Truck Crane 1: GT-900XL

Publication No.
GT-900XL-1/S1(U)-2E
02
Truck Crane
Model GT-900XL-1
Applicable Serial No. 475376 --
Safety
Safety
Most accidents that occur during machine operation [NOTICE]
and maintenance are caused by failure to observe [NOTICE] indicates an important operational or
basic safety rules and precautions. Before operating maintenance procedure or condition, which, if not
strictly observed, can result in damage to machine
your machine or performing maintenance, read and
components or deteriorated machine performance.
become familiar with all the safety precautions and
recommendations given in this section. It is virtually impossible to anticipate every situation
Remember that failure to observe even a single pre- that might present a hazard. The safety precautions
caution could involve you and the people around the given in this manual and on the machine labels are
machine in a serious accident. not exhaustive.
Foreseeing potential dangers is vital for preventing It is important, therefore, to strictly follow the instruc-
accidents. All personnel working with the machine, tions in this manual and be sensitive to potential dan-
including the supervisor, machine operator and oiler, gers in order to prevent bodily injury and damage to
should be sensitive to potentially dangerous situations the machine.
and take the necessary measures to prevent Remember that your most important duty is to ensure
accidents. the safety of you, your co-workers and any other peo-
Safety precautions and recommendations are outlined ple in the area.
in this section and are also included in the operation
and maintenance instructions given in subsequent
sections. Warning labels are also provided on the
machine.
The cautionary instructions in this manual are identi-
fied as "DANGER", "WARNING", "CAUTION" or "NO-
TICE". These terms are defined as follows:
DANGER
DANGER indicates an imminently hazardous
situation, which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
a minor or moderate injury.
1 WA01-0041E
Safety
1. Fundamental cautions fatal accidents, as there is a possibility that the

vehicle loses its balance and falls down on a
Servicemen inexperienced in the units of this machine worker in a dismounting process of certain units.
should be cautious about safety operations. They
must acquire sufficient knowledge about the equip- 7.When the working is done on a team of more than
ment before dismounting and disassembling it. one person, make arrangements about
Before dismounting each component, a serviceman co-operation and communication between workers
should read this service manual thoroughly and find beforehand. Give a sign without fault and make
out the weight of the component, then lift it by proper sure that the sign has been transmitted to other
means. workers before starting the next operation.
The following are cautions to be observed all the time. 8.When it is inevitable to measure oil pressure,
rotational speed, and temperature for machine
1.Before starting repairs, find out the origin of the
inspection without stopping the engine, be careful
problem. When it becomes clear that
not to be caught or pinched in rotating or moving
disassembly and maintenance are necessary, first
parts such as a fan, fan belt. Make sure that
of all read this manual and parts catalog and
there is no obstruction or no person around the
thoroughly understand the principle of operation
machine before operating it.
and construction. Then carefully check and
examine each portion. Don't disassemble
portions unrelated to the problem. Unless taking
all possible measures before starting disassembly, 2. Cautions in working
new troubles or decline in performance may be
induced. 2.1 General
2.Before operating the machine, oiling or repairing, 1.When hoisting up components weighing more than
read warning labels and instructions on the 20 kg, use hoist or the like to prevent injury to your
machine and understand the contents. lumbar or spine. For specific components, their
weights are listed on the chapter for "service data"
3.Wear a safety helmet and safety shoes whenever
in this manual.
you carry out maintenance operation around the
machine. Be sure to wear safety goggles when 2. When using eyebolts, lift parts vertically so that
you hit the machine or its attachments with a only tension is applied to them.
hammer. In welding operation, wear safety gears
such as leather gloves, helmet, goggles, apron 3.Protect wire ropes and plastic lifting slings by
and proper working clothes, but don't wear loose covering corners with pads so that they are not
or torn clothes. Take a ring and so on off your bent sharply by directly contacting corners.
finger when you conduct maintenance or repair. Keep the sling angle of wire ropes within 60qand
as vertical as possible.
4.Park the machine on as level and hard ground as
possible. Place chocks under wheels to prevent 4.Be careful about hot or heated portions when
the vehicle from moving when doing maintenance conducting repair or maintenance just after the
on or below the machine. vehicle has stopped or the machine operation has
been finished or interrupted.
5.Before starting maintenance, remove cables to the
battery and allow the capacitors to discharge. 5.When hitting parts, be sure to either hit on a pad
Pull out the ignition key and hang a tag saying, placed on the parts or use a plastic hammer.
"Don't start the engine." in the cab.
6.Put units, especially similar parts, in order. Mark
6.Don't carry out maintenance while lifting the them with tags or marker if necessary.
vehicle with only a jack or a hoist. Sustain the
vehicle positively with blocks and so on to prevent
2 WA01-0041E
Safety
7.Put disassembled parts in order so that parts such In case that the position of the center of gravity is
as bolts are not left behind in the machine. And not clear and there is a possibility of swing of load
check that no parts run short at assembly. after removing, use two hoists.
8.Watch your step in the following cases: 8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
When stepping up to or stepping down from the
hinder removing.
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble 2.3 Remounting & assembling
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder 1.Before assembling, clean all the parts and repair
When checking engine oil, radiator coolant, or or replace defective parts.
battery fluid.
2.As dirt and soil adversely affect sliding portions
When replacing a filter of air cleaner
and they may decrease the life of the machine,
When getting on and off the cab
pay special attention to avoid intrusion of dirt and
Be careful not to slip in the above operations in soil.
winter as snow and ice may attach to the exterior
3.Use special tools for parts when specified to do so.
of boom and it becomes very slippery.
4.Remove dirt, soil, water, and resin completely from
2.2 Dismounting & disassembling surfaces where liquid gasket will be applied.
1.Before dismounting and disassembling, make sure 5.After remounting, be sure to inspect the machine
of the construction and part sales unit by reading and verify that there is no error by oversight. If
this manual and the separate parts catalog, then adjustment or air bleeding is required, conduct it
understand the procedures of dismounting & according to instructions. Conduct function and
remounting and disassembling & reassembling. performance test to verify its integrity.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging 3. Cautions in operation
the confined pressure.
3.Before removing, clean the part to be dismounted 3.1 Brake fluid replenishment
and the area surround it. Seal the opening with a
1.When the brake-warning lamp (for fluid level) is
plug or tape, etc. to prevent foreign material from
lighted, replenish brake fluid and check and make
entering it.
sure of the thickness of disk brake pads. (Refer
4.Measure and record the data such as shim to Chapter Y for periodical inspection periods.)
thickness adjustment and pre-load at disassembly
2.Check the thickness of disk brake pads whenever
that will be required at reassembly.
brake fluid is replenished.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling. 3.2 Handling of battery
6.If a part cannot be removed after removing bolts or 1.Erroneous handling of a battery may cause it to
nuts fixing it, don't apply too much force to it but catch fire and explode.
check the part for the cause. Only after relieving Be extremely sure to avoid short circuits, sparks
the cause, proceed disassembling. and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
7.Use lifting slings appropriate for the weight and Charge up batteries and use them only in well
characteristics of a part. Lift up it in balanced ventilated places.
condition.
3 WA01-0041E
Safety
2.Battery fluid (dilute sulfuric acid) may cause loss of 4.1 Gasoline
sight or burn injury.
1.Spill or leak: Review fire and explosion hazards
If battery fluid stains an eye, skin, or clothes,
before proceeding with clean up. Use appropriate
immediately wash down them with a great deal
personal protective equipment during clean up.
of water.
Dike spill. Prevent liquid from entering sewers,
If battery fluid enters into an eye, immediately
waterways, or low areas. Soak up with sawdust,
wash it down with water and see a doctor for
sand, oil dry or other absorbent material. Shovel or
medical aid.
sweep up.
3.When removing terminals, remove the minus (㧙)
2.Remove source of heat, sparks, flame, impact,
terminal first. When connecting terminals,
friction or electricity including internal combustion
connect minus (㧙) terminal last.
engines and power tools. If equipment is used for
spill cleanup, it must be explosion proof and
3.3 Handling of radiator
suitable for flammable liquid and vapor.
1.Don't open the radiator cap while the coolant is still
Note: Vapors released from the spill may create an
hot.
explosive atmosphere.
2.Check the coolant at the reservoir tank.
3.Waste disposal method: Treatment, storage,
3.If high-pressure water is used for radiator cleaning, transportation and disposal must be in accordance
fins may be damaged. with applicable federal, state, provincial, and local
regulations. Do not flush to surface water or
3.4 Cooling fan sanitary sewer system.
1.Stop the engine completely before checking the 4.By itself, the liquid is expected to be a RCRA
tension of the engine fan belt. ignitable hazardous waste.
2.The oil cooler fan may rotate the moment the

4.2 Hydraulic oil
engine is started. Be sure to pull out the ignition
key before accessing the cooling fan. 1.Spill of leak: Contain spill immediately in smallest
area possible. Recover as much of the product
itself as possible by such methods as vacuuming,
4. About waste disposal followed by soaking up of residual fluids by use of
absorbent materials. Remove contaminated items
1.Waste oils, used filters, and other such
including contaminated soil and place in proper
petrochemical-related products, if disposed of
containers for disposal. Avoid washing, draining or
thoughtlessly, will cause environmental
directing material to storm or sanitary sewers.
contamination.
2.Waste disposal method: Recycle as much of the
2.Obtain a proper-sized vessel before releasing
recoverable product as possible. Dispose of
waste oils from the machine. Never discharge
nonrecyclable material as a RCRA hazardous
waste oils on the ground or into rivers, lakes or
waste by such methods as incineration, complying
marshes.
with federal, state, and local regulations.
3.Follow all governing environmental rules and
regulations when disposing of oils, fuels, cooling 4.3 Motor oil
water, brake fluid, solvents, filters, batteries or any See HYDRAULIC OIL above.
other damaging substances.
4 WA01-0041E
Foreword
Foreword
This service manual describes the composition of the Model GT-900XL-1 truck crane, its repair, check and
adjustment methods and other relevant matters. Note that this service manual does not provide the information
in the separate service manuals given below.
This service manual applies to the cranes with the specification numbers given below. Check the specification
number on the nameplate of your crane.
Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.
1. Applicable spec. NO.
SPEC. NO. SERIAL. NO.
MFG.DATE㪅
KAGAWA, JAPAN
ISA04-001601

Spec. No. Applicable serial No.
GT-900-1-90102 475376 --
2. Separate service manual

Separate Service Manual Publication No.
General Cautions SA01-01-2E
Load Moment Indicator (AML-L C ) W301-0139E
Please note that, for product improvement, some changes may have been
incorporated in the machine that are not covered in this manual.
1 WA04-2281E
Foreword
3. Outline of specifications
Spec. No.
Item GT-900-1-90102
2M2D
(North America)
No. of boom sections 5
No. of jib stages 2
Single top Option
Main winch Fitted
Auxiliary winch Fitted

Winch
Winch brake Automatic brake (Neutral brake)
Drum rotation indicator Touch-type (Option)
Weight Counterweight Removable type
Load moment indicator lamp AML- L C
Auto. stop solenoid valve energizing type Normally energized
AML external indicator lamp Fitted
Oil cooler Fitted
Air conditioner Option
Carrier model FAUN / KF90-4
Carrier type Left hand steering, 8×4
Engine model Mercedes - Benz OM460LA
2 WA04-2281E
Foreword
4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’
-1 -3 -2
1 1×10 1×10 3.93701×10 3.28084×10-3
1×10 1 1×10-2 3.93701×10-1 3.28084×10-2
1×103 1×102 1 3.93701×10 3.28084
-2
2.54×10 2.54 2.54×10 1 8.33333×10-2
3.048×102 3.048×10 3.048×10-1 1.2×10 1
mile, mi kilometer, km
1 1.60934
-1
6.21373×10 1
Area
square millimeter, mm2 square centimeter, cm2 square meter, m2 square inch, in2 square foot, ft2
1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5
1×102 1 1×10-4 1.55×10-1 1.07639×10-3
1×106 1×104 1 1.55×103 1.07639×10
2 -4
6.4516×10 6.4516 6.4516×10 1 6.94444×10-3
9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1
Volume
cubic centimeter,
cm3, cc cubic meter, m3 cubic inch, in3 cubic foot, ft3
1 1×10-6 6.10237×10-2 3.53147×10-5
1×106 1 6.10237×104 3.53147×10
-5
1.63871×10 1.63871×10 1 5.78704×10-4
2.83168×104 2.83168×10-2 1.728×103 1
gallon, gal cubic inch, in3 liter, lit, L

2
1 2.31×10 3.78541
-3
4.329×10 1 1.63871×10-2
2.64172×10-1 6.10237×10 1
Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
-3 -2 -3 -6
1 1×10 3.5274×10 2.20462×10 1×10 1.10231×10-6
1×103 1 3.5274×10 2.20462 1×10-3 1.10231×10-3
2.83495×10 2.8349×10-2 1 6.25×10-2 2.83495×10-5 3.12494×10-5
4.53592×102 4.53592×10-1 1.6×10 1 4.53592×10-4 5×10-4
1×106 1×103 3.5274×104 2.20462×103 1 1.10231
5 2 4 3 -1
9.07185×10 9.07185×10 3.2×10 2×10 9.07185×10 1
3 WA04-2281E
Foreword
Pressure
Pa kPa MPa kgf/cm2 lbf/in2, psi
1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4
1×103 1 1×10-3 1.01972×10-2 1.45038×10-1
1×106 1×103 1 1.01972×10 1.45038×102
9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10
3 -3 -2
6.89476×10 6.89476 6.89476×10 7.03072×10 1
bar MPa kgf/cm2

1 1×10-1 1.01972
1×10 1 1.0972×10
-1 -2
9.80665×10 9.80655×10 1
Torque
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
in-lbf
1 1×10-2 1.01972×10-1 1.01972×10-3 7.37562×10-3 8.85074×10-2
1×102 1 1.01972×10 1.01972×10-1 7.37562×10-1 8.85074
-2 -2 -2
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10-1
9.80665×102 9.80665 1×102 1 7.23301 8.67961×10
2 -1
1.35582×10 1.35582 1.38255×10 1.38255×10 1 1.2×10
-1 -2 -2
1.12985×10 1.12985×10 1.152513 1.15213×10 8.33333×10 1
N-m kgf-m ft-lbf

-1
1 1.01972×10 7.37562×10-1
9.80665 1 7.23301
-1
1.35582 1.38255×10 1
Centigrade-Fahrenheit
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78
-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33
o
Conversion equation: t°C=5(T F-32)/9, T°F=(9t°C+160)/5
Force
N kgf lbf
-1
1 1.01972×10 2.24809×10-1
9.80665 1 2.20462
-1
4.44822 4.53592×10 1
4 WA04-2281E
5. GROUP INDEX
B Hydraulic Power Generating System
D Swing System
E Boom Elevating System
F Winch System
G Boom Telescoping System
H Safety System
K Cab
L Control System
Y Data, Adjustment and Checks
Z System Diagrams
5 WA04-2281E
Foreword
6. Contents
Spec. No.
Chapter Section GT-900-1-90102
2M2D
(Noth America)
General
General Cautions Refer to separate service manual SA01-01-2E

A
Hydraulic Power Generating System
Hydraulic Power Generating System B-1
Hydraulic Pump B-2
Flow Control Valve B-3
Rotary Joint B-4
Hydraulic Pilot Control Valve

B-5
(Elevating, Telescoping, Winch)
Sequence Valve (Pilot Pressure) B-6
Solenoid Valve (Pilot Pressure) B-7
Solenoid Control Valve (Jib Set and

