Kobelco Crane rk250 3 Shop Manual PDF

SHOP MANUAL RK250-3 APPLICABLE : EZ-5003~ Book Code No. SSEZO005E Read and understand these instructions. Faillure to do so will increase risk of injury.1, GENERAL TERMINOLOGY 1.1 TERMINOLOGY OF OUTSIDE VIEW REAR TIRE ‘TOOL BOX REAR COMBINATION LAMPS Figure 1-1. ‘Terminology ana1.2 ‘TERMINOLOGY OF INSIDE OF OPERATOR'S ROOM SWING LOCK LEVER SHIFT SELECT LEVER EMERGENCY STEERING SWITCH SWING CONTROL LEVER STEERING WHEEL TOP PANEL, HORN SWITCH TEI ‘TELESCOPE SELECT LEVER DRUM LOCK KNOBS COPE LEVER INTERCEPTIVE LEVER FOR ON AND OFF ‘TRAVEL SERVICE BRAKE PEDAL WINCH DRUM BRAKE PEDALS L CRANE CONTROL LEVERS AUXILIARY SEAT Lain WINCH PEDAL “srep LAMP swiTcH BOOM HOIST (OR TELESCOPE) PEDAL HOTICOOL BOX. OPERATOR'S SE. JUICE PLACE SWING BRAKELEVER! LcLuTcHLEVERS TOP PANEL| OPTIONAL SWITCHES AIR CONDITIONER SWITCH AM RADIO ‘TOP (SKYLIGHT) WIPER SWITCH 1 ROOM LIGHT Figure 1-2 1-21.3. TERMINOLOGY OF UPPER / LOWER OPERATOR'S ROOM (CAB) SWING MOTOR AUXILIARY WINCH MAIN WINCH ‘TELESCOPE CYLINDER SLEWING RING HYDRAULIC OIL TANK TORQUE CONVERTER STEERING CYLINDER WORKING LIGHT TRANSMISSION REAR AXLE Figure 1-3 1-3 MAIN HOOK AUXILIARY HOOK 100M WORKING LIGHT DOOM LENGTH DETECTOR1.4 FRONT PANEL KEY SWITCH Hee a) TRAVEL METERPANEL) HIGH BEAMINDICATOR LAMP TACHOMETER TURN SIGNAL INDICATOR LAMP ‘TURN SIGNAL INDICATOR LAMP (RIGHT) (LEFT) TORQUE CONVERTE} AIR oI PRESSURE TEMPERATURE GAUGE GAUGE WATER FUEL GAUGE TEMPERATURE GAUGE GLow SENSOR InpicaTor fer =9][es = =} rrounte LAMP WARNING CHARGING WARNING LAMP RADIATOR WATER LAMP ENGINE OIL PRESSURE WARNING LEVEL WARNING LAMP LAMP HOUR METER ODOMETER (TOTAL DISTANCE) eve A TOROUE CONVERTER ON PROS, LOW BRAKE FLUID LEVEL WARNING LAME WARNING LAMP HYDRAULIC OIL WARNING LAMP ‘TRIP METER (SECTIONAL DISTANCE) | _ REAR STEERING NEUTRAL INDICATOR LAMP LOW AIR PRESSURE WARNING LAMP [TRAVEL CONTROL PANEL MONITOR TELEVISION REVERSE STEI SELECTOR SWITCH ‘TRAVEL SELECTOR SWITCR, (MODE SELECTOR SwITcH) —~~f- TTT) PARKING BRAKE, HIGH/LOW SPE SWITCH JRESET SWITCH INDICATOR LAMP AUXILIARY BRAKE Ss INDICATOR LAMP PARKING BRAKE SWITCH (AUX. BRAKE DEVICE SWITCH) ‘SUSPENSION LOCK/FREE SELECTOR SWITCH PARKING LIGHT SWITCH LOCK PIN PULLING OUT SWITCH MONITOR TELEVISION ‘CONTROL SWITCH 2/4 DRIVE SELECTOR SWITCH CPU DOWN INDICATION BACK MIRROR EXTENSION /STOWING SWITCH D SELECTOR 1-4WW MOMENT LIMITER (LOAD SAFETY DEVICE) PANEL, ML (AUTOMATIC STOP) RELEASE SWITCH [MOMENT LIMITER PANEL] 00M LENGTHILIFTING } = INDICATION SELECTOR SW! MOMENT LIMITER BOOMLENGTH MOMENT RATIO INDICATOR CPU ABNORMALITY ILIFTING HEIGHT 2 INDICATOR LAMP INDICATOR See eT RCNG HOE OVERLOAD WARNING Farag oa |-SELECTOR SWITCH OVERLOAD PRENOTICE LaMP|Bg—ty {wae OO) eee HOOK OVERHOIST 11Sa—a, }— WORKING AREA INDICATOR LAMP, 2 LIMITING DEVI TELESCOPE MISTAKE “[{Qaam OPERATION INDICATOR LAMP--[( nites) {a ‘SWING STOP WARNING LAMP. WINCH/CLUTCH LOW’ PRESSURE WARNING LAMP SWING AREA INDICATOR + be |_ML FUNCTION LI CHECK SWITCH OPERATING RADIUSINDICATOR TrTING LOAD INDICATOR BOOMANGLEINDICATOR LIMITSD(RATED) LOAD INDICATOR (OUTRIGGER CONTROL INDICATOR] ONTROL SWITCHES) (TT OUTRIGGER SETTING swircHES r P.T.0.SWITCH 1— WORKING LIGHT ourricorn c SWITCH \UTRIGGER CONTROL. 1 : R |-|—SWING WARNING SWITCHES (INDIVIDUAL) RT ASHRR STITCH f=) fH SWING FREE SELECTOR SWITCH OUTRIGGER CONTROL SWITCII (ALL) MOVEMENT SELECTOR: SWITCHES2, GENERAL SPECIFICATIONS 2.1. SPECIFICATIONS (1) PERFORMANCE OF CRANE ‘Boom ‘9. im (90, aft) Boom X 25, 065, 115 Ibs) (6 parts) Boom fength 16, 4m (63. ft) Boom % 18. 0 (39, 683 Ibs) (6 parts) X lifting capacity 23, 5m (77. 10ft) Boom ¥ 1. 5t (25, 353 ba) (4 parts) (No.of reeving parts) __| 30.6m (100.4ft) Boom % 7. 0¢ (15, 432 Ths) (4 parts) 7.5m (24. 61ft) Jib (*) X 3. Ot (6 614 Ibs) (1 part) Maximum ‘i Jib Jib (25") % 2. 1t 4, 690 Ibs) 1 part) Rated Gopacsty Jib US") % 1. 5¢ (2,756 Ibs) (1 part) - “ib length (otfset angle) m (89.371) Jib (©) % 2.0 (6 409 Ibs) (part) X lifting capacity 12, Om (88, 37) Jb (25°) X 1.2 (2,646 Ibs) (part) (No.of reeving parts) __| 12. 0m (89, 374) Jib 45°) % 1. O& (2, 208 ibs) (I part) ‘Auxiliary Sheave ‘3. 2t (7, 055 Ibs) (I part) _ Lifting Capacity at Max. Operating Radius with Boom | 0. 95t (2, 094ft) at 28. 0m (91. B6fi) Maximum Boom Length ~ 0.6m (100. dt) “Fb Lenath Tim G4. 614) Tm GO. 3TED Maximum Lifting Height Main hook /Jib hook | 31. im 104. 31)/43. 7m (143. 40, ‘Main Winch Line Speed High speed/ Low speed | 124m (406.8) / 60m (196. 85) / min th layer) ‘Aux. Winch Line Speed High speed /Low speed | 107m (351. 1ft) /52m (170. 6ft)/ min @2nd layer) Boom Extending Speed 95. 2600/21.3m (9, 68ft) “Boom Raising Speed | Ar bec 70" 1082" - Slewing Speed 3.06pm Swing Radius to Rear End 3.03m 9.9470 (2) MAIN STRUCTURE OF CRANE Box type, 4 section, Bnd independent, Srd/ th synchronows? Type of Boom independent telescope selection type. Side stowing and down extending type, new lift up twist jib Type of Jib (power tilt twist jib as an option). (Offset angle) Basic truss / tip box type drawing out form, variable inclining type (5°, 25° and 45° at offset angle). “Boom Telescoping Device ‘Two hydraulic cylinders together with use of wire ropes. ‘Boom Raising / Lowering Device (Boom angle) | One directly pushing hydraulic eylinder type (0° to82"). | Hydraulic motor drive (2 units), spur gear reduction type, |_with free fall device and automatic brake attached. | Hydraulic motor drive, planetary gear reduction type, Winch System ‘Swing System Free / lock selector type with hand brake attached, ‘Type Full hydraulic type, and type H / type X selector type. Outrigger 6. 3m (20. 674t)/5. 1m (16.7344) /3. 8m (12.4740) / 2. 1m (6. 69 Extended Width £1) (E-type outrigger only) () WIRE ROPE — IWRC 6 X Fi (22-7) c/o, special class 2, hard to twist type. ‘Main Winch Wire Rope 16an dia. X 170meters. (5/ 8° X558') “ IWRC 6 X Fi @2++7)/ o, special clase, hard to bist type, Anuiliary Winch Wire Rove ‘160 dia. X YOmeters.(5/ 8295") (@ HYDRAULICSYSTEM “Hydraulic Pump Type [_2tandem (variable plunger) + tandem gear “Hydraulic Oi tank capacity 358. (04. S7gals) (4208 110. 95eals))(©) TRAVELING PERFORMANCE ‘Maximum Traveling Speed ‘Minimum Turning Radius Zhe steer /4 wheel steer. “Gradability in tan@ (degree) Steering Mode. (6) ENGINE 49ka Th (30. Amp) 9.3m (90.51f¢)/5. 35m (17. 554) 0.661) “4 modes (normal, crab, crampand rear) Model Type “Total Displacement “Maximum Output ‘Maximum Torque (7) MAIN STRUCTURE OF CARRIER Mitsubishi DI6T. Water cooled, 4 cycle, direct injection type, with turbo charger. 7, 545ce (460. feu. 220psat 2, 800rpm 65kg + m (47Oft - Tbs) at 1, 600rpm ) Tie Fe — sre (Hw ie EH son GS Seems, 1 stay 2 pases: ‘orgue Converter Tye Electron cote al soma with eck each Transton : Forward anges reverse? range [samara ue euermes een a “rypect Gear Rei 2atageredvction pe Typeof Axles Front axle/ Rear axle Type of Steering |All floating type//all floating type Fully hydraulic power steering. Eng. rpm sensitive travel, power loss reducing system. With emergency steering device and reverse steering correcting device attached. Main Brake Brake Parking Brake ‘Air over hydraulic type, dise type 4 wheel brakes, with electronic control exhaust brake linked with torque converter lock-up clutch Propeller shaft braking internal expanding type, auxiliary brake for work attached, ‘Suspension Form Capacity of Fuel Tank Tires (8) GENERAL DIMENSIONS AND WEIGHT Hydro-pneumatic suspension (with hydraulic lock eylinder) 3008 (79. 25gals) 16,00-25.28PR (OR) “Overall Length of Machine ‘Overall Length of Carrier 11, 10a 6.127) 7, 590m (24 908) Overall Width, 2,490an( 8.178) Overall Height 3, 450m (11. 324) Wheel Base 3, 7005 (12. 14ft) Tread Front Wheels / Rear Wheels 2, 020an (6. 63ft)/ 2, 020 __ Overall Weight of Machine 26, 500k (58, 420 Ibs)2.2 WORKING RANGE (1) H-TYPE OUTRIGGER 50m, 30,62m BOOM + 12m JIB (OFFSET) — 30,62m BOOM + 12m JIB @5° OFFSET) ms 30.62m BOOM + 12m JIB. (45° OFFSET) 30.62m BOOM + 7.5m JIB (© OFFSET) 062m BOOM + 7.5m JIB (@5° OFFSET) 40m— 30,62m BOOM + 7.5m JIB: (4S OFFSET) 35m} 30.62m BOOM. (100.4%) 30m} 23.52m BOOM .. (77-1080) 25mm} HEIGHT ABOVE GROUND (m) 1642m Boom 207 (asitt) 15m] 932m BOOM. (a0sart) v Sm Tom ism 20m 2m 30m ‘Sm OPERATING RADIUS (m) 2-3@) SKY TILT IIB 50m; 30.62m BOOM + 12m JIB (OFFSET) 30.62m BOOM +12m JIB. 8 OFFSET) 45mi= 30,62m BOOM + 12m JIB, 5" OFFSET) 30,62m BOOM + 7.5m JIB, & QFESET) 30,62m BOOM +7.5m JIB. (25° OFFSET) 40m} 30.62m BOOM + 75m JIB GS" OFFSET) 35m} 30.62m BOOM - | (100.4%) 30m} 2352m BOOM (774081) 25m) HEIGHT ABOVE, GROUND (m) (mn) 16.42m Boom 28 (asitty 15m) 932m BOOM (a0.52tty 0 om 10m 1m 20m 2m 30m om. OPERATING RADIUS (m)23 RATED LIFTING CAPACITY ()_ RATING CHART ON OUTRIGGERS IN TONS 20 Ly .0 7.0 7 aT ur0og EA. 3 T 1 Te 3 08 = | os 3 Ct O77 z t 1 ow < TT om g TT] ou a z= oer g z_| I o8t 2 z i out a3 *€ oor 53 °E ost ae ¥ 1 ov g 5 + Ore et g¢ OF? | 06 E | Ser a? or 027 | wer Zs Gtmssemieni eer va] 52 $60 T % 29 [58s | or 2 eT | $0T 6 0679 | $0 | oor 2¢ oot | OFT * or [soe | 06 BE Ore _| 06 T | OF" ists 0L'8_| 06 OF oe 33 #2 |oe ort [ss st6 | on Tt oh as sez _[09e | S07 Lore one | ost OL 23 se [se [0% T3979 06 | 082 | OO ro EE see [sre [srt [8% [ood cy “oF | ov er | oF aT £9 ge ose [see [s6% [ore | 007 od Ov | OFS oe 2 a 3076 os st | 08 at a 3s oes | O6F [ocr | es [ooe | ez or OF OF | 09 OF ‘OL 91 | OF '6T oe 23 Toss ost fooet | ov zt | oer | oat oF 38 can Of TT [ost | O: ST ‘00°81 | 00" oF Ze [086 (os -11 | 00st [00 "02. ost | 00'sz. oe 38 t ‘00°8T | 00°se 1 "1 "8a, OF BS coat woz | 1 $2 35 hea 08 eS TWEE 6 [ED OG RE TECH OT] WEG [LD ONES HEY OT 1aaa 0 Sawa) 5 | | ameeto | $l | |_pavoq moog | & wy PEER) reo PEER PRT ROT T ze PopoNS um eANG | (uigE) Mpg pUsEANNG | (uIS)medpRE wERNNG | Papua AMMEN | Bs stability.(2) RATING CHART WITHOUT USE OF OUTRIGGERS IN TONS Stationary lifting Pick and carry(overfront) | Pick and carry (alaround) - (over front) Lomax. Zha/h (124mph) | (max. 2ka/h 1.24mph)) Boom Length - Operating Radius inmeters_| 9.32m [16.42m|23.52m] 9.32m |16. 42m|23. 52m) $.32m [16.42m|23.52mn| 9. 32m 3.0 [14.00 10.10 5.90 35 [14.00 10.10 440 oe 10 3.30 45 11.25 8.10 2.60 5.0 8.90 7.10 2.10 5.5 6.55, 6.20 1.70 | 1. 60 7.20 5.20 1.30 | 85 6.15 440 1.00 5|a|a/s|a/3|3/5} 16.0 17.0 [Min.boom angle! O° | a | ae | a0" | sx | ae | 0" a | sr | oF(3) RATING CHART WITH BOOM AND JIB IN TONS © Outrigger Maximum Extended Boom + 75m ib oom + 120m i _ Outrigg (6.3m) extended (all around) Outrigger max. (6.3m) extended (all around) Boom Angle | 5° offset 25" offset | 45° offset 5 offset 25 offset ¢) | “Lead (ton) | ~Load (ton) | Load (on) | Load ton) | Load ton) | Load (ton) 30.0 3.0 7.10. 1.25 2.00 1.20 75.0 3.00. 1.25 113 73.5 3.00 1a 1.08 [Min, boom angle| © Outrigger Mi point Extended (1) Outrigger mid Boom + 7.5m jib oin (5.1m) extended (oer side) Boom Angle | 5° offset 25" offset ©) Load (ton) Load (ton) ~ 50.0 19.0 in. boom angle] Ei ie F © Outrigger Mid-point Extended (2) Boom + 7.5m ib Boom + 120m jib _ Outrigger mid-point (3.8m) extended (all around) | Outrigger mid-point (3.8m) extended (all around) | Boom Angle [__$° offset 25° offset | 45° offset 5! offset | 25° offset [45° offset ¢) Lead Gon) [Lead ton) {Land on) | Lend on) "Load on) [Load Gon] 2.10 1.25 2.00 | _ 1.20, 60.0 Nin, Boom angle|2.4 NOTES FOR RATED CAPACITY CHARTS [RATINGS WITH USE OF OUTRIGGERS] Load ratings do not exceed 78 percents of tipping load with the machine set horizontally on a firm and level ground, satisfy the specified stability over front, and include weight of hook block (s) and other load handling accessories. Rating in the area are based on the machine's structural strength, and others are determined by the machine's stability. Kind of hook ton 32ton 210k«s 7Okes ‘Weleht (463 Ibs) (154 1bs) @Since the operating radius given in the chart includes allowances for laden boom deflection, the machine must always be operated on the basis of actual operating radius. ©lib operation must be based on main boom angle. ©The outrigger maximum extended width is 6.3m (20.7ft), mid-point extended widths are 5.1m (16.7ft) and 3.8m (12.5¢t), and minimum extended width (H-type outrigger only) is 2.1m (6.89ft).. ORatings in “Over Side” vary according to the outrigger extended width condition, therefore, operation must be based on the rating chart corresponding to each outrigger extended condition. Operation in “Over Front” and “Over Rear” areas must be as per the ratings when the outrigger is extended to maximum. es ov REAR & ‘Outrigger | Mid-point | Mid-point | Minimum extended | width width, width condition | 5.1m 3.8m 2.4m _ asm) | aasty | asm, ‘Area a 28° 20" s ORatings with use of the auxiliary sheave are the same as the ratings with the boom less weight of 25ton hook (210kgs), but should not exceed 3,200 kgs (7,055 Ibs). ©When the boom length exceeds the specified length shown in the rating chart, operation must be performed basing on the smaller rating of the specified length or the rating for the next longer boom length shown. When operating with the boom with the jib attached deduct 1,550kes (3417 Ibs) when one step jib is extended, and deduct 1,750k«s (3,858 Ibs) when two step jib is extended besides weight of lifting slings, etc. At this time, do not use the auxiliary sheave. ©Do not operate in a condition not shown in the rating chart. When the min, boom angle is indicated at the bottom of the rating chart, tipping may result if the boom is lowered beyond the stated angle. ©The minimum reeving is determined so that the single line load does not exceed 3,125kes (6,889 Ibs). ‘The standard reevings of the hook block are shown below. Boom length | 93m] 164m | 235m Used hook ~ 2ton hook Number of eeving 8 6 ‘ Boomlength | 806m | Jib/aux.sheave Used hook | 25tonhook | 32ton hook ‘Number of reeving ‘ : Free falling operation shall be, as a rule, be used. when lowering the hook block only. When it is required to free fall a load, the load should not exceed one fifth of the rated load, and sudden brake must be absolutely avoided.[RATING WITHOUT USE OF OUTRIGGERS] @Since the operating radius given in the chart includes allowances for laden boom deflection, the machine must always be operated on the basis of actual operating radius. ©Load ratings are the approved maximum lifting capacity with the specified air pressure of the tires and with the suspension lock cylinders fully retracted on a firm and level ground, and include weight of hook block (s) and other load handling accessories. Rating in the area are based on the machine's structural strength, and others are determined by the machine's stability. ind of hooks 25ton ‘Baton 2i0kes 70kes Weight (463 Ibs) (454 Tbs) Specified air pressure of tire :7.75ke / caf (110psi) When performing stationary lifting, be sure to engage the parking brake and the auxiliary brake for work. ‘When performing picking and carrying operation, be sure to place the high speed / low speed selector switch in the LOW range position. ©When picking and carrying a load, hold the load near the ground and travel within 2kn (124 miles) per hour of speed not to allow the load to be swung. Especially be careful for comering, sudden start and sudden stop. ©Do not perform crane operation while traveling with a load suspended. ©The minimum reeving is determined so that the single line load does not exceed 3,125kus (6,889 Ibs). ‘The standard reevings of the hook block are shown below. Ratings in “Over Front” and ratings in “Over Boom Ten 33m_|_I64m | 285m Side” are different. When swinging from “Over | Used hi Zinn hook. Front" to “Over Side” , sufficiently be carefull ae 8 4 4 not to exceed the rated load. (The capacity in “Over Front” is set with the swing lock pin amie ier inserted.) Usedhook | 32tonhook | = ‘Number of 1 — reeving LOCK | FREE eee = AXEBLOCK Lights up ¢o fLO EPI Liens uv _ orr AUX. OVER FRONT Grane operation [Stationary liting | Pick and carry rea ¢ ¢ wis ORatings with use of the auxiliary sheave are awoIlllltow ‘equal to the ratings with the boom less weight of the 25ton hook block (210kss) (463 Ibs), but 24WD HIGH/LOW should not exceed 3,200ks (7,055 Ibs). ws ©Do not perform free falling operation and a operation with the jib. Lights up2.5 GENERAL DIMENSIONS (2) Machine Equipped with “H” Type Outriggers 17900 687) 2450an (11.32) (OVERALL HEIGHT) 210m 6.0 3800mn (12.47) 510000 (1673) {6300 (20.67 ) (WHEEL BASE) 3700um (12.14) 214000 (7.02) 51 70mm (16.96') 110100 (96.12) (2) Machine Equipped with “X” Type Outriggers 1790am Gar) 3450m0 (11.32') (OVERALL HEIGHT) 7 380m (12.47 ) 1000 (6.75) (63000 (20.67 ) (WHEEL BASE) 37000 (12.14') 5170am (16.96) (OVERALL LENGTH) 11010me (36.12) 214000 (7.02) Figure 2-1, General Dimensions 2-101, LOCATION OF MAIN PARTS 1.1 UPPER (BASE BOOM 2ND BOOM 4TH BOOM (TOP BOOM) JIB SUSPENSION ROD ‘TILT CYLINDER OUTER JIB INNER JIB HARNESS FOR DETECTING OVERHOIST LIMIT SWITCH CONTROL VALVE MAIN WINCH WIRE ROPE AUXILIARY WINCH WIRE ROPE MIRROR (oom) MAIN HooK GANTRY PIN SHEAVE AUXILIARY HOOK. BOOM HOIST CYLINDER COUNTERWEIGHT SWING MOTOR/REDUCER - UNLOADING VALVE MAIN CONTROL VALVE SWIVEL JOINT BOOM FOOT PIN (AUXILIARY) WINCH MOTOR MAIN WINCH DRUM AUX. WINCH DRUM anaREDUCER ACCUMULATOR Ca) \ ae @ 7 STEERING UNIT CONTROL VALVE, COOLER UNIT CONTROL VALVE CAB. WORKING LIGHT SWING MOTOR/REDUCER HYDRAULIC MOTOR SWING CONTROL VALVE swive HYDRAULIC MOTOR pel SWIVEL JOINT FAN -_ FRAME UNLOADING VALVE HYDRAULIC POWER. MAIN CONTROL VALVE, ‘SUPPLY VALVE ay oe: ACCUMULATOR raw i) CLUTCH VALVE COUNTERBALANCE VALVE | HYDRAULIC MoToR—__| COUNTERBALANCE VALVE HYDRAULIC MOTOR1.2 LOWER AIR CLEANER MUFFLER REAR AXLE, FRONT AXLE REAR STEERING LOCK CYLINDER SUSPENSION CYLINDER DISC BRAKE B LINE FILTER BAT’ ‘TORQUE CONVERTER BRAKE FLUID TANK ~ POWER CLUSTER 2-TANDEM HYDRAULIC PUMPS 3-TANDEM HYDRAULIC PUMPS, ‘TORQUE CONVERTER 3{a Ra VERTICAL CYLINDER HORIZONTAL CYLINDER | LENGTH DETECTOR STEERING FENDER CYLINDER OUTRIGGER: SOLENOID VALVE FUEL TANK HYDRAULIC ACCUMULATOR POWER CLUSTERS ‘TIE ROD ‘AIR DRYER AIR TANK, FLUID RESERVOIR TORQUE ROD FRAME HIGH SUSPENSION CYLINDER,1.3 ELECTRICAL APPARATUS CYLINDER EXTENDED L DETECTING CABLE CYLINDER EXTENDED LENGTH METER BOOM ANGLE DETECTOR — CYLINDER EXTENDED LENGTH DETECTING CORD REEL = BOOM LENGTH DETECTOR CORD GUIDE Rt SWING FREE SOLENOID VALVE/SWING PRESSURE. ‘SENSOR/SWING DIRECTION DETECTING LIMIT SWITCIL INTERCEPTIVE LIMIT SWITCH FOR ON AND OFF ft — poor swircnt | SWITCH LEVER [STEP LIGHT swircHt SLIP RING VOICE ALARM. (SPEAKER) LIMIT SWITCH ROPE LENGTH SENSOR DRUM LIGHT/CAMERA ‘SWING WARNING FLASHER ‘SWING WARNING FLASHERML (MOMENT LIMITER) SWING AUTOMATIC STOP CONTROLLER ‘TOP WIPER INTERMITTING UNIT ae ‘TRAVEL MI MONITOR EE: MLRELBASE switcH KEY SWITCH ‘TRAVEL CONTROL PANEL (ORKING LIGHT. VIEW A VOICE ALARM LAMP UPPER FUSE BOX UPPER MDT. CONNECTOR — / coo oO oOo omc VIEW C CAB VOICE ALARM \ AIR CONDITIONER SWITCII PANEL SPEAKER RADIO O00 ENGINE OVERRUN WARNING BUZZER ‘SWING WARNING FLASHER RELAY WORKING LIGHT RELAY _-PTORELAY A PTO RELAY BX PTORELAYC HEATER RELAY B .p MONITOR CONTROL SWITCHDLIGHT , ovrniccer soLexom TRIGGER LENGTH, VALVE @ucuT) | _—ourniccrr vescrn berectoR FRONT RELAY UNIT (SEB VIEW 8) SUSPENSION LEVEL SENSOR @ICHTD Pl SUSPENSION SOL ENON |__ suspensiox sonexow WALVECEPD VALVE wuGHT) BODY INCLINATION SENSOR STEERING MODE | SELECTOR SOL. VALVE EXHAUST BRAKE Sipe BRAKE PLUTD SENSORS an UENOID VALVE, (— sropane smreit STEERING CONFLUENCE ‘SOLENOID VALVE UNLOADING SOL. VALVE |-— AIR SOLENOID UNIT SOLENOID VALVE, Lock PIN Sot. VALVE] —] suiP RING —_| SPEED SENSOR EMERG, STEERING PUMP LOWER MDT FUEL LEVEL SENSOR LEVEL ——] ‘TACHOGRAPH overourmcees Fuse nox u 6 3 | rRansmission CONTRO} BOX HYDRAULIC PRESSURE BATTERY RELAY |~ TRANsMISsION SOLENOID VALVE PTO SOL. VALVE ‘TORQUE CONVERTER OIL, ‘TEMPERATURE SENSOR LOCK-UP SOL. VALVE ENGINE OIL PRESSURE SWITCH }— air HEATER EXHAUST BRAKE LIMIT SWITCH ENGINE OIL FILTER PRESSURE SWITCH EAR WHEEL NEUTRAL. GAP LIMIT SWITCH STARTER MOTOR ALTENATOR —_ RADIATOR WATER LEVEL. WARNING SENSOR OUTRIGGER SOLENOD-—| ENGINE STOP SOL. VALVE VALVE = WATER TEMPERATURE -—1 SENSORLIGHTING RELAY (LEFT) CLEARANCE LAMP LIGh RELAY (RIGHT) View A. Front Relay Unit AUXILIARY BRA\ ‘OR WORK SOL. VALVE OUTRIGGER IDLE-UP SOLENOID VALVE, PTO GOVERNOR ‘SOL. VALVE PARKING BRAKE SOL. VALVE, View C. Air Solenoid Unit SUSPENSION CYLINDER View from B LOWER MDT View D. Lower MDT FLASHER UNIT AUXILIARY BATTERY RELAY ENGINE STOP RELAY SAFETY RELAY | AIR HEATER RELAY View G. Rear Relay Unit HOURMETER RELAY HAZARD UNIT View E-E. MDT Relay Unit2. WEIGHT 5_ | 4TH BOOM SECTION s1 | SHEAVE(QTY) 52 | PIN ‘AUXILIARY SHEAVE. 3_fourer ns 9 PINNER J — “0 2ND BOOM TELESCOPE CYLINDER —) fsaprata noon ESCODE CYLINDER a His [Boon noisrovENDER 1s: | piv @rRAME) 600 (1928) 32 (705) 160 (353) 360 (772) 590 (1301) WIRE ROPE FOR THIRD DRUM Unit :ke (Ib) Na Name Weight 1 |BOOMASSEMBLY 620 (10187) [2 |BASEBOOMSECTION [1370 (3021) | 21 | BOOM FOOT FIN | a G35) | ‘aN BOOM SECTION [1000 (221) 4 [SRDBOOMSECTION | 765 (1687) 310 (684) 360 (772) L 50 (110) 103 (227) 80 (176) 8, OUTER JIB 9. INNER JIB 13. BOOMHOIST 18 CYLINDER 19. 131, PIN 10, 11 BOOM 132 LESCOPE CYLINDER Pig. 2-4 2-1 BOOM ASSEMBLY PIN 5. 4TH BOOM. SECTION 3 2ND BOOM] SECTION 4 F 3RD BOOM = 15,16 K 7 9, INNER JIB 8, OUTER JIB 7. AUXILIARY SHEAVE23, WINCH BLY 24. WINCH MOTOR 25, WINCH REDUCER 20, BRAKE ASSEMBLY 28, DRUM (MAIN) 27, DRUM (AUXILIARY) 29. HOSE REEL 21. CLUTCH ASSEMBLY 5-1. SHEAVE 5:2, PIN Fig.23 Unit : ke) me ne Want] [No Waa 20_| BRAKE ASSEMBLY 30 (66) 26 ma Gui) 2i_| CLUTCH ASSEMBLY 20 (44) ar_| DR “| 21 (267) 22_| WINCH ASSEMBLY (MAIN) _| 450 (992) SWING REDUCER 321 (267) LD OSE REE za | WINCH ASSEMBLY ‘as (ous HO: _ _ PIN@PORGANTRY) | _35 (77) 355_(783) st R GANTRY) 9 (20) 54 (119) ‘WINCH REDUCER a (WITH MOTOR) 340 (529)Unit : kg (1b) Weiaht 90 (198) 83 (183) 10 (22) 16 (35) 38. REVOLVING —_ 73 (161) FRAME X-TYPE | 250 (551) _ ieryPE | 340 (150) EE X-TYPE | 31 (68) | FLOAT: H-TYP 25 (55) ‘| HORIZONTAL _ 8 5) * | cyzinper 28) 17 (258) - 102 (225) A 34, CLUTCH VALVE 38. MAIN CONTROL VALVE 44, VERTICAL CYLINDER 39. SLEWING RING 47, HYDRAULIC OIL TANK 48. BATTERY 46. STEERING CYLINDER 42. FLOAT 41, OUTRIGGER BEAM61, TORQUE CONVERTER 65. 2TANDEM HYDRAULIC PUMP. ° Ut 66, TANDEM HYDRAULIC PUMP al ! 26 60, ENGINE ot FENDER 75. TRE 67. RADIATOR 61. TORQUE CONVERTER —7- PROPELLER SHAFT ee LJ «tomas wo’ Ps TS 72, PROPELLER SHAFT \ 7 No, Name Weight No. Name 60 [ENGINE 550 (1213) 73_| TORQUEROD 61_| TORQUE CONVEI 160 (353; 78, @2_| TRANSMISSION 380 (772) 76 _ ?