnect all 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.

3. .
3. Remove the w i n c h rope follower.
4.
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. .

Fig. 2
. 2
5. Remove t he h y d r a u l i c m o t o r f r o m the 5. .
winch a s s y.
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)
1) T i g h t e n t he w i n c h a s s m o u n t i n g

bolts to 45 to 50 k g . m .
45 50 .

2) 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
2)
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 3) ,
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

1. U n p l u g p l u g , a nd d i s c h a r g e the g e a r 1. ,
oil. .

2. R e m o v e b e a r i n g stand, an d r e m o v e 2 .
@ , @ .
ba l l bearing .

3. @ ,
3. Unscrew n u t , and remove t he d r u m
.
a s s y
4. ,
4. Unscrew b o l t s , a nd r e m o v e bearing @ .
retainer .
5. ,
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 th e m u n le s s
n e c e s s a ry . @

5. 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 .
6.
,
6. 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 case .
7.
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.

C LE A N IN G A N D CHECKS

1) C l e a n i n g 1)


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 the p a r t s thoroughly in ,
kerosine, a nd d r y them. .

2) Checking 2)

Oil 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 c o n t a c t a r e a of ,
the s h a f t for w e a r 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


H A N D L E T H E O IL S EA LS A N D T H E " " (
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 "THREE-BOND 1215",
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 . .

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. .

2.
1. S h r i n k fit sleeve an d b al l bearing @ .
@in th is sequence on d r u m sh a f t .
3.
,
2. Force fit ba l l bearings a nd on -
gear @ .

4.
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 "THREE-BOND 1215"
with screw locking compound. Apply
grease to the oil seal lip, a nd .
apply 3 ~ B 0 N D 1215 to t he m a t i n g 5. ,
s u r f a c e s of b r a c k e t a nd g e a r case
i n ad v a n c e . .
"THREE-BOND 1215"
,
5. 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
6.
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. 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 7.

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 "THREE-BOND 1215"

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 8.
) ,
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 , tighten n u t , and
l o c k it w i t h w a s h e r .
9. Install bearing retainer @ to g e a r 9.
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
"THREE-BOND 1215
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
in ad v a n c e . .

10.
10. 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 socket head bolts . "THREE-
BOND 1215".

11. 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 11. @
w i t h b o l t s , and f o l d l o c k p l a t e @
.

12.
12. 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 (9) @

with washer . .

13. Force fit ball bearing onto drum 13.


.
sh a f t .
14.
14. Install bearing stand . @ .

15. ) ,
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 .

Oil q u a n t i t y : .
a ppro x . 4 l iters. : 4
COUNTERBALANCE VALVE

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

This cou nt e r b a l a n c e val ve has the f o l l o w


in g f u n c t i o n s : .

1)
1) B a l a n c i n g a nd h o l d i n g functions

D u r i n g h o i s t i n g do w n , 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
, ,
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 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 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.
,
.
PRINCIPLE OF OPERATION (Fig. 1)

1. W h e n c o n t r o l valve is in n e u t r a l (. 1)

The holding pressure of t he h y d r a u l i c 1.


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

relief valve.
"
2. Hoisting - .

When the c o n t r o l valve sends oil to 2.


p o r t A, the oil pushes open the
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 .
D,

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 3.


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 B. ,
D,
. ,
This pressure flows through orifice b ,
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 "b ",
"", ,
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
, "d".
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 " d "
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
"d",

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 , 4.
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 in land d to h o l d the
load at a desired height. ""
, ..
"" ,

,

"d",

.
Fig. 1
. ]

1. Valve body 16. H e x . socket 1. 15.


2. Plug head bolt 2. 16.
3. -
3. 0-ring 17 . Spring washer
17.
4. 0-ring 1 8. Plunger 4. - 18.
5. 0-ring 1 9. Spring 19.
6. Hex. socket 20. Check valve 5. - 20.
21.
head bolt 21. Seat
6. 22.
7. Spring washer 22. Spring 23.
8. Cover 23. Plug 7. 24. -
9. Cover 24. 0-ring 8.
9. 1 25.
10. Plug 25. Orifice
10. 26.
11. Plug 26. Relief valve 11.
12. 0-ring ass'y 12. - 27.
13. 0-ring 27. Spacer 28.
13. - 29.
14. Hex. socket 28. Steel ball
30.
head bolt 29. Spring 14.
15. Spring washer 30. Orifice
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 c ir c u it
a n d th e u n its , a n d te s t th e o p e ra tio n ,
to m ai<e s u re of th e absence of ,
fa u lty 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 C H A P TE R ,
A T O W O R K C O R R E C T LY . .
W H EN D IS A S S E M B LIN G A N D R EASSEM
B LIN G T H E V A L V E , T A K E C A R E TO
PR EVEN T D A M A G E TO TH E TH R E A D S , ,
F IN IS H E D SUR FAC ES A N D S E A LIN G
P A R T S , A N D A V O ID IM P R O P E R H A N .
D L IN G . W H IL E D IS A S S E M B LIN G , T A K E
NECESSARY M EASU R ES T O ASSURE ,
.
T H A T A L L T H E P AR TS W IL L BE R E
A S S E M B LE D IN T H E IR O R IG IN A L
PO SITIONS.