B-8
Counterweight Cylinder)
B Pilot Check Valve (Jib Set) B-9
Solenoid Valve (Oil Cooler) B-10
Hydraulic Motor (Oil Cooler) B-11
Jib Lock pin B-12
Jib Offset Cylinder B-13
Counterweight Cylinder B-14
Pilot Check Valve B-15
Relief Valve B-16
Check Valve (Gauge Isolator) B-17
6 WA04-2281E
Foreword
Spec. No.
2M2D
(Noth America)
Swing System
Swing System D-1
Swing Assembly D-2
Hydraulic Pilot Control Valve (Swing) D-3

D
Hydraulic Motor (Swing) D-4
Swing Speed Reducer D-5
Select Valve (Dolly) D-6
Boom Elevating System
Elevating System E-1
Elevating Cylinder E-2
E Counterbalance Valve (Elevating) E-3
Select Valve (Dolly) E-4
Winch system
Winch System F-1
Winch F-2
Hydraulic Motor (Winch) F-3

F
Counterbalance Valve (Winch) F-4
Hydraulic Valve (Winch Brake Release) F-5
7 WA04-2281E
Foreword
Spec. No.
2M2D
(Noth America)
Boom Telescoping system
Telescoping System G-1
Boom (Five-Section Boom) G-2
Jib G-3
G Telescoping Cylinder G-4
Counterbalance Valve (Telescoping) G-5
Hose Reel G-6
Hydraulic Valve G-7
Safety System
Safety System H-1
Load Moment Indicator (AML-L C ) Refer to separate service manual W301-0139E
Boom Length and Angle Detector H-2

H
Outrigger Extension Length Detector H-3
Solenoid Valve (Auto Stop) H-4
Cab
Crane Cab Glass K-1
Air Conditioner (Option) K-2
K Hydraulic Motor (Air conditioner, Option) K-3
Solenoid Valve (Air conditioner, Option)

K-4
(--475376)
Solenoid Valve (Air conditioner, Option)
K-5
(475377--)
8 WA04-2281E
Foreword
Spec. No.
2M2D
(Noth America)
Control System
Control System L-1
Remote Control Valve (Lever) L-2
Remote Control Valve (Pedal) L-3
L Shuttle Valve (Lever, Pedal) L-4
Solenoid Valve
L-5
(Boom Telescoping/Aux. Hoist)
Solenoid Control Relief Valve
L-6
(Elevating Slow Stop)
Data, Adjustment and Checks
Hydraulic Pressure Setting Table Y-1
Air Bleeding Procedure Y-2
Electric Switch Adjustment Y-3
Check (Crane Operation) Y-4
Adjustment and Checks Y-5
Oil and Grease Table Y-6

Y
Mass Table Y-7
Boom Connecting Pin and Thread Size

Y-8
Table
9 WA04-2281E
Foreword
Spec. No.
2M2D
(Noth America)
System Diagrams
Hydraulic Circuit Z-1
Electric Circuit Z-2
Electric Circuit
Z-3
(Outrigger Operation, Option)
Location of Installation
Location of Hydraulic Parts Z-4
Location of Electric Parts (Upper) Z-5
Location of Electric Parts (Lower) Z-6
Location of Electric Parts

Z-7
(Outrigger Operation, Option)
Hydraulic, Electric, Carrier Equipment
Z-8
Comparison Table
Z
Harness Diagrams
Harness (Inside Cab) Z-9
Harness (Swing Table, Left) Z-10
Harness (Swing Table, Right) Z-11
Harness (Boom) Z-12
Harness (AML, Upper) Z-13
Harness (Overwind) Z-14
Harness (Lower) Z-15
Harness (Outrigger Operation, Option) Z-16
10 WA04-2281E
B B
Contents
B-1 Hydraulic Power B-5 Hydraulic Pilot Control Valve

Generating System.................. 1 (Emergency Telescoping,
Winch).....................................21
1. Functions of units....................................... 1
1.1 Hydraulic pump........................................... 1 1. Structure .................................................. 21
1.2 Rotary joint ................................................. 1
1.3 Hydraulic pilot control valve........................ 1
1.4 Sequence valve .......................................... 1 B-6 Sequence Valve (Pilot Pressure) ..33
1.5 Flow control valve....................................... 1
1.6 Solenoid valve (for venting pressure for 1. Structure .................................................. 33
remote control) ..................................... 1
1.7 Hydraulic motor (for oil cooler) ................... 1
1.8 Solenoid valve (for oil cooler) ..................... 1 B-7 Solenoid Valve
(Pilot Pressure) ......................36
B-2 Hydraulic Pump................................ 2 1. Structure .................................................. 36
1. Structure .................................................... 2
1.1 General view............................................... 2 B-8 Solenoid Control Valve
1.2 Inside view.................................................. 3 (Jib Set and Counterweight
1.3 Pump Mounting ........................................ 12 Cylinder) .................................38
1. Structure .................................................. 38
B-3 Flow Control Valve......................... 13
1. Structure .................................................. 13 B-9 Pilot Check Valve (Jib Set) ............44
1. Structure .................................................. 44
B-4 Rotary Joint .................................... 14
1. Structure .................................................. 14
2. Potentiometer .......................................... 20
2.1 Adjustment................................................ 20
2.2 Soldering .................................................. 20
i
B-10 Solenoid Valve (Oil Cooler) ........... 45
1. Structure .................................................. 45
B-11 Hydraulic Motor (Oil Cooler) ......... 47
1. Structure .................................................. 47
2. Air bleeding procedure............................. 47
B-12 Jib Lock Pin.................................... 48
1. Structure .................................................. 48
B-13 Jib Offset Cylinder ......................... 49
1. Structure .................................................. 49
B-14 Counterweight Cylinder ................ 50
1. Structure .................................................. 50
B-15 Pilot Check Valve (Counterweight

Cylinder)................................. 51
1. Structure .................................................. 51
B-16 Relief Valve..................................... 52
1. Structure .................................................. 52
B-17 Check Valve (Gauge lsolator) ....... 53
1. Structure .................................................. 53
ii
B-1. B-1.
B-1 Hydraulic Power 1.6 Solenoid valve (for venting pressure for
Generating System remote control)
1. Functions of units It supplies and vents the pilot pressure for the
remote control. While the solenoid valve is
1.1 Hydraulic pump deenergized, the oil flow to the remote control
valve is shut off, making crane operation
This pump consists of double variable
impossible.
displacement piston pump and double gear pump.
Pump A1 is used for the winch circuit, pump A2 for
1.7 Hydraulic motor (for oil cooler)
the boom telescoping, boom elevation and winch
circuits, pump A3 for the swing circuit, and pump 1. If the crane is used under high load for a long time
A4 for the winch accumulater, remote control, in summer, the hydraulic oil temperature will rise,
swing brake release, jib setting, c/w leading to oil deterioration such as oxidation and
mounting/dismounting, oil cooler drive motor and reduced oil viscosity that can cause leaks in the
air conditioner (option) circuit. pump and motor and reduce volume capacity.
2. To prevent such troubles, the returned oil is

1.2 Rotary joint
force-cooled (while the motor is driven by the oil
The rotary joint allows pressurized oil from the delivered from the A4 pump).
hydraulic pump and current from the battery to be
sent to the swing table, and at the same time 1.8 Solenoid valve (for oil cooler)
allows operation of the accelerator from the swing
It serves to start/stop the hydraulic motor which
table.
drives hydraulic oil cooler. When the oil cooler is
functioning, it is energized and drives the
1.3 Hydraulic pilot control valve
hydraulic motor.
By moving the spool utilizing the external pilot
pressure from the remote control valve, it changes
the direction of the pressurized oil introduced from
the port P into the hydraulic cylinder or inlet/outlet
port of the hydraulic motor and controls the oil
flow by changing the displacement of the spool.
1.4 Sequence valve
1. This valve incorporates a sequence valve and a

reducing valve.
2. The reducing valve regulates the oil pressure

below the specified value; the sequence valve
regulates it above the specified value.
1.5 Flow control valve
This valve is installed on the A4 pump circuit and

ensures fixed amount oil flow to the hydraulic
motor for the air conditioner and oil cooler, as well
as prevents troubles caused by pulsation.
1 WB02-0271E
B-2 B-2
Hydraulic Pump
B-2 Hydraulic Pump

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1.1 General view Hydraulic Symbols
Symbol Name Size

A1, A2 Delivery port SAE11/4 (High pressure type)
A3, A4 Delivery port SAE1 (Standard type)
S1 Suction port SAE3 (Standard type)
S3, S4 Suction port SAE11/4 (Standard type)
X1, X2 Pilot port G1/4
L1, L2 Drain port G3/4
U1, U2 Air bleeding port G3/8 (Plug)
2 W101-0381E
B-2 B-2
Hydraulic Pump
1.2 Inside view
Variable displacement piston pump
3 W101-0381E
B-2 B-2
Hydraulic Pump
1.Control section (C.W. rotation) 9.shaft section (front) 17.--- 25.Plug

2.Control section (C.C.W rotation) 10.shaft section (rear) 18.O-ring 26.O-ring
3.Port plate section 11.Pump housing 19.O-ring 27.Hexagon socket head bolt
4.Rotary section (C.W. rotation) 12.Pump housing 20.O-ring 28.Adapter ring
5.Rotary section (C.C.W rotation) 13.Cover 21.--- 29.Coupling
6.Piston section 14.Coupling 22.--- 30.Gear pump
7.Hanger section (C.W rotation) 15.--- 23.Hexagon socket head bolt 40.Elbow joint
8.Hanger section (C.C.W right rotation) 16.--- 24.Plug
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m kgf-m ft-lbf
T2 G3/4 212 - 282 21.6 - 28.8 156.4 - 208
T3 G3/8 62 - 82 6.3 - 8.4 45.7 - 60.5
T4 (*1) - 12 - 15 1.2 - 1.5 8.8 - 11
T5 M8 28 - 35 2.9 - 3.6 20.6 - 25.8
T6 - 56 - 70 5.7 - 7.1 41.3 - 51.6
T7 M8 28 - 35 2.9 - 3.6 20.6 - 25.8
T8 M16 230 - 270 23.5 - 27.5 169.6 - 199.1
T9 (*2) - 126 - 157 12.8 - 16 93 - 115.8
1. Be careful to the direction when installing 7. and 8. (Refer to the hanger section in
attached paper)
2. Be careful to the direction when installing 28.
(Install 28. so that the discharge ports of the variable displacement pump and gear
pump become same direction.)
3. Be careful to the falling when assembling 18.
(*1):Apply LOCTITE 241
(*2):Apply THREE BOND 1305
4 W101-0381E
B-2 B-2
Hydraulic Pump
Control Section 1, 2 (This view shows “C.W rotation”)
1.Regulator cover section 10.Adjust screw 18.Parallel pin 26.Nut

2.Body 11.Arm 19.O-ring 27.Plug
3.Guide 12.Spring 20.O-ring 28.Hexagon socket head bolt
4.Barrel 13.Spring 21.O-ring 29.Orifice
5.Spool 14.Spring 22.O-ring 30.Shim
6.Spring seat 15.Spring 23.O-ring 31.Shim
7.Spring seat 16.Parallel pin 24.Hexagon socket head bolt 32.Shim
9.Guide 17.Parallel pin 25.Hexagon socket head bolt
Tightening torque
N-m kgf-m ft-lbf
T1 M6 12 - 15 1.2 - 1.5 8.8 - 11
T2 M6 12 - 15 1.2 - 1.5 8.8 - 11
T3 M8 28 - 35 2.9 - 3.6 20.6 - 25.8
T4 M8 28 - 35 2.9 - 3.6 20.6 - 25.8
5 W101-0381E
B-2 B-2
Hydraulic Pump
Regulator cover section (Control section)
1.Cover 3.Plug 5.O-ring

2.Piston 4.Hexagon socket head bolt 6.O-ring
Tightening torque
N-m kgf-m ft-lbf
T1 M6 12 - 15 1.2 - 1.5 8.8 - 11
T2 M6 12 - 15 1.2 - 1.5 8.8 - 11
6 W101-0381E
B-2 B-2
Hydraulic Pump
Port plate section 3
1.Port plate 7.Hexagon socket head bolt 9.O-ring

6.Plug 8.Parallel pin 10.O-ring
Tightening torque
N-m kgf-m ft-lbf
T1 M16 230 - 270 23.5 - 27.5 169.6 - 199.1
Apply THREE BOND 1305 to the plug 5 (12 places)
7 W101-0381E
B-2 B-2
Hydraulic Pump
Rotary section 4, 5 Piston section 6
1.Piston 7.Spring 1.Piston 4.Piston

2.Cylinder block 9.Pressure pin 2.Cylinder 5.Spring
4.Retaining plate 10.V ring 3.Cylinder
6.Retaining ball 11.Backup plate
8 W101-0381E
B-2 B-2
Hydraulic Pump
Hanger section 7, 8
1.Joint (control piston) 2.Hanger 3.Metal 4.Orifice
9 W101-0381E
B-2 B-2
Hydraulic Pump
Shaft section 9 (front) Shaft section 10 (rear)
1.Shaft 6.Bearing 1.Shaft 4.Bearing

2.Seal case 7.Oil seal 2.Shim 5.Bearing
4.Shim 8.C-retaining ring
5.Bearing 9.O-ring
1. Apply the grease equivalent to MORITON

GREASE NO.2 (Product by “SUMICO”) to the lip
of oil seal 7.
10 W101-0381E
B-2 B-2
Hydraulic Pump
Gear pump 30
1.Frame 10.Side plate 19.C-retaining ring 28.Bolt

2.Body 11.Seal ring 20.Plain washer 29.Stud bolt
3.Body 12.Coupling 21.Plug 30.---
4.Case 13.Collar 22.Plain washer 31.Name plate
5.Gear 14.Bolt 23.Nut 32.---
6.Gear 15.Bearing 24.Parallel pin 33.---
7.Gear 16.Square ring 25.O-ring 34.---
8.Gear 17. ------ 26.Bolt 35.Metal
9.Side plate 18.O-ring 27.Spring washer 36.Bush
366-544-50000 ٌ
0
11 W101-0381E
B-2. B-2.
Hydraulic Pump
Applicable serial No. ٌ
4 㧦475402 - -
1.3 Pump Mounting
1. The drive power from P.T.O is transferred to the [NOTICE]

hydraulic pump by the propeller shaft. L: Installation dimension of propeller shaft
Standard .......................712 mm (28.0 in)
Maximum allowance .....690 mm (27.2 in)
Minimum allowance ......730 mm (28.7 in)
Tightening torque
N-m kgf-m ft-lbf
Bolt•1 M16 186 - 206 19 – 21 137.2 - 151.9
Bolt•2 M16 186 - 206 19 – 21 137.2 - 151.9
Bolt•3 M12 81 - 91 8.3 – 9.3 59.7 - 67.1
Bolt•4 M12 81 - 91 8.3 – 9.3 59.7 - 67.1
Bolt•5 (*1) M12 36 - 40 3.7 – 4.1 26.6 - 29.5
Bolt•6 M14 119 - 133 12.1 – 13.6 87.8 - 98.1
Nut•1 M14 59 - 67 6 – 6.8 43.5 - 49.4
(*1): Apply thread locking agent
338-207-00000 ٌ
4
12 W101-0381E
B-3. B-3.
Flow Control Valve
B-3 low Control Valve
[NOTICE]
1. Structure
PB
4
T
1
PA IW114-0130E02
2
PA
T 5
PB
6
IW114-0130E01 IW114-0130E03
1.Valve body 3.Spring 5.Plug 7.Relief valve assy

2.Spool 4.Plug 6.O-ring
Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
4, 5 - 80 - 110 8.2 - 11.2 59 - 81
7 - 120 - 160 12.2 - 16.3 88.5 - 118
PA G3/4 167 17 123
T, PB G1/2 98 10 72
366-104-20000 ٌ
0
13 W114-0133E
B-4 B-4
Rotary Joint
B-4 Rotary Joint Applicable serial No. ٌ