-TANDEM HYDRAULIC 77 8 lpuw 80 (176) ne = 3-TANDEM HYDRAULIC 31 (68) 7 PUMP | 79 | (eoR DISC BRAKE) #8) RADIATOR ) @_| AXLE @RONT) ~_ [tae (ear) | PROPELLER SHAFT | 11 (24) 81_| AXLE (REAR) 960 (2116) PROPELLER SHAFT | _30 (66) PROPELLER SHAFT 15.5 (34)1, PERFORMANCE STANDARDS AND TEST PROCEDURES (1) ‘Terms used in the standards tables have the following meanings : Standard value : Standard to be applied to a new machine when it is assembled. Unless specifically noted, standards apply to machines (fitted with standard attachments). Allowable value : Limit above which the machine must not be used. If this value is reached, the machine must be repaired or components must be replaced to maintain machine performance and safety. Oil temperature : That of the object in question. ‘The temperature of hydraulic oil refers to that of the hydraulic oil in the tank, Circulate hydraulic oil so that the temperature of the hydraulic oil in the circuit will be equal to that in the tank, 1.1 ENGINE REVOLUTIONS © Test Procedures a. Machine posture : With outriggers extended. b, Measurement : Measure after warming running. c. Load : No load. d. Number of measurements : 3, use average for value. (2) When no allowable value is mentioned, use the standard value as the approximate allowable value for repair or replacement. (3) Since rubber components such as hydraulic hoses, O-rings and oil seals deteriorate with time, replace them periodically or during overhaul. (4) For hoses and the like that are particularly important to safety, it is recommended that they be designated “very important parts” (V. LP.) for safety and be replaced regularly. (5) Before any attempt to service the machine, a full understanding is required of procedures and precautions for handling it safely, and of check and lubrication procedures, To this end, read the operator's manual together carefully. e. To confirm engine revolutions when the exhaust brake functions, lower the engine speed to a low idling speed after the exhaust brake functions, then depress the accelerator pedal, and read the engine rpm when the exhaust brake switch is turned off. (Unit : rpm) Item Standard Value Remarks Confirm the engine rpm with the enuine tachometer in P.7.0. fONJ 1880~2000 {ront ofthe operator's seat High ale - P.7.0, OFF) 040~3040 Low idle P.7.0. [OFFS 660~700 When exhaust brake functions 700~7501.2 OU, TIGHTNESS (1) Boom hoist cylinder © Test procedures a, Machine conditions : Outriggers extended, and boom fully retracted. b. Boom angle : After raising boom to max. , lower it to 75° , then measure c. Load :2.3tons (5071 lbs.) d. Hydraulic ofl temperature : Normal temperature e. Test time :30 minutes £, Part of rope reeving :4 parts MEASURING POSITION Tem Slandard Value Remarks ‘Amount of boom hoist cylinder | Less than retraction 10m 30min (Ainch) (2) Boom telescoping cylinder and whole boom system © Test procedures a. Machine conditions : Outriggers extended b, Boom angle :75° c. Reeving :4 parts 4, Load :2.3tons (5071 Ibs.) e. Hydraulic oil temperature : Normal temperature £. Test time : 30 minutes g. Boom length when starting measurement 2nd boom : Extend fully and retract Im. 3rd / 4th booms : Extend to more than half length, then retract to half length, h. Place a mark on each boom section and measure how far the boom retracts under load. i, Determine overall oil tightness of the whole boom system by measuring how much the load falls. em Standard Valve Remark Less thaa 20 (0.984")/ 30min “Amount of 2nd boom retraction ;A (Oil tightness of 2nd boom {elescoping cylinder) Tess than 2am (0.988")/ 30min “Aroustof th boom retraction 8 Ol tightness of rd and 4th boom telescoping eylindes) | Less 12am (172")/ 20min “Amount of suspending Toad fall ;C (Overall ol tightness boom system) Tecluding amount of boom hoist, einer fll(3) Winch, With winch negative brake on, winch drum shouldn't rotate. (4) Winch motor drain volume, and, swing motor drain volume © Test procedures Hydraulic oil temperature : 50:£5°C (122:49'F) Engine revolutions : High idle . Hydraulic load : Relief Measuring point : Disconnect the drain piping then measure the drain volume caught ina container e. Before testing the winch motor, be sure to apply the drum lock and move the lever to the LOWERING side. £. Before testing the swing motor, be sure to apply the swing brake lock g. Test time : 1 minute DRAIN HOSE ) | =a ‘SWING MOTOR DRAIN OF SWING MOTOR Tem ‘Standard Value Remarks ‘Armount of dain from winch motor | Less than 100 / min 2.09) “Anount of dain feom swing motor — | Less than 102 / min uals) 1.3. OIL PRESSURE (1) Oil pressure measurement precautions a. Use pressure gauges with capacity at least 50ke Jai (711 psi) greater than the pressure to be measured. b. Only use pressure gauges that have passed rigid inspection. (2) Boom hoist / telescope circuit and circuit © Test procedures inch a. Engine revolutions : high idle b. Hydraulic oil temperature : Normal temperature c. Boom hoist : Relieve hydraulic pressure by fully extending and retracting the boom hoist cylinder with the boom fully retracted, and measure relief pressure at pressure measure port “A” . d. Boom telescope Relieve hydraulic pressure by fully extending and retracting the 2nd boom, and measure relief pressure at pressure measure port “A” . ‘MAIN CONTROL VALVE(3) Winch, With winch negative brake on, winch drum shouldn't rotate. (4) Winch motor drain volume, and, swing motor drain volume © Test procedures Hydraulic oil temperature : 50:£5°C (122:49'F) Engine revolutions : High idle . Hydraulic load : Relief Measuring point : Disconnect the drain piping then measure the drain volume caught ina container e. Before testing the winch motor, be sure to apply the drum lock and move the lever to the LOWERING side. £. Before testing the swing motor, be sure to apply the swing brake lock g. Test time : 1 minute DRAIN HOSE ) | =a ‘SWING MOTOR DRAIN OF SWING MOTOR Tem ‘Standard Value Remarks ‘Armount of dain from winch motor | Less than 100 / min 2.09) “Anount of dain feom swing motor — | Less than 102 / min uals) 1.3. OIL PRESSURE (1) Oil pressure measurement precautions a. Use pressure gauges with capacity at least 50ke Jai (711 psi) greater than the pressure to be measured. b. Only use pressure gauges that have passed rigid inspection. (2) Boom hoist / telescope circuit and circuit © Test procedures inch a. Engine revolutions : high idle b. Hydraulic oil temperature : Normal temperature c. Boom hoist : Relieve hydraulic pressure by fully extending and retracting the boom hoist cylinder with the boom fully retracted, and measure relief pressure at pressure measure port “A” . d. Boom telescope Relieve hydraulic pressure by fully extending and retracting the 2nd boom, and measure relief pressure at pressure measure port “A” . ‘MAIN CONTROL VALVEe. Winch cireuit : Relieve hydraulic pressure by operating lowering with the drum locked, and measure relief pressure at pressure measure port “B” . £, Tilt jib hoist : Relieve hydraulic pressure by fully extending and retracting the jib hoist cylinder with the jib extended and with the basic boom length, and measure relief pressure at pressure measure port “C” ‘Unit : ke / ef (psi) ‘Mensur ing tem Pasition Remarks a {of boom hoist (484 to 3625) | valve Relief pressure | gy, | 24510255 [Main relief 1849 t0 1991) | valve circuit Rew, | 180t0M0 [Port velit Relief pressure Ext. ‘| of boom tele 2i5to2r7 | valve 160t0170_ | Port relief scope circuit Rett. | (2344 to3057) | valve 20000215 [Port relief circuit (9555 to 3657) | valve B [Relief pressure of winch |” 250t0260 | Main reiet c_fottitabhoist (41067 to 1209) | valve Relief pressure | py | 751085 [Port relich circuit Rew. (2215 03057) | valve 205t0215 | Main reliot (3). Pilot circuit © Test procedures a. Engine revolutions : Low idle b, Hydraulic oil temperature : Normal temperature c. Measure unloading pressure and loading pressure of clutch valve. Unloading pressure : Measure pressure when the gauge pressure stops at the highest pressure. Loading pressure : Operate the clutch lever to ON and OFF continuously from the unloading condition, and measure the pressure when the gauge pressure stats rising again from lowering condition, NOTE : When operating the clutch lever to ON and OFF continuously, be sure to operate with the drum lock applied. MAIN CONTROL VALVE, Measuring Position of Pilot CircuitUnit : ke / if (psi) Measure Ten Starded | Remarke position valve Gistch pressure | 851095, “Lending 20810 351) a Glutch presse | 115t0190 *Unloatig | 1635 t0 1810) resure (4) Swing Cireuit © Test procedures a. Engine revolutions : High idle ‘b, Hydraulic oil temperature : Normal temperature c. Swing Circuit : With the swing brake engaged and with the swing lock pin engaged, operate swing, and measure the relief pressure. Measure the pressure for left swing and right swing respectively. Unit : ke / et (psi) Measure sndard position em mndard | Remarks E | Swingmain 2000210 [Gauge port relief pressure | (2844 to 2986) | PPIS4 (5) Outrigger Circuit © Test procedures a. Engine revolutions : High idle b. Hydraulic oil temperature : Normal temperature c. Outrigger Circuit : Measure relief pressure of the vertical cylinder or horizontal cylinder. ‘Unit : ka / ea (psi) OUTRIGGER Measure ‘Standard CONTROL Dostion heen ‘Value__| Remarks VALVE BP |Outriguer main | _165t0 175 _|Gnage pore [ relief pressure | (2346 to 2489) |" PFL/4 PORE =~ | } (©) i a PARC i i lage I eo \i Measuring Position of Swing Cireuit ‘T PORT 25) [prort V PORT ‘Measuring Position of Outrigger Circuit1.4 SPEED PERFORMANCE (1) Raising and Lowering Speeds of Main Winch © Test procedures a. Machine conditions : Outriggers extended. . Engine revolutions : High idle ¢. Hydraulic oil temperature : Normal temperature 4, Load :No load e. Reeving :4 parts ft g h. - Boom length : Fully retracted. . Boom angle :35° Measuring range :2 meters (6.56ft,) (Measure in process of raising and lowering) Unit Sane tem anda Remtke Tater [| Unoso | “Dive winter Yeni aedamesd | Unto | -Mesture tice tines 8 sndavcrage here imccd | Unto | -Stnnnd valu shows ave the" tine raul for grit aodapeod | umwoas | St enue es i For measurement of the Ist speed, measure with the telescoping relieved. (2) Raising and Lowering Speeds of Auxiliary Winch © Vest procedures a. Machine conditions : Outriggers extended b. Engine revolutions : High idle c. Hydraulic oil temperature : Normal temperature 4d. Load : No load e. Reeving :1 part £. Boom length : Fully retracted g. Boom angle :35" h, Measuring range : 2 meters (6.56ft) (Measure in process of raising and lowering.) Unit sec Sand nem ‘ee ema vet] “Previn Rae Tot | -dterne tee tines Speed and average the results, Tac 20 | “Stine ae owe tewiae + | teed | amie ne tr Se nota | vagy sis m For measurement of the Ist speed, measure with the telescoping relieved.(3) Free Fall of Main Winch © Test procedures a. Engine revolutions : Low idle .. Hydraulic oil temperature : Normal temperature Load :No load Reeving :4 parts - Boom length : Extended fully . Boom angle :75° . Measure range : Time required for hook falling from the bottom of the overhoist preventive device weight to 2 meters (G.56ft, above the ground, weep eoe ‘Standard em ee Remarks Freefall | Lesathan | Menaure thee tines, and avesae Shee theresuls (4) Free Fall of Auxiliary Winch, © Test procedures a. Engine revolutions : Low idle .. Hydraulic oil temperature : Normal temperature Load :No load |. Reeving : 1 part Boom length : Extended fully Boom angle :75" mpegs . Measure range : Time required for hook falling from the bottom of the overhoist preventive device weight to 2 meters (656ft) above the ground. ew Stair Rens Freefal | Teigtiaa | Mevare tee ines a avenne ame" | herent HOOK FREE FALLING FROM HIGHEST POSITION. | te 2m (6.56) HOOK FREE FALLING FROM HIGHEST POSITION 1 1 1 ' q ] | | 1 1 1 1 | } 1 1 1 | } 4 ' 1 } i } 1 1 i 2m (650°)(5) Boom hoist speed © Test procedures a, Machine conditions : Outriggers extended b. Engine revolutions : High idle cc. Hydraulic oil temperature : Normal temperature 4. Load : No load. e. Boom length : Retracted fully Measuring range :0~75" tem Syndacd Remacks Toon | Lesthan [Measure the time] -Neneare vaning | “S0eee.” | requed for boom to be | “three times, ‘reed clita tot of | and average ‘oom sna theren Boom | Les than | Lower boom from 8 of tewertag | "Gbsee:” | boom analy and masare ‘wee the time reauired for ‘em to be lowered fo TS a0? of bam aoe MBASURING RANGE 0° 15° (6) Boom telescoping speed © Test procedures a, Machine conditions : Outriggers extended b, Engine revolutions : High idle cc. Hydraulic oil temperature : Normal temperature a. Load :No load e. Reeving :4 parts £. Boom angle :75° g. Measure the time it takes for the boom telescope cylinder to go from the fully retracted (or extended) position to the fully extended (or retracted) position. Standard tem ‘ale Remark 2uiboomextcndingsnced | Lesathan | Mneure tyes tines aad Si7ocer | average the rl, 2nd bomreleaciog peed | Les than ‘Seer ‘ed J ath booms extending | Letham eee ‘ed ath booms erating ye aRD/4 TH BOOM ‘TELESCOPE 2ND BOOM ‘TELESCOPE,(7) Swing speed ‘© Test procedures a, Machine conditions : Outriggers extended. b, Engine revolutions : High idle c, Hydraulic oil temperature : Normal temperature d. Boom length : Retracted fully e. Boom angle : 75° £. Load : No load g. Measure the time required for two turns from the end of the 1st turn to the end of the 3rd turn. Item Saat Rennes Swing sed [Lesethan d73eee] Mensur te time required for 2 tras en turns | from th ent ofthe Ist turn to the en Swng sped othe Sd tur ahh (8) Sky tilt jib hoist speed © Test procedures a. Machine conditions : Outriggers extended, one step jib extended and boom fully retracted. . Engine revolutions : High idle .. Hydraulic oil temperature : Normal temperature Load : No load - Boom angle : 60" . Measure the time it takes for the jib hoist cylinder to go from the fully retracted (or extended) position to the fully extended (or retracted) position. Standard ews "Value Remarks ‘ibeiing apoed [Les than 3.4 see] Mensa tives Wine, and average he Taller | remit “blowering [ese than 650200 peed Tall roe1. TIGHTENING TORQUE OF CAPSCREWS AND NUTS Unless otherwise specified, torque all screws and nuts on this machine to the values shown in the following tables. 1.1 METRIC COARSE THREADS Unit: kg-m (tbs) Classi Metrie Coarse Threads cation Nominal 4 TT 107. size Dr Lubricated Dry Lubricated Dr Lubricated M6 0.45 (3.25) |0.38(2.75) | 0.916.561) | 0.86.79) | 1.7028) | 1.5(00.9) M8 1.09(7.88) | 0.9651) | 2407.4) | 20045) | 431.0 | 3626.0) M10 2.25.9) | 1803.0) | 4.7340) | 4.08.9) | 2.5061.) | 7.2(62.1) M12 3726.8) | 323.2) | 8168.6) | 6.a49.2) | 14.6106) | 12.3189.0) M14 5.9(42.7) | 5.0(36.2) | 12.8(92.6) | 10.8(78.1) | 23.0066) | 19.5041) M16 9.0 (65.1) | 7.6(65.0) | 19.6141) | 16.4019) | 35.0(253)_| 29.0(210) Mis 12.4(69.7) |10.5(76.0) | 27.0095) | 23.0066) | 49.0(364)_| 41.0297) M20 17.5127) _|14.7(06) | 38.0(275)_| 32.0(232)_| 68.0(492)_| 57.0(412) M22 23.0(166) |19.6042) | 51.0(369) | 43.0311) | 92,01665)_| 77.0057) M24 30.017) [24.0074 | 65.0470) _| 53.0(383)_|118.00854)_| 96.0(964) M27 44.0(318) |36.0(260) | 96.0(694)_| 78.0(664)_|173.001251) | 140.001012) M30 60.0(434)_|50.0(362) _|131.0(948)_| 110.0796) = = M33 81,0(686)_|68.0(492) _|176.0(1273) | 148.0(1070) = = M36 105.0(760)_|88.0 (637) = = = = 1.2 METRIC FINE THREADS Unit: kg-m (ft-4bs) Classifi- Fine Threads cation Nominal ar W 10r ise Dr} Lubricated | __Dry | Lubricated | Dry __| Lubricated M6 117.96) | 0.4(2.89) | 2.505.2) | 2105.2) | 4502.6) | 3.8@7.5) M10 231166) | 1903.7) | 4905.4) | 42604 | 8.9644) | 7.5643) M12 4.0(28.9) | 3.4(24.6) | 8.0629) | 7.90628) | 15.7014) | 13.2(95.5) M16 9.0(65.1) | 7.30628) | 20.0045) | 17.2024) | 37.0268) | 31.0224) M20 19.0037) [15.8414 | 41.097) | 34.0(246)_| 74.00635)_| 62.0(448) M24 32,0(232) |27.0(195) | 70.0606) | 56.0(405) |126.0(911) _| 105.0(760) M30 65,0 (470) _|54.0(391) _|142,0(1027) |118.0(854) = = M36 109.0(788)_|91.0(658) = = = = li1. TIGHTENING TORQUE OF CAPSCREWS AND NUTS Unless otherwise specified, torque all screws and nuts on this machine to the values shown in the following tables. 1.1 METRIC COARSE THREADS Unit: kg-m (tbs) Classi Metrie Coarse Threads cation Nominal 4 TT 107. size Dr Lubricated Dry Lubricated Dr Lubricated M6 0.45 (3.25) |0.38(2.75) | 0.916.561) | 0.86.79) | 1.7028) | 1.5(00.9) M8 1.09(7.88) | 0.9651) | 2407.4) | 20045) | 431.0 | 3626.0) M10 2.25.9) | 1803.0) | 4.7340) | 4.08.9) | 2.5061.) | 7.2(62.1) M12 3726.8) | 323.2) | 8168.6) | 6.a49.2) | 14.6106) | 12.3189.0) M14 5.9(42.7) | 5.0(36.2) | 12.8(92.6) | 10.8(78.1) | 23.0066) | 19.5041) M16 9.0 (65.1) | 7.6(65.0) | 19.6141) | 16.4019) | 35.0(253)_| 29.0(210) Mis 12.4(69.7) |10.5(76.0) | 27.0095) | 23.0066) | 49.0(364)_| 41.0297) M20 17.5127) _|14.7(06) | 38.0(275)_| 32.0(232)_| 68.0(492)_| 57.0(412) M22 23.0(166) |19.6042) | 51.0(369) | 43.0311) | 92,01665)_| 77.0057) M24 30.017) [24.0074 | 65.0470) _| 53.0(383)_|118.00854)_| 96.0(964) M27 44.0(318) |36.0(260) | 96.0(694)_| 78.0(664)_|173.001251) | 140.001012) M30 60.0(434)_|50.0(362) _|131.0(948)_| 110.0796) = = M33 81,0(686)_|68.0(492) _|176.0(1273) | 148.0(1070) = = M36 105.0(760)_|88.0 (637) = = = = 1.2 METRIC FINE THREADS Unit: kg-m (ft-4bs) Classifi- Fine Threads cation Nominal ar W 10r ise Dr} Lubricated | __Dry | Lubricated | Dry __| Lubricated M6 117.96) | 0.4(2.89) | 2.505.2) | 2105.2) | 4502.6) | 3.8@7.5) M10 231166) | 1903.7) | 4905.4) | 42604 | 8.9644) | 7.5643) M12 4.0(28.9) | 3.4(24.6) | 8.0629) | 7.90628) | 15.7014) | 13.2(95.5) M16 9.0(65.1) | 7.30628) | 20.0045) | 17.2024) | 37.0268) | 31.0224) M20 19.0037) [15.8414 | 41.097) | 34.0(246)_| 74.00635)_| 62.0(448) M24 32,0(232) |27.0(195) | 70.0606) | 56.0(405) |126.0(911) _| 105.0(760) M30 65,0 (470) _|54.0(391) _|142,0(1027) |118.0(854) = = M36 109.0(788)_|91.0(658) = = = = li1.3 COARSE THREDS UNC Unit: kg-m (ft-lbs) Classitt- Coarse Threads UNC cation Nominal, Grade 2 Grade 5 Grade 8 size Dry [Lubricated | Dry | Lubricated | Dry | Lubricated WA 0.86.79) | 0.76.08 | 139.40 | 117.96 | 1803.0 | 1500.8) 56 16016) | 1400.1 | 26088) | 2205.9) | 3.6260) | 3.10224) 318 2,921.0) | 24074 | 45026 | ase76) | 6345.6 | 6.988.3) 76 4.5026) | 3.87.5) | 7.0606) | 5.9427 | 9.oc71.6) | 8.3(60.0) 12 7.0150.6) | 5.9(42.7) | 10.8(78.1) |_9.165.8) | 15.2010) | 12.8(92.6) 96 10.072.3) | 8.460.) | 16.5012) | 13.0940) | 22.0089) _| 18.4033) 58 14.0101) | 11.8(85.3) | 22.0189) | 18.2(132) | 31.0224) | 26.0188) 34. 25.0181) | 21.0052) | 38.0275) | 32.0232) | 54.091) | 45.0(825) 18, ae.oc210) | 25.0081) | 61.0441) | 61.0369) | 86.0622) | 72.0(621) 1 35.0(258)_| 30.0(217) | 91.00658)_|_76.0(550)_| 128.0926) _| 108.0¢781) 11/8 si.0;69)_| 43.0(811)_|114.0825)_[_95.0(687)_| 184.0(1331) | 154.001114) 1d 71.0(614)_| 59.0427) _|159.00150) [133.0(962)_| 257.0869) | 216.0(1562) 13/8 93.0(673)_| 78.0(564) | 209.0(1612) |175.0(1266) | 338.0(2445) | 284.0(2054) 1 ue 124,0(897)_|104.0(752)_| 277.0204) | 232.0(1678) | 449.0(3248) | 376.0(2720) 1.4 FINE THREADS UNF Unit: kg-m (ft-lbs) Olassifi- Fine Threads UNF cation Nominal Grade 2 Grade 6 Grade 8 size Dry Lubricated Dry Lubricated Dry Lubricated ua oa6sn | 086.7) | 14001 | 12668 | 2106.2) | 1.7023) 5/16 1.8132) | 1.5008) | 28203) | 24074 | 4028.9 | 3.4246) 3/8 3231) | 27095) | 49136.) | 41297 | 7060.6) | 5.8420 Ti6 5.0(36.2) | 4.2(30.4) | 7.70657) | 6.446.3) | 10.878. | 9.1065.8) 12 7.71(65.7) | 6.4463) | 11.9066.1) |_9.9°71.6 | 16.8022) | 14.0a01) 96 10.9(78.8) |_9.2(66.5) | 1691122) | 14.1002) | 24.0074 | 19.9044) 5/8 15.5012) | 12.9(93.3) | 24.0074) | 20.0045) | 34.0(246) | 28.0(203) 3/4 27.0195) | 22.0(159) | 42,0(904) | 35.0(253) | 58.0420) | 49.0(354) 718 31.0(224) | 25.0081) | 66.0477) | 55.0398) | 93.0673) | 77.00657) 1 38.0(275) | 31.0(224) | 98.0(709) | 82.0693) | 138.0(998)_| 115.0(832) 11/8 56.0 (405) | 46.0(333)_|124,0(897) | 104.0(752) | 201.0(1454) | 168.0(1215) 1a "17.0 (687) _| 64.0(463)_| 153.0(1107) | 143.0(1034) |279.0(2018) | 232.0678) | 13/8 103.0(745) | 86.0 (622) |231.0(1671) | 192.0(1389) |374.0(2705) | 311.0(2249) [112 136.0984) |113.0(817)_[304.0.2199) | 253.011830) | 499.0(3566) | 410.0(2966) 121.3 COARSE THREDS UNC Unit: kg-m (ft-lbs) Classitt- Coarse Threads UNC cation Nominal, Grade 2 Grade 5 Grade 8 size Dry [Lubricated | Dry | Lubricated | Dry | Lubricated WA 0.86.79) | 0.76.08 | 139.40 | 117.96 | 1803.0 | 1500.8) 56 16016) | 1400.1 | 26088) | 2205.9) | 3.6260) | 3.10224) 318 2,921.0) | 24074 | 45026 | ase76) | 6345.6 | 6.988.3) 76 4.5026) | 3.87.5) | 7.0606) | 5.9427 | 9.oc71.6) | 8.3(60.0) 12 7.0150.6) | 5.9(42.7) | 10.8(78.1) |_9.165.8) | 15.2010) | 12.8(92.6) 96 10.072.3) | 8.460.) | 16.5012) | 13.0940) | 22.0089) _| 18.4033) 58 14.0101) | 11.8(85.3) | 22.0189) | 18.2(132) | 31.0224) | 26.0188) 34. 25.0181) | 21.0052) | 38.0275) | 32.0232) | 54.091) | 45.0(825) 18, ae.oc210) | 25.0081) | 61.0441) | 61.0369) | 86.0622) | 72.0(621) 1 35.0(258)_| 30.0(217) | 91.00658)_|_76.0(550)_| 128.0926) _| 108.0¢781) 11/8 si.0;69)_| 43.0(811)_|114.0825)_[_95.0(687)_| 184.0(1331) | 154.001114) 1d 71.0(614)_| 59.0427) _|159.00150) [133.0(962)_| 257.0869) | 216.0(1562) 13/8 93.0(673)_| 78.0(564) | 209.0(1612) |175.0(1266) | 338.0(2445) | 284.0(2054) 1 ue 124,0(897)_|104.0(752)_| 277.0204) | 232.0(1678) | 449.0(3248) | 376.0(2720) 1.4 FINE THREADS UNF Unit: kg-m (ft-lbs) Olassifi- Fine Threads UNF cation Nominal Grade 2 Grade 6 Grade 8 size Dry Lubricated Dry Lubricated Dry Lubricated ua oa6sn | 086.7) | 14001 | 12668 | 2106.2) | 1.7023) 5/16 1.8132) | 1.5008) | 28203) | 24074 | 4028.9 | 3.4246) 3/8 3231) | 27095) | 49136.) | 41297 | 7060.6) | 5.8420 Ti6 5.0(36.2) | 4.2(30.4) | 7.70657) | 6.446.3) | 10.878. | 9.1065.8) 12 7.71(65.7) | 6.4463) | 11.9066.1) |_9.9°71.6 | 16.8022) | 14.0a01) 96 10.9(78.8) |_9.2(66.5) | 1691122) | 14.1002) | 24.0074 | 19.9044) 5/8 15.5012) | 12.9(93.3) | 24.0074) | 20.0045) | 34.0(246) | 28.0(203) 3/4 27.0195) | 22.0(159) | 42,0(904) | 35.0(253) | 58.0420) | 49.0(354) 718 31.0(224) | 25.0081) | 66.0477) | 55.0398) | 93.0673) | 77.00657) 1 38.0(275) | 31.0(224) | 98.0(709) | 82.0693) | 138.0(998)_| 115.0(832) 11/8 56.0 (405) | 46.0(333)_|124,0(897) | 104.0(752) | 201.0(1454) | 168.0(1215) 1a "17.0 (687) _| 64.0(463)_| 153.0(1107) | 143.0(1034) |279.0(2018) | 232.0678) | 13/8 103.0(745) | 86.0 (622) |231.0(1671) | 192.0(1389) |374.0(2705) | 311.0(2249) [112 136.0984) |113.0(817)_[304.0.2199) | 253.011830) | 499.0(3566) | 410.0(2966) 1215 TIGHTENING TORQUE OF HYDRAULIC FITTINGS Excessive or insufficient tightening of hose or tube fittings can cause oil leak and deformation or damage to the metal fittings. (1) BITE TYPE TUBE FITTINGS Therefore, to secure and obtain good fixing and performance of fittings it is necessary to tightin to the proper torque. The follows are the recommended torques. Size in mm (inch) (Outside diameter x thicknes ‘Tightening torque in kg-m (ft-lbs ) Remarks 10 (0.364) x 1.5( 0.059) 5 to _7(36 to 61) 15 (0.591) x 2.0(0.079) 13 to 16(94 to 116) 180.709) x 2.5( 0.098) _|16 to 17(116 to se SLEEVE 123) 220.866) X 3.0 (0.118) 20 to 22(145 to 159) Condition after 28 (1.102) x 4.0 (0.157) 25 to 29(181 to 210) Tightening 35 (1.378) x 6.0(0.197) _]33 to 36(239 to 260) (2) SPLIT FIANGES (Prom SAE Standard) ‘Tightening torque in_kg-m (ft-lbs) size Remarks 3000 psi(210 ke/em*) | 6000 psi (420 kg/em®) 12" | 2 to 2.6(145 to 19) = Ch 3/4 [2.9 to 4.0(21 to 29) | 3.45 to 4.6(25 to 33) SUIT FLANGE: | 3.75 to 4.9(27 to 35) 5.75 to 6.9( 42 to 50) 11/4" | 4.9 to 6.3(35 to 45) | 8.6 to 10.3(62 to 74) 11/2" | 6.3 to 8.0(45 to 58) | 16.1 to 18.4(116 to 133) 7 2 | 7.5 to 9.5(54 to 69) | 27.6 to 30.0200 to 217) (3) FLARE TYPE TUBE FITTINGS (30°FLARE, PF THREADS) Size | Tightening torque in kg-m (ft-lbs) Remarks 4/4 2.5 to 3.5 (18 to 25) MALLE FEMALE 3/8" 6 to 7 (36 to 51) 12" 6 to 8 (43 to 58) 314" 12 to 16 (87 to 116) 1 15 to 19 (108 to 137) 1/4 17 to 23 (123 to 166) LJ ie 22 to 28 (159 to 202) x 26 to 34 (188 to 246) 13(4) Jubilee Clip (Low Pressure and Suction) Nominal cord Diameter Recomended torque | Working pressure range BS5315 inches mm kg-em | in: Ibs. kefem? psi 12 38 =e 95-12, 34.5 29.9 56.0 196 16 12 — 58" l- 16 34.5 29.9 56.0 796 20 ia — 3a" 13— 20 345 29.9 56.0 7196 2 Be — 18" 16— 22 457 39.7 B60 796 5 wae 18 25 457 39.7 36.0 796 30 78 118 22 30 457 39.7 56.0 796 a [r —138 25-3 aT 39.7 56.0 796 40 [ie — 158" T= 40 45.7 39.7 35.0 498 Bo | tia — 178" 35 50 457 30.7 35.0 498 5 | tae — 208 40-56 604 b24 21.0 299 60 | 13a — 238 w= 60 604 bad 210 298 7 [2 — 23 55-70 604 B24 168 239 80 | 238 — 318" 60 80 604 524 16.8 239 90 | 234" = 31 70-90 69.0 399 168 Too [sia —4 85-100 69.0 B99 168 120 | 39a — 4078 90-120 68.0 59.9 105) i40__(| 418" = 51 110-140 69.0 59.9 105 10 |S — 53d 130-150 69.0 59.9 105 165 | sua — 61 135— 165 69.0 59.9 98 i90_| 614" = 712" 160-190 69.0 59.9 98 215 | 7a — 8172" 185215 78.0 ort 9.0 240_*| 814" — 912" 205-240 78.0 nt 9.0 270 | 91d —10 112" 235-270 78.0 61.7 9.0 290 *|lowa” — 1 255—290 78.0 617 90 320 [iw — 12172" 285320 78.0 C17 90 141. GENERAL 1.1 LOCATION OF SYSTEM COMPONENTS, ‘The locations of the drive / travel system components are as follows. ACCELERATOR PEDAL SUSPENSION CYLINDER. (REAR) SUSPENSION CYLINDER PROPELLER SHAFT (FRONT) (TRANSMISSION TO PR. AXLE) TORQUE CONVERTER REAR AXLE PROPELLER SHAFT | PROPELLER SHAFT (@.CONV.TO'TM) (TRANSMISSION TO REAR AXLE)2, CONSTRUCTION AND FUNCTION 2.1 DRIVESYSTEM ‘The engine driving power enters torque converter _ transmitted to front axle (8) and rear axle (7) (2) directly connected to the engine, rotates through propeller shafts (5 and 6) from hydraulic pumps (9 & 10), and the same time is, transmission (4). ENGINE TORQUE CONVERTER PROPELLER SHAFT. ‘TRANSMISSION PROPELLER SHAFT PROPELLER SHAFT REAR AXLE . FRONT AXLE - 2-TANDEM PUMPS 3-TANDEM PUMPS, Fig.2-1 Drive System 2-1w Power Plant Mounting Engine (1) is mounted on the lower frame by rubber mounts (7). Torque converter (2) is directly connected to the engine flywheel by capscrews (8) ; the flywheel housing and torque converter housing are fitted together with nuts (9). Two knock pins are provided to match the joint positions of the engine flywheel and torque converter. 