W ASH T H E D IS AS S E M B LED P A R TS IN
K E R O S IN E , A N D C H E C K T H E IR S L ID IN G
S U R FAC E S, S E A LIN G P A R T M O U N T IN G ,
.
S EA TS , A N D THREADSw C O R R EC T M IN O R
, ,
D E N TS , S C U F F, RUST O R B U R R W IT H

F IN E A B R A S IV E C LO TH O R O ILS TO N E .

W H EN T H E SUR FAC ES A R E N IC K E D ,
.
W O R N O R O TH ER W IS E D A M A G E D SUB ,
S T A N T IA L L Y , R EP LA C E T H E PAR TS. , ,
C H E C K T H E C O N TA C T SU R FAC ES O F
TH E V A L V E A N D V A LV E S E A T, A N D .
R EP LA C E T H E M IF T H E C O N TA C T , ,
P A T T E R N IS N O T E V E N , O R EXCESSIVE .
W E A R IS O BSER VED .

IN P R IN C IP L E , R E P LA C E A L L T H E S E A L .
IN G P A R TS . O B S E R V E 'G E N E R A L C A U
,
TIO N S ( S E A LIN G P A R T S )' IN C H A P T E R
, .
A IN IN S T A L L IN G T H E M , T A K IN G
"
C AR E T O IN S T A L L IN T H E C O R R EC T
" ( )
O R IE N T A T IO N .
,
,
.
W H E N R E A S S E M B LIN G , T A K E E X T R E M E
CARE NOT TO A LLO W THE EN TR Y OF
D U ST A N D O T H E R FO R EIG N M A T T E R , ,

A N D A P P L Y H Y D R A U L IC O IL FO R L U - .

B R IC A T O N T O T H E S L ID IN G S U R FA C E D
.
IN S E R T T H E V A L V E O R P LU N G E R
,
S T R A IG H T , T A K IN G C A R E N O T T O P R Y ,
,
A N D C H E C K T H E IR S M O O TH M O V E M E N T
.
AFTER IN S E R T IO N .
, .

366 - 028 - 2000


ROTARY JOINT

CONSTRUCTION AND FUNCTION

Fig. 1
. 1
P ort N o.
C ir c u it

PI W in c h
,
P2 E l e v a t i o n , t e l e s c o p i n g , w in c h ,

P3 S w in g

13 D r a in

TO Tank
Details of electrical assembly

Connector
()

View D View
D

Slip
B r u s h No
. Wire ring Wire


1.25 YR g 1.25 YR
1.25 G h 1.25 G
0.85 R i 0.85 R
d 1.25 WL j 1.25 WL
1.25 RB k 1.25 RB
f 3.0 R l 3.0 R

Fig. 2
. 2
WIRE INDICATION
Code Color


YR Yellow w/red
G Green

Color of stripe R Red



WL White w / b lue

RB Red w / b lack
Ground color
R Red

Sectional area of conductor (mm2)


-
, 2
Fig. 3
. 3

1. Swivel joint 20. Packing 1. 23.


2. 24.
2. S u p p o r t 21. Seal r i n g
3. 25.
3. P l u g 22. Body 4. 26.
4. C a s e 23. Core 5. 27.
5. F i t t i n g 24. Plain bearing 6. 28.
7.
6. H o s e 25. Grommet

7. Hex. s o c k e t 26. Hose 29.
h e a d bo l t 27. Fitting flange 8. 30.
8. S p r i n g w a s h e r 28. Hex. s o c k e t 9. 31. -

9. Hex. s o c k e t h e a d bol t
32. -
head bolt 29. S p r i n g w a s h e r 10.
10. S p r i n g w a s h e r 30. F i t t i n g 11. 33. -
11. C l a m p 31. 0 - r i n g 12.
13. 34. -
12. B r u s h a s s ' 32. 0 - r i n g
14.
13. N u t 33. 0-ring 15. 35. -
14. W a s h e r 34. 0-ring
15. S l i p r i n g a s s ' y 35. 0-ring 16. 36.
17.
16. I n s u l a t o r 36. Hex. s o c k e t
18.
17. S p a c e r h e a d bol t 37.
19.
18. Connector 37. Plain washer 20. 38. 1
19. Plain bearing 38. Cover 21.
22.
DISMOUNTING

1. Set the outriggers, elevate the boom 1. ,


to approximately 60, and stop the 60
engine. .
2.
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. .


REMOUNTING
,
NOTE .

After remounting, bleed the circuit , "F"
and the units, and test the operation .
to make sure of the absence of
faulty conditionSo (10 X 25)
:
Remove any dust, dirt and rust from 23515 .
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
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& ,
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

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 (6,
MATTER. @
,
To connect hose (D to fittings and ,
insert the hose end fully into 1-1/4 .
the fitting body, tighten the nut @ , @
, "F" .
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.
1 1 6 -0 0 3 0 R 116-0030R

CHECK VALVE

CONSTRUCTION AND FUNCTION

1 1 1
Hydraulic symbol

Fig. 1
. 1
1. Body 6. 0-ring 1. 6. - -
7. 0-ring 2.
2. Plug
3. 7. 0-
3. Plug 8. Plug 4.
4. Filter 9. Steel ball 5. 8.
5. Spring 10. Plug 9.
10.

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.
.
116 -0030R. 116-0030 R.

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 .