2 㧦437626 - -
475376 - -
[NOTICE]
1. Structure
14 W181-0303E
B-4 B-4
Rotary Joint
19
Upper (view A)
P2
W2 P2'
AC1
W1
11 GR2
DR
27 T'
FRONT
P1
P3
T1 T2
T'
P4
AC2
GR1
11
Tap for slinging (2 places)

(M10)
A
IW181-0300E02
Lower (view B)
15 W181-0303E
B-4 B-4
Rotary Joint
1.Slip ring assy 8.Core 15.Ring seal 22.Clamp

2.Plain bearing 9.Plain bearing 16.Bolt 23.Nut
3.Packing 10.Support 17.Flange bolt 24.Plate
4.Ring seal 11.Grease nipple 18.Plate 25.Hexagon socket head bolt
5.Body 12.Plain bearing 19.Plug 26.Ring seal
6.Core 13.Ring seal 20.Plate 27.Plug
7.Shaft 14.Packing 21.Flange bolt 2 28.O-ring
Thread Tightening torque

Sign / port
size N-m kgf-m ft-lbf
16 *1 M12 74 - 82 7.6 - 8.4 55 - 61
17 *1 (to secure the plate [18]) M8 11.8 – 13.7 1.2 - 1.4 9 - 10
21 *1 (to secure the slip ring assy [1]) M6 4.4 – 5.9 0.45 - 0.55 3.5 - 4
25 *1 M8 23.5 – 27.5 2.4 - 2.8 17 - 20
*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.
Hydraulic section
Tightening torque
N-m kgf-m ft-lbf
Upper
P1 Winch G1 196 20 145
Lower
Upper G1/4 29.4 3 22
P1’ Gauge
Lower - - - -
Upper
P2 Boom elevating, Boom telescoping G1 196 20 145
Lower
Upper G1/4 29.4 3 22
P2’ Gauge
Lower - - - -
Upper G3/4 167 17 123
P3 Swing
Lower G1 196 20 145
Upper
P4 Option G1/2 98 10 72
Lower
AC Upper RC3/8 49 - 69 5-7 36 - 51
Accelerator
1 Lower G3/8 49 5 36
AC Upper G1/2 98 10 72
Accelerator (Air bleeding)
2 Lower - - - -
Upper
T1 Tank - - - -
Lower
Upper G3/4 167 17 123
T2 Tank
Lower - - - -
Upper
DR Drain G1/2 98 10 72
Lower
L.L.C. section
Tightening torque
N-m kgf-m ft-lbf
Upper
W1 Heater (IN) Rc3/8 49 - 69 5-7 36 - 51
Lower
Upper
W2 Heater (OUT) Rc3/8 49 - 69 5-7 36 - 51
Lower
16 W181-0303E
B-4 B-4
Rotary Joint
Slip ring assy 21 22 20 31 28
31 C C
15
23
B
D D
24 19
7 30
A A
3 25
E E
2
B
IW181-0260E03
13
27 26
5
11
12
F F
10
B-B
IW181-0260E04 4
12
8
6
29
16,17
3
9 18
7 1
P
A-A IW181-0290E03
P IW181-0260E05
17 W181-0303E
B-4 B-4
Rotary Joint
36 14
E-E
IW181-0260E09
C-C
IW181-0260E07
25
24
23
32,33 F-F
D-D IW181-0260E10
IW181-0260E08
1.Shaft 10.BH+CB 19.O-ring 28.Hose band

2.Ring set plate 11.Spacer 20.Potentiometer 29.Hexagon socket set screw
3.Bearing 12.Spacer 21.Cover 30.Machine screw
4.Ring 13.BH+CB 22.Packing 31.Bolt
5.Ring 14.Support 23.Lever 32.Bolt
6.Ring set plate 15.Base 24.Pin 33.Spring washer
7.U nut 16.Dry lock nut 25.Guide 36.Hexagon socket head bolt
8.Support 17.Coned disc spring 26.Air breather
9.Stud bolt 18.Guide 27.Hose joint
Tightening torque
N-m kgf-m ft-lbf
*1 *1
16 , T1 M6 4.9 0.5 3.6
31, 32, 36 M4 1.5 0.15 1.1
30 M3 0.63 0.064 0.5
*1㧦Apply LOCTITE 496 (strong quick-drying glue) to threaded sections.
18 W181-0303E
B-4 B-4
Rotary Joint
Wiring diagram
LOWER (Slip ring) UPPER (Brush holder)

G

W
R

3
2 B
2QV 1
B
3
2
2QV 1
Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y

Y Y
Y Y

Y Y

Y Y

Y Y

W W

W W

W W
%% %%
W W
&& &&
W W
## ##
W W
$$ $$
%QPPGEVQT Ring No.
Connector terminal No. 㧦 Silver-plating ring
Mark No. IW181-0290E04
19 W181-0303E
B-4. B-4.
Rotary Joint
2. Potentiometer 3. Turn the potentiometer shaft using a slotted

screwdriver so that the resistance between the
2.1 Adjustment upper terminals 1 and 2 is minimum between 1
ohm and 15 ohm. Leave the terminals (6 pieces)
1. Install the potentiometer as shown in the figure
of the potentiometer disconnected.
below. However, tighten the bolt for fixing the lever
lightly. (Do not fix the lever to the potentiometer
shaft because you must turn the potentiometer
shaft using the slotted screwdriver to adjust the
position of the shaft.)
3
Slotted screwdriver 2
1
Hexagon socket head bolt Potentiometer
Terminal 3
Terminal 2
Terminal 1
Potentiometer
Slotted screwdriver
Upper terminals 1, 2 and 3
Bolt (Tighten lightly.) Lever

IW181-0260E12
2. While keeping the stamp mark on the guide

oriented as shown in the figure below, adjust the
potentiometer as described in the following steps.
(If you adjust the potentiometer with the slip ring
assy installed on the crane, direct the boom Lower terminals 1, 2 and 3 IW181-0260E14
over-left to orient the stamp mark as shown in the
figure below.) 4. Remove the hexagon socket head bolts (4 pieces),
take out the potentiometer and fully tighten the
bolt for fixing the lever. Then install the
potentiometer and make sure that the resistance
between the upper terminals 1 and 2 is 15 ohm or
less.
Slip ring assy
2.2 Soldering
1. After finishing the potentiometer adjustment,

remove the hexagon socket head bolts (4 pieces)
and take out the potentiometer. Then solder the
wiring to the terminals (6 pieces).
2. To insulate the terminals (6 pieces) from one

another, coat the terminal section with epoxy
Stamp mark Guide adhesive (equivalent to 3M DP-420).
IW181-0260E13
346-306-92000 ٌ
2
346-307-62000 ٌ
2
20 W181-0303E
B-5 B-5
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
B-5 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

[NOTICE]
1. Structure
21 W134-0272E
B-5 B-5
C1 C2
Vent
Vent
(down) (down) (extending) (lowering)

b3,b4
b1 b2
b3 b4
B1 B2 T2 B3 B4
T1 P2 C3
A1 A2 A3 A4
a3 a4
a1 a2
a3,a4
Aux. winch Main winch Telescoping Elevating
(up) (up) (retracting) (raising)
P1
IW134-0270E02
22 W134-0272E
B-5 B-5
Tightening torque
N-m kgf-m ft-lbf
C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 3 22
A3,B3,A4,B4 G3/4 167 17 123
P1,P2,A1,B1,A2,B2 G1 196 20 145
23 W134-0272E
B-5 B-5
Cross section of whole body
B A
Aux. winch
Main winch
Telescoping
Elevating
B A
14 13
IW134-011012
24 W134-0272E
B-5 B-5
1
12
࡮
8
C C
Aux. winch
D D
Main winch
12
࡮
9
E E
2
F F
Telescoping
3
G G
Elevating
4 7 16
A-A IW134-0270E03
25 W134-0272E
B-5 B-5
Aux. winch
Main winch
Telescoping
Elevating
5 15 6
B-B
IW134-011004
1.Winch selector valve 5.O-ring 9.Main relief valve 15.Plug

2.Telescoping selector valve 6.O-ring 12.Hexagon socket head bolt 16.Eye bol
3.Elevating selector valve 7.Hexagon socket head bolt 13.Plug
4.End cover 8.Main relief valve 14.O-ring
Tightening torque
N-m kgf-m ft-lbf
7 M12 57 - 59 5.8 - 6 42 - 43
12 M10 44 - 49 4.5 - 5 32.5 - 36
13 G1/4 24.5 - 29.4 2.5 - 3 18 - 22
15 - 10 - 12 1 - 1.2 7-9
26 W134-0272E
B-5 B-5
Winch selector valve
6 2 4 20 19 21 22 1
Overload relief valve
25,24,23,13 9 8 12,23,24,25
7
11 10
30
29
18 17 15 28 27 26 28 14 16,17
C-C (Aux. winch) , D-D (Main winch) IW134-0270E04
1 Main relief valve
18 17 15 28 27 26 5 28 16,17
E-E IW134-0110E07
27 W134-0272E
B-5 B-5
1.Winch selector valve body 8.Return spring 16.Plug 23.Hexagon socket head bolt
2.Spool (main,aux. winch) 9.Return spring 17.O-ring 24.Plain washer
3.-------------------------------- 10.Spring seat 18.Spring retainer 25.Spring washer
4.Flow control valve 11.Spool end (flow control valve) 26.Plug
(main winch), (aux. winch) 12.Pilot cover 19.Check valve 27.O-ring
5.Flow control valve (junction) 13.Pilot cover 20.Spring (check valve) 28.Plug
6.O-ring 14.Orifice 21.Plug (check valve) 29.Steel ball
7.Spring seat 15.Spring (flow control valve) 22.O-ring 30.Hexagon socket set screw

Tightening torque
N-m kgf-m ft-lbf
M27×1.5 78 - 88 8-9 58 - 65
(Main winch), (Aux. winch)
11*1 - 18 - 20 1.8 - 2 13 - 14
2
14* M6 5-6 0.5 - 0.6 3.5 - 4.5
30*1 M8 12 - 14 1.2 - 1.4 8.5 - 10
16 M33 98 - 118 10 - 12 72 - 87
18 - 98 - 118 10 - 12 72 - 87
21 - 78.5 - 88.3 8-9 58 - 65
23 M8 27.5 - 29.4 2.8 - 3 20 - 22
26 G 3/8 39.2 - 49 4-5 29 - 36
28 - 10 - 12 1 - 1.2 7-9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
28 W134-0272E
B-5 B-5
Telescoping selector valve
5 4 29 30 2 3 22 21 23 24 1
11 10
27,26,25,13 7 8 9 12,25,26,27
6 19,20 18 17 28 14 16 15 19,20
F-F (Telescoping) IW134-0270E03
1.Telescoping selector valve 7.Spring seat 15.Plug (shuttle valve) 23.Plug (check valve)
body 8.Return spring 16.O-ring 24.O-ring
2.Spool (telescoping) 9.Return spring 17.Orifice 25.Hexagon socket head bolt
3.Flow control valve 10.Spring seat 18.Spring (flow control valve) 26.Plain washer
(telescoping) 11.Spool end 19.Plug 27.Spring washer
4.Steel ball 12.Pilot cover 20.O-ring 28.Plug
5.Hexagon socket set screw 13.Pilot cover 21.Check valve 29.Plug
6.O-ring 14.Steel ball 22.Spring (check valve) 30.O-ring

Tightening torque
N-m kgf-m ft-lbf
Overload relief valve (Telescoping) M27×1.5 77 - 88 8-9 58 - 65
1
5* M8 12 - 14 1.2 - 1.4 8.5 - 10
11*1 - 18 - 20 1.8 - 2 13 - 14
1
15* - 18 - 20 1.8 - 2 13 - 14
2
17* M6 5-6 0.5 - 0.6 3.5 - 4.5
19 M33 98 - 118 10 - 12 72 - 87
23 - 78.5 - 88.3 8-9 58 - 65
25 M8 27.5 - 29.4 2.8 - 3 20 - 22
28 - 10 - 12 1 - 1.2 7-9
29 G3/4 78.5 - 88.3 8-9 58 - 65
29 W134-0272E
B-5 B-5
Elevating selector valve

5 4 18 19 18 19 2 1
11 10
22,21,20,13 7 8 9 12,20,21,22
6 16,17 15 14 23 3 16,17
G-G (Elevating) IW134-0110E09
1.Elevating selector valve body 7.Spring seat 13.Pilot cover 19.O-ring

2.Spool (elevating) 8.Return spring 14.Orifice 20.Hexagon socket head bolt
3.Flow control valve (elevating) 9.Return spring 15.Spring (flow control valve) 21.Plain washer
4.Steel ball 10.Spring seat 16.Plug 22.Spring washer
5.Hexagon socket set screw 11.Spool end 17.O-ring 23.Plug
6.O-ring 12.Pilot cover 18.Plug

Tightening torque
N-m kgf-m ft-lbf
M27×1.5 78 - 88 8-9 58 - 65
㧔Elevating㧕
5*1 M8 12 - 14 1.2 - 1.4 8.5 - 10
11*1 - 18 - 20 1.8 - 2 13 - 14
2
14* M6 5-6 0.5 - 0.6 3.5 - 4.5
16 M33 98 - 118 10 - 12 72 - 87
18 G3/4 78.5 - 88.3 8-9 58 - 65
20 M8 27.5 - 29.4 2.8 - 3 20 - 22
23 - 10 - 12 1 - 1.2 7-9
30 W134-0272E
B-5 B-5
Main relief valve

(Main winch, Aux. winch), (Elevating, Telescoping)
20 19 14 13 12 11 10 9 8 7 6 3 2 1 5 4
15
16
17
18
IW134-011010
1.Socket 6.O-ring 11.Adjust screw 16.Valve

2.Valve 7.Packing 12.O-ring 17.Valve seat
3.Spring 8.Body 13.Nut 18.O-ring
4.O-ring 9.O-ring 14.Body 19.Seal lead
5.Backup ring 10.Cap nut 15.Spring 20.Tie up wire

Tightening torque
N-m kgf-m ft-lbf
1 - 28.4 - 30.4 2.9 - 3.1 21 - 22.4
10 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
13 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
14 - 38.2 - 40.2 3.9 - 4.1 28.2 - 29.6
31 W134-0272E
B-5. B-5.