3. 2-TANDEM PUMPS (VARIABLE PUMP + VARIABLE PUMP) 4. 3-TANDEM PUMPS (GEAR PUMP + GEAR PUMP + GEAR PUMP) - SENSOR (ENGINE RPM) ‘THERMO-SENSOR RUBBER MOUNT. CAPSCREW. nur CAPSCREW NUT GS Regarding the tightening torques of the main parts, refer to 4. ‘Maintenance Standards. Fig.2-2 Power Plant Mounting(2) Governor Control Mounting ‘The governor control functions as follows : © When the accelerator pedal in the operator's cab is depressed, air chamber (2) functions to control the governor control lever for the injection pump via lever (3) Therefore, when the PTO functions, the engine revolution are limited to approximately 2000 rpm at maximum, considering decrease of noise and save of fuel consumption during operation as compared when traveling. 26,27 38 37 ® When the PYO which drives the hydraulic pumps for work is turned on, air cylinder (1) functions to limit the movement of lever (3). F 1A ay 23,21 STNG 28. Vj 26 B) 30 AIRCYLINDER 12. SPLIT PIN AIRCHAMBER 13. PIN LEVER M4. PIN LEVER 15, LEVER B. NUT. 36. SPLIT PIN 26. BRACKET 7. WASHER u. SPRING 18. FILTER 29. ROD 18. PIN 30. ROD END 20. SEMS BOLT a1 PLATE 21. NUT 2. LEVER WASHER CAPSCREW BOLT. BOLT LOCK WASHER SPLIT PIN VIEW FROM “A-A" NEEDI f BEARING Fig.2-3. Governor Control Mounting@ Operating system diagram THROTTLE VALVE FROM COMPRESSOR SWIVEL JOINT ACCELERATOR PEDAL ‘AIR TANK LAIR CHAMBER IDLING Fig.2-4 Governor Control Operating System Diagram(3) Radiator Mounting Speeit Radiator (1) and hydraulic oil cooler (2) form ‘Radiator one single unit and are mounted on lower cations Pressure Cap Relief Pressure | Oke Vel (ilps) frame (10) with rubber mount (8). Torque Radiator Water Capacity aopron. 250 (606g) converter oil cooler (6) is mounted on lower frame (10) under radiator (1) (see Fig 2-5). 5 7 RADIATOR HYDRAULIC OL COOLER CROSS STAY PRESSURE CAP OVER-FLOW PIPE OIL COOLER (FOR TORQUE CONVERTER) + RESERVE TANK ~ RUBBER MOUNT : BRACKET 10. LOWER FRAME, DETAIL 01 Fig.2-5 Radiator Mounting and Torque Converter Oil Cooler Mounting 2-5(4) Transmission Mounting Specifications : ‘Transmission shift “Forward 3 speeds Reverse I speed 2 High / Low selection Direction of rotation Input side (view from input side) Output side (view from input side) ~ For forward : For reverse: Counterclockwise ‘Transmission oil : Equivalent to ATF Dexron IL Capacity of oil---H level :approx.29 0 (7.66gal) evel :approx.26 0 (6.87gal) However, the oil should be supplied in accordance with the specified level. Regarding the way of supply, see the operator's manual. Clockwise Clockwise L}* 4 fle | fear oR T CTION “A.A” - TRANSMISSION BRACKET + RUBBER MOUNT PLATE WASHER CAPSCREW NUT CAPSCREW PARKING BRAKE |. AIR BREATHER, LOWER FRAME Fig.2-6 ‘Transmission Mounting(5) Parking Brake n output shaft, works on the spring force of Operation of Parking Brake air chamber (3), and is released by air pressure. ‘The parking brake, provided on the trans- 4 uo ; sy © 2 ai tei T T . , é s BRAKE ADJUSTING wit 1. TRANSMISSION 4, BRACKET 2] PARKING DRAKE 5. ROD 3. AIR CHAMBER 6. AIR CYLINDER (BUILT IN TRANSMISSION) Fig.2-7. Parking Brake (6) Air Chamber 5 ‘TIGHTENING TORQUE OF CLAMP BOLT 1500 200k cm (108 TO 14 Sits) | ob Pri 2 a7 - ——— 1, SPRING oon 2, PUSH ROD (0.669") 3, DIAPHRAGM. 4. BODY ) 4 5. COVER To 6. CLAMP 207en(3.15") a] @786")~ Fig.2-8 Air Chamber Specifications Soke ‘40na (L759) ‘Maximum using pressure PO |e @B4psi) Spring load (stroke = Own) 1170kg (375 Ibs) 24h 624 Ib)(7). Shift Operation of High Speed / Low Speed, Shift of High / Low speed of the transmission is operated by shifting the High speed hydraulic clutch and the Low speed hydraulic clutch built in the transmission with the hydraulic pressure of the transmission. Shift operation is performed with the selector switch provided in the operator's room. HAD LAD =< 1. ~ urep — + Selection of High and Low Shift of High speed and Low speed can be operated even during travel at a speed less than 10kn /h (62 mph). When the Low speed is selected, the driving mode becomes automatically 4 wheel drive ® Shifting from High Speed to Low Speed (When traveling speed is more than 1ke / h (0.62mph) and less than 15k / h (9.32mph)] HIGH-2nd > LOW-3rd HIGH-Ist > LOW-2nd When traveling with the HIGH-3rd, the speed is not shifted to the LOW even by pushing the LOW switeh. ® Shifting from Low Speed to High Speed [When traveling speed is more than tke / h (0.62mph) and less than 10k / h (6.2mph)] LOW-Ist > HIGH-Ist LOW-2nd > HIGH-Ist LOW-3rd > HIGH-2nd ® Shifting High Speed and Low Speed (When carrier stops) Position of shift lever R HIGHR <> LOWR D (Automatic)” <> LOW 3rd 2 HIGH-2nd = <> LOW 2nd 1 HIGH-Ist = <> LOW 1st ‘Shift of 2 Wheel Drive and 4 Wheel Drive Shifting 2 wheel drive and 4 wheel drive is operated by the air cylinder which is built in the transmission, (8) Propeller Shaft Mounting (a) Funetion ‘The propeller shafts transmit power from the torque converter to the transmission, and from the transmission to the front axle and rear axle (Fig 2-10). 1, TORQUE CONVERTER 5 9. NUT 2. PROPELLER SHAFT 6. REAR AXLE 10. CAPSCREW 3. TRANSMISSION 7. FRONT AXLE 11, CAPSCREW 4. PROPELLER SHAFT 8. GUARD 12. GUARD Fig.2-10 Propeller Shaft Mounting 2-8(b) Propeller Shafts 2 1 1. CAPSCREW 5. FLANGE ASSEMBLY 9. GREASE FITTING 13, BEARING ASSEMBLY 2. LOCKWASHER 6. FELT RING 10. PLUG. 14. GREASE FITTING 3. WELDEDFLANGE 7, RETAINER 11, JOURNALASSEMBLY 15, TUBE ASSEMBLY 4. SHAFT END 8. SLIDEFLANGE 12. SPIDER 16. TUBE Fig. 2-11 Propeller Shaft (Torque Converter to Transmission) 2 15 1 1, FLANGE YOKE 5. SNAPRING 8. SLEEVE YOKE 13. WELDED YOKE 2. JOURNAL ASSEMBLY 6. GREASEFITTING 10. SEAL M4. TUBE 3, BEARING 7. PLUG A. SHAFT END 18. TUBE ASSEMBLY 4, SPIDER 8. GREASE FITTING 12. PLUG Specifications Fig.2-12 Propeller Shaft (Transmission to Axles) Use Item “Torque converter to transmission Fig. 2-11 ‘Transmission to front axle ‘Transmission to rear axle Fig.212 L: Length at mounting 760 to 800an (29.82 to 31.50in) 753 to 79am (29.65 to 31.22in)_(9) Torque Converter ~ Transmission Hydraulic Pipings SECTION “BE: 1. PIPING FROM TORQUE CONVERTER TO ‘TRANSMISSION(OIL PASS) 2. PIPING FROM TRANSMISSION TO TORQUE CONVERTER (TO PUMP) 3. PIPING FROM TORQUE CONVERTER TO LINE FILTER (FROM PUMP) 4. PIPING FROM TRANSMISSION TO TORQUE CONVERTER (FROM VALVE) 5, PIPING FROM LINE FILTER TO TRANS: MISSION (TO VALVE) Y 6. PIPING FROM OIL COOLER TO TRANS- MISSION. 7. PIPING FROM TORQUE CONVERTER TO OIL COOLER 10. PIPING FROM TRANSMISSION TO TORQUE CONVERTER (AIR PASS) 11. PIPING FROM LINE FILTER TO TORQUE CONVERTER Fig.213 Torque Converter to Transmission Hydraulic Pipings 2-10(0) Axle Mounting Both the front and rear axles are mounted on the lower frame through the torque rods. The four suspension cylinders work as suspensions by the function of the hydro-pneumatic suspension MactINE FRONT <3 ‘TORQUE ROD system when traveling on roads. ‘They are also fully retracted to offer no suspension function during crane operation and improve stability by unifying the axles and chassis into one. LOWER FRAME, =uMACHINE, FRONT. REAR AXLE FRONT AXLI en SECTION “BB “L DETAIL OF “A” (sHowS LEFT sips MOUNTING OF REAR WIIEBL) (EH Rewarding the tightening torque, refer to 4. Maintenance Standards, DETAIL OF “ 2. SUSPENSION CYLINDER 4. REAR STEERING LOCK PIN 3. STEERING CYLINDER 5. STEERING NEUTRAL POSITION DETECTING LIMIT SWITCH Fig.2-14 Axle Mounting (2/2) 2-2INSPECTION AND ADJUSTMENT 3.1 ADJUSTMENT OF GOVERNOR CONTROL (FIG. 3-1) With the PTO switch, which is provided on the meter switch panel in the left front of the operator’ s seat, placed in the OFF position, depress the accelerator pedal to operate air chamber (2), and to control governor control lever (4) for the injection pump via lever (3). The engine speed will rise to appro rpm at maximum. When the PTO switch is placed in the ON position, air cylinder (1) operates to limit movement of lever (3), and the engine speed is limited to approximately 2000rpm at maximum. When adjustment is required, proceed as follows : ately 3000 (1) Place the shift lever in the neutral position, and the parking brake switch in the ON position, (2) Adjust the set bolt of air cylinder (1) so that engine speed comes in the following values. When the PTO switch in the ON position (when operating). 2000 + 20rpm (without load) (3) Adjust and fix bolt (25) so that the exhaust brake limit switch operates with engine speed at 700 to 750rpm. (When the PTO switch in the OFF position). Fig.3-1 Adjustment of Governor Control ann3.2 ADJUSTMENT OF PARKING BRAKE (FIG. 3-2) (1) Normally the parking brake is adjusted with brake drum adjusting wheel (6). (a) With the parking brake released (travel position), feed compressed air into the air chamber. (b) Turn the adjusting wheel in the shoe expansion direction (arrow) until the shoe is tight against the drum. (c) Then back off 8 notches ; this way, the clearance between the drum and the shoe will be adjusted to 0.23ma (0.009"). (2) When installing a new air chamber, proceed as follows : (a) Install air chamber (3) to bracket (4) without air supplied. (b) Loosen nuts (7 and 8), and adjust rod (5) so that the distance from the end surface of bracket (4) to the center of yoke pin comes in 113%0m (4.45%:9in). Then tighten nuts (7 and 8). (c)_ Then, perform the normal adjustment (step D. (@) Connect yoke (5) and the parking brake lever. ‘TURN DIRECTION TO EXPAND BRAKE SHOE, Fig.3-2 Adjustment of Parking Brake -23.3 HYDRAULIC PRESSURE TAKING OUT PORTS FOR TRANSMISSION CONTROL VALVE PL(PTUS) Ee F3(PTU8) F2PT1) PY HPTUS) Ror) CO Of swan HYDRAULIC PRESSURE 5 (PTL8) 7" (PRESSURE | eppya) p OY swircn port) DRAIN PLUG visForward tt 2: Forward 2nd [TORQUE CONVERTER 3: Forward Sed R Reverse LU Crys) ie L P.T.0.(PTUS) rh ie Lys \S} IO Fig.3-3 Hydraulic Pressure Port Size4, MAINTENANCE STANDARDS (1) Power Plant Mounting (Fig. 4-1) Code Trem Standard Value Remarks ‘A’ | Tightening torque of capscrews for | 23 to 29k« - m (166 to 210ft-Ibs) __| Tighten after applying Locktite © ‘engine mount. 271 or equivalent to threaded _ | section. B [Tightening torque of nuts for|41tosike- m0 tosTitibs) | Tighten after applying Locktite # _|toraue converter housing mount. 242 or equivalent to threaded Tightening Gl to7.5ke = m(H toSiftlbs) | section ‘gear pump mount. D__| Tightening torque of capscrews for [4.1 to Ske = m(30 to S7ft-Ibs) engine flywheel and torque converter mount. - _ E | Mounting faces of engine flywheel | Align knock pins attached to engine, housing and torque converter. Fig. 4-1 Power Plant Mounting(2) Governor Control Mounting (Fig.4-2) Coie Ttem Standard Value Remarks ‘A |Tightening torque of bracket | 24k - m(17.3it-bs) Tighten after applying Locktite # ‘mount nut, Tightening torque of bracket ‘mount nut, Tightening torque of air chamber ‘mount capscrew. 1 to5.lke « m (80 to STE (0.88 to LOkg + m (6000 to 7.22{t-Ibs) 242 or equivalent to threaded section. AIR CHAMBER Fig.4-2 Governor Control Mounting(3), Radiator Mounting (Fig. 4-3) Code Item Standard Value ‘Remarks A | Tightening torque of bolt and nut [49 to89kx » m @54 to 42.6ft-Ibs) for rubber mount Fig.4-3. Radiator Mounting (4). ‘Transmission Mounting (Fig. 4-4) Code Tem Standard Value Remarks ‘A__| Tiahtening torque of bolt and nut | 29 to 29k - m (166 to 209ft-bs) | Tighten after applying Lockie # for rubber mount. 271 or equivalent to threaded section [Tightening torque of bracket | 16.9 t020:7k« - m (122 to 150tt-lbs) | Tighten after applying Locktite # mounting capscrew. 242 or equivalent to threaded section Pigle | of SECTION A-A Fig.4-4 Transmission Mounting 4-3(8), Parking Brake (Fig.4-5) Code Ttem T Standard Value Remarks ‘A | Tightening torque of eapscrewa for | 169 t020-7ky - m (122 to 150ft-Ibs) | Apply Locktite #242 or equivalent air chamber bracket mount. to threaded section B [Rod adjusting length when | iito 1ida@37to4dain) mounting air chamber. (When air pressure is Ok / ef) | ‘ightening torque of nul for yoke fixing 10 6.Bky - m (40.5 to49.1ft-Ibs) ial] @) mel of ee 1 (6) Propeller Shaft Mounting (Fig. 4-6) Code Trem Standard Value Remarks ‘A. | Tightening torque of capscrews for | 5.5 to 65l« « m (39.7 to47.0ft-bs) | Apply Locktite #242 or equivalent ‘mount of propeller shaft between to threaded section, torque converter and transmission. B | Tightening torque of capscrews for | 135 to 14 5ke - m (G75 to 1O47it- mount of propeller shaft between | Ibs) transmission and front axle, _ © | Tightening torque of capscrews for | 135 to 14.5kx-m (075 to 104.7 ‘mount of propeller shaft between | tbs) transmission and rear axle, A = rh Fig.4.6 Propeller Shaft Mounting 4-4(1), Propeller Shaft — Code Item Standard Value ‘Remarks ‘A [Shaft Bend (one sideincenter) | Standard Value | Service Limit | Replace. ~~ B [Clearance between Spider and 0.25am (0.01") Needle Bearing C | Playin Spline | Circumferential = 0am (0.04") Direction Tt Centripetal = 0.5mm 0,02") Direction BETWEEN TRANSMISSION AND AXLE Fig.4-7 Propeller Shaft(8) Axle Mounting (Fig, -8) ‘Code Trem Standard Value Remarks ‘A [Tightening torque of torque rod mounting bolts, cylinder mounting pin fixing capscrews, lock device mounting capscrews Tightening torque of steering ‘ghtening torque of rear steering 31 to ST « m (224 to 267K Iba) 65 to 79k + m (47.0 to 97. Aft-Tbs) ‘Apply Locktite #242 or equivalent to threaded section E [Tightening torque of tire wheel {62 to 6k» m (4B to 498K Tbs) nuts F |Wheelalignment [Toe in v Camber Caster King pin angle Fig.4-8 Axle Mounting‘When removing or installing the torque rod from or to the axle and lower frame, do not incline it more than £7 inthe upward and downward direction from the horizontal. (Inclining more than + 7° has possibility to damage the torque rod seal or to allow it to get out.)5, DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY OF TORQUE ROD 5.1.1 DISASSEMBLY (1) Remove four seals (6). Since these are damaged when they are removed, replace with new ones. (2) Remove four snap rings (4). Draw out pins (2) with spherical bushings (3) attached from torque rod (1). (3) Removing snap rings (8), draw out spherical bushings (3) from pins (2). 5.1.2 ASSEMBLY (1) Remove rust preventive oil coated on the spherical surface of spherical bushings (3) before assembling. (For bleeding the inside air ‘when pressing the dust seal in.) (2) Install spherical bushing (3) so that the split section on the outer race of the bushing is directed in the direction of the arrow mark shown in the figure. (3) Confirm that pin (2) can lightly shake and move before installing dust seal (5). (4) Coat Locktite #515 on the outside circumference of dust seal (5) when installing it. However, do not coat anything on the inside sumference. Press the outside circumference brim in until it contacts closely the end surface of rod (1). (5) After assembly is completed, supply Nippon Oil Molynoc grease 2 (containing molybdenum. disulfide) or equivalent until grease comes out through relief fitting (6). 1. TORQUEROD 4. SNAPRING 7. GREASE FITTING 2. PIN 5. DUST SEAL 8. SNAPRING 3. BUSHING 6. RELIEF FITTING 9. GREASE FITTING Fig.5-15, DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY OF TORQUE ROD 5.1.1 DISASSEMBLY (1) Remove four seals (6). Since these are damaged when they are removed, replace with new ones. (2) Remove four snap rings (4). Draw out pins (2) with spherical bushings (3) attached from torque rod (1). (3) Removing snap rings (8), draw out spherical bushings (3) from pins (2). 5.1.2 ASSEMBLY (1) Remove rust preventive oil coated on the spherical surface of spherical bushings (3) before assembling. (For bleeding the inside air ‘when pressing the dust seal in.) (2) Install spherical bushing (3) so that the split section on the outer race of the bushing is directed in the direction of the arrow mark shown in the figure. (3) Confirm that pin (2) can lightly shake and move before installing dust seal (5). (4) Coat Locktite #515 on the outside circumference of dust seal (5) when installing it. However, do not coat anything on the inside sumference. Press the outside circumference brim in until it contacts closely the end surface of rod (1). (5) After assembly is completed, supply Nippon Oil Molynoc grease 2 (containing molybdenum. disulfide) or equivalent until grease comes out through relief fitting (6). 1. TORQUEROD 4. SNAPRING 7. GREASE FITTING 2. PIN 5. DUST SEAL 8. SNAPRING 3. BUSHING 6. RELIEF FITTING 9. GREASE FITTING Fig.5-11, TERMINOLOGY AND LOCATION OF MAIN HYDRAULIC EQUIPMENTS Fig. 1-1 shows the terminologies and locations of the main hydraulic equipments. SWIVEL JOINT HOSE REEL. ‘TELESCOPE CYLINDER PILOT CHECK VALVE WINCH HYDR. MOTOR (MAIN) COUNTERBALANCE, VALVE BOOM HOIST HYDR. CYLINDER CLUTCH VALVE, WINCH HYDR. MOTOR (AUXILIARY). COUNTERBALANCE VALVE MAIN CONTROL VALVE UNLOADING VALVE VERTICAL HYDR. CYLINDER HORIZONTAL, HYDR. CYLINDER ‘SUSPENSION CYLINDER \ ry i aigeeb ” i [op 2-TANDEM PUMP.2. COMPOSITION g a 5 5 : Eee f. H gag 2.1 HYDRAULIC CIRCUIT DIAGRAM AND SPECIFICATIONS OF COMPONENTS g 2s se z Bes 2.1.1. Standard Specification (Figure 2-1 and Figure 2-2) & Sesh « 8 See Bobet g o£ 288 » noo sn those creat #8 E 5 ‘The part names (terminologies) for the numbers in these circuit diagrams are described in 2. 1. 3 | Specifications of Components on page 2-4. Chee ota ® j * x me i rower nis oT / mn ] HIGH SUSPENSION j= er ans f i are] 4 (asec ke st PUMP. exp puMP ope tore pe-------- he . F U ty ei Lan ONT Tar mont Sem FROM? WitrPosT id Oe LEPTREAR “Tart ReaR Tir Rean ONT REAR sreenine | tall TEX S00 stone < pe -fias| SENSE ri Fig 2-1, Hydraulic Circuit Diagram (Lower)2 ~ i aaa ee 5 iWhE si & a ps i: eel pe ee SRE LL NR oF swine sToP| hell gl cum 1 o PRR, | | Ay A (Lwrnow _j roo TER a Py eal hot i fel a rt il i hal ro | yb be @ “ save sor cae TER iF soca d ar bonnes ere | i F tT = al ‘orrien) [hee Trove 1 ° eetion | SEERNG ‘STEERING Ly oo] Fig 22. Hydraulic Circuit Diagram (Upper)2.1.2 — Optional specification (Fig 2-3) 4 ‘ PUMP FIXING (PRONT (OPTION) rected O1L COOLER (OPTION) TAGLINE (OPTION) {IB AUTOMATIC STOP SOLENOID VALVE “THIRD WINCH (OPTION FROM ACCUMULATOR Tale POWER TILT (OPTION) PRESSURE SOURCE (OPTION) j Fig 2-3. Optional Devices CIVIL SPOOL AND WINCH DETENT (OPTION)2.1.3 Specifications of Components Tem Ne, ‘Name of Components ‘Specifications (Use, specification, and et value) 1 [Bydralie [41 For boom heist, oom telescope and winch 2nd speed pump Variable displacement | 129 to 146 € (046 to.16cu.f)/ min delivery, pump 260k I at (9697psi set pressure at 708 @47eu.ft)/ min, 12 For winch fst speed, Variable displacement | 129 to 146 ¢ (046 to6.16cu.f)/ min delivery, [pomp | 25k of (5855p) set pressure at 708 (2A7eu. £)/ min, 2 |Hydrautie [21 For swing and steering. Pilot low pressure pump Gear pump 8628 (B0{cu.f)/ min delivery, 205ke / of (2015pei) et pressure. 22 For pilot (clutch / negative brake) and option (cabin cooler aad il cooler 37.8 Gear pump (13cu.2)/ min delivery, 210k /e® (2086pei set pressure. 23 For steering flow jing Gear pump 37.08 (1Stcu. 1) min delivery, 210k / ef 29B6psi set pressure at 35. I min 3 _ | Blectric motor drive pump unit For emergency steering. Akw (DC24 volts electric motor drive 720 (025cu,f4)/ min deli © | Control valve Relief valve set pressure: (Gor steering flow Joining and high | DC 24 volts, suspension pressure source) ry, 60k | (8S3psi) set pressure. 10k cf (2986s). 5 | Solenoid valve For outrigger extension /stowing, DC 24 volts (Outrigger control valve) Reliet valve set pressure “6 | Winch pressure raising valve Relief valve et pressure Solenoid valve ‘Outvinger cylinder selection. DC24 volts. ~ Vertical hydraulic cylinder Double-neting type ior *X" typecontriggers) __| 17600 (60in inside, 190mm (517) rod dia. x 22am (12.605 stroke, ® | Vertical hydraulic einer Doable-cting type ___| Wor "2 type oatrivzers) 120 (472i) inside dia. 1000 (3.9 od di. 63am 25.) stroke 10 | Horieontat hydraulic elder Double-rcting typ ~ Gor "X” type outriggers) ‘2am 248i) inside dia, 40am (157) rod da. x 209Saa (248i) stroke. 1L__| Horizontal hydrmalic evlinder Double-actng ype or "i" type outcgners) {em Ain) inside da, 400m (157in) od dia, X 24030 (88) stroke. 12,13_|Iligh suspension valve For high suspension control. DC 24 volts. 15 | Steering cylinder Double-acting type. - 60am (2:36in) inside da, > 3640 (38in) rod dia. x 302an (LL) stroke, 16 _ | Double pilot check valve ‘Maximum using pressure :380ke / ef 404psi 17 __ | Solenoid valve teeing) Selection of steering mode. DC24 volts. 18 | Swivel joint WBports | A.drain B.return C. steering (elt) 1D. Boom hoist and telescope B, Winch Steering (right). G. swing and steering pilot air eondit. Lairsource J. ir (front brake) K.air(rear brake) L-aie (accelerator) ee [M.tilt 5 (optional 19-1 | High suspension cylinders Double-acting type. __| (Lett front and right rear) 106am (1% inside dia. Ban (2.35) rod Wa, % 85a (3.74) stroke, 20-1 | High suspension cylinders Double-acting type. ight front and eft rear) 10am (4.13in) inside dia. 8Snn (2.36in) rod dia. x Sam (3.74) steoke,tem. Name of Components ‘Specifications (Use epeciiction, and set valu) 192 | Double pilot check valve For high suspension lock. Maximum using pressure: 230ke/ of (271s. 202 21_ | Accumulator For high suspension circuit. Precharged gas pressure :50he/ of ipa. 23_ | Pressure reducing valve ~__| Set pressure : 25h et Bsns 24 | Retief valve Set pressure 2104 / of 2986p) at 708 @ATeu. {01 mi 25__ | Solenoid valve G24 vlts - 26 | Inline strainer Filtering accuracy : 1027+ (0.004). Flow :37 8 (13teu 9) / min, Retief valve opening pressure: Ske / of 7.psi _ 2_ | Check valve Cracking pressure : O5ks/ ol 7s Port diameter :PP-3768 28 [Check valve Cracking pressure 0.1 Fo (Api) Port diameter: PF 1/2. 2 | Check valve Cracking pressure: Ake / of (dps) Port diameter :PF 3/4. at | Suction strxiner accuracy: 105 (0.004in) (150 mek). area: 25600 3869. in). Flow :500€ (17:66cw.0/ min 3 | Return iter accuracy 107+ (0.0004). Flow :450 0 (15.u,£/ mi Bypass valve opening pressure : 105k / ot (4.92p). 35 _| Drain iter Bypass cracking pressure :05ke /e& Spi) - 40 [Marin control [18a (For 2 var. pump) Valve Main relief valve presse 250k (9555p) at 708 @ATeust)/ nin 188 (For 11 variable pum) Mainrelie valve | Set pressure: 260he / et (3607p st 708 @2A7eu, in, 1c (Por boom extension) Port relief valve __| Set pressure: 160ks/ (2275p) at 1200 (4.24. )/ min. 16D ‘or boom retraction) Port relief valve | Set presoure:210ks/ (2086p) at 85 ¢ (3:00cu.)/ rin, (inch 8E ‘For boom lowering) soring return) | Port relief valve | Set pressure: 120k cf (1706p) at 1008 (35cu, mis 41 | Swing control valve Main relief valve set pressure 190k / et (2700 Pressure gauge pott:PF 1/4 42 | Clutch valve Unloading set pressure: 120kx 7 o@ (1706p) Loading st pressure : 90k / of (1280psi) 43 | Winch unlonding valve ‘Maximum using pressure: 20h / af (@982psi) “Maximum using flow : 1502 (50eu.{0)/ sn, 461 | Winch hydraulic motor (ind ‘Swash plate type, axial punger type. 1490 (8.08 in) rev displacement. 442, | Counterbalance valve (winch) ‘Maximum using pressure :350ke / of 4977psi) 452 Relief valve set pressure : 260k! of (082psi) 45:1 _| Winch hydraulic motor ‘Swash pate type, axial plunger type (Gusitiary wineh) - Displacement : 485ce (8.06, n)/ rev. 46-1 | Boom hoist hydraulic eyinder Double-scting type. 29000 (1142) inside di X 180 (7.0) rod din, x 17160m (672i stroke, 270 ____| ke of 309s) overtond rei vave set pressure 46-2 | Counterbalance valve boom hoist) | Maximum using pressure : 2804s / of (982i)Sng mar control valve ‘Swing pump control valve Kem No. Name of Components Specifications (Use, specification, and eet value) 47-1 | Boom telescope hydraulic eyinder | Double-acting type. ‘1400 (5.5tin) inside di 120mm (472in) rod dia. X 711000 (280i) stroke, 260k / cf (3607esi) overioad relief valve set pressure, 48 | Swing hydraulic motor ‘wash plate type, axial punger type. (ith planetary 1 step reduces) 184.1ce (11.28 in) rev displacement 49 | Priority valve ‘Maximum using flow :81.18 @86cu.£0/ min, Retief valve set pressure :210ke / xt (2986psi) 50 | Orbit rit Maximum using flow : 81.18 (286cu.f1)/ min. Displacement :277ec (16.Sewin)/ rev. Hose reel Ten (050i) inside dia. 19.en (0788in) outside dia. X 1100058 (433.1 53 | Pressoreswiteh For detecting plot creuit accumulator pressure, - ON for less than 70ks / of (9p), and OFF for more than 75ks / af (W065) 55 [Fan motor Swash plate type, axial plunger type. Displacement: 16ec (098 cuin)/ rev. 56 [Master cylinder For winch positive brake. | 71 Binch (22.200 dia). Stroke : 350m 1. 38in) 571 | Brake cylinder For winch postive brake. _ 300 (138i) dia, Maximum stroke : 1200 (047in), _ 57-2 | Brake eylinder Fr winch negative brake. 4500 (.7Tin) din, Maina stroke: 208 (0.79) 58 | Clutch cylinder For winch etch, 1 &/B inches (24 93mm dia). Maximum stroke : 12a (0.4Tin}. |For swing automatic stop. DC 24 volts. For swing automatic stop. DC 24 volts. Sivel at [ For wich clutch. ate presse: is 6p Oiewervir For Winch postive broke Capacity: 190: (Ox nh Dhar Creer For sving peste rake Caracity :60e (06x in). ot inser. Master cylinder For swing positive brake. 5 /8inch (1588am dia), Stroke : 3a (138) @ | Accumulator For swing positive brake. recharged gas pressure :20ks/ ed (284psi) Capacity :30ee(183cu. in) _ @7 (Solenoid valve ~_| For automatic stop.DC24 volts, 73 _ | Control vaive for power twist) Rated flow :10. (036cu.f0)/ min, 74__[ Motor (for power twist) Capacity 192,7ee (1000. in) - 76 | Control vaive for power tit) Retief valve set pressure :210ke / of (2986psi at 308 (L080. Port rlif valve set pressure : 75kx /e (065i)Tem No, ‘Name of Components Specifications (Use, specific and ect value) 7 | Tiltevlinder (or power til Double acting type. 100m (3.94) inside din. 40m (157i) rod in, x 68600 (27.On) stroke. Fase valve (for power tlt) Pilot check valve for power tilt) Swivel ont (Cor power tit Pressure 210k I et (2086s, 2 ports ose reel or power tit) Maximum using pressure :210ks of 86s). Control valve for thied drum winch) | Relief valve et pressure :270he / 3890p. Pressure gauge port:PP 1/4 _ BA | Gitch valve Wor third drum winehy | Maximum clutch wing presrare 1280 / af @OG2pa. 85 | Winch motor (for third drum winch) | Swash plate type, axial phunger type. Displacement : 0c (88x. in) ev Counterbatace valve reli set presure: 80s! of (3082p) Clute ylinder (for third drum wine) Brake eylinder (for third drum winet) | For postive brake. 1 3/8 inches (4.9900) 88 | Brake cylinder for tied drum winch) | For negative brake 38.1un (1 UZinches) di, Stroke : 20mm (0.79in)_ Stroke: ea (0ATin). 0 | Fan for oil cooler) Outside diameter :42000(16.54in). Number of blades: 10 90 [Oil cooler core Maximum using pressure :20ke ef @84psi) Amount of flowing:-in oil :280 6 (9:89cust) min, 1 | Check valve (Cracking pres 92 | Manual valve (for oil cooler) Maximum using pressure :210kg / of (2986p). ~ 93 | Control valve (for tagline) ‘Sequence valve set pressure: 60ke / et (85¥ps). 94 [Motor fortretine) Orbit motor. Displacement :78ce (4.76eu.jn)/ rev. 95 | tandem control valve (for taking out | Port reli valve set pressure : pressure source) AL, BI, A2and B2 220k fof (27Ipsi) at 700 @.A7ev. Pilot minimum working pressure :45kx / of (40ps Pilot maximum working pessure: 120 (1706p) 96 | Solenoid valve DC2A volte (for taking out pressure source) 100 | Main control valve (Winch deten kit) | Main relief | PL:2b0e/ of GSBsps) at 706 @A7eu. 7 min. vaveset | P2:260Ke / ef G607ps at 700 2A7eu. ft/min, mesure Port eli | Az: 160k / ot z7Gpei) at 1200 4.24a. £97 min valve set_| 82:20 / of Ca66psi at 85 € 3.00eu. 0) / in resoure_| AL: 12044 of 1706p a 1 2 (590.19 min2.2 LOCATION OF HYDRAULIC COMPONENTS ‘The iocations of the main hydraulic components are shown in Figures 2-4, 2-5 and 2-6. The item numbers in figures are linked with the item numbers in the hydraulic circuit diagrams. 2, HYDRAULIC PUMP FILTER ELEMENT Location of Hydraulic Components (Lower) ‘SUSPENSION CYLINDER T SN a comes SOLENOID VALVE 15, STEERING CYLINDER 87. HYDRAULIC OIL TANK TORQUE CONVERTER 2, HYDRAULIC PUMPS| (TANDEM) PILOT CHECK VALVE 1. HYDRAULIC PUMPS (TANDEM) 10, HORIZONTAL CYLINDERS 5. SOLENOID VALVE 17. SOLENOID VALVE a. (STEERING) 8. VERTICAL CYLINDERS 9. Fig. 2-4 Location of Hydraulic Components (Lower)Location of Hydraulic Components (Upper) 56. POSITIVE BRAKE CYLINDER 55. CABIN COOLER MOTOR 48, SWING MOTOR/REDUCER 50. ORBIT ROLL aS | 65, ACCUMULATOR 62. OIL RESERVOIR hes PL 159 SWING AUTOMATIC STOP VALVE 18. SWIVEL JoINT-| 55. OIL COOLER MOTOR oy (OPTIONAL) = CONTROL VALVE 9%. CONTROL VALVE GHYDR.PRESSURE (IYDR. PRESSURE Z SOURCE)(OPTIONAL) SOURCE) (OPTIONAL) SOLENOID VALVE (HYDR.PRESSURE 96, soLENoID VALVE f SOURCE) (HYDR, PRESSURE (OPTIONAL) SOURCE) (OPTIONAL) 442. COUNTERBALANCE VALVE 44-1. WINCH MOTOR (MAINS ° RELIEF VALVE, ACCUMULATOR (HYDR. PRESSURE SOURCE) 58, MAIN WINCH CLUTCH CYLINDER 57, NEGATIVE BRAKE CYLINDER POSITIVE BRAKE CYLINDER 88. NEGATIVE BR, CYLINDER EGATIVE BR. CYLINDER + 87, POSITIVE BR. CYLINDER He THIRD DRUM WINCH (OPTIONAL) (SWING POSITIVE BRAKE) 49. PRIORITY VALVE 60. SOLENOID PROPORTIONAL 43. UNLOADING VALVE 40. MAIN CONTROL VALVE 67. SOLENOID VALVE (AUTOMATIC STOP) 88. CONTROL VALVE. (RD DRUM) (OPTIONAL) PRESSURE TAKING OUT 42, CLUTCH VALVE 45-2. COUNTERBALANCE '45-1. WINCH MOTOR (AUXILIARY) ‘54, ACCUMULATOR 50. ORBIT ROLL 64, SWING POSITIVE BRAKE CYLINDER 62. OIL RESERVOIR @ ‘84. CLUTCH VALVE (3RD DRUM) 57, AUXILIARY WINCH NEGATIVE BR. CYLINDER AUXILIARY WINCH POSITIVE BR. CYLINDER VALVE 58. AUXILIARY WINCH CLUTCH CYLINDER il (ics COUNTERBALANCE VALVE 85-1. WINCH MOTOR Fig. 2-5 Location of Hydraulic Components (Upper)47-2 BOOM Horst CYLINDER, 77. TILT CYLINDER 81,82. SWIVEL JOINTS, 74. MOTOR (FOR POWER TWIST) Fig.2-6 Location of Hydraulic Components (Boom) 2-03, CIRCUIT COMPOSITION OF EACH SYSTEM ‘The hydraulic pumps are installed on the torque converter. No. 1 pumps (2 tandem variable piston pumps) and No. 2 pumps (3 gear pumps) are the hydraulic power sources for the hydraulic system. 3.1 HYDRAULIC PUMP SYSTEM 3.1.1 FULL POWER CONTROL ‘These are controlled with the regulator valve provided on the No. 1-1 variable displacement piston pump, 3-TANDEM PUMPS (GEAR TYPE) \ 2-TANDEM PUMPS, (PISTON TYPE) Ee] Fig. 3-1 Installing Location of Pumps DRAIN PORT VARIABLE DISPLACEMENT DELIVERY PORTS ROTATING DIREK TON REGULATOR VALVES PISTON PUMP, AIR BLEEDER FULL POWER PILOT PORT Fig.3-2 Installation of Regulator Valve (1) ‘The basic control method is what is called a ‘position control method’ which controls the pump delivery by allowing the servo spool to be displaced according to the balance of the self pump delivery pressure with the spring force and by allowing the cam lever, fixed to the swash plate through the power piston, to follow this displacement of the spool. (2) Operation of regulator valve Fig. 3-3 shows the circuit schematic diagram. The regulator controls the full power of the self pump delivery pressure and gear pump delivery pressure.‘Under the condition shown in Fig.3-4, self pump delivery pressure (P.) flows into the servo system) and always acts on the shaded section. When pressure (P4) is lower than a value, the cam lever, that is, the pump swash plate is held in the preset ‘maximum inclined position shown in Fig.3-4 with spring (R) and pressure (P.) which acts on the piston. PISTON (R) CAM LEVER PISTON (B) :VO SPOOL SPRING (R) ay” (a Seine POWER CONTROL ‘SPRING @) PRESSURE PORT SPRING (1) POWER CONTROL FIGS.36AND 37 relents PG ACTING SECTION Fig. 3-4 8 /min {3) Next, when the self pump delivery pressure rise until it exceeds the first bent point pressure (P,) in Fig. 35, the servo spool receives hydraulic reaction force acting on inserted piston (B), and moves to the left PI NOLOAD Pa a @ against force of spring (1) or springs (1 and 2). GEAR PUMP As the result, the secondary pressure chamber WITH HIGH LOAD ° is opened at the high pressure section (shaded section), and high pressure flows into the right end of the power piston. Pa stint Fig.3-5 Full Power Control SERVO SPOOL SECONDARY PRESSURE CHAMBER W (INTERCEPTION) (DURING OPEN) Fig.3-6 Servo Spool(4) Since the sectional area of this power piston is larger than that of piston (R), the piston overcomes the reacting force of the swash plate and the force of piston (R), and follows the movement of the servo spool tomove to the left (delivery decreasing direction), then stops at the position where it intercepts the servo secondary pressure chamber. POWER PISTON SPRING (1) SPRING (2) PLUG cam ever El Yl SPRING (R) SECONDARY PRESSURE CHAMBER (WHILE OPENING) (5) When the spring force acting on the servo spool is that of spring (1) only, the delivery is in the range of P; to Ps in Fig. 3-5, and when force is both of spring (1) and spring (2), the delivery is in the range of Pzto Ps. In opposition, when the self pump delivery pressure is changed from high pressure to low pressure, the hydraulic pressure acting on piston (B) is lowered. Therefore, the servo spool is returned to the right by the force of springs (1 and 2), and the secondary pressure chamber is opened to the tank circuit, ‘Therefore, the cam lever is returned to the right (delivery increasing direction) by the force of spring (R) and piston (R), and stops at the position where it intercepts the servo secondary pressure chamber. SERVO SPOOL SECONDARY aL\ eae CHAMBER (INTERCEPTION) POWER PISTON Fig. 3-7 ‘SPRING (1) (EQUIVALENT TO HYDRAULIC PRESSURE (oka (995 psi) PISTON (B1) PISTON (B) ‘SPRING (2) Fig. 3-8 TOTANK =. LL. sgconDary PRESSURE CHAMBER Fig.3-9 Drain of Secondary Chamber(6) Besides, when the delivery pressure of the gear pump rises, signal pressure (Pc) acts on piston (B,) from the full power control pilot port. By balance of this pressure and piston (B) with the force of springs (1 and 2), the servo spool is displaced to control the delivery with the same operation as mentioned above. 1 CAMLEVI PISTON (R) ‘ SERVO SPOOL PISTON (B) iO Ok ‘SPRING (R) RING @) FULL POWER CONTROL. SPRING PRESSURE PORT oO Oo FULL POWER CONTROL PILOT SIGNAL Pg ACTING SECTION Fig. 3-10 As mentioned above, this pump system moves the servo spool to the left and right by balance of the hydraulic pressure acting on pistons (B and B) with the force of the power setting springs, and allows the power piston to follow this spool movement, changing the cam lever, namely the swash plate inclining angle. (7) Fig. 3-5 shows controlled P.-Q conditions. The broken line shows the condition when the gear pump delivery pressure is the maximum and the solid line shows that in case of no load.[ADJUSTING METHOD OF CONTROL! A, Adjusting Method of Set Theoretical Delivery (See Fig. 3-11) ‘The cam lever fixed to the swash plate is held in the maximum in and force of spring (R) until the delivery pressure reaches a preset value. ‘This maximum inclining position, that is the set theoretical delivery can be adjusted via the power piston by screwing in or loosening the sleeve. ing position by the self pressure SPRING (R) CAM LEVER SPRING (1) SHIM PLuG SERVO COVER LW NUT(A) SLEEVE oO oO SPRING (2) Fig. 3-11 B, Adjusting Method of Set Power (See Figs. 3-11 and 3-12) ‘The first bent point can be adjusted by changing the screwing in position of nut (A) for the servo spool. When changing the second bent point, change the thickness of the shim, 8 fmin Adjustments A and B above cannot be performed from the outside. Therefore, it is necessary to remove the servo cover when changing after setting has once been done. Do not perform control adjustment. Pa keto Fig. 3-42 Full Power Control3.1.2 HYDRAULIC PUMP SYSTEM-1 (PTO SHIFT NO. 1-1 PUMP) PTO Shift No. 1-1 Pump ‘This pump is of variable displacement type, and the delivery pressure is supplied to the circuits of @ boom hoist, ® boom telescope and @ confluence of winch 2nd speed of RT BALANCE FLOW CONTROL, LYALVE VALVE FLOW dn (re conTROL auegcore, (SI ] VALVE ORDER BOOM BOOM Hoist |TELESCOPE, Jeol VALVE uu ‘AUTO. STOP pny (OPTIONAL) SWIVEL, JOIN WINCH UNLOADING VALVE OIL Lu COOLER Yo1-1 PUMP Pro REGULATOR} 1 TO STEERING & SWING CIRCUITS G3) TORQUE CONVERTER Fig. 3-13 PTO Shift No. 1-1 Pump Circuit 3-63.1.3 HYDRAULIC PUMP SYSTEM-2 (PTO SHIFT NO. 1-2 PUMP) + PTO Shift No.-2 Pump ‘This pump is of variable displacement type, and the delivery pressure is supplied to © outrigger circuit and winch Ist speed circuit of the main winch and auxiliary winch. AUXILIARY MAIN WINCH MOTOR WINCH MOTOR aca PORTER] | EAM ERATTE — | —— s| af | ae e , ls] Le 35] [ee PE Leo Ee ||, EL Lf oe Peet ie PE orochon lett 5 iB Reed ee] EE = la OIL COOLER (OPTIONAL) ee « ) set HINT ~ VERTHORT ugen SELECT SOL, VALVE FRONT) 2 DOUBLE PILOT ner [YES CHECK VALVES REAR) (RIGHT REAR) uw RELIEF VALVE PRESSURE CoS ESSING WARE Tc _ tob-2 PUMP PTO eeauLATOR} -9 { TO STEERING & SWING CIRCUIT 2-1 TORQUE CONVERTER Fig.3:14 PTO Shift No. 1-2 Pump Circuit a-73.1.4 HYDRAULIC PUMP SYSTEM-3 (ALWAYS DRIVEN NO. 2-1 PUMP) + Always driven No. 2-1 pump is of fixed displacement type, and the delivery pressure is supplied to the circuits of © steering (main pressure and pilot pressure), @ high suspension (pilot pressure for free / lock), @ swing, ® outrigger extension / retraction select valve (pilot pressure) and © steering confluence valve. @and @ are divided by the priority valve, but the load sensing pilot pressure from the steering valve gives, priority to the steering circuit and controls necessary flow. + In case of transmission stop of the multiplex transmission system (CPU down) or trouble of the pump itself, by operating the emergency steering switch, the minimum necessary oil flow is secured from the motor pump unit provided separately. -— sume » ; smnesrorvaive| mpm] att EOL /(p Me BE (a | {ey P ‘Were Reel “| pave] cr wae PRIOR Ha0H SOLENOID EF a PROPORTIONAL —} T eoranrionat \ >]: - uve XQ J JOINT OIL cooler —}—L1] Cor] Ik DOUBLE PILOT CHECK VALVES, DOUBLE PILOT CHECK VALVE: [SreeRING MODE po efsetect |SOLENOIDVALVE| ‘SPOOL SHIFT! g ® ® PILOT 1 Pressure oO rc 4 | 4 ' {ra I z i iS 1 if {| te @ | ! i Ingeenock | 4 | SELE \SELECT VALVE WALVEy | { I 1 t | | DOUBLE PILOT rot | CHECK VALVES 1 ot | 1 | emercency sreerinc — J MOTOR PUMP UNIT 3[ 70 wopump” Pig-315 No.2-1Pump Circuit 3-83.1.5 HYDRAULIC PUMP SYSTEM-4 (ALWAYS DRIVEN NO.2-2PUMP) + Always driven No. 2-2 pump is of fixed displacement type, and the delivery pressure is mainly supplied to the following circuits as the pilot pressure. Clutch and negative brake cylinders of winches through clutch valve ® Swing stop valve pilot pressure source ® Cabin cooler and oil cooler fan (optional) ‘SWING MO or a WINCH MOTOR Oo I ---! 5 FOE: CLUTCH CYLINDERS a | ACCUMULATOR 1 PILOT UNLOADING | wry SOLENOID VALVE 1 UNEQADING 1 LE | 1 WINCH i MOTOR be CLUTCH VALVE P T uh CABIN COOLER @ SWIVEL JOINT | om COOLER] LINE FILTER sure ( TELE ABD TORQUE VALVE CONVERTER N22 PUMP. Fig. 3-16 No. 2-2 Pump Circuit 3-93.1.6 HYDRAULIC PUMP SYSTEM-5 (ALWAYS DRIVEN NO. 2-3 PUMP) ‘This pump is of fixed displacement type, and the delivery pressure is supplied to the following circuits. ® Steering confluence (when PTO switch is in OFF and engine speed is less than 1000rpm.) ® High suspension (when PTO switch is in OFF and high suspension signal is in ON) ® Power tilt (when PTO switch is in ON) POWER TILT POWER TWIST CYLINDERS: MOTOR aaa Twist CONTROL V. LAT {Ch ‘TO STEERING VALVE HOSE REELS a (ORBIT ROLL) i POWER Tr CONTR PRIORITY WAL. VALVE DOUBLE PILOT DOUBLE PILOT _ CHECK VALVE CHECK VALVE, Cit [COOLER] + H (OPTIONAL) C SWIVEL, JOINT HIGH SUSPENSION HIGH SUSPENSION VALVE VALVE lL, DOUBLE PILOT CHECK VALVE @ TORQUE CONVERTER 9 DOUBLE PILOT| CHECK VALVE ign. SUSPENSION PRESSURE. ESSURE, Fig.3-17 No. 2-3 Pump Circuit STEERING CONFLUENCE POWER TILT ul 3-103.2 SYSTEM FOR EACH FUNCTION 3.2.1 HIGH SUSPENSION CIRCUIT 09 HIGH SUSPENSION VALVE HIGH SUSPENSION VALVE aoe TO DRAIN FILTER | ‘TO STEERING AN SWING CIRCUITS | ‘0 STEERING AND SWING CIRCUITS ue Y TODRAIN FILTER Fig. 3-18 High Suspension Circuit 3-uSTEERING VALVE + (ORBIT ROLL). | 3.2.2 STEERING CIRCUIT TO SWING PRIORITY VALVE SWIVEL JOINT ») TORIGH SUSPENSION | STEERING CONFLUENCE, VALVE TO PISTON TOPOWERTILT |_| | PUMP PILOT. 2 POINT CHAIN LINE af coos TODRAIN STEERING iiss ‘TANK UNLOADING STEERING EMERGENCY + PUMP-MOTOR | oir FRONT Fig.3-19 Steering Circuit 3-123.2.8 OUTRIGGER CIRCUIT ‘TO WINCH CIRCUIT —— TO STEERING AND ‘SWING CIRCUIT Fig.3-20 Outrigger Circuit 3-13fal ‘TO STEERING CIRCUIT lait Fro TO PRESSURE REDUCING VALVE PRIORITY VALVE Fig.3-21 Swing Circuit 3-4 ug t rxowsteza row eunxENcY CONFLUENCE muneaoror uatr A VALVE3.2.5 BOOM HOIST CIRCUIT T BOOM HOIST CYLINDER PRESSURE SOURCE ‘TAKING OUT VALVE (OPTIONAL) SWIVEL JOINT. ~-— TODRAIN FILTER ‘TO PRESSURE REDUCING VALVE Ly TO -ERING AND SWING CIRCUIT oy Fig. 3-22 Boom Hoist Circuit =153.2.6 BOOM TELESCOPE CIRCUIT HOSE REEL PRESSURE SOURCE ‘TAKING OUT VALVE (OPTIONAL) Py IRIE “ERIE + automatic! STOP VALVE OIL COOLER _, (OPTIONAL) C ) SWIVEL JOINT ‘TO PRESSURE, REDUCING VALVE uh TO STEERING AND SWING CIRCUIT Fig. 3-23 Boom Telescope Circuit 3-163.2.7 WINCH CIRCUIT r if rociurcn — |{rocLvren VALVE el PRESSURE SOURCE (ai automatic ap OIL COOLER (OPTIONAL) $P_p = TO OUTRIGGER ciRcurr TO DRAIN FILTER ‘TO STEERING AND SWING CIRCUIT Fig.3-24 Winch Cireuit 3-73.2.8 WINCH PILOT (CLUTCH, NEGATIVE BRAKE AND POSITIVE BRAKE) CIRCUIT . gl ra a on | & iE l a AUXILIARY 4 WINCH DRUM | ~ Toswinc STOP VALVE {| MAINCONTROL VALVE { CABIN COOLER |~o1L COOLER — @PTIONAL) ) SWIVEL JOINT ww Fig.3-25 Winch Pilot Circuit 3-184, CONSTRUCTION OF MAIN HYDRAULIC COMPONENTS 4.1 HYDRAULIC OIL TANK ‘TIGHTENING TORQU L9TO23«-"m A, (3.770166 fulbs) FRONT SIDE ‘TIGHTENING TORQUE 1970 2.3ks + m (13.7 TO 166 ft-lbs) i) OIL LEVEL (207 C)(68" FY 395.50 (104 Seal) DEADIITSe 4 (31.04ga { TIGHTENING TORQUE :1.2ks + m (8.68ft-bs) roy s rim OPW) BS )d (Pr sisy_ (PE va) JWR 1/2) SECTION “t 1. TANK 4. BYPASSVALVE 7. PILL PORT CAP 2) BAND 5. SPRING 8. srRAINER 8. RETURNFILTER 6. LEVEL GAUG 9. DRAIN PLUG Fig.4-1 Hydraulic Oil Tank EE @ Tank Specifications @If return filter (3) is clogged, bypass valve (4) is tank Capacity dS opened to prevent damage to the filter. Tyga Vave Release Preware | 0a Sea 100 (2.64gal) of oil corres ponds to 17am (0.67 Weist exclu hydra | Appr. 8s inch) of change in the oil levelTIGHTENING TORQUE :7.8k¢ + m (56.3ft-Ibs) 4,2. HYDRAULIC PUMPS (66.3 Ibs) ENGINE SIDE DIRECTLY CONNECTED 3-TANDEM PUMPS. 7 1a 4.2.1 PTO SHIFT 2-TANDEM PUMPS |e Fig. 4-2 Plunwer pump [Plunger pump Delivery 2A to Bees (146 to 5.0eu.in) ev. Using pressure | 260ks fed (@697px) [ 250k / af (5550s) Rotating direction Countere W. oka bs) ROTATING DIRECTION — O worm BPE ©, U Ld ® ® soto 108) 27900 10.98") Fig. 4-3, ‘ANDEM PUMPS 4.2.2. DIRECTLY CONNECTED PASI PLS a5I6 Dativery 372s 2c. ee, [62 (0 98.) Fe. _Set pressure 205k / af (2915psi) | 210k5/ af (2086psi) | 210k) ‘Approx the (68s) 56am 22") 139.7 6550") (2086s) 135 mm 6315") 11900 (4.585") 58.0am, 58.9an 2.886") 2319") esis") ERRUReISTuaes ole fH 1 | ae 0 [9, olo, ) q 174m 6.85") TiGan 5.745") foraTiNG DIRECTION es os 101.600 (4.007)TIGHTENING TORQUE :7.8k¢ + m (56.3ft-Ibs) 4,2. HYDRAULIC PUMPS (66.3 Ibs) ENGINE SIDE DIRECTLY CONNECTED 3-TANDEM PUMPS. 7 1a 4.2.1 PTO SHIFT 2-TANDEM PUMPS |e Fig. 4-2 Plunwer pump [Plunger pump Delivery 2A to Bees (146 to 5.0eu.in) ev. Using pressure | 260ks fed (@697px) [ 250k / af (5550s) Rotating direction Countere W. oka bs) ROTATING DIRECTION — O worm BPE ©, U Ld ® ® soto 108) 27900 10.98") Fig. 4-3, ‘ANDEM PUMPS 4.2.2. DIRECTLY CONNECTED PASI PLS a5I6 Dativery 372s 2c. ee, [62 (0 98.) Fe. _Set pressure 205k / af (2915psi) | 210k5/ af (2086psi) | 210k) ‘Approx the (68s) 56am 22") 139.7 6550") (2086s) 135 mm 6315") 11900 (4.585") 58.0am, 58.9an 2.886") 2319") esis") ERRUReISTuaes ole fH 1 | ae 0 [9, olo, ) q 174m 6.85") TiGan 5.745") foraTiNG DIRECTION es os 101.600 (4.007)4.3 SWIVEL JOINT 192na (7:56") 1 22500 (8.86") 625am (24.61") VIEW FORMI 1. STEM 7. O-RING 12. PLUG 21, O-RING 2. BODY 8. SEAL 13. PLUG 2. O-RING 3. COVER 9. SLIPPERSEAL 14. PLUG 2, O-RING 4. THRUST PLATE 10. CAPSCREW 1, WASHER 24. O-RING 5. O-RING ML. PLUG 20. O-RING 2. SPRING PIN 6. O-RING Fig. 4-5 Symbol ‘Name of circuit Port size Usual pressure Flow A__|Deain PRis2 Oke of (tpi) 108 (034. f0/ win B [Return 050 10k / ol 1429 4008 (14186. £0) / min C_| Steering det) Pri/2 Aik 29866) [608 @ Ben. £0 min D__| Winch, boom hes telescope PFI 25pke/ of C5S5ps) | M6 Gl6ev, 7 min B__ | Winch Pri Bike ok GADAesi) | NGF G.6cu. 17 min F_ | Steering Fight) PRU2 20k of 286) 608 @ideu.f0)/ min y — 6 [Swing Pra 205k fei @15pe) | 868 (B040u, £7 min H_ [Pilot PFI/2 ‘oke/@I83pe) | 378 (L3teu.f8\/ ein 1 [Airsource PRS/6 0h / ei 42ps) | [Air ron brake) Pra/6 10ke/ of 42s) - x [Rie Gene ben : Pra/B 10k 2142p) _ L__| Air (cceterato) Pra/6 ka oP 142s) M__ | Skytie Pr3/8 _ Number of revolution __85rpm0 Weight (ry) Approx. 7th (15656)5. DISASSEMBLY AND ASSEMBLY 5.1 HANDLING HYDRAULIC COMPONENTS Keep the following points in mind whenever handling hydraulic components : 1. All mechanical components have strength and durability limits. Because the relief valves are provided to limit the amount of pressure that acts on each hydraulic component, thereby preventing internal damage to the various parts of the machine, do NOT tamper with the set pressure. 