(Main winch), (Aux. winch), (Elevating), (Telescoping)
14 11 12 13 10 8 9 6 7 5 4 2 3 1
16 15 T
IW134-011011
1.Socket 5.Valve seat 9.Valve 13.Nut

2.Valve 6.O-ring 10.Spring 14.Cap nut
3.O-ring 7.O-ring 11.Adjust screw 15.Tie up wire
4.Spring 8.Body 12.O-ring 16.Seal lead

Tightening torque
N-m kgf-m ft-lbf
1 - 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
8 M27×1.5 78.5 - 88.3 8-9 58 - 65
13 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
14 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
366-405-40000 ٌ
0
32 W134-0272E
B-6 B-6
Sequence Valve (Pilot Pressure)
B-6 Sequence Valve (Pilot Pressure)

[NOTICE]
1. Structure

Tightening torque
N-m kgf-m ft-lbf
P, V G1/2 58.5 - 68.6 6-7 43 - 51
Dr G3/8 39.2 - 49 4-5 29 - 36
Pi, G G1/4 24.5 - 29.4 2.5 - 3 18 - 22
33 W122-0114E
B-6 B-6
Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)
6
1.Body
2.Filter
3.Filter retainer 5
4.Back pressure regulating valve
5.Pressure reducing valve
6.Hexagon socket head bolt
7.Plug
8.O-ring
9.Plug 4
A-A 1 2 3
IW122-0112E01
Tightening torque
N-m kgf-m ft-lbf
3 G1/2 9.81 - 11.8 1 - 1.2 7.2 - 8.7
6 M6 9.81 - 10.8 1 – 1.1 7.2 - 8
Back pressure regulating valve

(illustrated as 4 in the cross section along the line A-A)
1 2 6 7 3 4 8 5
1.Spring cover
2.Stopper
3.Piston
4.Valve
5.Socket
6.Spring
7.O-ring
8.O-ring
IW122-011004
Tightening torque
N-m kgf-m ft-lbf
1 M24×1.5 58.8 – 68.6 6-7 43.4 – 50.6
34 W122-0114E
B-6. B-6.
Pressure reducing valve

(illustrated as 5 in the cross section along the line A-A)
7 9 1
11 10 8 6 3 5 12 2 13 4
IW122-011005
1.Body 5.Spring seat 9.O-ring 13.O-ring

2.Spool 6.Spring 10.Nut
3.O-ring 7.Adjust screw 11.Cap nut
4.Plug 8.Body 12.O-ring
366-038-80000 ٌ
0
366-060-30000 ٌ
0
35 W122-0114E
B-7 B-7
Solenoid Valve (Pilot Pressure)
B-7 Solenoid Valve (Pilot Pressure)
[NOTICE]
1. Structure
A2 A1
T
P
IW121-067001
701
Connector
IW121-0671E01
171
T
A2 A1
P
101.Casing
701.Solenoid valve (DC24V)
101 T1 IW121-067002

Tightening torque
N-m kgf-m ft-lbf
P,T,A1,A2 G1/4 34 - 38 3.5 - 3.9 25 - 28
171 M5 6-8 0.6 - 0.8 4.5 - 6
T1 M8 26 - 32 2.7 - 3.3 20 - 24
36 W121-0673E
B-7. B-7.
Solenoid Valve (Pilot Pressure)
Solenoid valve assy
31 1 326 324
P A T
312 361 362 363 861 801 802
IW121-067003
311.Spool 326.Retaining ring 363.O-ring 861. O-ring

312.Sleeve 361.O-ring 801.Solenoid valve
324.Spring 362.O-ring 802.Seal nut

Tightening torque
N-m kgf-m ft-lbf
802 M6 6.9 - 7.9 0.7 - 0.8 5.1 - 5.8
367-401-00000 ٌ
0
37 W121-0673E
B-8 B-8
Solenoid Control Valve (Jib Set and Counterweight Cylinder)
B-8 Solenoid Control Valve (Jib Set and Counterweight Cylinder)

[NOTICE]
1. Structure
C㨯O
A3
B3
A2
B2
P㨯P A1
B1
G P T
IW112-0240E01
38 W112-0242E
B-8 B-8
18.Name plate 27.Plug 31.Nut 33.Ball

21.Tigh rod 29.Hexagon socket head bolt 32.Rivet screw 38.O-ring
Tightening torque
N-m kgf-m ft-lbf
P, T G1/2 98 10 72
A1, B1, A2, B2, A3, B3, G3/8 49 5 36
C•O G1/2 98 10 72
P•P G1/4 29.4 3 22
39 W112-0242E
B-8 B-8
6.Collar 16 28 34 19 38 23 27 33
7.Spring folder
8.Plug
9.Spring 8
16.Solenoid 7
19.Body
20.Spring 22
22.Spring 25
6
23.Filter 44
25.Spool end 35
35
27.Plug
33
33.Ball
34.O-ring
35.O-ring
37.O-ring
38.O-ring
44.O-ring
35 33
35
28
37
8
9
33
16 34 19 38 27 23 20
A-A
IW112-0220E03
40 W112-0242E
B-8 B-8
14.Spool
15.Housing
17.Housing plunger
24.Housing 14
14
35.O-ring 35
43.O-ring
24
17
43
15
35
B-B IW112-0240E03
41 W112-0242E
B-8 B-8
C-C
IW112-0220E05
CO
D-D IW112-0220E06
42 W112-0242E
B-8. B-8.
Relief valve
39 11 13 5 36 42 12 2 41 1 40 10 4 30 3
IW112-0220E07
1.Spring 5.Spring 13.Poppet 40.O-ring

2.Needle valve 10.Housing 30.Screw 41.O-ring
3.Nut 11.Sleeve 36.O-ring 42.O-ring
4.Gasket 12.Sleeve 39.O-ring
366-404-20000 ٌ
0
43 W112-0242E
B-9. B-9.
Pilot Check Valve (Jib Set)
B-9 Pilot Check Valve (Jib Set)

[NOTICE]
1. Structure
B A
D C
IW115-027001
7 6 5 3 4
B A
D C
8 1 9 2 10 11
X-X IW115-027002
1.Body 4.Spring 7.Backup ring 10.O-ring

2.Sleeve 5.Piston 8.O-ring 11.Plug
3.Poppet 6.O-ring 9.O-ring 12.Plug
Tightening torque
Sign /port Thread size
N-m kgf-m ft-lbf
A,B,C,D G1/4 29.4 3 22
366-241-40000 ٌ
1
44 W115-0272E
B-10 B-10
Solenoid Valve (Oil Cooler)
B-10 Solenoid Valve (Oil Cooler)

[NOTICE]
1. Structure
4
b f
3
2
a
b f
1
P A
a T B
e T1
P
B
A
T
IW121-025001 IW121-025002
1.Solenoid valve assy 2.Body 3.Valve 4.Plug
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/2 98 10 72
T1 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
45 W121-0254E
B-10. B-10.
Solenoid valve assy
Connector
(+): Red
(-): Blue
IW121-0542E01
T1 3
A P B
T T
T2 12 9 1 15 8 7 11 2
IW121-025003
1.Body 7.Spring seat 11.Spring

2.Plug 8.Square ring 12.Solenoid (DC24V)
3.Spool 9.O-ring 15.Hexagon socket head bolt
Tightening torque
N-m kgf-m ft-lbf
2 - 44 - 49 4.5 - 5 32.5 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
366-457-50000 ٌ
1
46 W121-0254E
B-11. B-11.
B-11 Hydraulic Motor (Oil Cooler)

[NOTICE]
1. Structure
25 14 2 4 7 5 32 8 10 1 33 34 13
A,B
27 12 21 17 19 20 16 22 23 3
IW102-012001
1.Front case 8.Spherical pin 17.Needle bearing 23.Retaining ring

2.Rear case 10.Collar 19.Thrust roller bearing 25.Hexagon socket head bolt
3.Shaft 12.Spring 20.Thrust plate 27.O-ring
4.Cylinder block 13.Straight key 21.Hexagon socket head bolt 32.Piston assy
5.Piston retainer 14.Plain washer 22.Ball bearing 33.Seal plate
7.Spherical retainer 16.Oil seal 34.Flat head machine screw
Tightening torque
Sign /port Thread size
N-m kgf-m ft-lbf
A, B G3/8 64 6.5 47
D G1/4 40 4.1 30
21 M5 4-6 0.4 - 0.6 2.9 - 4.3
25 M8 34 - 39 3.5 - 4 25 - 29
34 M5 2-3 0.2 - 0.3 1.4 - 2.2
2. Air bleeding procedure 366-632-60000 ٌ

0
Refer to “Air Bleeding Procedure” in chapter Y. 366-631-10000 ٌ

0
366-631-20000 ٌ
0
47 W102-0123E
B-12. B-12.
Jib Lock Pin
1 㧦475392 - -
B-12 Jib Lock Pin

[NOTICE]
1. Structure
1.Spring pin 5.O-ring 9.Rod cover 13.Packing

ٌ
1 2.--- 6.Piston 10.Plain bearing 14.Backup ring
3.Plain bearing 7.Cylinder 11.O-ring 15.Dust seal
4.Ring seal 8.Rod 12.Damper ring
*1 : Face the notch or the lip toward the pressurized side.

*2 : Apply sealant equivalent to three bond 1104.
Tightening torque
N-m kgf-m ft-lbf
A, B G1/4 29.4 3 22
360-531-60001 ٌ
1
48 W180-0023E
B-13. B-13.
Jib Offset Cylinder
B-13 Jib Offset Cylinder

[NOTICE]
1. Structure
1.Cylinder 5.Plain bearing 9.O-ring 13.Plate

2.Split pin 6.O-ring 10.Damper ring 14.Dust seal
3.Nut 7.Rod 11.packing 15.---
4.Piston 8.Rod cover 12.Backup ring 16.Plain bearing
Tightening torque
N-m kgf-m ft-lbf
A, B G1/4 29.4 3 22
360-520-90000 ٌ
0
49 W180-0032E
B-14. B-14.
Counterweight Cylinder
B-14 Counterweight Cylinder
[NOTICE]
1. Structure
15
䋪2 䋪1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
IW180-0040E01
1.Cylinder 5.plain bearing 9.Plain bearing 13.Backup ring

2.Split pin 6.O-ring 10.O-ring 14.Dust seal
3.Nut 7.Rod 11.Damper ring 15.Orifice
4.Piston 8.Rod cover 12.Packing

*2 : Apply LOCTITE638 (Do not stick out the end face)
360-532-60000 ٌ
0
50 W180-0040E
B-15. B-15.
Pilot Check Valve (Counterweight Cylinder)
1 㧦475421 - -
B-15 Pilot Check Valve (Counterweight Cylinder)
[NOTICE]
1. Structure
A B
C D
IW115-023001
1.Body 4.Sleeve 7.Check valve 10.Plug

ٌ
1 2.O-ring Cap seal 5.O-ring 8.O-ring 11.O-ring
3.Piston 6.Backup ring 9.Spring ٌ12.Backup ring ---
1
Tightening torque
N-m kgf-m ft-lbf
A G1/4 29.4 3 22
B G1/4 29.4 3 22
366-242-30000 ٌ
1
51 W115-0045E
B-16. B-16.
Relief Valve
B-16 Relief Valve
[NOTICE]
1. Structure
T
P IW111-025001
Tightening torque
N-m kgf-m ft-lbf
P, T G3/8 49 5 36
T1 M24×1.5 69 - 88 7-9 51 - 65
366-047-70000 ٌ
0
52 W111-0301E
B-17. B-17.
Check Valve (Gauge Isolator)
B-17 Check Valve (Gauge lsolator)
[NOTICE]
1. Structure
Hydraulic symbols
P' S
P1 P2 P3 IW116-012001
Tightening torque Remark

N-m kgf-m ft-lbf
P1, P2, P3, P’ G 1/4 29.4 3 22
G 3/8 49.0 5 36
S
TT-300XL-1
M18×1.5 127 - 147 13 - 15 93 - 108
only
Mounting bolt M8 13 - 15 1.3 - 1.5 9.6 - 11.0
1.Body 3.Poppet 5.O-ring 7.Plug

2.Plug 4.Spring 6.Screw 8.O-ring
366-244-50000 ٌ
2
366-251-20000 ٌ
1
53 W116-0124E
D
Swing System D
Contents
D-1 Swing System................................... 1 D-6 Select Valve (Dolly) ........................15
1. Description of the units .............................. 1 1. Structure .................................................. 15

1.1 Swing drive unit .......................................... 1
1.2 Hydraulic pilot control valve........................ 1
1.3 Solenoid valve (swing free/lock selet) ........ 1
1.4 Select valve (dolly) ..................................... 1
D-2 Swing Assmbly ................................ 2
1. Structure .................................................... 2
2. Swing bearing mounting bolt ..................... 3

2.1 Bearing Inner ring bolts .............................. 3
2.2 Bearing outer ring bolts .............................. 4
D-3 Hydraulic Pilot Control Valve

(Swing) ..................................... 5
1. Structure .................................................... 5
D-4 Hydraulic Motor (Swing)................ 11
1. Structure .................................................. 11
D-5 Swing Speed Reducer ................... 13
1. Structure .................................................. 13
i
D-1. D-1.
Swing System
D-1 Swing System
1. Description of the units
1.1 Swing drive unit
1. A hydraulic motor with wet-type brake and the

double reduction planetary gear is integrated in
the unit. This unit converts the pressurized oil
delivered from the pump into the low-speed
high-torque turning force to employ it for driving
the swing structure.
1.2 Hydraulic pilot control valve
1. It shifts the flowing direction of the pressurized oil

by the pilot pressure in order to control the
rotating direction of the hydraulic swing motor.
2. The proportional valve provided for swing slow

stop stops the swing movement gradually.
1.3 Solenoid valve

(swing free/lock select)
1. When it is energized, it delivers the pressurized oil

to the brake cylinder of the swing drive unit to
release the swing brake.
1.4 Select valve (dolly)
1. To travel with a dolly hitched to the rear of the

carrier, it is required that the hydraulic circuits for
the boom elevating cylinder and swing motor be
free so that the boom can follow the movements
of the dolly while travelling.
1 WD02-0320E
D-2 D-2
Swing System
D-2 Swing Assembly

[NOTICE]
1. Structure
1.Bolt
2.Plain washer
[NOTICE]
Apply torque control agent to the threaded sections of the bolts.
Tightening torque
Sign/port Thread size
N-m kgf-m ft-lbf
1 M18 294 - 343 30 - 35 217 - 253
2 W514-0202E
D-2 D-2
Swing System
2. Swing bearing mounting bolt
2.1 Bearing Inner ring bolts
5 6 7 8 6,9
50mm (19.7in)
View A 1,2
A
"S" mark
3,4
Front
1.Pain washer
2.Bolt (L=180mm) 10
3.Plain washer
4.Bolt 3,4
5.Support
6.Nut
7.Bolt 1,2
8.End
9.Spring washer
10.Pin
IW514-0200E01
[NOTICE]
Install the bearing inner ring with the "S" mark
facing the front of the carrier.
Apply torque control agent to the threaded sections Thread Tightening torque
Sign/port
size
of the bolts. N-m kgf-m ft-lbf
Install the plain washer, orienting its chamfer on the 2
M30 1620 - 1810 165 - 185 1195 - 1335
internal periphery as shown below. (48 points)
4 M12 69 - 82 7 - 8.4 51 - 60
3 W514-0202E
D-2. D-2.
Swing Assembly
2.2 Bearing outer ring bolts Applicable serial No. ٌ

2 㧦545543 --
ٌ168
2
1.Bolt (L=160mm)
2.Bolt (L=190mm)
3.Plain washer (50points)
4.Nut (5points) D
5.Reamer bolt (L=185mm)
6.Plain washer (2points)
D 1
C
3
A
C
B 5
B 6
D
3
D B 4
A
4
3
FRONT
Swing table
3
C 2
3
D
IW514-0140E02
[NOTICE]
Apply torque control agent to the threaded sections
of the bolts.
Install the plain washer, orienting its chamfer on the Thread Tightening torque
Sign / port
size
internal periphery as shown below. N-m kgf-m ft-lbf
1
(42 points)
2
M27 1177 - 1275 120 - 130 868 - 940
(3 points)
5
(2 points)
343-007-20000 ٌ
1
338-502-20000 ٌ
3
342-312-50000 ٌ
0
4 W514-0202E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)
D-3 Hydraulic Pilot Control Valve (Swing)