2. Hydraulic components are high-precision devices in which even a speck of dust o foreign matter in the hydraulic circuit could cause wear or damage ; this could lead to machine failure or erratic performance and may be even to an accident. Hydraulic oil MUST be clean at all times and the return cireuit filter element should be inspected periodically and replaced when necessary. 3. Every 6 months, take out approximately 200ce (122cu. in) of hydraulic oil after the oil is heated to normal working temperature. If possible, “have a specialist analyze it to determine whether to replace all of it or not, Replacement intervals vary due to location and operating conditions. Hydraulic ofl must always be CLEAN. Metal particles and foreign matter often show up ina circuit when a component is damaged. If this happens, drain and flush the circuit, replace the filter element and clean the tank thoroughly. ‘Then fill the circuit with all NEW oil. 5. If metal particles are found on the filter element, drain and flush the circuit, and then {ill the circuit with all new oil. The presence of ‘metal patticles indicates that some component might be damaged so investigate the SOURCE and repair or replace. When adding or replacing the hydraulic oil, use only the recommended hydraulic oi (Refer to the recommended Lubrication Chart in the respective Operator's Manual.) Do NOT mix different types or brands of hydraulic oil. 7. When replacing hydraulic oil, use a clean container and funnel to pour the oil into the tank. Do NOT use any pieces of cloth, since lint may enter the circuit. 5.2 REMOVING AND INSTALLING HYDRAULIC COMPONENTS ‘The following are general notes to be kept in mind when removing or installing hydraulic components : 1. Secure the machine with wires, blocks, ete. to prevent abrupt movement during work. Hydraulic oil will gush out from those sections directly linked to the hydraulic tank by piping, so drain the tank thoroughly. 3. When removing the hydraulic components, relieve any remaining pressure from the system. 4, When removing the hydraulic components, be sure to place plugs and caps on the hoses, tube lines or ports of the removed components, and place mating marks or indexes to facilitate later matching. 5. Disassemble or assemble the hydraulic components in a place free from any dirt and dust. Be sure to note the interchangeability of each part and clean the disassembled parts with clean mineral cleaning oil. Also clean the internal passages. After they have dried, wipe them with a clean lint-free cloth, and be certain that parts have no lint on them, When overhauling the hydraulic components, replace all the O-rings, backup rings and oil seals. Coat the new O-rings with grease or vaseline before installing. 7. Replenish the amount of oil which was lost when a hydraulic component was removed after the component has been re-installed. 6.5. DISASSEMBLY AND ASSEMBLY 5.1 HANDLING HYDRAULIC COMPONENTS Keep the following points in mind whenever handling hydraulic components : 1. All mechanical components have strength and durability limits. Because the relief valves are provided to limit the amount of pressure that acts on each hydraulic component, thereby preventing internal damage to the various parts of the machine, do NOT tamper with the set pressure. 2. Hydraulic components are high-precision devices in which even a speck of dust o foreign matter in the hydraulic circuit could cause wear or damage ; this could lead to machine failure or erratic performance and may be even to an accident. Hydraulic oil MUST be clean at all times and the return cireuit filter element should be inspected periodically and replaced when necessary. 3. Every 6 months, take out approximately 200ce (122cu. in) of hydraulic oil after the oil is heated to normal working temperature. If possible, “have a specialist analyze it to determine whether to replace all of it or not, Replacement intervals vary due to location and operating conditions. Hydraulic ofl must always be CLEAN. Metal particles and foreign matter often show up ina circuit when a component is damaged. If this happens, drain and flush the circuit, replace the filter element and clean the tank thoroughly. ‘Then fill the circuit with all NEW oil. 5. If metal particles are found on the filter element, drain and flush the circuit, and then {ill the circuit with all new oil. The presence of ‘metal patticles indicates that some component might be damaged so investigate the SOURCE and repair or replace. When adding or replacing the hydraulic oil, use only the recommended hydraulic oi (Refer to the recommended Lubrication Chart in the respective Operator's Manual.) Do NOT mix different types or brands of hydraulic oil. 7. When replacing hydraulic oil, use a clean container and funnel to pour the oil into the tank. Do NOT use any pieces of cloth, since lint may enter the circuit. 5.2 REMOVING AND INSTALLING HYDRAULIC COMPONENTS ‘The following are general notes to be kept in mind when removing or installing hydraulic components : 1. Secure the machine with wires, blocks, ete. to prevent abrupt movement during work. Hydraulic oil will gush out from those sections directly linked to the hydraulic tank by piping, so drain the tank thoroughly. 3. When removing the hydraulic components, relieve any remaining pressure from the system. 4, When removing the hydraulic components, be sure to place plugs and caps on the hoses, tube lines or ports of the removed components, and place mating marks or indexes to facilitate later matching. 5. Disassemble or assemble the hydraulic components in a place free from any dirt and dust. Be sure to note the interchangeability of each part and clean the disassembled parts with clean mineral cleaning oil. Also clean the internal passages. After they have dried, wipe them with a clean lint-free cloth, and be certain that parts have no lint on them, When overhauling the hydraulic components, replace all the O-rings, backup rings and oil seals. Coat the new O-rings with grease or vaseline before installing. 7. Replenish the amount of oil which was lost when a hydraulic component was removed after the component has been re-installed. 6.8. Tighten the joints securely. Hydraulic oil will leak from any loose joint. This lowers the oil level in the tank and could damage the pump when air is drawn into the tank. When the joint on the suction line is loose, the pump draw in air, developing abnormal noise, ‘malfunctions and damage. 5.3 REMOVING AND INSTALLING SWIVEL JOINT « Removing Swivel Joint When removing the swivel joint, bear in mind the following points Remove the slip ring fitted on top of the swivel joint. Refer to the Electrical System. Remove the swivel joint with piping attached. Attach M8 eyebolt to the tapped holes on the top of the swivel joint, and temporarily suspend the swivel joint with a crane. Remove the fixing link and capscrews. Weight of Swivel Joint : approx. 82ks (180 tbs). (a) (2) (3) « Installing Swivel J Install the swivel joint by following the removal procedure in reverse order. Pay attention to the following points : Apply Locktite #242 or equivalent to threaded parts of capscrews fixing the swivel joint and tighten, Fix the swivel joint after attaching the piping to the main body. Ensure that no leakage occurs at any part. Once the swivel joint is mounted on the frame, joints, etc., can be mounted or removed only with difficulty. () (2) M8 EYEBOLT UPPER FRAME LOWER FRAME \ Fig. 5-1 Removal and Installation of Swivel Joint8. Tighten the joints securely. Hydraulic oil will leak from any loose joint. This lowers the oil level in the tank and could damage the pump when air is drawn into the tank. When the joint on the suction line is loose, the pump draw in air, developing abnormal noise, ‘malfunctions and damage. 5.3 REMOVING AND INSTALLING SWIVEL JOINT « Removing Swivel Joint When removing the swivel joint, bear in mind the following points Remove the slip ring fitted on top of the swivel joint. Refer to the Electrical System. Remove the swivel joint with piping attached. Attach M8 eyebolt to the tapped holes on the top of the swivel joint, and temporarily suspend the swivel joint with a crane. Remove the fixing link and capscrews. Weight of Swivel Joint : approx. 82ks (180 tbs). (a) (2) (3) « Installing Swivel J Install the swivel joint by following the removal procedure in reverse order. Pay attention to the following points : Apply Locktite #242 or equivalent to threaded parts of capscrews fixing the swivel joint and tighten, Fix the swivel joint after attaching the piping to the main body. Ensure that no leakage occurs at any part. Once the swivel joint is mounted on the frame, joints, etc., can be mounted or removed only with difficulty. () (2) M8 EYEBOLT UPPER FRAME LOWER FRAME \ Fig. 5-1 Removal and Installation of Swivel Joint1, LOCATION OF MAIN COMPONENTS ‘The main and auxiliary winches are located in the ‘The pressurized oil produced in No. 1-2 pump also rear of the upper. The right side winch is the flows into the winch motors when boom hoisting auxiliary winch, and the left side is the main winch. and telescoping are not operated (see 2. 1 ‘The winch motors are driven by the pressurized oil __ Hydraulic Schematics). produced in No. 1-1 pump of the two sets of the 2- tandem pumps. FOR FOR AUXILIARY WINCH MAIN WINCH se WINCH MOTOR (FOR a (FOR AUX. WINCH] prumiock AUXILIARY WINCH DRUM LEVER ‘MAIN WINCH DRUM Fig.1-1 Location of Main and Auxiliary Winches a-aIn addition to the main and auxiliary winch drums, ‘The clutch and brake of the third drum can be the third drum can be provided as an option in rear __ operated independently. of the main and auxiliary winch drums. _-THIRD DRUM WINCH MOTOR —— COUNTERBALANCE VALVE, Fig.1-2 Location of Third Drum Winch (Optional)2, CONSTRUCTION AND FUNCTION 2.1 HYDRAULIC SCHEMATICS DRAIN wincni(y RETURN BOOM HOIST. TELESCOPE i PILOT / AIR CONDITIONER "AND WINCH 2) I OIL COOLER ‘TO OUTRIGGER CIRCUIT PISTON PUMP TOs TERING | RETURN SWING CIRCUIT Fi DRAIN1, RESERVOIR (BRAKE FLUID) 2-1 POSITIVE BRAKE MASTER CYLINDER (MAIN WINCH), 2-2 POSITIVE BRAKE MASTER CYLINDER (AUXILIARY WINCH) 3-1 POSITIVE BRAKE WHEFL CYLINDER (MAIN WINCH) 3-2. POSITIVE BRAKE WHEEL CYLINDER (AUXILIARY WINCH) 4-1 CLUTCH CYLINDER (MAIN WINCH) CLUTCH CYLINDER (AUXILIARY WINCH) NEGATIVE BRAKE CYLINDER (MAIN WINCH) GATIVE BRAKE CYLINDER x te EI ) ACCUMULATOR NI (AUXILIARY WINCH) MAIN CONTROL VALVE | | q Ch) et ellel eel i f) a "| fat ae = aide Fide EL | | i oo swver sont ( o Fig. 2-1 Hydraulic Circuit Schematic (2/2) (Upper)‘The table below shows the position of the clutch (1) lever and the winch lever in relation to the state of the load. (a) Winch Nexatve Glutehever | ciutch | Winchlever |"prakte | Lond state position | teh | “position | Wake rward | Off = ont all 7 ~On_| Neatrat On _| Hod Backward Raising | _Of_| Raising Lowering | Of [Lowering WINCH MOTOR (AUX. WINCH) Winch Raising Operation Clutch lever position : backward th lever position : Raising position Oil from No. 2-2 pump enters the clutch valve and branches into two directions ; one supplies the clutch cylinder and extends it, causing the clutch to be engaged, and the other goes through the pilot-actuated directional control valve to the negative brake cylinder, releasing the negative brake. ‘The unloading valve and the accumulator located between pump and clutch valve maintain the pressure in the circuit within the set pressure range. COUNTERBALANCE VALVE ‘TO SWING STOP VALVE MAIN CONTROL VALVE | ACCUMULATOR ol > swiver joe No2-2 PUMP Fig.2-2. Clutch and Brake Hydraulic Circuit (Raising) 2-3{b) Raising can be done at two speeds : low and high. When the winch lever is pulled a half stroke distance, the hook is raised at low speed. Oil from No. 1-2 pump passes through the control valve and counterbalance valve and enters the winch motor to rotate it. At this time, oil from No. 1-1 pump returns to the hydraulic oil tank through the unloading valve. When the winch lever is pulled a full stroke distance, the hook is raised at high speed. Since the passage from the unloading valve to the tank is closed, oil from No. 1-1 pump joins oil from ‘No. 1-2 pump in the control valve, passes through the counterbalance valve, enters the winch motor, and rotates. ‘The turning force of the winch motor is transmitted through the reduction unit to the drum, rotates the drum and raises the load. ‘When the boom is raised, lowered or telescoped, the amount of joining oil from No. 1-1 pump, becomes less as much the amount of oil flowing to the boom hoist cylinder or telescope cylinder. < COUNTERBALANCE VALVE, WINCH MOTOR 1 (AUX. WINCH) L-—WINCH MOTOR (1 i COUNTERBALANUE (MAIN WINCH) ‘TO CLUTCH VALVE UNLOADING VALVE, NoJ-1 PUMP 7 J; [-RETURN FILTER Fig.2-3 Winch Motor Drive Hydraulic Circuit (Raising) 2-4(2) Holding in neutral) Because the winch lever is in neutral, the Clutch lever postion : backward pilot-actuated directional control valve is also » in neutral, connecting the brake cylinder ‘Winch lever position : neutral hydraulic cireuit to the tank through the pilot (2) Oil from No. 22 pump is supplied through the actuated directional control valve and the clutch valve to the clutch cylinder, extending clutch valve drain. Therefore, the negative the clutch cylinder and causing the clutch to brake is in operation and keeps the winch drum is stop condition. Oil from pumps 1-1 and 1-2 returns to the tank. through the control valve. be engaged. /COUNTERBALANCE VALVE WINCH MOTOR (AUX. WINCH) TO SWIN' ‘STOP VALV! i Laermer al CLUTCH VALVE ACCUMULATOR I ka | FILTER Fig.2-4 Clutch and Brake Hydraulic Circuit (Holding) 2-8(3) Pree fall Clutch lever position : forward Oil from pump No. 2-2 passes through the clutch valve and the pilot-actuated directional control valve and is supplied to the negative brake cylinder, releasing the negative brake. Since the cireuit to the clutch cylinder is led to the tank through the drain of the clutch valve, the clutch cylinder is opened, and the clutch is, disengaged. BRAKE PEDAL LI POSITIVE BRAKES cou VALY) LUE MAIN CONTROL VALVE | a i BALANCE Because both brake and clutch are disengaged under this condition, the drum is free and the load free falls under its own weight. In this condition, operating the winch lever will have no effect on the free fall except that the drum shaft is rotated clockwise, stopped, and rotated counterclockwise. Depressing the brake pedal causes the positive brake cylinder to function, stopping drum rotation, COUNTERBALANCE VALVE 1_- WINCH MOTOR (AUX. WINCH) TO SWING STOP VALVE ACCUMULATOR Fig.2-5 Clutch and Brake Hydraulic Circuit (Free Fall) 2-6(a) {a} {b) Lowering operati Clutch lever posi Winch lever posi See (1)-(a). ‘As raising the hook, two speeds are available here, low and high. Pushing the winch lever a hal stroke distance causes the hook to be lowered at the low speed. Oil from No. 1-2 pump passes through the control valve and the counterbalance valve into the winch motor, rotating the motor. When the winch lever is pushed a full stroke distance, the hook is lowered at the high speed. ‘When the boom is not being hoisted or telescoped, oil from pump No. 1-1 joins oil from No. 1-2 pump, passes through the counterbalance valve into the winch motor and rotates the motor. The turning force of the winch motor is transmitted through the reduction unit to the drum and lowers the load, WINCH MOTOR (AUX. WINCH), fags i > swver rom 0, OUrRIGG Ti CMC }a mo Tost {5 | TQSTEERING ey TSWING CIRCUTT uy Fig.2-6 Winch Motor Drive Hydraulic Circuit (Lowering) 2 -7(5) Third winch (optional) hydraulic circuit ‘The third drum (optional) is mounted behind the main and auxiliary winch drums, and added, as an option, including the exclusive winch motor, counterbalance valve, clutch and brake, Operation of the third drum is performed with the added exclusive clutch lever, control lever and brake pedal, ete. cLUTCH NEGATIVE BRAKE BRAKE PEDAL = [miner torox (POR THIRD DRUM) | counTERBALANCE cLuTcH VALVE F~ VALVE CONTROL VALVE t Fig.2-7 Third Winch (Optional) Hydraulic Cireuit2.2 WINCH BRAKE (1) Main and auxiliary winch brakes. ‘The winch brake for the main winch and auxiliary winch are of exactly the same construction with the exception of opposite mounting. The dead end of the brake band is secured to the side wall of the revolving frame and the band is supported in the revolving frame by a spring. It is so designed that the band does not come into contact with the drum while it is rotating. Fig. 2-8 shows the construction of the winch brakes. ‘The winch brake is a two way type that functions as both a spring set, hydraulically released negative brake and a hydraulically set, spring released positive brake. AUXILIARY WINCH BRAKE ASSEMBLY MAIN WINCH BRAKE ASSEMBLY Fig.2-8 Brake Band Assembly (1/2) 2-9. BRAKE BAND LINK BRACKET . BRACKET . SPRING CYLINDER ~ PLATE . RETAINE SPRING IN CASE OF MAIN WINCH 21,22 WA 2319 20 LO) IN CASE OF AUXILIARY WINCH SECTION B-B 3 10. W 1. 1B. uM. 15. 16. 1. 18. VIEW FROM A-A SPRING EYEBOLT, NUT CAPSCREW NUT PIN COTTER PIN 19. 20. a. 22. 23 24 PIN COTTER PIN CAPSCREW. LOCKWASHER SPACER POINTER SPACER Fig. 28 Main and Auxiliary Winch Brake Assemblies (2/ 2) 2-0(2) Third drum brake (optional) ‘The third drum brake is of a two way type that ‘The third drum brake is somewhat different functions as both a negative brake of spring set from the main and auxiliary winch brakes. hydraulically release and a positive brake of The dead end of the brake band is secured to _—_—hydraulically set-spring release. the third frame, and the brake band is supported to the third frame by a spring so that the band does not come into contact with the drum while it is rotating. Fig. 2-9 shows the construction of the third drum winch brake, Fig.2-9 Third Drum Brake Assembly (1/2)2 4 4 12 13 22,8 30 23 25 a - LINK . DEADENDLINK CYLINDER CAPSCREW ~ LOCKWASHER PIN . BRAKE BAND ‘CAPSCREW |. LOCKWASHER CYLINDER 1B Me 16. Wr. 18. 19. 20. 22. 23. 24. GUIDE SPRING NUT PIN COTTER PIN PIN COTTER PIN COTTER PIN BRACKET SPRING RETAINER 25. 26. 2. 28, 29, 30. 31. 32. SPRING FLANGE. COMPRESSION SPRING PUSH ROD EYEBOLT NUT. BOLT AIR BLEEDER Fig.2-9 Third Drum Brake Assembly (2/2) 2-122.3 CLUTCH (1) Main and auxiliary winch clutches. ‘The winch clutches for the main winch and auxiliary winch are of exactly the same construction with the exception of the opposite installation. They are fixed to the drum shaft with the spline by means of the clutch spider, and control the transmission of power between the winch drum shaft and the ASSEMBLE SO THAT STOPPER COMES TO THIS POSITION. 6 OPPOSITE SIDE 2| 4THISSIDE drum. e 1, CLUTCH BAND 6. LEVER (FOR AUX) - |__. 2. SPIDER 7. NUT HE 3. CAPSCREW 8. CYLINDER ! 4. LEVER 9. SEMS BOLT a T aa 5. LEVER (FOR MAIN) STOPPER’ POSITION FOR AUXILIARY WINCH 4. Ly | ASSEMBLE HAT PER comes To ‘THIS POSITION. 12,13 WHEN ASSEMBLING, p— APPLY EP GREASE 14 FOR MAIN WINCH (SHELL ALBANIA 14) TRUNNION EP.2 OR EQUIVALENT) ‘TO THESE PLACES. Py SECTION “B-B” OR EQUIVALENTYTO 2 PIN AND GREASE RESERVOIR. 1,18 | ff % U ESI SECTION “A-A” 7 10. BANDGUIDE 15. PUSH ROD. 15 1. BOLT. 16. TENSION SPRING WHEN ASSEMBLING, 12. NUT 17. BOLT "APPLY GREASE, 13. COTTER PIN 18. NUT Fig.2-10 Main and Auxiliary Winch Clutch Assembly 2-13(2) Thi 1 2 3 4 5 6 7 8 10. nL. 12, 13. u 5. BRACKET NU PIN LOCK PLATE + SPRING CLEVIS PIN SPRING BYEBOLT ). NUT |. CAPSCREW . NUT |. CAPSCREW WASHER CAPSCREW 16. . 18 19. 20. a. 22 2. 24 2. 26, 27 2 29, 30 drum clutch (optional) ‘The third drum clutch is of a shoe type construction, and is fixed to the drum shaft with the spline by means of the clutch spider. COTTER PIN CAPSCREW, LOCKWASHER CAPSCREW, LOCKWASHER NUT CLUTCH CYLINDER CLUTCH SHOE LOCKWASHER LINK LATCH PLATE CLEVIS LEVER PUSH ROD CLUTCH SPIDER ‘This clutch is used to control the transmission of power between the winch drum shaft (front) and the third drum. SECTION “A-A” 28. 29. 22, a Fig.2-11, Third Drum Clutch Assembly 2-42.4 WINCH ASSEMBLY (1) Main and auxiliary winches (standard). ‘The winch drums, installed at the rear of the machine, consist of the main drum located at the left and the auxiliary drum at the right when see from the counterweight side. As shown in Fig. 2-12, the output side gear in the second reduction unit is fixed to the drumshaft with splines, and power is transmitted to the drum by means of the clutch, aI ‘The clutch and the brake drums are integrally cast with the wire drum, and the flange of the drum is provided with drum lock pawl ratchets. VIEW FROM “B. Fig.212 Main Winch Assembly (1/2) =1516. 16. 1 18. 18. 20, a. 22. 23, 12:22 31 20 42640 Cc . MOTOR ASSEMBLY (MAIN WINCH) MOTOR ASSEMBLY (AUX. WINCH) GEAR CASE (OUTSIDE) | GEAR CASE (INSIDE) ~ PINION (MAIN WINCH) PINION (AUX. WINCH) | GEAR (MAIN WINCH) | GEAR (AUX. WINCH) + PINION . GEAR |. SHAFT (MAIN WINCH) 9. SHAFT (AUX. WINCH) |. DRUM (MAIN WINCH) |. DRUM (AUX. WINCH) GEAR CASE (OUTSIDE) BALL BEARING ROLLER BEARING ROLLER BEARING ROLLER BEARING ROLLER BEARING BALL BEARING BALL BEARING BALL BEARING Fig. 212 i 20 —18 28 10 (ROTATING DIRECTION OF DRUM) IN CASE OF AUXILIARY WINCH wu. 2, 6, 2. 28. 31 32. 33, 34 35. 36. 37. 38, 39, 0. 4. 2. 2. aM 48. 46 O-RING O-RING OIL SEAL OIL SEAL COVER COVER SPACER SPACER ‘SNAP RING SNAP RING SNAP RING SNAP RING CAPSCREW CAPSCREW CAPSCREW SLEEVE PIN SPACER PLUG SET SCREW CLUTCHASSEMBLY 51. (MAIN WINCH) VIEW FROM “C-C” a. 48. 49. 50. CLUTCH ASSEMBLY (AUX. WINCH) ELBOW ELBOW HOSE. BRAKE ASSEMBLY (MAIN WINCH) BRAKE ASSEMBLY (AUXILIARY WINCH) Main and Auxiliary Winch Assembly (2/2) 2-16(2), Thied drum winch (optional) ‘Third drum winch is installed behind the main ‘The clutch and brake drums are integrally cast and auxiliary winches. As shown in Fig. 2-13, with the wire drum, and the flange on the other the output side spider in the planetary end of the drum is provided with the drum lock reduction unit is fixed to the drumshaft with __ pawl ratchets. splines, and power is transmitted to the drum by means of the clutch. VIEW FROM “A-A”_ 1, REDUCTION UNIT 9. OIL SEAL 17. SNAP RING 2. DRUM 10. SPACER 18 COVER. 3. SHAFT 11. O-RING 19, HOSE ASSEMBLY 4. BEARING 12. CAPSCREW 20. CONNECTOR 5. BEARING 13. WASHER 21. CONNECTOR 6. SNAP RING M4, CLUTCH ASSEMBLY 22. O-RING 7. COVER 8 O-RING Fig.213 ‘Third Drum Winch Assembly 02.5 DRUM LOCK () Main and auxiliary drum locks. Construction of the winch drum lock is shown, in Fig. 2-14. ‘The winch drum lock is a safety device preventing the drum from winding off when the operator leaves his seat with the load kept aloft, when the machine is not at work, when the vehicle travels and soon. ON / OFF operation of the lock is performed by the lock knob mounted at the left side of the operator's seat in the operator’s cab. Do not stop the lifted load by use of the lock. during power or free falling. VIEW FROM “A.A” DETAIL OF “G” SECTION *C.C" Fig.2-14 Main and Auxiliary Winch Dram Lock (1/2) 2-18SECTION “B-B" iJ a ‘ a CONTROL CABLE 11. SPRING 22. NUT (FOR MAIN WINCH) 12. CAPSCREW 23. COTTER PIN . CONTROL CABLE 13. PIN 21, WASHER (POR AUXILIARY WINCH) 14. WASHER 28. MACHINE SCREW PAWL 15. PLATE 29. WASHER PIN 16. LOCKWASHER COVER 17. CAPSCREW EYEBOLT Fig.2-14 Main and Auxiliary Winch Drum Lock (2/2) 2-19(2) Third drum lock (optional). ON / OFF operation of the drum lock is performed Fig. 2-15 shows construction of the third drum by the lock knob mounted at the left side of the lock. operator's seat in the operator's cab. A A L VIEW FROM “A-A” DETAIL OF “G” Fig.2-15 ‘Third Drum Lock (1/2) 2-218,19 SECTION “B-B" wm 1] 21 23 i a | SECTION “E-E" SECTION “D-D" 6. CONTROL CABLE. 11. SPRING 22, NUT (FOR THIRD DRUM) 13. PIN 23. COTTER PIN 7. PAWL 14. BOLT. 24. COTTER PIN 8. PIN 18. CAPSCREW 27. WASHER 9. COVER 19. LOCKWASHER 10. EYEBOLT 20. NUT Fig.2-15 ‘Third Drum Lock (2/2)3. REMOVAL 3.1 BRAKE BAND ‘To remove the brake band, follow these steps separately for the main winch and auxiliary wineh : (a) Stop the engine, and set the drum lock ON. ‘Then free the brake pedal. (b} Remove the brake piping, cotter pin for fixing the brake band, brake band hanging eyebolts and brake adjusting bolt and nut. {c) Remove the brake band. NOTE When the brake band for the third drum (optional) is equipped, the brake band can be removed with the same procedures. 3.2 MASTER CYLINDER ‘To remove the main and auxiliary winch brake master cylinders, proceed as follows respectively for the main winch and auxiliary winch (see Fig. 3 y (@) After setting the drum locks (main and auxiliary) ON, free the brake pedals (main and. auxiliary). Remove the piping and hose connected to the master cylinders. o) Plug the piping and hose to prevent brake oil from flowing out. (c) Remove the pin and mounting bolts and take out the master cylinder from the front panel NOTE ‘When the brake pedal for the third drum (optional) is equipped also, the master cylinder can be removed with the same procedures. @ POSITIVE BRAKE FRONT PANEL PEDAL BRACKET | l CONNECTOR 2am si) I BRAKE PEDAL a MASTER CYLINDER [MASTER CYLINDER, MOUNTING BOLT MOUNTING BOLT FOR POSITIVE BRAKE ASSEMBLY Fig.3-1 Brake Master Cylinder3. REMOVAL 3.1 BRAKE BAND ‘To remove the brake band, follow these steps separately for the main winch and auxiliary wineh : (a) Stop the engine, and set the drum lock ON. ‘Then free the brake pedal. (b} Remove the brake piping, cotter pin for fixing the brake band, brake band hanging eyebolts and brake adjusting bolt and nut. {c) Remove the brake band. NOTE When the brake band for the third drum (optional) is equipped, the brake band can be removed with the same procedures. 3.2 MASTER CYLINDER ‘To remove the main and auxiliary winch brake master cylinders, proceed as follows respectively for the main winch and auxiliary winch (see Fig. 3 y (@) After setting the drum locks (main and auxiliary) ON, free the brake pedals (main and. auxiliary). Remove the piping and hose connected to the master cylinders. o) Plug the piping and hose to prevent brake oil from flowing out. (c) Remove the pin and mounting bolts and take out the master cylinder from the front panel NOTE ‘When the brake pedal for the third drum (optional) is equipped also, the master cylinder can be removed with the same procedures. @ POSITIVE BRAKE FRONT PANEL PEDAL BRACKET | l CONNECTOR 2am si) I BRAKE PEDAL a MASTER CYLINDER [MASTER CYLINDER, MOUNTING BOLT MOUNTING BOLT FOR POSITIVE BRAKE ASSEMBLY Fig.3-1 Brake Master Cylinder3.3. CLUTCH (1) {b) te) (2) fa) (o) (@) ) i) (a) (a) (i) (i) Main and auxiliary winch clutches. Removal and installation of the band assemblies and wheel cylinders on the main and auxiliary winch clutches are possible with the winch units installed on the machine. However, removal and installation of the clutch spiders are impossible. To remove the clutch band, proceed as follows respectively for the main winch and auxiliary winch. Stop the engine, and set the drum lock in ON and the clutch lever in FREE. Turning the clutch band adjusting bolt to loosen the clutch fully, remove the clutch band return spring. After turning the band in the direction of the circumference to shift the guide, take out the band to the outside and remove it. ‘Third drum clutch (optional) To remove the third drum clutch (optional), proceed as follows : Stop the engine, and set the drum lock in ON and the clutch lever in FREE. Remove the swivel joint for the clutch together with the piping for the clutch. Using a suitable crane or chain block, hold the third drum. Remove the support mounting capscrews (see Fig. 3-2), Remove cover (1) (see Fig. 3:3). Using a bearing puller, remove the support. At that time, use a protective metal not to injure the mounting face of the swivel joint. Remove snap ring (2). Remove the clutch piping and connector. Remove snap ring (3). Draw out the clutch assembly from the drumshaft. Fig.3-3. Third Drum Clutch3.4 WINCH ASSEMBLY For removal, proceed as follows : (8) Wind the rope onto the drum and tie it to the drum with tie-wire, or remove all the wire rope from the drum, and stop the engine. (b) Set the brake pedal free (release) and the clutch lever and drum lock OFF. (c) Remove the cotter pins fixing the brake band, lifting eyebolt, swivel joint and brake piping. (a) Remove the clutch swivel joint from the drum shaft. (e) Remove the drum plug of the reduction unit, and drain the gear oil. {f) Remove the winch motor piping. (s) Install a support for carring to the end of the drum shaft with the capscrews (see Fig. 3-4). (i) Remove the mounting capscrews, and remove the winch assemblies (main winch, auxiliary winch, reduction units and motors) from the revolving frame with the use of a suitable crane (see Fig. 3-5). Weight : Main winch assembly approx. 452kss (996 Ibs) Auxiliary winch assembly approx. 417kgs (919 Ibs) ‘Third drum winch assembly (optional) approx. 442kgs (974 Ibs) 2.1300 DRILL ek) Saar 38 cate ea [yssge ses = Ska Fan 0.31") (18mm) oa") SECTION A-A Fig.3-4 | CAPSCREW ; A —capscrew Fig.3-5 Winch Assembly THIS PART IS USED AS A TOOL, ONLY WHEN as SSEMBLING THE N4, DISASSEMBLY AND ASSEMBLY 4,1 BRAKE AND BRAKE CYLINDER 4.1.1 BRAKE ‘To disassemble and assemble the brake, referring to Fig. 2-8 on page 2-10, proceed as follows : (1) Disassembly (a) With spring (9) compressed by hydraulic pressure, tighten spring retainer (8) for the negative brake until it contacts closely with a M20 bolt of 40 to 50am (1.57 to 1.97inches) length under its head. (b) Removing cotter pins (20) and pin (19), take out cylinder (6). (2) Assembly To assemble, proceed in the reverse order of disassemble, taking care in the following respects. (a) Cleanly wipe dust off from each part (to prevent misadjustment when adjusting dimensions). (b) Before assembling, apply a thin coat of extreme pressure grease (Shell Albania EP-2 or equivalent) to each pin. (c) (a) Be careful not to allow oil and grease to adhere to the lining surface of brake band (1). Since the negative brake cylinder and the positive brake cylinder are of one body type, be careful for installing direction. Install the cylinder so that the larger side of the piston diameter comes to the negative brake spring (9) side. Besides, since the installing position of pointer (24) is different for the main winch side and the auxiliary winch side, carefully install it as, shown in Fig. 2-8 on page 2-10.4.1.2 BRAKE CYLINDER To disassemble and assemble the brake c referring to Fig. 4-1, proceed as follows : (1) Disassembly (a) Send compressed air through the air beeding port or oil supply port into the cylinder to push pistons (2 and 5) out from the cylinder. (b) Remove packings (3 and 6) and scrapers (4 and 7) from the cylinder. (2) Assembly ‘To assemble the brake cylinder, proceed in the reverse order of the disassembly, but take care for the following respects. CYLINDER PISTON(NEGATIVE BR) PACKING(NEGATIVE BR.) » SCRAPER(NEGATIVE BR) + PISTON(POSITIVE BR.) + PACKING(POSITIVE BR) SCRAPER(POSITIVE BR.) BLEEDER SCREW CAP fa) tb) (e) (a) Carefully wash each part with hydraulic oil for the positive brake. Do not assemble the parts as they are dry. If wear, scratches or rust is observed on the inner wall of cylinder (1) and pistons (2 and 5), replace the brake cylinder assembly with a new one. When installing packings (3 and 6) and scrapers (4 and 7), be careful for the direction, of the lips. Apply a thin coat of grease to the sealing surface. Install the bleeder screws after the brake assembly has been installed to the winch. Plug the bleeder screw holes with tape, ete. to prevent dust from entering.4.1.3. MASTER CYLINDER For disassembly and assembly of the master cylinder, refer to Fig. 4-2. 1. CYLINDER 5. VALVE AS 2. PISTON 6. CAP 3. CUP 7. CLAMP 4. CUP 8. GASKET 9, LOCKNUT. 43, PUSH ROD 40. SPRING 44. BOOT. AL. STOP PIN 12, STOP PLATE Fig. 4-2 Construction of Master Cylinder 2 CLUTCH AND CLUTCH CYLINDER 2.1 CLUTCH (see Fig. 4-4) For disassembly and assembly of the clutch, referring to Fig. 2-10 on page 2-13, proceed as follows : (1) Disassembly (a) Loosen four lock nuts (18), turn back four adjusting bolts (17), contract clutch band (1), and remove two return springs (16) for clutch band (1). (b) Remove guide (10). (c) Remove band (1). (a) Removing cotter pin (13), remove nut (12), and remove bolt (11). (ce) Remove levers (4 and 5). (f) Remove cylinder mounting capscrew (3) (2) Assembly ‘To assemble, proceed in the reverse order of the disassembly, but take care for the following respects. (@) Apply a thin coat of extreme pressure grease (Shell Albania EP-2 or equivalent) respectively to the spherical surface of push rod (15), the sliding section of trunnion (14), the outside circumference of bolt (11) and its grease reservoir, then install these parts. (b) Be careful not to allow oil and grease to adhere to the surface of the lining. (c}_ Coat Locktite #242 or equivalent to capscrew (2), then tighten it. ‘The levers are different for the main winch and the auxiliary winch. Carefully install them as shown in Fig. 2-10. 4-34.1.3. MASTER CYLINDER For disassembly and assembly of the master cylinder, refer to Fig. 4-2. 1. CYLINDER 5. VALVE AS 2. PISTON 6. CAP 3. CUP 7. CLAMP 4. CUP 8. GASKET 9, LOCKNUT. 43, PUSH ROD 40. SPRING 44. BOOT. AL. STOP PIN 12, STOP PLATE Fig. 4-2 Construction of Master Cylinder 2 CLUTCH AND CLUTCH CYLINDER 2.1 CLUTCH (see Fig. 4-4) For disassembly and assembly of the clutch, referring to Fig. 2-10 on page 2-13, proceed as follows : (1) Disassembly (a) Loosen four lock nuts (18), turn back four adjusting bolts (17), contract clutch band (1), and remove two return springs (16) for clutch band (1). (b) Remove guide (10). (c) Remove band (1). (a) Removing cotter pin (13), remove nut (12), and remove bolt (11). (ce) Remove levers (4 and 5). (f) Remove cylinder mounting capscrew (3) (2) Assembly ‘To assemble, proceed in the reverse order of the disassembly, but take care for the following respects. (@) Apply a thin coat of extreme pressure grease (Shell Albania EP-2 or equivalent) respectively to the spherical surface of push rod (15), the sliding section of trunnion (14), the outside circumference of bolt (11) and its grease reservoir, then install these parts. (b) Be careful not to allow oil and grease to adhere to the surface of the lining. (c}_ Coat Locktite #242 or equivalent to capscrew (2), then tighten it. ‘The levers are different for the main winch and the auxiliary winch. Carefully install them as shown in Fig. 2-10. 4-34.2.2 CLUTCH CYLINDER For disassembly and assembly of the clutch cylinder, referring to Fig. 4-3, proceed as follows : (1) Disassembly Wash each part with new hydraulic oil, and reassemble before they dry. Apply a thin coat of grease to the sealing surface. (2) Remove boot (6). Then piston (2) can be taken _(b)_‘If wear, scratches or rust is observed on the ‘out of the cylinder. inner wall of cylinder (1) or the surface of (b) Remove cup (3) and back-up ring (4) from the piston (2), replace the clutch assembly. piston, (c)_ In assembling cup (3) into piston (2), be sure (c) Remove bleeder screw (7). Be stre not to miss the direction of the lip is correct. ball (). (4) Be careful not to mistake the bleeder screw port and the piping port. (2) Assembly (The port which has the O-ring seat surface is To assemble, proceed in the reverse order of the piping port.) disassembly, being careful to the followings : a7 6 O-RING SEAT SURFACE 32 O 5, OF PIPING PORT ~ CYLINDER . PISTON . CUP . BACK-UP RING : BOOT BALL - BLEEDER SCREW . CAP Fig.4-3. Clutch Cylinder4.3. WINCH ASSEMBLY (1) Disassembly of the main and auxiliary winches (see Fig. 4-4). Since the main and auxiliary winches are of the same construction, describe disassembly of the main winch as follows : (a) Place the winch assembly on the workbench. NOTE When removing the winch assembly, oil in the reduction unit was drained in 3.4 Winch Assembly, step (e). If oil has not been drained, remove plug (43), and drain oil. (b) Match mark motor (1), gear cases (15 and 4) and covers (28 and 29) so that they will be assembled in the same positions. CAPSCREW ‘SUPPORT, 9 te) (a) fe) Remove four capscrews (37), and remove the motor. Weight of the motor with the counterbalance valve attached is approx. SAkes (119 Ibs). Remove each six capscrews (38), and remove covers (28 and 29) from gear cases (15 and 4). Remove twenty-two capscrews (39), and separate outside gear case (15) from inside gear case (4). At this time, use the three puller bolt tapped holes (M12) to prevent damage to three pins (41) which are installed into the matching surfaces of gear cases (15 and 4). ‘The tapped holes are protected with set screws (44). When using the holes, remove the set screws (see Fig. 4-5). THIS PART IS USED AS A TOOL, ONLY WHEN ASSEMBLING THE WINCH AND WHEN TRANSPORTING. Fig.4-4 Winch Assembly (Main Winch)(f) (a) (a) a (i) a (s) After match marking pins (41) and gear case (#), remove pins (41) from gear case (4). Using a bearing puller, remove bearing (18) from pinion (9). Remove snap ring (33), and remove spacer (42) and gear (10). Remove pinion (8), snap ring (34), gear (2), pinion (6) and bearing (16) as assembled. Remove bearings (17 and 19). Remove snap ring (34), and remove gear (7). Remove bearing (16) from pinion (5). Remove inside gear case (4) from the drumshaft assembly. Using a bearing puller, remove sleeve (40) and bearing (20) from drumshaft (11). Remove spacers (30). Remove snap ring (32), and remove the clutch. assembly from drumshaft (11) Press out shaft (11) from drum (13) with the procedure shown in Fig. 4-6, and remove the drum. Remove spacer (31). Using a bearing puller, pull bearing (22) out from drum (13). Remove snap ring (36). Using a bearing puller, pull out bearing (23) from the other end of shaft (1). With the same procedure, remove snap ring (32), and pull out bearing (21) from shaft (11). Disassembly of third drum winch (optional) (see Fig. 4-7) Place the third drum winch assembly (optional) on the workbench. 8 cnr UPPER SIDE f 43 RIGHT LOWER ‘SIDE. {4 41 Fig.4-5 Gear Case ¥_ rrorecrwve METAL af 22 " + — 15 a B 32 “KA ZA) Fig.4-6 Disassembly of Drum{b) Match mark motor (110), cover (108), internal (2) gear (117) and housing (101) so that they will be assembled in the same positions. Remove four capscrews (111), and remove the motor. At this time, spacer (107) and sun gear (106) will be removed together with the motor shaft. Weight of the motor with the counterbalance valve attached is approximately 44kes (97 Ibs). Remove twelve capscrews (115), and remove cover (108) and internal gear (117) from housing (101). ) (6) (s) (a) Remove snap ring (114), and remove pinion (113) together with thrust washer (116). Then, pull out sun gear (104). Remove spider (105) together with thrust washer (102). Then, pull out sun gear (104). Remove capscrews (119) and lock plates (118), and pull out shaft (121). Extend thrust washer (120) flat. Move pinions (122) in spider (103), and remove the pinions in order. NOTE ‘When removing the third drum winch assembly, oil in the reduction unit was drained in 34 Winch Assembly, step (e). If oil has not been drained, i228 NT 115 113 Ry yey 16 Wy VY Mt remove plug (109), and drain oil. a \ \ KAAS (——| | 101 | 103 105! 105 \108 110 ° tz 104 102 107109 10. HOUSING 109, PLUG 117. INTERNAL GEAR 102. THRUST WASHER 110. MOTOR ASSEMBLY 118. LOCK PLATE 103. SPIDER U1. CAP SCREW 119. CAPSCREW 104, SUNGEAR 112. O-RING 120. THRUST WASHER 105. SPIDER 3. PINION 121, SHAFT 108. SUNGEAR 114. SNAPRING 122. PINION 107. SPACER 18. CAPSCREW 123, BEARING 108. COVER 116. THRUST WASHER Fig.4-7 Third Drum Winch Reduction Unit 4-7(a) Pull out spider (103) together with thrust washer (102) from the drumshaft. At this time, bearing (123) will be pulled out with the spider. Using a suitable bearing puller, remove the bearing from the spider. (i) Insert a wooden block into between the dram and the workbench to hold the drum not to be moved. (3) Remove capscrews (12), and remove housing (101) (see Fig. 4-8). Bearing (5) will be left on the shaft. {k) Remove snap ring (6). While pushing cover (7) toward the drum side, using a bearing puller, remove bearing (5) from the shaft. (i) Remove cover (7) and spacer (10) together with oil seal (9) and O-rings (8 and 11). (us) Remove cover (18) (see Fig. 4-9). (n) Using a bearing puller, remove the support. At that time, use a protective metal not to injure the swivel joint mounting face. (o) Remove snap ring (17) and bearing (16). (>) Remove snap ring (6), clutch assembly (14) and spacer (15). (a) Push shaft (3) out from drum (2) with the procedure shown in Fig. 4-10, and remove the drum. (x) Using a bearing puller, pull out bearings (4) from drum (2) and shaft (3) respectively. (3) Checking component parts Clean and wash all component parts before they are checked. Remove all locktite with spatula, etc. If there are any burrs, dents, etc. caused during disassembly, remove them with care, (a) Check gears for pitting, scratches on tooth face, cracks, chips. wear, etc. If they are found detective, replace them. (b) If beatings do not rotate smoothly, have pitting and wear on the rolling surface, ot are damaged in retainers, balls, rollers, etc., replace them. to LE 19 1213 101 Fig.4-8 Removal of Housing 16 18 ‘SUPPORT Fig. 4-9 Removal of Clutch(c) Check splines for deformation. If they are ¥ PROTECTIVE. found outside the allowable ranges, replace them. For allowable ranges, refer to Section 6. i L 4 ‘TEST PROCEDURES AND MAINTENANCE STANDARDS. = — (@)_ Replace all oil seals and O-ring. (e) other parts are found defective because of cracks, bending, strain, scratches, ete. replace them, Ll \ (4) Assembly of the main and auxiliary winches 5 For assembly, reverse the steps taken for disassembly, and pay attention to the following respects : (a) When assembling pinions (5 and 6) and gears \ (7 and 8), confirm their helix direction not to mistake (see Figs. 4-11 and 4-13). mt Van\ | | (b) Take care not to allow grease or oil to adhere to the clutch lining surface and drum surface. ‘ When assembling the clutch assembly onto the Fig.4-10 Disassembly of Drum drumshaft, be sure to arrange the relative positions between the connector mounting CYLINDERS hole of the dramshaft and the clutch cylinder CONNECTOR as shown in Fig. 4-12, Be careful not to mistake the directions of the main winch clutch and the auxiliary winch clutch. Apply a thin coat of grease which contains molybdenum di-sulfide to the splines of the shaft on which the clutch is assembled. CONNECTOR {c) Take care not to allow grease and the like to MAIN WINCH CLUTCH AUXILIARY. adhere to the brake lining and the drum on the WINCH CLUTCH, link side. MAIN WINCH Fig. 4-12 Installation of Clutches IN 5 Conti ONE MOTOR MARK 37 LINE ON THE END § FACE OF ITEM 6) WHEN f HELIX DIRECTION OF ASSEMBLING. oe HELICAL GEAR (CONFIRM WHEN ASSEMBLING) (CONDITION BEFORE HYDRAULIC 8 MOTOR IS INSTALLED) THIS PART IS USED AS A TOOL, z ONLY WHEN ASSEMBLING THE ig WINCH AND WHEI ‘TRANSPORTING. (GREASE THE SUPPORT HOLE) Ne | SUPPORT: 2416120931 2 Na CAPSCREW : 2S23C12025 2 (BE SURE TO REMOVE THE ‘SUPPORT BEFORE 18% OPERATING THE WINCH) § Fig.d-11 Assembly of Main Winch(a) (e) Be sure to install the each oil seal in the correct direction. Before installing them, be sure to apply Locktite #515 to the periphery of oil seal (26), apply grease to the periphery of oil seal (27) and fill about 1/ 3 grease of the empty space between the sealing lips and the dust lips of the oil seals. ‘When inserting the oil seals into the gear case, do not insert them to the bottom, but provide approximately 051m (0.02in) of clearance as shown. When assembling, apply a thin coat of grease to the oil seal lip contacting surface of the shaft. Before installing the each O-ring, apply a thin coat of grease to them. Coat the each capscrew with Locktite #242 or equivalent, then tighten it with a torque shown below. ‘Tightening torque : Ttem (37)-":255 to 31.5ke » m (185 to 228ft-Ibs) Them (38)-+"6.0 to 7Akg + m (43.4 to 53.5ft-Ibs) Tem (39)-*+10.5 to 12.9ke + m (76.0 to 93.3ft-Ibs) APPROX. 