[NOTICE]
1. Structure
(+):Red
(-):Blue
BM AM Sol.2
Sol.3
Sol.1 Dr
RV
Sol.4
P
G Pi1
Pb
Pa Pi2
Pa Pi2 Pi1 Pb
Pa' Pb'
IW134-0122E01
5 W134-0124E
D-3 D-3
Tightening torque
N-m kgf-m ft-lbf
P, R G1 200 - 240 20 - 24 145 - 174
AM, BM G3/4 150 - 180 15 - 18 108 - 130
G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 3.5 - 3.9 25 - 28
Dr G1/4 34 - 38 3.5 - 3.9 25 - 28
6 W134-0124E
D-3 D-3
Cross section
706 702 703
A B
Sol.3 BM AM Sol.2
Sol.1 Dr
RV
Sol.4
352
G Pi1 Pb
Pa Pi2
353
253 351
263
RB RA
B
152 701 701 151
A
IW134-012003
Enlarged view (Sol.1, Sol.4, RV)
BM AM
Sol.1 Dr
RV
Sol.4
G
IW134-012007
7 W134-0124E
D-3 D-3
Cross section along the line A-A C
Dr
C1
C2
R
C
152
414 413 401 450 412 411 415 151
A-A
IW134-012004
Cross section along the line B-B AM
152
644
643
642 CA2
641
661
RA
B-B
IW134-012005
8 W134-0124E
D-3 D-3
Cross section along the line C-C
261 561 511 521 551 101 152 201 243 242 222 261
Sol.3 Sol.2
231 211 212 234 235
C1
BM P AM
Pa Pb
Pi2 Pi1
CB1 CA1
221 252 251 241 552 562 522 512 R 251 252
C-C
IW134-012006
Enlarged view (Sol.2, Sol.3)
Sol.3 Sol.2
Pa Pb
Pi2 Pi1
IW134-012008
9 W134-0124E
D-3. D-3.
101.Casing 242.O-ring 401.Plug 552.Plug

151.Plug 243.O-ring 411.Plunger 561.O-ring
152.Plug 251.Orifice 412.Spring 562.O-ring
201.Spool 252.Plug 413.O-ring 641.Spring seat
211.Spacer bolt 253.Plug 414.Steel ball 642.Spring
212.Stopper 261.Solenoid 415.Stopper 643.Steel ball
221.Cover inverse-proportional 450.Air bleeder screw 644.Seat
222.Cover reducing valve 511.Poppet 661.O-ring
231.Spring seat 263.O-ring 512.Poppet 701.Relief valve
234.Spring 351.Hex. socket head bolt 521.Spring 702.Solenoid relief valve
235.Spring 352.Hex. socket head bolt 522.Spring 703.Relief valve
241.O-ring 353.Hex. socket head bolt 551.Cap 706.Solenoid valve (DC24V)
Tightening torque
Sing / port Thread size
N-m kgf-m ft-lbf
151 R1/4 20 - 24 2 - 2.4 14 - 17
152, 252 NPTF1/16 6-8 0.6 - 0.8 4.5 - 6
211 *1 M8 16 - 18 1.6 - 1.8 12 - 13
251 *1 M5 3.5 - 4.5 0.35 - 0.45 2.5 - 3.5
253 G1/4 34 - 38 3.5 - 3.9 25 - 28
261 M22 39 - 49 4-5 29 - 36
351, 352, 353 M6 10.5 - 13.5 1.05 - 1.35 8 - 10
401 M24 58 - 70 5.9 - 7.1 43 - 51
450 M10 14.5 - 17.5 1.45 - 1.75 10.5 - 12.5
551 M33 190 - 210 19 - 21 140 - 155
552 M24 120 - 140 12 - 14 88 - 103
641 G1/8 8 - 10 0.8 - 1 6-7
701 M30 110 - 130 11 - 13 81 - 96
702 M22 39 - 49 4-5 29 - 36
703 M27 69 - 79 7-8 51 - 58
706 M22 39 - 49 4-5 29 - 36
366-461-30000 ٌ
1
366-489-60000 ٌ
0
366-489-70000 ٌ
0
366-409-60000 ٌ
0
367-416-20000 ٌ
0
10 W134-0124E
D-4 D-4
Hydraulic Motor (Swing)
D-4 Hydraulic Motor (Swing)
[NOTICE]
1. Structure
DR PB
A B
IW102-050001
464 485
A- A
443 106 432 117 121 118 114 706 702 707 712 472 106 438 303 401
471 A(B) A
A
304
433
444 DR
101 DR
491
437
PB PB
301 113 124 122 123 116 111 742 743 131 451 IW102-050002
11 W102-0502E
D-4. D-4.
Hydraulic Motor (Swing)
101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring

106.Spacer 123.Guide plate 437.Iocking ring 491.Oil seal
111.Cylinder 124.Shoe plate 438.Iocking ring 702.Brake piston
113.Spherical bush 131.Valve plate 443.Roller bearing 706.O-ring
114.Cylinder spring 301.Casing 444.Roller bearing 707.O-ring
116.Push rod 303.Valve cover 451.Spring pin 712.Brake plate
117.Spacer 304.Font cover 464.Plug 742.Friction plate
118.Spacer 401.Hexagon socket head bolt 471.O-ring 743.Separator plate
121.Piston 432.Stop ring 472.O-ring
Tightening torque
N-m kgf-m ft-lbf
PB G1/4 36 3.7 26.6
A, B G3/4 167 17 123
DR G1/2 108 11 80
464 G1/4 36 3.7 26.6
401 M20 430 43.8 317
366-635-90000 ٌ
0
12 W102-0502E
D-5 D-5
Swing Speed Reducer
ٌ
2 㧦475394 - -
D-5 Swing Speed Reducer Applicable serial No. ٌ

1 㧦475377 - -
[NOTICE]
1. Structure
13 W511-0243E
D-5. D-5.
Swing Speed Reducer
[NOTICE]
Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer
bracket (19). ٌ 2 (2)
Inject SHELL ALBANIA S3 grease to the mating faces of the retainer (34) and the spacer (35).
Enclose SHELL ALBANIA S3 grease with the roller bearing (36) (3). ٌ 2
After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into
casing(4).
Apply lithium based grease to the inner circumference of oil seal(5).
The amount of the gear oil is approx. 1 gal (US). (3.8 L).
Do not disassemble the king pins (8), (27) nor spacer (13).
1.Spur gear 10.Bearing washer 19.Bracket 28.Sun gear

ٌ
1 2.Retainer ٌ 2 2. Retainer 11.Needle bearing 20.Bolt 29.Snap ring
ٌ
1 3.Roller bearing 12.Planetary gear 21.Spring washer 30.Bolt
4 Casing ٌ2 3. Roller bearing 13.Spacer 22.Snap ring 31.Seal washer
5.Oil seal 14.Carrier 23.Coupling 32.---
6.Ball bearing 15.Bearing washer 24.Planetary gear 33.---
7.Plug 16.Bolt 25.Needle bearing ٌ
1 34.Retainer ٌ 2
8.King pin 17.Spring washer 26.Bearing washer ٌ

1 35.Spacer ٌ 2
9.Carrier 18.Sun gear 27.King pin ٌ

1 36.Roller bearing ٌ
2
Tightening torque
N-m kgf-m ft-lbf
16 M10 49 5 36
20 M16 206 21 152
30 M10 24.5 2.5 18
Mounting bolt (*1) M18 294 - 343 30 - 35 217 - 253
*1: Apply torque control agent to threaded sections.
360-816-51000 ٌ
2
14 W511-0243E
D-6. D-6.
Select Valve (Dolly)
D-6 Select Valve (Dolly)
[NOTICE]
1. Structure
IW129-0120E02
1. Valve body 26. Lever 101. Bolt 125. Backup ring

3. Ball 36. Collar 105. Hexagon socket set screw 126A. O-ring
8. Valve seat 40. Support 106. Machine screw 126B. O-ring
10. Valve stem 46A. Name plate 109. Thrust washer 142. Rivet
14. Retainer 46B. Name plate 109. Plain washer 145. Pad lock
21. Pointer 46C. Name plate 116. Pin
366-381-10000 ٌ
0
15 W129-0120E
E
Boom Elevating System
E
Contents
E-1 Elevating System ............................. 1
1. Description of the units .............................. 1

1.1 Elevating cylinder ........................................... 1
1.2 Counterbalance valve .................................... 1
1.3 Select valve (dolly)......................................... 1
E-2 Elevating Cylinder............................ 2
1. Structure .................................................... 2
E-3 Counterbalance Valve(Elevating) ... 4
1. Structure .................................................... 4
2. Function ..................................................... 6
2.1 When control valve is at the
neutral position ..................................... 6
2.2 While actuator is being pushed up................. 6
2.3 While actuator descends................................ 6
E-4 Select Valve (Dolly).......................... 7
1. Structure .................................................... 7
i
E-1. E-1.
Elevating System
E-1 Elevating System
1. Description of the units
1.1 Elevating cylinder
1. The elavating cylinder serve to elevate the boom.
2. A pressure sensor is installed to input the value to

the AML for calculating load moment.
1.2 Counterbalance valve
1. This valve serves to prevent the cylinder piston

rod from pushed in by the load during boom
lowering to maintain the lowering speed at a level
determined by the oil entry flow rate to the
cylinder.
2. It also prevent the retraction of the piston rod

when the piping between it and the manual control
valve is broken.
1.3 Select valve (dolly)
1. To travel with a dolly hitched to the rear of the

carrier, it is required that the hydraulic circuits for
the boom elevating cylinder and swing motor be
free so that the boom can follow the movements
of the dolly while travellring.
1 WE02-0230E
E-2 E-2
Elevating Cylinder
E-2 Elevating Cylinder

[NOTICE]
1. Structure
33,34 32
22,23
30,31
G1/2
G3/4
20,21 41 26 42 24 25 28,29 26 27 28,29 22,23 19

22,23
44 43 22,23 37
IW155-0240E01
2 W155-0242E
E-2. E-2.
Elevating Cylinder
2 㧦475424 - -
1.Cylinder 12.Damper ring 23.O-ring 34.O-ring

ٌ
2 2.Spring pin --- 13.Packing 24.Pipe 35.Orifice
3.Plain bearing 14.Backup ring 25.Pipe 36.Grease nipple
4.Packing 15.Dust seal 26.T-fitting 37.Pipe
5.Backup ring 16.Retainer 27.Pipe 38.O-ring
6.Backup ring 17.Spring washer 28.Clamp assy 39.Head cover
7.O-ring 18.Bolt 29.Sleeve 40.Backup ring
8.Piston 19.Support 30.Bolt 41.Pipe
9.Rod assy 20.Fitting 31.Spring washer 42.Pipe
10.Rod cover assy 21.O-ring 32.Counter balance valve assy43.Select valve assy
11.O-ring 22.Fitting 33.Fitting 44.Hexagon socket head bolt
ٌ
2 45.Set screw
*1: Face the notch or the lip toward the pressurized side.
*2: Apply Three-bond 1401 or equivalent.
*3: Apply Three-bond 1104 or equivalent.
*4: Apply KONISHI car body sealer or equivalent (waterproof), however it is not possible to paint on the rubber
side of dust seal.
ٌ
2 *5: After tightened, punching (2 places).
Tightening torque
N-m kgf-m ft-lbf
A G3/4 108 - 123 11 - 12.5 80 - 90
B G1/2 54 - 64 5.5 - 6.5 40 - 47
C, D G3/8 25 - 30 2.5 - 3 18.5 - 22
30 M8 23.5 – 27.4 2.4 – 2.8 17 - 20
45 M8 13.2 - 16.2 1.35 - 1.65 9.7 –11.9
360-267-90000 ٌ
2
3 W155-0242E
E-3 E-3
Counterbalance Valve (Elevating)
E-3 Counterbalance Valve (Elevating)

[NOTICE]
1. Structure
B
P.P
A
IW119-021001
7 6 5 4 2-6 2-5 2-3 2-4 2-9 1 2-10 2-2 2-1 2-16 2-15
P.P B
2-8 2-7
2-11 2-12 2-13 2-14
3-7
3-8 3-5
3-6 3-4
3-1 3-2 A 3-3
IW119-021002
1.Valve block 2-8.Backup ring 2-16.O-ring 3-8.O-ring

2-1.Valve seat 2-9.Spool 3-1.Valve seat 4.Orifice
2-2.O-ring 2-10.Orifice 3-2.O-ring 5.Filter element
2-3.O-ring 2-11.Steel ball 3-3.O-ring 6.Snap ring
2-4.Backup ring 2-12.Spring 3-4.Backup ring 7.Stopper
2-5.O-ring 2-13.Holder 3-5.Poppet
2-6.Backup ring 2-14.Spring 3-6.Spring
2-7.O-ring 2-15.Cap 3-7.Cap
4 W119-0213E
E-3 E-3
Tightening torque
N-m kgf-m ft-lbf
A G3/4 167 17 123
P.P G3/8 49 5 36
2-1 - 177 - 196 18 - 20 130 - 145
2-15 - 127 - 147 13 - 15 94 - 108
3-1 - 108 - 127 11 - 13 80 - 94
3-7 - 59 - 78 6-8 43 - 58
Mounting bolt M8 23.5 - 27.4 2.4 - 2.8 17 - 20
5 W119-0213E
E-3. E-3.
2. Function
a
P.P B
b
A
IW119-021003
This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the pilot spool to move the main
2.1 When control valve is at the neutral position spool.
The actuator holding pressure is sealed by seat 2. Consequently, the holding hydraulic pressure in
“a” of the main spool and seat “b” of the check port B is vented to port A.
valve.
3. At this time, the main spool motion is smoothened
2.2 While actuator is being pushed up by orifices.
1. The pressurized oil entering through port A of the

control valve enters chamber C, flows out through
port B by opening the check valve, and enters the
holding side of the actuator.
2. At this time, since port PP is connected to the tank

circuit, the main spool is kept forced to the valve
body by the spring, and remains inactive.
366-051-70000 ٌ
2
6 W119-0213E
E-4. E-4.
Select Valve (Dolly)
E-4 Select Valve (Dolly)

[NOTICE]
1. Structure
IW129-0120E02
1.Valve body 40.Support 105A. Hexagon socket set screw 125B. Backup ring
2.Cover 46A. Name plate 105B. Hexagon socket set screw 126A. O-ring
3.Ball 46B. Name plate 106.Machin screw 126B. O-ring
9.Valve seat 46C. Name plate 109A. Thrust washer 126C. O-ring
10.Valve stem 60.Shim 109B. Plain washer 142.Rivet
13.Adapter 101.Bolt 116.Pin 145.Pad lock
21.Pointer 102A. Hexagon socket head bolt 118.Spring pin
26.Lever 102B. Hexagon socket head bolt 125A. Backup ring
366-381-20000 ٌ
2
7 W129-0131E
F
Winch System
FF
Contents
F-1 Winch System .................................. 1 F-5 Hydraulic Valve

(Winch Brake Release) ..........12
1. Description of the units .............................. 1
1.1 Hydraulic motor .......................................... 1 1. Structure .................................................. 12
1.2 Counterbalance valve................................. 1
1.3 Hydraulic valve ........................................... 1
1.4 Solenoid valve (telescoping/aux. hoist)...... 1
F-2 Winch ................................................ 2
1. Structure .................................................... 2
1.1 General view............................................... 2
1.2 Reducer assy.............................................. 4
F-3 Hydraulic Motor (Winch) ................. 6
1. Structure .................................................... 6
2. Air bleeding procedure............................... 8
F-4 Counterbalance Valve (Winch) ....... 9
1. Structure .................................................... 9
2. Function ................................................... 10
2.1 Balancing and holding functions............... 10
2.2 Overload relief function ............................ 10
3. Principle of operation ............................... 11