0.5mm 0.02") HELIX DIRECTION OF HELICAL GEAR (CONFIRM WHEN 6 ASSEMBLING) 31 {z) Coat Locktite #515 or equivalent to the respective mating surface between covers (28 and 29) and gear cases (15 and 4), and the mating surface between gear case (15) and gear case (4), then assemble them. Besides, using benzine, etc. , degrease thoroughly the surface to be applied with Locktite. Fill about 1/2 grease (heat proof type multipurpose grease No. 2) of the empty space of bearings (20) shown in Figs. 4-11 and 4-13, After assembling, supply gear oil (Spirax EP #0 or equivalent) to the gear case until the oil level reaches the opening of the level plug. Cover the end hole of the drumshaft and the motor mounting bore on the gear case, before mounting the motor, to prevent dust from entering them. (n) (i) NOTE Ifa support is used to the hole of the drumshaft end as a tool only when assembling the winch and ‘when transporting, be sure to remove the support before operating the winch. Do not operate the winch as the support is attached. AUXILIARY WINCH MOTOR MARK CONFIRM TWO LINES ON THE END FACE OF ITEM (6) WHEN ASSEMBLING. oles E (CONDITION BEFORE HYDRAULIC MOTOR IS INSTALLED.) “21 f 29: | (| * | 15 9 THIS PARTIS USED ASA ONLY WHEN ASSEMBLING WINCH AND WHEN TRANSPORTING. (GREASE THE SUPPORT HOLE) SUPPORT : 24167203431 CAPSCREW : 2S23C12025 2 OL, HE (BE SURE TO REMOVE THE SUPPORT BEFORE OPERATING THE WINCH) Fig.4-13 Auxiliary Winch Assembly 4-1 0(3) (b) te) (a) (e) ‘Assembly of the Third Drum Winch (Optional) For assembly, reverse the steps taken for disassembly, and pay attention to the following respects : Be careful for the direction of each oil seal when installing. Apply grease to the lip brake, and apply Locktite #515 to the periphery of oil seal (9) of the reduction unit cover, then install them. ‘When inserting the oil seal into cover (7), do not insert it to the bottom, but provide approximately 0.2 to 0.5en (0.008 to 0.02in) of clearance. Fill about 1/3 grease (heatproof type multipurpose grease No. 2) of the empty spaces of bearings (5 and 16). Apply grease containing molybdenum disulfide to the splines of spider (103) of the reduction unit and shaft (3) on which the clutch is assembled. When assembling the clutch assembly onto the drumshaft, be sure to arrange the relative positions between the connector mounting hole of the drumshaft and the clutch cylinder as shown in Section A-A. ‘Take care not to allow grease or oil to adhere to the clutch lining surface and the drum surface. {f) Fill about 1/3 grease of the empty space between the sealing lip and the dust lip of oil seal (9). ‘When assembling, apply a thin coat of grease to the outside surface of the shaft where the oil seal contacts. (2) Coat the each capscrew with Locktite #242 or equivalent, then tighten it with a torque shown below. Tightening torque : Item (12) - 6.0 to 7Ake + m (43.4 to 53.5ft-Ibs) Item (L11) - 10.5 to 12.9kg - m(76.0 to 93.3ft- Ibs) Item (115) -~ 16.5 to 20.5ke » m(119 to 148ft- Ibs) Item (119) Ibs) (s) Apply a thin coat of grease to the each O- ring, then install it. 3.05 to 3.75kg + m(22.1 to 27-1ft- cLUTCH SECTION “A-A” Fig.4-14 Third Drum Winch Assembly 4-1 CYLINDER(i) Coat Locktite #515 to the mating surface between cover (18) and the mating support and the mating surfaces between the both surfaces of internal gear (117) and housing (101) and cover (108). At this time, Using benzine, etc. , degrease thoroughly the surfaces to be applied with Locktite. (i) After assembling, supply gear oil (Spirax EP #90 or equivalent) to the reduction unit until the oil level reaches to the opening of the level plug. (6) Installation of the winch assemblies (Fig. 4-15) For installation, reverse the steps taken for removal, and pay attention to the following respects : (a) Coat the each capscrew with Locktite #242 or equivalent, then tighten with a torque shown below. Tightening torque : Item (63)--51 to 63ke + m (369 to 456ft-Ibs) Item (65)~-3.6 to 4.4ks « m (26.0 to 31.8ft-Ibs) Item (56)-+-48 to 58ke » m (347 to 420Ft-Ibs) 51. THIRDFRAMB $5. CAPSCREW 52. SUPPORT 56. CAPSCREW 53. CAPSCREW 57. WASHER 34. WASHER 58. CAPSCREW i i iain “THIRD DRUM. | WINCH DRUM wf (OPTIONAL) i f ‘VIEW FROM “BB” AUXILIARY, vm WINCH DRUM a SECTION “D-D" VIEW FROM “A-A” Fig. 4-15 Installation of Winch Assemblies(a) (b) (c) (a) (e) o (s) 5. ADJUSTMENT AND AIR BLEEDING 5.1. POSITIVE AND NEGATIVE BRAKES If the drum brake lining is worn or if air is trapped in the piping, braking force will lower. Adjust and bleed air from the drum brakes for the main and auxiliary winches separately, as follows (1) Adjustment of Brake If the brake lining is worn and the pointer on the negative brake adjusting spring is in the red zone, the braking force is below specification. In that case, adjust the pointer with the adjusting nut © on the top of the brake band so that the pointer comes to the black zone as follows : Engage the drum lock. ‘Move the crane to a level and firm ground. Set the clutch lever in FREE, release the drum brake pedal slowly, and check that the drum lock functions surely. Place the clutch lever in the ON position, and confirm that the set length of the negative brake adjusting spring (B) is 134.5 to 135m (6.295 to 5315inches). If dimension (B) is out of. 134.5 to 1350m, place the clutch lever in the FREE position, and adjust brake band upper adjusting nut ©. Repeat this operation until the spring set length becomes 134.5 to 135an. When spring set length (B) is 134.5 to 135mm, confirm that the pointer on the spring is in the black zone of the wappen (Fig. 5-4). Place the clutch lever in the FREE position, adjust the brake band hanging eyebolts, brake band supporting bolt and brake assembly hanging bolt so that the clearance between the brake drum and the lining is uniformly 0.6 to 1.0mm (0.24 to 0.04inch) all around. Place the winch clutch lever in the ON position, raise the hook slightly by operating the winch lever, and release the drum lock. Place the winch clutch lever in the FREE position, slowly release the brake pedal, and confirm that the hook free falls with no load. BRAKE BAND HANGING EYEBOLTS — Fosdcesuno Ml oes SUPPORTING BOLT. MAIN WINCH BRAKE : AS SHOWN IN THIS FIG. AUXILIARY WINCH BRAKE : OPPOSITE TO THIS FIG. Fig.5-1 Main and Auxiliary Winch Drum Brake Adjustment BAND HANGING e EYEBOLT BRAKE BAND: ADJUSTING NUT © Fig.5-2. ‘Third Drum Brake AdjustmentNOTE If the hook does not free fall with no load, readjust the clearance between the brake drum and lining with the eyebolts and supporting bolt. (4) Place the clutch lever in the ON position, lift a load, depress the brake pedal, then place the clutch lever in the FREE position. ‘At this time, confirm that the allowable maximum load per single wire rope can be held. (Confirmation of the positive brake performance.) Place the clutch lever in the ON position, lift a load as the same as step (h), shut down the ‘engine, and leave as itis for a while. At this time, confirm that the allowable maximum load per single wire rope can be held. (Confirmation of the negative brake performance.) NOTE If the lifted load cannot be held, it is considered that the contact of the brake drum and the lining is improper. Allow a light load to slip with the brake pedal to improve the contact. NOTE For adjustment of the third drum brake, adjust the brake band adjusting nut, band hanging eyebolt and adjusting bolt with the same procedure as adjustment of the main and auxiliary winch drum brakes (see Fig. 5-2) NOTE After readjusting, confirm again that the hook can be free fallen. (2), Bleeding Air from Positive Brake Cylinder. (a) Engage the winch drum lock, attach a vinyl hose to the positive brake whee! cylinder bleed screw and submerge the other end of the hose into a container holding a small amount of brake fluid (see Fig. 5-6). 8 HOOK FRI WITHOUT LOAD. ‘ALLS 3 Fig.5-3 Correct Adjustment of Brake (le [PT] -e-repzowe Fig.5-4 Winch Brake Adjustment(b) Push the brake pedal several times and with the pedal depressed, loosen the bleed screw slowly. Brake fluid containing air bubbles wil out of the vinyl hose. (c) ‘Tighten the bleed screw once, depress the brake pedal again, and loosen the bleed screw. Repeat these steps until no air bubbles come out. (d) After air is removed completely, tighten the bleed screw and detach the vinyl hose. come Be careful not to allow hydraulic oil for the positive brake to get on the clutch lining and brake lining. (3) Bleeding Air from Negative Brake Cylinder (see Fig. 5-6). (a) Engage the drum lock. Attach a vinyl hose to the negative brake wheel cylinder bleed screw and submerge the other end of the hose into a container holding a small amount of brake fluid. (b) Start the engine, turn the clutch lever FREE, and loosen the bleed screw. Brake fluid containing air bubbles will come out of the vinyl hose. When no air bubbles come out, tighten the bleed screw and detach the vinyl hose. Be careful not to allow hydraulic oil for the brake to get on the clutch lining and brake lining.NEGA’ ivenrae /]] DIVE BRAKE SEEEDER SCENT BOSITIVE BRAKE MAIN WINCH BRAKE : AS SHOWN IN THIS FIGURE. AUXILIARY WINCH BRAKE : OPPOSITE TO THIS FIGURE. Fig.5-6 Bleeding the Negative and Positive Brake Cylinders of the Main and Auxiliary Winches 6 a sau) ea oO POSITIVE BRAKE WHEEL CYLINDEI wNGATIVE DRAKE WHEEL CYLINDER Fig. 5-7 Air Bleeding of Third Drum Brake Cylinder FRONT PANEL (REFERENCE) POSITIVE BRAKE. 5.2 MASTER CYLINDER 22000866") PEDAL BRACKET (1) Adjusting master cylinder — CONNECTOR To adjust the master cylinder, follow these sys uoring steps for the main winch, auxiliary winch and BOLT third drum separately. Adjust the adjusting rin—= bolt so that the distance from the inside surface of the front panel, on which the BRAKE master cylinder flange is mounted, to the PEDAL MASTER ster cylinder flange ted, to th bese ape MASTER center of the yoke pin is 97.51m (3.84in), and Baim | lock the adjusting bolt. ‘ EO POSITIVE BRAKE ASSEMBLY MASTER CYLINDER __-) MOUNTING BOLT MOUNTING BOLT —NEGA’ ivenrae /]] DIVE BRAKE SEEEDER SCENT BOSITIVE BRAKE MAIN WINCH BRAKE : AS SHOWN IN THIS FIGURE. AUXILIARY WINCH BRAKE : OPPOSITE TO THIS FIGURE. Fig.5-6 Bleeding the Negative and Positive Brake Cylinders of the Main and Auxiliary Winches 6 a sau) ea oO POSITIVE BRAKE WHEEL CYLINDEI wNGATIVE DRAKE WHEEL CYLINDER Fig. 5-7 Air Bleeding of Third Drum Brake Cylinder FRONT PANEL (REFERENCE) POSITIVE BRAKE. 5.2 MASTER CYLINDER 22000866") PEDAL BRACKET (1) Adjusting master cylinder — CONNECTOR To adjust the master cylinder, follow these sys uoring steps for the main winch, auxiliary winch and BOLT third drum separately. Adjust the adjusting rin—= bolt so that the distance from the inside surface of the front panel, on which the BRAKE master cylinder flange is mounted, to the PEDAL MASTER ster cylinder flange ted, to th bese ape MASTER center of the yoke pin is 97.51m (3.84in), and Baim | lock the adjusting bolt. ‘ EO POSITIVE BRAKE ASSEMBLY MASTER CYLINDER __-) MOUNTING BOLT MOUNTING BOLT —5.3. MAIN AND AUXILIARY (INCL. THIRD) WINCH BRAKE, (1) Adjustment of Main and Auxiliary Winch Brakes 1. Be careful not to allow oil and grease to (a) Set dimension (B) to 134.5 to 13508 (5.295 to adhere to the lining surface of brake band (1). 5.316inches) (adjusting with brake band upper 2. Apply a thin coat of extreme pressure grease adjusting nut © in Fig. 5-0). (Shell Albania EP-2 or equivalent) to pins (15 (b) Set dimension (A) to 80 to 80.5mm (3.15 to 3.17 and 19) when asembling. inches) (adjusting with item (12)} . B=1345~135an 6.295 TO 53315") APPLY A THIN COAT OF EXTREME PRESSURE, (SPRING SET LENGTH) 1 GREASE (SHELL ALBANIA EP-2) TO PINS AND — 1 1500 (059 PIN HOLES WHEN A BSS A~80~80 5am (3.15 TO 3.17") TL 447 5m (17.62") INCASE OF MAIN WINCH Fig.5-9 Main and Auxiliary Brake Assembly(2) fa) tb) (c) (@) e) Adjustment of Third Drum Brake Set dimension (A) to 408.0an (16.06in) by adjusting item (16). Set dimension (E) to 30m (1.181in) by adjusting item (30). With the negative brake engaged, set dimension (C) to 35mm (1378in). Adjust dimensions (C) with the brake band adjusting nut (see Fig. 5-2). With the negative brake released, adjust dimension (C) to 29am (1.142in) and stroke (F) to 6nn (0.236in). After adjusting step (d), set dimension (B) to 82.7 am (3.256in) by adjusting item (16). . Be careful not to allow oil and grease to adhere to the lining surface of brake band (1). - Apply a thin coat of extreme pressure grease (Shell Albania EP-2 or equivalent) to pins (8, 17 and 19) when assembling. Apply a thin coat of extreme pressure grease (EPG) to this spherical surface when assembling. Apply a thin coat of extreme pressure grease (EPG) to this spherical surface when assembling. fA S SOS = R= 378") A=408a0, (16.08") 0236") Fig. 5-10 Third Drum Brake Adjustment5.4 MAIN AND AUXILIARY (INCL. THIRD) WINCH CLUTCHES (1) Adjustment of Main and Auxiliary Winch Clutches If the clearance between the clutch lining and the clutch drum is not proper, or if air exists in the clutch cylinder, the winch operation might be impossible. To adjust the winch clutch, proceed as follows : (a) Engage the winch drum lock. (&) Place the winch clutch lever in the FREE position. (c) Loosen lock nuts (1), loosen adjusting bolts (2, 3 and 4) so that the clutch band does not contact the head of the adjusting bolts. (a) Adjust dead end adjusting bolt (3) in the dead end of the clutch band so that the clearance between the drum and the clutch lining becomes approximately 0.6as (0.024"). In the same way, adjust adjusting bolt (4) in the live end so that the clearance becomes approximately 1.0am (0.04”). (e] Turn push rod (5) so that wheel cylinder (6) is, retracted completely when the clutch is released. NOTE ‘The piston in the wheel cylinder must return to the stroke end position in the cylinder whenever the clutch is disengaged. (f) Adjust two adjusting bolts (2) so that the clutch lining face does not contact the drum when the clutch is released. (Adjust the clearance to be approximately 0.6m.) NOTE ‘To raise the performance of the clutch, repeat the procedures of steps (d) to (f), (e) Pull the main winch clutch lever toward the operator to engage the clutch and check for performance. After confirming that the performance is proper, tighten all lock nuts (1) firmly. (i) Release the drum lock. (i) Upon completion of adjustment, under the conditions of free fall, make sure that the hook can be lowered freely. 1. LOCK NUT 4, ADJUSTING BOLT 2. ADJUSTING BOLT (LAVEENDSIDE) 3. ADJUSTINGBOLT — §. PUSH ROD (DEADENDSIDE) 6, WHIBEL CYLINDER ‘MAIN WINCH CLUTCH : AS SHOWN IN THIS FIG. AUXILIARY WINCH CLUTCH : OPPOSITE ‘TO THIS FIG, Fig.5-11 Main and Auxiliary Winch Clutch Adjustment 1. BLEEDERSCREW = §, NUT 2. ADJUSTINGNUT 6, SPRING 3. LOCKNUT 7. EYEBOLT 4, ADJUSTINGBOLT 8. LOCK NUT Fig.5-12 Third Drum Clutch AdjustmentNext, lift a weight which is sufficiently heavy (allowable maximum load per one rope), and confirm that the clutch is engaged surely without any slippage. NOTE Itis necessary to adjust the clearance between the clutch lining and the clutch drum according to wear of the lining. (2) Adjustment of Third Drum Winch Clutch (a) Lower the hook, and place it on the ground. (b) Place the clutch lever in the FREE position. (¢) Loosen lock nut (5), turn adjusting bolt (4) so that the clearance between the clutch shoe and the bolt becomes 1.5am to 3an, (0.059" to 0.118"), and lock nut (6). This adjustment is necessary only when using a new clutch shoe or new linings. (4) Loosen tock nut (3), turn adjusting nut (2) so that the clutch shoe slightly clears the clutch drum and so that operating feeling is proper when operating the clutch lever, and secure lock nut (3). (e) With eyebolt (7) and nut (8), adjust the length of spring (6) so that engagement and disengagement are proper and so that the clutch lining does not contact the clutch drum. during rotation when the clutch is released, (f) Upon completion of adjustment, lower the hook under the condition of free fall, and make sure that the hook can be lowered smoothly. Next, lift a load, and confirm that the clutch is surely engaged without any slippage. (s) Tighten the all lock nuts securely. NOTE 1. The piston in the wheel cylinder must return to the stroke end position in the cylinder whenever the clutch is disengaged. 2. Distance of the clutch shoes should be adjusted according to wear of the linings.5.5 AIR BLEEDING AND DRUMLOCK (1) Bleeding Air from the Clutch Cylinder (@) Place the machine on a firm and level ground. Engage the winch drum lock. (b) Rotate the clutch so that the bleeder screw of the clutch cylinder comes to the top position. NOTE Keep the engine in an idle running (c) Put the clutch lever in the FREE position. (q) Attach a vinyl hose to the bleed screw and submerge the other end of the hose in a container holding a small amount of hydraulic, oil (Fig. 5-13). (e) Pull the clutch lever to turn it ON and loosen the bleed screw, and hydraulic oil containing air bubbles will come out of the hose. ({) Tighten the bleed screw once, turn the clutch lever ON again and loosen the bleed screw. Repeat these steps until no bubbles appear. (e) After air is removed completely, tighten the bleed screw and detach the vinyl hose. (i) Air bleed the other clutch cylinder in the same way, and check that the clutch works properly. NOTE Because of the high pressure hydraulic oil involved, be sure to use vinyl hose for safety. Make sure that no spilled oil is on the clutch lining and brake lining. VINYL HOSE AUXILIARY WINCH CLUTCH : OPPOSITE TO THIS FIG. AIR BLEEDING OF MAIN AND AUXILIARY WINCH CLUTCHES AIR BLEEDING OF THIRD DRUM CLUTCH EB Fig. 5-13 Air Bleeding of Clutch Cylinder(2) (a) Adjusting the Drum Lock To adjust the drum lock, proceed as follows : With the drum lock ON, make sure the pawl is completely engaged with the bottom of the drum ratchet. (b) With the drum lock disengaged, adjust the adjusting bolt so that the clearance between the pawl and the top of the drum ratchet teeth. is 10mm (0.394in), then tighten the lock nut securely. Do not forget lubrication to the pin for the drum lock pawl. CONTROL CABLE, MAIN WINCH DRUM LOCK : AS SHOWN IN THIS FIG. AUXILIARY WINCH DRUM LOCK : OPPOSITE TO THIS FIG. LOCK NUT ADJUSTING BOLT £ Paw. DRUM RATCHET a “41 CONTROL CABLE ‘THIRD DRUM LOCK Fig.5-14 Adjustment of Drum Lock 5-105.6 ADJUSTMENT OF FREE FALL INTERLOCK (a) (b) e) POSITIVE BRAKE PEDAL MAIN WINCH AUXILIARY WINCH Fig. 5-15 Normal condition When stroke @ reaches 50 to 55am (1.97 to 2.16 inches), interlock of the clutch lever is released and the clutch lever can be operated freely. This case is normal and adjustment is unnecessary. When adjustment is required. After adjusting the master cylinder, adjust the cable lock nut so that point @ comes in contact with point @ surely without depressing the pedal, and that the interlock is released when the pedal stroke is 50 to 55am. After adjustment, make sure the pedal stroke by step (a) ADJUST SO THAT INTERLOCK IS CLUTCH LEVERS RELEASED FOR 50 TO Sm OF PEDAL STROKE 6-1 Free Fall Interlock Device (REFERENCE) 22nn(0.866") 97 San(3.84") i b> Fig. 5-16 CABL6, TEST PROCEDURES AND MAI 6.1 TEST PROCEDURES (1) BRAKE INTENANCE STANDARDS “Text Procedure ‘Maintenance Standards 1, Lining Wear Lirit ‘Measure “A” for minimum thickness. r NOMINAL, DIMEI San (o315in) [LINING a BAND 10} Replace lining when “A” isless than tna (004i) 2. Brake Cylinder Pressure Test Apply 250ke J af (555ps) hydraulic pressure to brake eylinder for seconds NoTE Do not allow brake cylinder to reach its stroke end, Limit stroke before applying pressure as shown, t PRESSURE OF 250k / of (555psi) 5 | Cylinder should be free from cil leakage and any other abnormal condition Check brake eylinder and piston for wear and scratches. Measure clearance between cylinder and piston Master Cylinder Pressure Test seconds, ‘Time Required for Cylinder Piston Returning Fill eylinder with brake fuid at normal temperature. fullextended, ‘Check for wear and scratches on master eylinder and piston. ‘Measure clearance between cylinder and piston. Apply 250k ef (2555p) hydraulic pressure to master eylinder for 5 ‘Check time for piston to return when delivery port is closed with piston {ree from oi leakage ain say other Abnormal condition. ‘Within 1 second. Recommended clearance for replacement of those units is 02am (0.008in)‘Test Procedure ‘Maintenance Stendards 7, Brake Performance Check Lift load, under free fall condition, depress foot brake pedal and release clutch (OFF), Make sure thatthe load can be held only by the brake WeNXF W: Lead Number of part line of wire rope jie rope allowable lad (Main :3.125t, Aux. :32t) ‘NOTE 1, Lifting load (9 should not exceed rated lifting load. 2, Auxiliary winch brake performance check should be carried out by using auniiary sheave. Jib should not be used. 3. Testing load should not be lifted high up Load must be held in mid-air without: 8. Hook Free-fall Check With maximum of parts of hoist ine, maximum of boom angle, ‘maximum of lifting height and no load, check to see whether hook falls {reely or not, wth brake pedal released and clutch lever in OFF. 9. Function Test While testing in preceding step 8, check for abnormal noise and/or cil leakage from brake piping. ‘ook lifted should fall freely Correct clearance between drum and fining is 06 ~ 10 132(0.024 to O.0n), No abnormal nose or oi eakaye shouldbe observed. (2) CLUTCH ‘Test Procedure ‘Maintenance Standards 1. Liniog Wear Limit Meacure “A” ‘for minimum thickness NOMINAL DIMENSION 95a0 {are 2. Clutch Cylinder Pressure Test ‘Test procedure is the same as(1}2 “Brake Cylinder Pressure Test? Replace lining when dimension “A” is Jess than ta (oon ‘The same maintenance standards as (1)-2 Brake: Cylinder Pressure Test should be applied,“Teal Provedure Maintenance Standards 3 Cluteh Performance Check With the same conditions as (1)-7 “Brake Performance Check” lod and check clteh lining contacting condition, No slippaye is allowed and clutch should be securely engaged. Clearance between drum and lining should be 0.608 (0.02sin) at dead end and 1.000 (0.4in at live end } 4. Function Test ‘While testing in step 3 above, check for. No abnormal noise ool leakage should be observed. and/or abnormal noise, (3), DRUMSHAFT ‘Test Procedure 1. Funetion Test ‘With the same conditions as (1)-7 "Brake Performance Check” check {or cil leakage and abnormal noise while lifting or lowering load and Sree-elling hook with no load. ‘Maintenance Standards ‘There should be no ot leakage o abnormal noise, (4) DRUMLOCK Test Procedure “Maintenance Standards 1. Function Test ‘When drum lock eve and smoothly. operated, check to see if paw functions surely When drum lock lever is ON, pawl should engage perfectly with drum ratchet. With lever in OFF, 200n (0787in) of clearance should be snsintained between pawl and ratchet top. ‘When lever is operated, the said pawl should be turned smoothly ON or ORR,6.2 TIGHTENING TORQUE OF MOUNTING BOLTS ‘Table 6-1. Tightening torque of mounting capscrews ‘Unit : ke-m (ft-Ib) eve | ig | RE Name . Tbe #242 or equivalent with oil 37 _|Ntr mang ae steals oe net, Ge ic 105to 129 - a 2 au | (Third) Cover mounting 65t079 Fie ccapscrew 47.0t057.) _ Fess | 6 _ | Wishnoniog creer aes, —~} 6 ‘Cylinder mounting | 33t046 nie owe i Baie | ig. si0 rs a “ae y 10 | Cylinder mounting eapserew (esueen Clutch " ‘Cylinder mounting alta? assembly Fig.2410 3 | capacrew 224 10258)TROUBLE ' 7, TROUBLESHOOTING PROBABLE CAUSE ' REMEDY ' (| oitteatein clutch control ciruit, Repair cl leak. ‘Cth slips due toil or water on Load cannot be lifted, clutch lining. Tncase of water, ry ning. Incase il epac ining. FH Gluten sts. Bleed air and adjust cluteh, LJ sMantunction of relief valve. ‘Adjust relief valve. aire of reduction unit and drum shaft, Repair or replace, ‘Load caa neither be lifted nor lowered, }-{- Wong winch motor and control valve. Repair or replace, ‘Malfunction of relief valve ane flow control valve ‘Adjust relief valve. Wash or replace flow conteol valve, Tnterference between brake lining [antrum Adjust brake ook does wt fll Interference between teh ining frcey. sium Ais cute, Ly sattunetion of eateh valve Replace valve. Interference between clutch fining [| and drum, drum and frame, or brake band and drurs. Adjust or repair “Abnormal noise while lieing / lowering and Sroe-faling. LL, Feitureof reduction unit gent. Replace. | Frilure of drum shaft bearing. Replace. LY Peiture of winch motor. Replace.No braking power. Oiteak in brake hydraulic circuit Repair ol leak. ‘Brake lining slips due tool or Tr caoe of water, dy ning. water on lining. Tacave ool replace lining. Brake lining slips due to reasons ed anita rab, ‘other than above. Bioed alr and atnst brake ‘Master eylinder inner leak, Repair ot replace. No functioning, ‘Readjust, and then confirm function. Drumlock malfmetions. Cable does not move smoothly. Lubricate or replace CT awl doesnot move smoothly. Lubricate, aust or replace,1, LOCATION OF COMPONENTS ROTATION SENSOR SWING MOTOR REDUCTION UNIT “L_ roration SENSOR SWING MOTOR CARRIER chon REDUCTION [unir 2 g & B 8 z 5 Z Z $ ae VIEW FROM B-B Fig. 1-1 Location of Swing System and ComponentsSWING LIMIT SWITCH SECTION C-C SECTION B-B SWING CONTROL LEVER ‘SWING LOCK LEVER ‘WIRING AND OPERATION MATRIX OF LIMIT SWITCH [SYMBOL] OPERATION OF ‘OUTPUT TO LIMIT SW. SOLENOID, RIGHT | 5 DONOT PUSH SWING é Limit { E SWITCH LEFT } 1 no |f /-—Bnoxor! / Sol hina. ZPusi, 2u, Lint |9O-| jcur¥ean fuer} | —fowr}teat| weer] pucurirmal[uerr} | iciT| Tat Ler] MASTER CYLINDER FI & ow ‘SWING BRAKE LEVER V2, CONSTRUCTION AND FUNCTION 2.1 HYDRAULIC SCHEMATICS Fig.2-1 shows the hydraulic circuit of the swing system. TocLUTCH! | pat Peet Pebssuee Shia 15 Q : 13 TO HYDR. 1 MOTOR FOR AIR CONDITIONER ee a 1 1. HYDRAULIC OW. TANK ~ HYDRAULIC PUMP (FOR SWING AND STEERING) 3. SWIVEL JOINT + PRIORITY VALVE Fig. . SWING CONTROL VALVE 11. . SWING MOTOR (WITH REDUCTION UNIT) OIL RESERVOIR MASTER CYLINDER ACCUMULATOR. MAGNETIC PROPORTIONAL RELIEF VALVE CLUTCH VALVE 2-1 12, ACCUMULATOR 13. PRESSURE SWITCH 14. SWING STOP VALVE 14— 1. PRESSURE CONTROL VALVE 14~ 2. MAGNETIC PROPORTIONAL PRESSURE REDUCING VALVE 15. PRESSURE SENSOR Hydraulic Circuit Schematic of Swing System(1) Swing in Neutral (Swing Lever in the Neutral