3.1 When control valve is in neutral ............... 11
3.2 Hoisting up................................................ 11
3.3 Hoisting down ........................................... 11
i
F-1. F-1.
Winch System
F-1 Winch System 2. When the winch lever is returned to neutral, the
valve is spring-returned to the neutral position as
1. Description of the units the pilot pressure decreases, and the oil in the
winch brake cylinder flows to the tank.
1.1 Hydraulic motor Consequently the brake is applied by the spring.
1.A hydraulic motor provided with multiple wet brake, 1.4 Solenoid valve (telescoping/aux. hoist)
which converts the pressurized oil delivered from
the motor into the turning force. 1. Delivers the pilot pressure from the remote control
valve to either the block of the boom telescoping
2. When a winch lever is operated, this motor side or auxiliary winch operation side of the
releases the brake by the pressurized oil delivered hydraulic pilot control valve when the
from the hydraulic valve, as well as transmits the telescoping/aux. winch operation selector switch
turning force. is shifted to "Telescoping".
3. The motor power is transmitted to the winch drum.
While the rotating speed is reduced and torque is
increased with by the spur gear reduction device.
1. This valve gives back pressure to the return circuit

in order to prevent abrupt load falling or motor
rotation and ensure the hoist-down speed
corresponding to the oil rate delivered from the
hydraulic motor.
2. When high hold pressure is generated between

the winch motor and the counterbalance valve
due to quick switching of the winch operation
selector valve, the overload relief valve opens to
let the pressure escape to the tank in order to
prevent damage.
1.3 Hydraulic valve
1. Selects applying or releasing of the automatic

brake for the main and aux. winch. When the
winch lever is operated to hoist up or down,
pressure created by this operation shifts the valve.
Consequently, the pressurized oil from the
accumulator flows into the automatic brake
cylinder, presses the spring and releases the
brake, allowing the drum to rotate.
1 WF02-0200E
F-2 F-2
Winch
F-2 Winch
[NOTICE]
1. Structure
1.1 General view
2 W526-0381E
F-2 F-2
Winch
1.Air breather 5.Plug 9.Drum 13.Bearing stand

2.Coupling 6.Support 10.Bolt
3.Long nipple 7.Elbow joint 11.Ball bearing
4.Bolt 8.Reducer assy 12.Snap ring
Tightening torque
N-m kgf-m ft-lbf
4 (*1) M22 617 63 455
10 (*1) M16 215 22 159
Mounting bolt M24 632 - 667 64.5 - 68 466 - 492
Mounting bolt M20 431 - 470 44 - 48 318 - 347
(*1): Apply THREE-BOND 1305 to threaded sections.
3 W526-0381E
F-2 F-2
Winch
1.2 Reducer assy
3 2 1 29 28 27 26 25
*2
*1
4
5
*3
7
10
11
12 24
13,14
15 16 17 18 19 20 21 22 30
23 IW526-029002
4 W526-0381E
F-2. F-2.
Winch
[NOTICE]
(*1):Apply THREE-BOND 1215 to the mating face of the end cover(12) and the wheel(15).
(*2) (*3):When installing the oil seals(26), apply THREE-BOND 1215 to the external periphery and inject
lithium based grease to the internal periphery.
Do not disassemble the king pin(6), the king pin(20) and the sleeve(27).
1.Carrier 9.Sun gear 17.Plate 25.Bushing

2.Plate 10.Thrust plate 18.Idle gear 26.Oil seal
3.Planetary gear 11.Sun gear 19.Needle roller bearing 27.Sleeve
4.Thrust plate 12.End cover 20.King pin 28.Snap ring
5.Snap ring 13.Bolt 21.Plate 29.Ball bearing
6.King pin 14.Spring washer 22.Snap ring 30.Plug
7.Needle roller bearing 15.Wheel 23.Plug
8.Plate 16.Carrier 24.Spindle
Tightening torque
N-m kgf-m ft-lbf
13 (*1) M8 24 - 27 2.4 - 2.8 18 - 20
(*1): Apply THREE-BOND 1303 to threaded sections.
360-737-20000 ٌ
0
5 W526-0381E
F-3 F-3
Hydraulic Motor (Winch)
F-3 Hydraulic Motor (Winch)
[NOTICE]
1. Structure

Tightening torque
N-m kgf-m ft-lbf
DR G1/2 108 11 80
PR, a1, Dr1, Dr2 G1/4 36 3.7 27
D A1, DA2 M10x1.25 16 1.6 12
Mounting bolt M20 430 44 317
6 W102-0611E
F-3 F-3
Cross section of the hydraulic motor
7 W102-0611E
F-3. F-3.
101.Drive shaft 304.Front cover 471.O-ring 706.O-ring

111.Cylinder 401.Hexagon socket head bolt 472.O-ring 707.O-ring
113.Spherical bush 402.Hexagon socket head bolt 473.O-ring 710.Brake shim
114.Cylinder spring 431.Stop ring 485.O-ring 741.Separater plate
121.Piston 432.Stop ring 491.Oil seal 742.Friction plate
122.Shoe 437.Snap ring 567.Plug 771.Air bleeder screw seat
123.Set plate 443.Roller bearing 568.O-ring 772.Air bleeder screw
124.Shoe plate 444.Needle bearing 701.Brake cover 773.O-ring
131.Valve plate 451.Pin 702.Brake piston
301.Casing 463.Plug 703.Coupling
303.Valve cover 464.Plug 705.Brake spring
Tightening torque
N-m kgf-m ft-lbf
401 M16 235 24 173
402 M16 235 24 173
463 Rc1/2 65 6.6 48
464 G1/2 108 11 80
567 G1/4 36 3.7 27
771 G1/4 36 3.7 27
772 M10 16 1.6 12
2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.
366-638-00000 ٌ
0
8 W102-0611E
F-4 F-4
Counterbalance Valve (Winch)
F-4 Counterbalance Valve (Winch)
[NOTICE]
1. Structure
B1 A1
b1
a1
Dr
B A IW102-027006
273 202 162 382 381 331 251 301 313 324 351 354 371 361 321 201 271 261 252
262
b1 Dr
253
B A
B1
161
A1
600
101 511 561 551 521 514

171 165 151 256
B A
a1
Dr
B1 A1
163 IW102-027007
9 W119-0561E
F-4 F-4
101.Casing 251.Orifice 301.Spool 381.O-ring

151.Plug 252.Plug 313.Steel ball 382.O-ring
161.O-ring 253.Plug 321.Spring 511.Plunger
162.O-ring 256.Air bleeder screw 324.Spring 514.Seat
163.O-ring 261.O-ring 331.Pilot piston 521.Spring
165.O-ring 262.O-ring 351.Orifice 551.Plug
171.Hexagon socket head bolt 271.Hexagon socket head bolt 354.Orifice 561.O-ring
201.Cover 272.--- 361.Filter stopper 600.Relief valve
202.Cover 273.Hexagon socket head bolt 371.Filter

Tightening torque
N-m kgf-m ft-lbf
151 G1/4 34 - 38 3.5 - 3.9 25 - 28
171 M10 39 - 49 4-5 29 - 36
252 G1/4 34 - 38 3.5 - 3.9 25 - 28
253 G1/4 34 - 38 3.5 - 3.9 25 - 28
256 M10 15 - 17 1.5 - 1.7 11 - 13
271, 273 M10 52 - 62 5.3 - 6.3 38 - 46
551 M27 117 - 137 12 - 14 86 - 101
600 M28 117 - 137 12 - 14 86 - 101
Dr G1/4 34 - 38 3.5 - 3.9 25 - 28
2. Function 2.2 Overload relief function
When the circuit pressure rises above the preset

2.1 Balancing and holding functions
overload relief level, this valve vents it to protect
1. During hoisting down, this valve selectively opens the circuit.
and closes the motor outlet passage in
accordance with the pressure level of the motor
inlet pressure to control the speed of the load and
to prevent the load from falling under weight faster
than the hydraulic motor driving speed.
2. When the inlet pressure is below a certain level,

this valve closes the return passage to hold the
load at a desired position.
10 W119-0561E
F-4. F-4.
3. Principle of operation
3.1 When control valve is in neutral 3.3 Hoisting down
The holding pressure of the hydraulic motor is 1. As oil is sent to port B by the control valve, it flows
locked by the seat area a of the check valve, the to the motor via port B1.
land area d of the spool and the overload relief
2. The return oil from the motor is blocked at port A1,
valve.
to raise the pressure at port B.
3.2 Hoisting up 3. This pressure flows through choke b in the spool,
1. When the control valve sends oil to port A, the oil enters into chamber c, where it pushes the
pushes open the check valve and flows to port A1 plunger to the right by overcoming the spring force,
connected to the motor. and opens land d.
2. On the other hand, the return oil from the motor 4. As a result, the return oil from the motor is
port enters through port B1, and then, is discharged to the control valve via land d to drive
discharged through port B to the control valve. the motor.
5. When the load tends to pull the motor faster than

the speed corresponding to the flow rate to port B,
the pressure in chamber c drops.
6. Maintaining balance with the spring force to

automatically adjust the oil passage area in land d
to prevent the load from falling at speeds faster
than the motor drive speed.
366-633-10000 ٌ
0
11 W119-0561E
F-5. F-5.
Hydraulic Valve (Winch Brake Release)
F-5 Hydraulic Valve (Winch Brake Release)
[NOTICE]
1. Structure
T3
B1
P1
Dr
B1 P2
AC
P1
B2 T B2
T P2
9 4 10 2 6 7 1 5 2 3 8
Dr AC T2 T1
IW123-020001 IW123-020002
1.Valve body 4.Side cover 7.Plug 10.Spring seat

2.O-ring 5.Spool 8.Hex. socket head bolt
3.Side cover 6.Spring 9. Hex. socket head bolt

Tightening torque
N-m kgf-m ft-lbf
AC, B1, B2, Dr
G1/4 29.4 3 22
T, P1, P2
T1, T2 M8 23 - 27 2.3 - 2.8 17 - 20
T3 M10 21.6 - 24.5 2.2 - 2.5 16 - 18
366-452-90000 ٌ
0
12 W123-0282E
G
Boom Telescoping System
Contents G
G-1 Telescoping System ........................ 1 4.1 Greasing....................................................14
4.2 Install anti-buckling bolts for
1. General ...................................................... 1 telescoping cylinder ............................14
1.1 Telescoping cylinder ................................... 1 4.3 Installing lower slide plates .......................15
1.2 Counterbalance valve................................. 1 4.4 Installing slide plates onto sides of
1.3 Hydraulic valve ........................................... 1 rear end...............................................15
1.4 Hose reel .................................................... 1
5. Adjustment............................................... 15
2. Description of telescoping system (Refer to 5.1 Adjusting clearance for the boom.................15
the circuit diagram in Chapter Z.) ... 2 5.2 Adjusting boom telescoping wire rope .........15
2.1 Extension circuit ......................................... 2
2.2 Retraction circuit......................................... 3 6. Test ..................................................... 16
6.1 Operation test ...........................................16
3. Boom telescoping mechanism................... 4 6.2 Boom lateral warp test ..............................16
3.1 Extension.................................................... 4 6.3 Other functional test..................................16
3.2 Retraction ................................................... 5
G-3 Jib .................................................17

G-2 Boom (Five-Section Boom) ............. 7
1. Structure .................................................. 17
1. Structure .................................................... 7 1.1 Location of Jib...........................................17
1.2 Jib main body............................................19
2. Disassembly ............................................ 10
2.1 Removing the 2nd boom section.............. 10 2. Adjustment............................................... 21
2.2 Removing the 3rd boom section............... 11 2.1 Adjusting jib 1-2 connecting spring pin .....21
2.3 Removing the 4th boom section............... 12 2.2 Adjusting jib inclination..............................21
2.4 Removing the top boom section............... 12 2.3 Adjusting inclination of jib 2.......................22
3. Check ..................................................... 14
3.1 Boom ........................................................ 14 G-4 Telescoping Cylinder.....................23
3.2 Slide plate................................................. 14
3.3 Sheave ..................................................... 14 1. Structure .................................................. 23
3.4 Boom telescoping wire rope ..................... 14
4. Reassembly ............................................. 14
i
G-5 Counterbalance Valve
(Telescoping) ......................... 25
1. Structure .................................................. 25
2. Function ................................................... 26
2.1 When control valve is at the
neutral position ................................... 26
2.2 While actuator is being pushed up ........... 26
2.3 While actuator descends .......................... 26
G-6 Hose Reel ....................................... 27
1. Structure .................................................. 27
2. Dismounting............................................. 28
3. Mounting .................................................. 28
4. Disassembly ............................................ 28
5. Reassembly ............................................. 28
G-7 Hydraulic Valve .............................. 30
1. Structure ..................................................... 30
ii
G-1 G-1
Telescoping System
G-1 Telescoping System

1. General
1.1 Telescoping cylinder
1. The telescoping cylinders are incorporated in the

boom, and serve to telescope the boom to which
they are connected by pins.
2. It telescopes the 2nd boom section, and

telescopes the 3rd, 4th and top boom sections
simultaneously using two double-acting hydraulic
cylinders and wire ropes.
1. The counterbalance valve is directly connected to

the telescoping cylinder, and serves to prevent the
cylinder from retracting while the control lever is in
NEUTRAL, to prevent the cylinder from being
driven by the load during retraction, and to
prevent its violent retraction, when the hoses and
other parts of the extension circuit are damaged.
1.3 Hydraulic valve
This valve is electrically controlled to selectively

deliver the pressurized oil from the hydraulic pilot
control valve into the No. 1 cylinder circuit or the
No.2 cylinder circuit.
1.4 Hose reel
The hose reel serves to let out and take in the

hose as the boom telescopes to maintain the
hydraulic circuit to the No.2 cylinder all the time
1 WG02-0262E
G-1 G-1
Telescoping System
2. Description of telescoping system

(Refer to the circuit diagram in Chapter Z.)
Fold at the rear end the 3rd boom section.
Adjuster and sheave on the head of the 2nd boom section Sheave at the rear end of
the 3rd boom section
Sheave at the head of the 4th boom section Top boom section retraction wire
Sheave at the head of the telescoping cylinder
Fix at the head of
the 2nd boom section. Sheave at the rear end of Sheave at the rear end of
the top boom section. the 3rd boom section.
Top boom section extension/

4th boom section retraction wire Fix at the rear end of the 2nd boom section.
4th boom section extension wire Fix at the rear end of the 4th boom section.
Fix at the head of the 4th boom section. Fix at the rear end of the top boom section.
IWG02-0260E01
2.1 Extension circuit

4. In this case, you need not keep pressing the next
Telescoping mode I section extension switch when the No. 2
(The 2nd boom section extends first.) telescoping cylinder extends slightly because the
boom full retraction switch is shifted and the
1. When the boom telescoping lever (linked to the
solenoid self-holding circuit for the hydraulic valve
remote control valve) is operated to the extension
is established.
side, pilot pressure is led to the hydraulic pilot
control valve, shifting the telescoping control valve 5. The 4th and top boom sections are extended by
to extension side and delivering the pressurized the wire-rope mechanism linked to the No. 2
oil from the hydraulic pump to the selector valve. telescoping cylinder.
2. The pressurized oil is sent to the No. 1 Telescoping mode II

telescoping cylinder, making the 2nd boom (The 3rd through top boom sections extend first.)
section extend.
1. When the boom telescoping lever (linked to the
3. After the 2nd boom section is fully extended, remote control valve) is operated to the extension
press the next section extension switch while side, pilot pressure is led to the hydraulic pilot
keeping the boom telescoping lever operated. The control valve, shifting the telescoping control valve
hydraulic valve will be energized, the pressurized to extension side and delivering the pressurized
oil will be sent to the No. 2 telescoping cylinder oil from the hydraulic pump to the selector valve.
and the 3rd boom section will extend.
2. The pressurized oil is sent to the No. 2
telescoping cylinder, making the 3rd boom section
2 WG02-0262E
G-1 G-1
Telescoping System
extend.
3 WG02-0262E
G-1 G-1
Telescoping System
3. The 4th and top boom sections are extended by Telescoping mode II
the wire-rope mechanism linked to the No. 2 (The 3rd through top boom sections extend first.)
telescoping cylinder.
1. Pressurized oil for boom retraction is delivered
4. After the 3rd through top boom sections are fully from the hydraulic pilot control valve to the No. 1
extended, press the next section extension switch and No. 2 telescoping cylinder directly.
while keeping the boom telescoping lever
2. While the No. 1 telescoping cylinder is extended,
operated. The hydraulic valve will be energized,
the solenoid of the selector valve is energized due
the pressurized oil will be sent to the No. 1
to the boom full retraction detector switch.
telescoping cylinder and the 2nd boom section will
Consequently the return circuit of the No. 2
extend.
telescoping cylinder is closed and only the No. 1
5. In this case, you need not keep pressing the next telescoping cylinder retracts, resulting in retraction
section extension switch when the No. 1 of the 2nd boom section.
telescoping cylinder extends slightly because the
3. When the No. 1 telescoping cylinder is almost fully
boom full retraction switch is shifted and the
retracted, the boom full retraction detector switch
solenoid self-holding circuit for the hydraulic valve
is activated and disestablishes the solenoid
is set up.
self-holding circuit for the hydraulic valve.
2.2 Retraction circuit Consequently the selector valve automatically
shifts, the No. 2 telescoping cylinder retracts and
Telescoping mode I the 3rd boom section retracts.
(The 2nd boom section extends first.)
4. When the 3rd boom section retracts, the 4th and
1. Pressurized oil for boom retraction is delivered top boom sections retract simultaneously by
from the hydraulic pilot control valve to the No. 1 means of the wire rope mechanism.
and No. 2 telescoping cylinder directly.
2. While the No. 2 telescoping cylinder is extended,

the solenoid of the selector valve is energized due
to the boom full retraction detector switch.
Consequently the return circuit of the No. 1
telescoping cylinder is closed and only the No. 2
telescoping cylinder retracts, resulting in retraction
of the 3rd boom section.
3. At the same time, the 4th and top boom sections

retract by the wire-rope mechanism.
4. When the No. 2 telescoping cylinder is almost fully

retracted, the boom full retraction detector switch
is activated and disestablishes the solenoid
self-holding circuit for the hydraulic valve.
Consequently the selector valve automatically
shifts, the No. 1 telescoping cylinder retracts and
the 2nd boom section retracts.
4 WG02-0262E
G-1 G-1
Telescoping System
3. Boom telescoping mechanism

4. Top boom section
Extended by the wire rope mechanism that
3.1 Extension
synchronizes with the extension of 4th boom
1. 2nd boom section section
Extended by No.1 cylinder E4 F4
4th boom
(L1: No.1 cylinder stroke)
2nd boom section travel (E2)=L1 WT WT WT
2 2 2
2. 3rd boom section
Extended by No.2 cylinder
Top
(L2: No.2 cylinder stroke) E5
boom
3rd boom section travel (E3)=L2
3. 4th boom section Top boom

Extended by the wire rope mechanism that
WT
synchronizes with the extension of No.2 cylinder. 4th boom
F3
2nd boom
3rd boom
3rd boom
W4 W4
2nd boom
E4
4th 4th . IWG02-0420E02
boom boom
E5 : top boom section travel
W4 E3=L2
3rd E4 : 4th boom section travel
boom F4 : 4th boom section fotce
No.2 cylinder WT : Top boom section weight
2nd boom
2nd boom
IWG02-0420E01
WT
Balance of force : F4 = 3 ×
2
E4 : 4th boom section travel
Equation of workload : WT × E5 = F4 ×E4
E3 : 3rd boom section travel
(=L2: No.2 cylinder stroke) E4
㺯E 5 = F4 ×
F3 : 3rd boom section force WT
(=No.2 cylinder force) WT E 4
= 3× ×
W4 : 4th boom section weight 2 WT
3
= E
Balance of force : F3 = 2W4 2 4
From equation (a)
Equation of workload : W4 × E4 = F3 × E3
3
E3 E5 = × 2L 2 = 3L 2
㺯E 4 = F3 × 2
W4
E3 Top boom section travel (E5) = 3L2
= 2W 4 ×
W4
= 2E3 = 2L2 - - - (a)
4th boom section travel (E4) = 2L2
5 WG02-0262E
G-1 G-1
Telescoping System
3.2 Retraction WT
Balance of force : F3 = 6 × = 3 WT
1. Top boom section 2
Retracted by the wire rope mechanism that Equation of workload : WT × R5 = F3 × R3
synchronizes with the retraction of 3rd boom R3
section. 㺯R5 = F3 ×
WT
R3
2nd boom F3 = 3 WT ×
R3=L2 WT
3rd boom 3rd boom
= 3R3 = 3L2 - - - (b)
WT WT WT
2 WT 2
2 WT WT 2 Top boom section travel (R5) = 3L2
2 2
2. 4th boom section

Retracted by the wire rope machanism that
synchronizes with the retraction of top boom
2nd section.
boom
2nd boom
4th
boom
3rd boom
2nd boom
R5
4th boom
WT WT
2 2 F5
Top boom R5
Top boom
Top
Top
boom
boom
IWG02-0420E03
F5 R4
2 F5
F5
R5 : Top boom section travel 2 2
R3 : 3rd boom section travel
4th boom
(=L2: No.2 cylinder stroke)
W4
F3 : 3rd boom section force
IWG02-0420E04
(=No.2 cylinder force)
WT : Top boom section weight
R4 : 4th boom section travel
R5 : Top boom section travel
F5 : Top boom section force
W4 : 4th boom section weight
6 WG02-0262E
G-1. G-1.
Telescoping System
F5
Balance of force : 3× = W4
2
2W4
㺯F5 =
3
Equation of workload : W4 × R4 = F5 × R5
R5
㺯R 4 = F5 ×
W4
2W4 R5
= ×
3 W4
2
= R
3 5
From equation (b)

2
R4 = × 3L 2
3
= 2L2
4th boom section travel (R4) = 2L2
3. 3rd boom section

Retracted by No.2 cylinder
3rd boom section travel (R3) = L2
4. 2nd boom section

Retraction by No.1 cylinder
2nd boom section travel (R2) = L1
7 WG02-0262E
G-2 G-2 12 㧦475420 - -
ٌ G-2
11 㧦475413 - -
ٌ
Boom (Five-Section Boom) Applicable serial No. ٌ7 㧦475360 - -
G-2 Boom (Five-Section Boom)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures,
make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
8 W536-0763E 8
G-2 G-2 G-2
Boom (Five-Section Boom) 11 㧦475413 - -
ٌ
Applicable serial No. ٌ6 㧦475358 - -
9 W536-0763E 9
G-2 G-2
Boom (Five-Section Boom)
Applicable serial No. ٌ6 㧦475358 - - ٌ
7 㧦475360 - - ٌ
11 㧦475413 - -
1.Base boom section 49.Bolt 98.Spacer 147.Pin ٌ

12 㧦475420 - -
2.Second boom section 50.Adjuster assy 99.Pin 148.Plate

3.Third boom section 51.Bolt 100.Split pin 149.Spacer
4.Fourth boom section 52.Plain washer 101.Pin ٌ 6 --- 150.Spacer
5.Top boom section 53.Spring washer 102.Bolt 151.Pin
6.Slide plate 54.Set screw 103.Bolt 152.Sheave assy
7.Pin 55.Plain bearing 104.Set screw 153.Pin
8.Plate 56.Retaining ring 105.Plate 154.Retaining ring
9.Bolt 57.Spacer 106.Slide plate 155.Retainer
10.Spring washer 58. Pin 107.Retainer 156.Slide plate
11.Plate 59.Pin 108.Retainer 157.Plate
12.Nut 60.Pin 109.Slide plate 158.Plate
13.Tooth washer 61.Spacer 110.Plate 159.Slide plate
14.Pin 62.Retaining ring 111.Plate 160.Plate
15.Snap pin 63.Slide plate 112.Retainer 161.Plate
16.Spacer 64.Slide plate 113.Bolt 162.Retainer (L)
17.Spacer 65.Plate 114.Retainer 163.Retainer (R)
18.Sheave assy 66.Plate 115.Slide plate 164.Retainer
19.Spacer 67.Plate 116.Plate 165. ----------
20.Pin 68.Plate 117.Plate 166.Slide plate
21.Sheave assy 69.Hexagon socket head bolt 118.Retainer assy (L) 167.Bolt
22.Spacer 70.Bolt
ٌ 6
119.Retainer assy (R)
ٌ
6
168.Retainer assy (L)
23.Pin 71.Plate 120.Slide plate 169.Retainer assy (R) ٌ
6 ---
24.Bolt 72.Plate 121.Plate 170.Bolt
25.Nut 73.Support 122.Plate 171.Bolt
ٌ6
26.Pin 74.Support 123.Retainer assy (L) 172.Bolt
27.Snap pin 75.Slide pIate 124.Retainer assy (R) 173.Nut
28.Wire rope 76.Hexagon socket head bolt 125.Slide plate 174.Plate
29.Nut 77.Shim 126.Plate 175.Plate
30.Nut 78.Shim 127.Plate 176.Bolt
31.Wire rope 79.Slide plate 128.--- 177.Retainer (L)
32.Nut 80.Nut 129.--- 178.Retainer (R)
33.Nut 81.Tooth washer 130.Pin 179.Plate ٌ 7 ---
34.Wire rope 82.Sheave assy 131.Retaining ring 180.Pin

35.Plug 83.Guide 132.Support 181.Split pin
36.Grease nipple 84.Guide 133.Bolt ٌ 6 182.Retainer(R)
37.Hexagon socket head bolt 85.Bolt 134.Spring washer ٌ 6 183.Retainer(L)
38. ---------- 86.Spring washer 135.Spacer ٌ 11 187.Bolt
39.Bolt 87.Plain washer 136.Pin ٌ 11 188.Machine screw
40.Nut 88.Support 137.Guide ٌ 189.Slide plate

11
41.Support 89.Guide 138.Bolt ٌ12 190.Plain washer
42.Slide plate 90.Pin 139.Sheave assy

43.Grease nipple 91.Bolt 140.Bolt
44.Nut 92.Pin 141.Split pin
45.Bolt 93.Pin 142.Hexagon socket head bolt
46. ---------- 94.Sheave assy 143.Retaining ring
47.Hexagon socket head bolt 95.Bolt 144.Hexagon socket head bolt
ٌ 11 --- 96.Plate 145.Spring washer
48.Slide plate ٌ ---
11 97.Spacer 146.Support
342-016-60000 ٌ
12
10 W536-0763E
G-2 G-2
Telescoping cylinder
2. Disassembly
The procedure to remove the 2nd boom section and
further sections as an assembly is described below.
2.1 Removing the 2nd boom section
1. Retract the boom fully and set the crane level.
2. Remove the hook block and the rope socket. High-pressure hose
Wind up the wire rope on the drum.
3. Swing the boom to place where there is enough

Hose reel
clearance, then lower the boom to 0° and stop the
engine. IW536-0620E04
4. Remove the wiring connector, loosen the wiring

clip and secure the cable end using a tape at the 6. Pull out the connecting pin that connects the base
cable guide (a) located closest to the cord reel. boom section and the No. 1 telescoping cylinder
by removing the retaining ring. Then loosen the
nut and remove the bolt.
Connecting pin
Bolt
Wiring clip Cable Cable guide (a)

IW536-0620E03 Nut
5. Remove the high-pressure hoses (2 pieces) and

the hose leading to the hose reel from the
telescoping cylinder.
[NOTICE] IW536-0620E05
To prevent the hose reel from spinning, attach a

wire to the hose to the pipe sleeve of the hose and
secure the wire to the swing frame. 7. After removing the retainer on the top of the base
boom section head and removing the slide plate,
pull out the 2nd boom section by approx. 1 m.
8. While lifting up the 2nd boom section slightly,

remove the retainer from the bottom of the base
boom section head.
9. Lift up and pull out the 2nd boom section using a

crane, and place it on a level platform.
11 W536-0763E
G-2 G-2
2.2 Removing the 3rd boom section Top boom section

3rd boom section Bolt 1
1 Remove the wire rope for top boom section Pin 1 Support
Nut Sheave assy
extension/4th boom section retraction located on
the top of the 2nd boom head by loosening the
nut.
[NOTICE]
Before loosening the nut, measure the length of the
wire rope protrusion (L1) as a guide for reassembly.
Pin 2 Bolt 2 Wire rope (for top boom section retraction)
IW536-0620E08
Wire rope Nut L1
6. Remove the support assy of the No. 1 telescoping

cylinder located at the rear end of the 3rd boom
section by loosening the hexagon socket head
bolt.
Hexagon socket head bolt Support assy

IW536-0620E06
2. Remove the wire rope for top boom section

located on the top of the 2nd boom head by
loosening the nut.
No.1 telescoping cylinder
[NOTICE] IW536-0620E09

7. After removing the retaining ring, remove the pin
3. Remove the adjuster assy from the 2nd boom that secures the No. 1 telescoping cylinder and
section by loosening the bolt. No. 2 telescoping cylinder to the 2nd boom
section. Then loosen the nut and remove the bolt.
Nut Bolt Adjuster assy 2nd boom section
L2 Wire rope (for top boom section retraction)

IW536-0620E07
4. Remove the supports (on both sides of the rear

end of the 3rd boom section) by loosening the bolt
1, and remove the pin and sheave assy by
loosening the nut.
5. Remove the pin from the rear end of the top boom 8. Remove the nut for the wire rope (for 4th boom
section by loosening the bolt 2 and remove the section extension) located on the rear end of the
wire ropes for top boom section retraction (2 2nd boom section, then loosen the bolt and
pieces). remove the support.
12 W536-0763E
G-2 G-2
2. Lift up the rear end of the telescoping cylinder

[NOTICE]
slightly using a crane and pull out the connecting
wire rope protrusion (L3) as a guide for reassembly. pin that connects the 3rd boom section and the
No. 2 telescoping cylinder by removing the
Wire rope (for 4th boom section extension) retaining ring.
Support
Nut 3. Lift up the telescoping cylinder using a crane and
pull it out rearward together with the wire rope for
4th boom section extension.
3rd boom section No.2 telescoping cylinder

L3
2nd boom section

IW536-0620E11
9. After removing the retainer on the top of the 2nd

boom section head and removing the slide plate, Connecting pin
pull out the 3rd boom section by approx. 1 m. Wire rope (for 4th boom section extension)
IW536-0620E13
10. While lifting the 3rd boom section slightly, remove
the retainer from the bottom of the 2nd boom
section head. 4. After removing the retainer on the top of the 3rd
11. Lift and pull out the 3rd boom section using a pull out the 4th boom section by approx. 1 m.
crane, and place it on a level platform.
5. While lifting the 4th boom section slightly, remove
2.3 Removing the 4th boom section the retainer from the bottom of the 3rd boom
section head.
1. Remove the nut for the wire rope (for 4th boom
section extension) located on the rear end of the 6. Lift and pull out the 4th boom section using a
4th boom section, loosen the hexagon head bolt, crane, and place it on a level platform.
and remove the plate and support.
2.4 Removing the top boom section
[NOTICE]
Before loosening the nut, measure the length of the 1. Remove the four bolts and detach the guide.
2. Remove support by loosening the bolts 2 (4
4th boom section
pieces) on both sides of the 4th boom section
head, draw out the wire rope forward by approx.
Nut 0.5 m, remove the retaining ring, detach the pin
Plate and separate the wire rope from the support.
Hexagon
socket head bolt
Support L4 Support
Wire rope (for 4th boom section extension) Nut
IW536-0620E12
13 W536-0763E
G-2 G-2
Guide Bolt 1
Support
Bolt 2
Pin
Wire rope
(for top boom section extension / 4th boom section retraction)
IW536-0620E14
3. To prevent damage to the wire rope, secure it to

the head of the top boom section using a jig.
Jig Top boom section
Wire rope
(for top boom section extension / 4th boom section retraction)
IW536-0620E15
4. After removing the retainer on the top of the 4th

pull out the top boom section by approx. 1 m.
5. While lifting up the top boom section slightly,

remove the retainer from the bottom of the 4th
boom section head.
6. Lift up and pull out the top boom section using a

crane.
7. Remove the wire rope for top boom section

extension/4th boom section retraction from the
rear end of the top boom section.
14 W536-0763E
G-2 G-2
3. Check 4. Reassembly
3.1 Boom 4.1 Greasing
Check the boom for twist, deformation, wrap, and • When installing unplated pins, apply grease
cracks. beforehand.
3.2 Slide plate • Apply TNR-2 Grease sufficiently to the sliding

surfaces of the slide plates, the booms and
Check the slide plates for cracks and wear, and telescoping cylinders.
replace when these conditions are excessive.
4.2 Install anti-buckling bolts for telescoping
3.3 Sheave cylinder
Check the sheaves for damage, deformation and Base and 2nd boom section
wear, and replace them when these conditions are Boom side
A B
excessive. Cylinder side E
D
3.4 Boom telescoping wire rope
Wire rope in the condition described below must not