Position) (swing Neutral Lock) Pressurized oil delivered from the hydraulic pump enters the swing control valve through the swivel joint and through the priority valve. Ba However, the pressurized oil flows as shown with the arrow mark shown in Fig. 2-2, returns to the hydraulic oil tank as itis, and generates no slewing force in the swing motor. | eee ceed | rocuurcuy 27” SWING MOTOR (WITH REDUCTION UNIT) CLUTCH VALVE 4 BRAKE : TOHYDR MOTOR FOR AIR CONDITIONER _ + L B. PRIORITY [ka VALVE co pe q sf PIM SWIVEL JOINT a mo X. ‘SWING CONTROL VALVE TYDRAULIC PUMP 1 _ Fig.2-2 Circuit when Swing Lever in Neutral (Swing Neutral Lock)(2) Swinging to the Right (Pulling the Swing lever toward the Operator) When pulling the swing lever toward the operator, pressurized oil delivered from the hydraulic pump enters the swing motor through port MB as shown in Fig. 2-3, and rotates the swing motor to the left. ‘Therefore, the swing pinion also rotates to the left, turning to the right along the slewing ring gear. Then the upper turns to the right. While, the return oil from the swing motor passes port MA, enters the swing control valve, and returns to the hydraulic oil tank as shown, in Fig. 2-3. Gas PRESSURE 20ks fer In case of automatic stop mode, pressurized oil from the 2nd pump is led to the primary side of the magnetic proportional pressure reducing valve and generates a secondary pressure according to the stop signal. This secondary pressure generates braking pressure at the motor outlet port as a pilot pressure through the pressure control valve, and trols the motor inlet pressure through the proportional relief valve. Therefore, the revolving upper is stopped smoothly. (In case of neutral free, the same control is operated.) Tapucrion TO CLUTCH VALVE LUTCH/ BRAKE Th LS Poms TOHYDR. t MOTOR FOR AIR CONDITIONER SWING CONTROL VALVE Fig.2-3 Hydraulic Circuit when Swinging to the Right(3) Swinging to the Left (Pushing the Swing Lever forward) Pressurized oil flows in the opposite direction to the flow in topic (2) (see Fig. 2-4) cas PRESSURE Gta, 2 20ke fot 15 rocwurcn, © CLUTCH VALVE VALVE... fy ‘TOHYDR, Fig. 2-4 Hydraulic Circuit when Swinging to the Lett. -4(a) ‘Swing in Neutral Free ‘The swing in neutral free is operated with the swing lock / free selector switch on the crane operation control switch panel in the left side of the operator's seat or with the side-pull preventive switch on the winch lever. (5) When placing the selector switch in the SWING FREE position, or when pushing the side-pull preventive switch, the solenoid valve functions to open the relief valve, and the return oil from the swing motor passes the relief valve as shown in Fig. 2-5, then the both left and right return oil return to the hydraulic oil tank. Gas PRESSURE 20k fet 15 rocuurens © ‘Therefore, the machine becomes free for swing, and the boom is turned toward the center of a load when the winch lever is operated. ‘Swing in Neutral Lock. When placing the selector switch in the LOCK position, the oil flow becomes the condition shown in Fig. 2-2, and the return oil from the swing motor is blocked.” By operating the swing brake lever also, s motion can be locked (see page 2-9). ie CLUTCH “BRAKE VALVE _ ie ih MOTOR FOR AIR CONDITION ic Circuit for Swing in Neutral Free2.2 SWING CONTROL VALVE (1) Construction 2. RELIEF VALVE ASSEMBLY 7 9 a Be ue OVERLOAD RELIEF VALVE ASSEMBLY 1, BODY 12, CAPSCREW 28. BUSHING 2. SPOOL 13. CHECK VALVE 24, SPRING: a. DUST SBAL 14. SPRING 25. CHECK VALVE 4. O-RING 15. VALVE SEAT 28. PLUG 5. CAPSCREW 16. O-RING 21. O-RING 6. RETAINER 17. OVERLOAD VALVE 28. CAPSCREW 7. COVER 18, SPRING 31, ORIFICE 8. CAPSCREW 19. PLUG 32. SOLENOID VALVE 9. SPACER 20. CARTRIDGE ASSEMBLY 32. O-RING 10, RETURNSPRING 21. PLUG 31. ORING 11. SPRING SEAT 2. RELIEF VALVE Fig. 26 -6(2) Neutral Position il, which entered port P, passes the bypass passage, pushes valve (23), and returns to port v. At this time, the motor circuit is blocked by spool (2). {3) Operation of Spool By switching the spool to the arrow (<) direction, oil from port P pushes to open check valve (13), and flows to the motor (MB). At this time, the return oil from the motor passes as shown by the arrow marks (-—) from port MA, and flows to port T from valve (3). Fig. 2-72.3 SWING MOTOR WITH REDUCTION UNIT (1) Motor As shown in Fig. 2-9, the swing motor is mounted directly on the swing reduction uni and drives the swing pinion through the reduction unit, making the upper swing. ‘The swing motor is of swash plate, axial piston type. A single-plate disc brake is mounted on the cylinder block of the motor (see Fig. 2-10), and. is spring released - hydraulically set. When pressurized oil fed to the brake pressure port, the brake is engaged. This oil pressure works to press the brake piston against the friction disc, retarding the disc rotation. oon4 SWING MOTOR DISC BRAKE — SLEWING RING. (2) _— roration sensor | When there is no pressure in the brake chamber, the brake spring actuates the brake piston to release the brake discs, there by separating the input shaft from the housing and allowing the motor to turn. Reduction unit . ‘The reduction unit is a planetary reduction unit, and is motor-driven, ‘The hydraulic swing motor drives the sun gear of the reduction unit, and the swing pinion is intermeshed with the ring gear of the slewing ring. ‘Therefore, when the oil leaving the pump is supplied to the motor, the upper begins to swing. REDUCTION UNIT ‘SWING PINION Fig.2-9 Swing Motor2.4 SWING BRAKE (FOR LOCK) ‘The brake lock is manually operated. When the control lever is raised, the resulting pressure in the master cylinder depresses the brake piston and forces it against the brake discs mounted on the cylinder block of the swing motor, preventing the input shaft from rotaing. MASTER CYLINDER Lowering the control lever removes the pressurized brake oil. This allows the force of the spring to raise the brake piston, releasing the discs and allowing the input shaft to rotate. = ==. — orF SPRING Le-— ROTATION SENSOR HYDRAULIC ‘SWING MOTOR BRAKE PISTON BRAKE DISC ig.2-10 Operation of Swing Brake Lock 2-92.5 SWING LOCK PIN Fig. 2-11 shows the construction of the swing lock pin, ‘The swing lock pin locks the crane upper to the cartier mechanically to hold the upper from swinging, and can be engaged at the two positions of the forward position and backward position. ‘When traveling on roads or when picking and carrying @ load, use this lock pin. ON and OFF of the swing lock are operated with the swing lock lever provided in the left side of the operator's seat. Lift the lever a little and move it to the side to release the swing lock, and push it down to engage the lock. When locking, be sure to arrange the upper to be parallel with the carrier. When releasing the lock, pull the lifted lever backward, and place it surely in the lock-release position, LOCK LEVER carnier reams ©) SIDE PIN HOLE Fig.2-11 Swing Lock Pin -102.6 SLEWING RING ‘As shown in Fig. 2-12, the slewing ring consists of an inner race, an outer race and balls. The inner race (swing ring gear) is secured to the bearing seat of the carrier, and the outer race is secured to the revolving frame respectively with the REAMER BOLT. 1 a ROTATION SENSOR 2 4 SECTION “B-B" | fl SECTION “A-A” capscrews. The pinion of the swing reduction unit is meshed with the swing ring gear of the inner race, making it possible for the upper to rotate 360 degrees continuously. BRAKE OIL FILL PORT THREADS FOR LIFTING REAMER BOLT GEAROIL DRAIN PORT WHEN INSTALLING PINION, ‘THIS CLEARANCE MUST BE 0.1 T0 Onn (0.004 TO 0.016"), 1, OUTER RACE 2. INNER RACE 3. BALL 4. CAPSCREW 5. CAPSCREW 6. REAMER BOLT 7. WASHER | 8. NUT Fig. 2-12 Slewing Ring3.1 SWING MOTOR (WITH REDUCTION UNIT) Since the swing motor and the reduction unit are integral, they are to be removed and installed as an assembly. (1) Removal fa) Extend outriggers, angle and stop engine. (b) Move swing control lever back and forth several times to relieve residual pressure from hydraulic circuit. (c)_ Remove gear oil from inside reduction unit. (a) Clean motor and piping connections. (e) Disconnect pipings to the swing control valve, motor drain and dise brake (brake lock). raise boom to maximum NOTE Be sure to keep swing brake lever in the brake release position. (f) After piping is disconnected, cap motor ports and hydraulic hose ends to prevent dust from entering. (g) Remove’ the six reducer mounting bolts. Attach suitable rope between motor and a hoist. Use puller bolt holes to raise assembly until it goes out of fit. (h) Lift motor vertically and remove from the upper. Weight of motor (with reduction unit) : about 117kg (258 Ibs) (i) Fix the removed motor (with reduction unit) tothe workbench upright. (i) Remove the lifting wires. Loosen the capsctews and remove the swing pinion. After the motor and the reduction unit are removed, the upper becomes free to move and may swing. For this reason, fix the revolving frame to the carrier with the swing lock pin shown in Fig. 2- u. REMOVAL AND INSTALLATION TAPPED HOL! FOR LIFTING M12X 230m (29 / 32”) arn erm filter [fet ean om Fig.3-1 Swing Motor Assembly Fig.3-2 Removing Swing Motor Assembly(2), Instatiation To install, reverse the removal procedure, paying attention to the following : (a) When the pinion is to be installed, adjust with shims so that the clearance (a) shown in Fig. 3- is 0.1 to Oda (0.004 to 0.01Gin). ain' + (o} Tightening torque : Sv —_ + # ‘Swing motor (with reduction unit) mounting, + WHEN INSTALLING capscrews “26 to 32kg - m (188 to 231ft-Ibs) f Swing pinion mounting escrews | PINION, CLEARANCE { (@) MUST BE 0.17 (47 to S7ft-tbs) (with Locktite #271 or Grae toon! TO aoteen, equivalent coated to threads). , reins (c) Gear oil for the reduction unit after ZN LA installation : #90, 1.3 liters (034zals). (4) Bleed air from the brake lock circuit. Fig.33. Instalting Swing Pinion (e) Start the engine. With the swing brake lock in ON, operate left and right swing to relive and bleed air. (f) Idle the motor to check for noise and oil leak during operation. 3.2 MASTER CYLINDER (1) Removal la) Place the lever in the OFF position and remove the pin connecting the lever and the master cylinder. (&) Disconnect the tube and hose from the master cylinder. NOTE Plug tube and hose to keep oil from flowing out. (c) Remove the mounting bolts and take out the master cylinder. (2) Installation ‘To install the master cylinder, reverse the removal procedure. MASTER CYLINDER LEVER NOTE ‘The machine’s swing brake lock system is a static hydraulic pressure type. If any air reminas in the piping, the brake will be ineffective. Because of this, after the piping is connected, fill it with brake fluid and then be sure to bleed air from the bleeder PIN. COTTER PIN. and block of the swing reduction unit. WASHER Fig.3-4 Master Cylinder(2), Instatiation To install, reverse the removal procedure, paying attention to the following : (a) When the pinion is to be installed, adjust with shims so that the clearance (a) shown in Fig. 3- is 0.1 to Oda (0.004 to 0.01Gin). ain' + (o} Tightening torque : Sv —_ + # ‘Swing motor (with reduction unit) mounting, + WHEN INSTALLING capscrews “26 to 32kg - m (188 to 231ft-Ibs) f Swing pinion mounting escrews | PINION, CLEARANCE { (@) MUST BE 0.17 (47 to S7ft-tbs) (with Locktite #271 or Grae toon! TO aoteen, equivalent coated to threads). , reins (c) Gear oil for the reduction unit after ZN LA installation : #90, 1.3 liters (034zals). (4) Bleed air from the brake lock circuit. Fig.33. Instalting Swing Pinion (e) Start the engine. With the swing brake lock in ON, operate left and right swing to relive and bleed air. (f) Idle the motor to check for noise and oil leak during operation. 3.2 MASTER CYLINDER (1) Removal la) Place the lever in the OFF position and remove the pin connecting the lever and the master cylinder. (&) Disconnect the tube and hose from the master cylinder. NOTE Plug tube and hose to keep oil from flowing out. (c) Remove the mounting bolts and take out the master cylinder. (2) Installation ‘To install the master cylinder, reverse the removal procedure. MASTER CYLINDER LEVER NOTE ‘The machine’s swing brake lock system is a static hydraulic pressure type. If any air reminas in the piping, the brake will be ineffective. Because of this, after the piping is connected, fill it with brake fluid and then be sure to bleed air from the bleeder PIN. COTTER PIN. and block of the swing reduction unit. WASHER Fig.3-4 Master Cylinder3.3. SLEWING RING (1) Removal ‘When the slewing ring is to be dismounted, the upper and crane attachment must first be removed. (a) Remove the boom (see the separate shop manual “Boom System” . (b)_ Remove everything fitted to the swivel joint, such as the hydraulic piping, electric wires, and links. It is recommended to tag each and wire so that they may be more easily identified for reassembly. It is also recommended to cap hydraulic pipes and swivel joint ports to prevent dirt or dust from entering the hydraulic system. (c) Temporarily raise the upper with a crane. (4) Remove the bolts fixing the slewing ring outer race to the upper. If the upper tilts when the bolts are loosened, keep it level with a crane. (c) After all the bolts have been removed, slowly up and then lowe (f) Remove the bolts fixing the inner race of the slewing ring to the carrier. (s) Install eye bolts at two points on the slewing ring, and hoist and dismount the ring with a suitable crane (see Fig. 3-5). Weight of the slewing ting : approx. 354k (780 Ibs) (2) Installation (Slewing Ring and Carrier) (2) Before installing the slewing ring, clean the installing face of the carrier deck thoroughly to remove all dirt, dust or oil. (b) Coat the tooth section of the swing ring gear with grease containing molybuden disulphide (showa sunlight grease MB2 or equivalent). (c) Apply locktite #242 or equivalent to the mounting bolt threads. (4) Hand-tighten all bolts to hold the slewing ring temporarily. (e} Choose any two bolts located 180° apart and zhten them to torque 11ke-m (79.5 ft-Ibs). (f) Tighten to torque 11ks-m (79.5ft-Ibs) each pair of bolts in a position 90" from the bolts tightened in (e) above. Fig.3-5 Removing the Slewing Ring(a) (H) (3) (a) (b) (eh CARRIER FRONT By following the above procedure, tighten to torque Liks-m (795ft-Ibs) all the bolts symmetrically located two by two. Finally torque all the bolts to specified torque, Specified torque : 97 to 119kg. m (701 to 860ft- Ibs). Installation (Slewing Ring and Upper) After the slewing ring has been installed to the carrier, combine the upper to the slewing ring by the following procedure : Lift the upper horizontally and lower it slowly. onto the slewing ring while aligning the centers of ring and upper. After the swing pinion has intermeshed with the slewing ring gear, lower the upper and aligh the bolt holes of both, using fixing bolts. Insert the two reamer bolts marked with © to fix the position, and then mount other bolts and nuts (see Fig. 3-6). OUTER RACE SOFT ZONE i [ (HOLE FOR STEBL PALLS) Apply Locktite #242 or equivalent to the all mounting bolt threads. (d) Tightening procedures and torque of the reamer bolts and mounting bolts are the sam as those for mounting the inner race. (e) After the slewing ring and upper are completely reinstalled, reconnect the slewing ring lubrication piping, and all the hydraulic piping, electric cables and links fitted to the swivel joint. NOTE After 200 hours of operation, recheck the slewing ring mounting bolt tightening torque. INNER RACE SOFT 201 29kg-m. (2091t-Ibs) 7.2ke.n (2it-tbs) TIGHTENING i TORQUE 108kg-m + (7804t-1bs) SECTION “B-B”_ Fig.3-64, DISASSEMBLY AND ASSEMBLY 4.1 MASTER CYLINDER ‘To disassemble and assemble the master cylinder, follow the procedures below referring to Fig. 4-1. 4 Be uw 3 1 Rt 1, CYLINDER ASSEMBLY 7. ROD 2. RETURN SPRING 8. SPRING 3. PISTON 9. SPRING SEAT 4. SECONDARY CUP 10. STOPPER 5. PRIMARY CUP 11. GASKET 6. SUPPLY VALVE 12. SPEACER 16 13. M4 15. 16. PUSH ROD ASSEMBLY STOP RING Boor FILLER TUBE ASSEMBLY Fig.4-1 Construction of Master Cylinder (1) (a) Disassembly Remove boot (15) and stop ring (14), and then remove push rod assembly (13). Remove stopper (10), gasket (I1) and spacer (12), and take out piston (3) and spring (2). From piston (3), remove secondary cup (4), primary cup (6), spring seat (9), supply valve (6) and rod (7), tb) {e) (2) Assembly ‘To assemble the inaster cylinder, reverse the steps of disassembly while paying attention to the following items : (a Thoroughly clean all parts with new brake fluid. Do not attempt to reassemble them dry. If the internal walls of cylinder assembly (1) or the surface of piston (3) show signs of wear, damage, or rust, replace the master cylinder assembly as an assembly. Check the edges of cups (4 and 5) for damage. If any, replace. ‘The oil inlet, exit and bypass ports must be open. Clean them by passing through a wire, etc.5, BLEEDING AIR FROM SWING BRAKE Air trapped in the swing brake piping lowers the braking force. To bleed air from the swing brake, follow the same steps as for the winch brake. (a) Drive the crane to level, solid ground, pull the swing brake lever, and raise the boom. ‘Thereafter, connect one end of a vinyl hose to the bleeder screw of the swing reduction unit, and submerge the other end of the hose in a container containing a small amount of hydraulic oil. (b) Operate the swing brake lever several times, and the with the lever pulled back fully, loosen the bleeder screw, and hydraulic oil mixed with air bubbles will come out through the vinyl hose. (c) Tighten the bleeder screw, operate the swing brake lever again and loosen the bleeder screw. Repeat this procedure until no air bubbles appear. (a) After the swing brake has completely been bied, tighten the bleeder screw securely and disconnect the vinyl hose. (e) In the same manner, bleed air from the master cylinder too, then check brake function. Fig.5-1 Bleeding Air from Swing Brake6. MAINTENANCE STANDARDS. oe 5 08 or Fig.6-1 Swing System 6.1 TIGHTENING TORQUE 03 01, SLEWING RING 02, SWING MOTOR (WITH REDUCTION UNIT) 03. PINION 04, RETAINER 07. CAPSCREW 08. LOCK WASHER 09. REAMER BOLT 10, WASHER 4. NUT 14, CAPSCREW 15, CAPSCREW 16. CAPSCREW Tightening Torque No, Name (with Locktite #242 or equivalent) (07 _| Swing pinion mounting capscrew 65 t07. Sham (7 to 7H) 14] Swing veduction unit mounting capscrew _ 26 to 3ke-m (188 to 231 Ibe) 15 _| Stewing ring (inner race) mounting en 1 97 to 1i9ha-m (701 to 880K) 09 _| Slewing ring (outer race) mounting reamer bolt 97 to 1194a-m (701 to BBOKLLe) Slewing ring (outer race) mounting eapserew 97 to 119kg-1 (701 to BANAL)6.2 GEARS AND SPLINES Name Serviceabe iit ‘Slewing ring gear ‘No unusual wear, pitting andiniary ‘Swing pinion ‘on the tooth surface. Other gears Fitting clearance (0.1m (0.004inch) 6.3 BEARINGS ‘Name Serviceable init Play of inner race and outer race of slewing ting | (03en(0.012inch) Other bearings [No wear pitting and injury6.2 GEARS AND SPLINES Name Serviceabe iit ‘Slewing ring gear ‘No unusual wear, pitting andiniary ‘Swing pinion ‘on the tooth surface. Other gears Fitting clearance (0.1m (0.004inch) 6.3 BEARINGS ‘Name Serviceable init Play of inner race and outer race of slewing ting | (03en(0.012inch) Other bearings [No wear pitting and injuryTROUBLE ' Swing inoperative. 7, TROUBLESHOOTING PROBABLE CAUSE Faulty swing motor [| Repair or replace assembly. ‘Malfunction of swing control valve Reliet valve malfunctioning | Repair or replace assembly ‘ Broken pion Paton a | Bearing failure Brokeaivesatt ly Check valve malfunctioning Reduction unit failure Gere oF pinion failure [-LRenait or reptace assembly. ‘Shalt or bearing failure Faulty brake lock Piston scizing Disc seizing or failed Faulty slewing ring Slewing ting gear failure Repair or replace assembly [Repair or repice assembly “Malfunction of magnetic proportional pressure reducing valve “Malfunction of swing stop valve Check electric wiring. L Repair or replace valve, it H H, Maifunction of pressure control valve | | Repair or replace valve. ‘Malfunction of magnetic proportional relief valve H—{ Wrong set pressure of relict valve Repair or replace valve. Low swing speed. LY check electie wiring, Excessively worn valve plate Faulty swing motor Excessively worn piston | —[ Repair or replace assembly, Excessively worn cylinder High hydraulic oi temperature Lower oil temperature Malfunction of magnetic proportional relief valve |—[ Highs nyarautic ot temperature Lower oil temperature ‘Malfonction of ewing control valve Incorrectly st relief valve pressure ‘Aalust, repair or repince. Faulty brake lock Dise releaco malfunctioning | [Repair or replace parts,« Excessive over-swing Faulty swing motor [Excessive wear throughout the motor leading toexcessive drain olime Repair or replace assembly Relief valve malfunctioning Repair or replace assembly. ‘Malfunction of swing control valve Soler valve failure Repair or replace, ‘Check valve malfunctioning Replace assombly Malfunction of stop valve ‘Malfunction of mantic proportional pressure reducing valve Abnormal noise while swingi ‘Malfunction of swing control valve [ Repair o repace. Alc inside motor casing Bleed out the ar, ‘Motor pats failure Repair oF replace Relief valve malfunctioning Repair or rplnce assembly Alin the valve Bleed out air, Beating failure Repair or replace ascerbly Fruity reduction wit Low level or deterioration of tubricant ‘Ad or change cl Lf Pinion fire Replace assembly. Dalia tela Dise signa || Remi orrepace, Faulty slewing ring Lack olan Lubricate, Swing fer impossible Solenoid valve malfunctioning Rept or replace, LL stop vaive maltntioning Rept or replace, “Malfunction of magnetic proportional pressure | —{ Repair o replace. ‘Malfunction of stop valve reducing valve ‘Malfunction of pressure control valve Repair or replace ‘Malfunction of magnetic proportional relief valve Tacorrective cet pressure ‘Adjust o replace.1, LOCATION OF BOOM SYSTEM COMPONENTS ‘TERMINOLOGY AND LOCATION OF MAIN COMPONENTS: AUXILIARY SHEAVE BOOM HOIST CYLINDER ‘TELESCOPE CYLINDERS ] MAIN HOOK BLOCK AUXILIARY HOOK BLOCK. MAIN CONTROL VALVE TORQUE ~ CONVERTER TORQUE CONVERTER [ai / Ei 8,2, CONSTRUCTION 2.1 BOOM TELESCOPING SYSTEM i y ‘operate them, such as two telescope cylinders, hose reels, (1) General construction and hydraulic units pilot check valves extend / retract selector valve and As shown in Fig. 2-1, the telescoping’ control valve. mechanism is composed of four boom sections from base to 4th, a 4th boom telescoping wire rope, and the hydraulic components that 4TH BOOM 3RD BOOM 3. 3RD BOOM TELESCOPE CYLINDER 4, 2ND BOOM, 5. BASE BOOM 6. 2ND BOOM TELESCOPE CYLINDER 7. 4TH BOOM RETRACTING WIRE ROPE 8. 4TH BOOM EXTENDING WIRE ROPE 9. SHEAVE (FOR EXTENDING) 18 + 10. SHEAVE : (FOR RETRACTING) -ElHh' | Fe} TOwINcH BI Key conrro. 11, FLOW CONTROL VALVE t (FOR BOOM HOIST) ob 12, BOOM HOIST CONTROL 5 VALVE 2 »_={ENTOADING VALVE 13, TELESCOPE CONTROL Cy VALVE M, TELESCOPE SBLECT I VALVE 0 i 17. HYDRAULIC On, TANK, 18, AUTOMATIC STOP SOLENOID VALVE 19. NO.1PUMP (FOR BOOM 15, HOSE REBL 16. RELIEF VALVE (FOR UNLOADING) , Holst, TELESCOPE, WINCH 2ND SPEED) as. 0. SWIVEL JOINT 21. PILOT CHECK VALVE 2. PORT RELIEF VALVE SERIE SMT CTOTT (FOR EXTENDING) 23, PORT RELIEF VALVE (FOR RETRACTING) L4+— x. ocoouer t 28. RETURN FILTER Fig.21 Boom Telescope System Pro 2-1

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