S
be used.
C
IW536-0680E12
• Deformation or corrosion
3rd boom section
• Kinking
• 10% or more broken wire (filler wires excluded) in

one lay of the wire rope
• diameter reduction exceeding 7% of the nominal

diameter.
• Evidence of any heat damage from any cause.
1. Connect the boom and telescoping cylinder using

the pins A and B.
2. Adjust the bolt C locked with nuts D and E so that
it can be turned by hand and the clearance (S) is
0.5mm (0.02in) or less.(Apply thread locking
agent.)
[NITICE]
Refer to normal insert directions of bolt•C shown on
[2.Disassembly]
15 W536-0763E
G-2 G-2
4.3 Installing lower slide plates 5. Adjustment

1. Apply thread locking agent to the bolt, tighten it
5.1 Adjusting clearance for the boom
lightly and turn it in reverse for a quarter turn.
1. Lateral clearance at the bottom of the boom rear
2. If the tip of the bolt protrudes beyond the bottom
end
of the retainer, scrape it off with a grinder.
Place shims so that the total clearance
4.4 Installing slide plates onto sides of rear end (distributed to right and left) is 0.5 mm.
Apply thread locking agent to the bolt, tighten it
2. Upper clearance on boom rear end
lightly and turn it in reverse for a quarter turn.
Place shims that the lateral deviation of center is
±1.5 mm, and vertical deviation is 3-5 mm.
3. Lateral clearance at boom head
Place shims so that the total clearance is 0.5 mm

when the boom is 1 m longer than that of full
retraction.
4. Adjusting the bolt on the bottom of each boom

section head
After retracting each boom section fully, lock the

bolt with a nut while it is lightly pressed against
the A surface. Apply thread locking agent.
Bolt
Surface
A
(7)
Reference
value Nut
IW536-0630E15
5.2 Adjusting boom telescoping wire rope
See the "Adjusting boom telescoping wire ropes"

section in the Y chapter.
16 W536-0763E
G-2. G-2.
6. Test
[NOTICE]
ٟBleed the telescoping cylinders completely and
apply grease to the boom sliding surfaces before
starting the tests.
6.1 Operation test
Telescope the boom several times, and make sure

that the telescoping operation is in order.
6.2 Boom lateral warp test

[Conditions]
㨯Crane levelness : ± 6' max.
㨯Boom length : Full extension
㨯Boom elevation : Maximum
㨯Boom direction : Over-front, Over-rear,
Over-right, Over-left
㨯Other conditions: Free from solar heat and wind 6.3 Other functional test
Check all the electric and electric parts (boom

1. The hook displacement (A in sketch) under the
length & angle detector, etc.) that are influenced
above test conditions under no load must be
by boom dismounting, for function and accuracy.
brought within 200mm (7.9 in) in all boom
directions by shim adjustment.
2. After shim adjustment, the hook displacement (A

in sketch) under the above test conditions under
the total rated load must be within the specified of
500mm (19.7 in).
When the displacement is more than the specified
limit, readjust the shim.
17 W536-0763E
G-3 G-3 G-3
Jib 1 㧦545419,545430~,475327~ 4 㧦545419,545457~,475330~
Applicable serial No. ٌ ٌ
2 㧦545410~,475326~
ٌ 5 㧦545511~,475349~,437366~
ٌ
G-3 Jib 3 㧦545419,545430~,475330~
ٌ
1. Structure
1.1 Location of Jib
18 W537-0103E 18
G-3 G-3
Jib
1.Support assy 13.Support 25.End 37.Stopper

2.Plate 14.Plate 26.Pin 38.Stopper
3.Pin assy 15.Bolt 27.Split pin 39.Bolt
4.Bolt 16.Nut 28.Plain washer 40.Spring washer
5.Spring washer 17.Plain washer 29.Clamp 41.----------------------
6.Plain washer 18.Support 30.Flange nut 42.----------------------
7.Bolt 19.Pin assy 31.Control cable 5 43.Plate
8.Plain washer 20.Support 32.Support 5 44.Plate
9.Slide plate 21.Support assy 33.Spring 5 45.Plate
10.Shim 22.Support assy 34.Plate 5 46.Bolt
11.Slide plate 5 23.Support assy 5 35.Pin assy 5 47.Nut
12.Support assy 24.Plate 36.Stopper 5 48.Support
5 49.Nut
342-215-40500 ٌ
6
19 W537-0103E
G-3 G-3 G-3
Jib 1 㧦545410~,475326~ 4 㧦545419,545457~,475330~
Applicable serial No. ٌ ٌ
2 㧦545410~,475326~
ٌ 5 㧦545511~,475349~,437353~
ٌ
1.2 Jib main body 3 㧦545410~,475326~
ٌ
20 W537-0103E 20
G-3 G-3
Jib
1.Jib 2 15.Pin assy 29.Roller assy 43.Spacer

2.Jib1 16.Spacer 30.Spacer 44.Pin
3.Support 17.Sheave assy 31.Pin 45.Bolt
4.Snap pin 18.Plate 32.Bar 46.Spring washer
5.Pin 19.Pin 33.Pin 47.Roller assy
6.Pin 20.---------------------- 34.Split pin 48.Pin
7.Retaining ring 21.Link 35.Plate 49.Spacer
8.Sheave assy 22.Plate 36.Pin assy 50.Snap pin
9.Grease nipple 23.Plate 37.Nut 51.Spacer
10.Pin 24.Plate 38.Bolt 5 52.Pin
11.Snap pin 25.Pin 39.Plate 5 53.Pin
12.Guide assy 26.Plain washer 40.Pin assy 5 54.Spacer
13.Bolt 27.Split pin 41.Pin
14.Spring washer 28.Stopper 42.Support
342-215-42000 ٌ
5
21 W537-0103E
G-3 G-3
Jib
2. Adjustment
2.1 Adjusting jib 1-2 connecting spring pin

2.2 Adjusting jib inclination
Make sure that the clearance (X) between the
support and spring pin is 2 mm (0.08 in) while the In order to facilitate inserting and removing the
jib 1 supports the jib 2. elevating pin, adjust the jib inclination by using a
bolt and secure the bolt with a nut.
Support
Jib 2
X
Spring pin
Jib 1
Jib 1-2 connecting spring pin

IW537-0100E07
22 W537-0103E
G-3. G-3.
Jib
2.3 Adjusting inclination of jib 2

Slide plate
Shim (t 0.6)
Adjust the inclination to facilitate inserting and
removing the jib 1-2 connecting pin.
1) If the rear end of the jib 2 is too low for the pin to
be inserted and removed easily, apply shims (t0.6
mm (t0.02 in)) to the slide plate on the support on
the boom rear end.
2) If the rear end of the jib 2 is too high for the pin to Support on boom rear end
be inserted and removed easily, remove a shim IW537-0100E05
(t0.6 mm (t0.02 in)) one by one from the slide

plate on the support on the boom rear end until
the pin can be inserted and removed easily.
3) Add or remove shims (t0.6 mm (t0.02 in)) on the

support on the boom rear end and shims (t3 mm
(t0.12 in)) on the center support of the jib 2 to
facilitate the jib 1-2 connecting pin.
[NOTICE]
Boom rear end support: The rear end of the jib 2 is
raised when shims are added; lowered when shims
are removed.
Center support on jib 2: The rear end of the jib 2 is
lowered when shims are added; raised when shims
are removed.
23 W537-0103E
G-4 G-4
Telescoping Cylinder
G-4 Telescoping Cylinder

[NOTICE]
1. Structure
1. No.1 cylinder
2. No.2 cylinder
3. Hose
4. Hexagon socket head bolt
5. Bolt
Tightening torque
N-m kgf-m ft-lbf
A1, B G3/4 108 - 123 11 - 12.5 80 - 90
A2 G1/2 54 - 64 5.5 - 6.5 40 - 47
4 M12 68.6 - 82.4 7 - 8.4 50.6 - 60.7
5 M10 43 - 49 4.4 - 5 32 - 36
24 W157-0404E
G-4. G-4.
Telescoping Cylinder
3 㧦475426 - -
1.Plug 6. Backup ring 11.O-ring 16.Backup ring

ٌ
3 2.Spring pin --- 7.Plain bearing 12.Rod cover assy 17.Plain bearing
3.Nut 8.O-ring 13.Support 18.Dust seal
4.Piston 9.Cylinder 14.Damper ring 31.O-ring
5. Packing 10.Rod 15.Packing ٌ 33.Set screw
3
*1: Face the notch or the lip toward the pressurized side.
ٌ
3 *2: After tightened, punching (2 places).
Tightening torque
N-m kgf-m ft-lbf
ٌ
3 33 M8 13.2 – 16.2 1.35 – 1.65 9.7 – 11.9
360-171-10000 ٌ
2
360-171-20000 ٌ
3
360-169-10000 ٌ
1
360-169-20000 ٌ
2
25 W157-0404E
G-5 G-5
Counterbalance Valve (Telescoping)
G-5 Counterbalance Valve (Telescoping)

[NOTICE]
1. Structure
B
A
IW119-022001
6 12 11 3 2 5 4 10 9 1 8 20 14 13 15 16 17 19 18
B A M
IW119-022002
1.Body 6.Cap 11.Cap 16.Spring

2.O-ring 7.Orifice 12.O-ring 17.Spring
3.Backup ring 8.Spool 13.Holder 18.Cap
4.O-ring 9.Poppet 14.Steel ball 19.O-ring
5.Backup ring 10.Spring 15.Spring 20.Orifice

Tightening torque
N-m kgf-m ft-lbf
6 - 29 - 49 3-5 22 - 36
7 - 1 - 1.2 0.1 - 0.12 0.7 - 0.9
11 - 56 - 62 5.7 - 6.3 41 - 46
18 - 78 - 98 8 - 10 58 - 72
20 - 1 - 1.2 0.1 - 0.12 0.7 - 0.9
M M6x1 - - -
26 W119-0223E
G-5. G-5.
Counterbalance Valve (Telescoping)
2. Function
b a
P.P B C A
IW119-022003
This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the main spool to move the main
2.1 When control valve is at the neutral position spool.
The actuator holding pressure is sealed by seat 2. Consequently, the holding hydraulic pressure in
“a” of the main spool and seat “b” of the check port B is vented to port A.
valve.
3. At this time, the main spool motion is smoothened
2.2 While actuator is being pushed up by orifices.
1. The pressurized oil entering through port A of the

control valve enters chamber C, flows out through
port B by opening the check valve, and enters the
holding side of the actuator.
2. At this time, since port PP is connected to the tank

circuit, the main spool is kept forced to the valve
body by the spring, and remains inactive.
366-054-80000 ٌ
0
27 W119-0223E
G-6 G-6
Hose Reel
G-6 Hose Reel
[NOTICE]
1. Structure
1.Drum plate 9.Nut 17.Set screw 25.Spacer

2.Drum plate 10.Bearing 18.Nut 26.O-ring
3.Seat packing 11.Bush 19.Spring washer 27.Bolt
4.Spring case 12.Bearing 20.Plate 28.Spring washer
5.Spring 13.Seal ring 21. Bolt 29.Stop Plate
6.Aux. spring 14.Backup ring 22. -------- 30.Gulomet
7.Special bolt 15.Pin 23.Retaining ring
8.Spring washer 16.Support 24.Oil seal
28 W183-0133E
G-6 G-6
Hose Reel
2. Dismounting 1) Remove the protection plate from the case 4

[NOTICE] and secure the case 4 in a sufficiently wide
When the circuit is suspected to retain high space.
pressure oil, be sure to vent pressure before
dismounting the hose reel. 2) Tie one end of a wire of a sufficient length to
Since the spring force for extra winding turns is the inner end of the spring 5 and pull the other
applied to the hose, hold the drum when end of the wire by hand to take out the spring 5.
disconnecting the hose.
5. Reassembly
3. Mounting
1. Install seal rings and backup rings on pin, apply
[NOTICE] grease thinly on these rings and their surrounding
After installation and bleeding the circuit and the areas,and install the pin in spring case.
device, test the operation check and check any
abnormality. 2. To reinstall spring in case proceed as follows:
1. After making sure that the whole hose is reeled in, [NOTICE]
turn the reel further (for 4.5 - 5.5 turns). If the spring recoils, it may hurt personnel. Be sure
to clamp it securely with vice pliers.
2. Draw out the hose and install it. Clamp with vice pliers, paying attention to the
installation orientation of the spring.
4. Disassembly 1) With spring clamped by vice pliers, remove

the spring holder constricting the spring.
[NOTICE]
This process is very dangerous. Take extreme
caution in executing it to secure safety.
1. Unscrew hexagon socket set screws, and remove

support from spring case .
2. Unscrew nuts, and remove drum plates from

spring case.
3. After attaching protection plates as shown,

utilizing the case mounting holes, to prevent
spring from hurtling out, unscrew special bolt on
the pin side, and extract pin.
4. To replace spring, remove it from spring case as

follows:
29 W183-0133E
G-6. G-6.
Hose Reel
2) With the lower side coated with grease,

place spring in case clamped in a vise, and
install the protection plates.
3) Fasten spring and pin with special bolt

coated with screw locking compound.
4) Remove the vise pliers on the outer end side

of spring and attach auxiliary spring.
5) Fasten the spring to spring case with special

bolt coated with screw locking compound.
6) After installation, apply water repellent

compound to nut.
7) Remove the remaining vice pliers.
3. Temporarily install drum plate, to spring case,

install support to pin, and fasten with set screws.
4. Remove the protection plates, install seat packing,

coated with adhesive on both sides, aligning with
the bolt holes to spring case.
5. Install drum plates to the spring case with nuts.
6. Apply water repellent compound to the mating

surfaces of drum plates.
366-716-50000 ٌ
1
30 W183-0133E
G-7 G-7
Hydraulic Valve
G-7 Hydraulic Valve
[NOTICE]
1. Structure
PP
P C T Dr
IW123-017001
PP
Dr
C P T
IW123-017002
Tightening torque
N-m kgf-m ft-lbf
P, C, T G3/4 167 17 123
PP, Dr G1/4 29.4 3 22
31 W123-0173E
G-7 G-7
Hydraulic Valve
19 6
17
15
C P T Dr
15 3 10 1 2 7 10
IW123-017003
1.Body 3.Cover 7.Spring 15.Hex. socket head bolt

2.Spool 6.Solenoid valve 10.O-ring 17.Plug
19.Orifice
Tightening torque
N-m kgf-m ft-lbf
Mounting bolt
M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
(for solenoid valve.6)
32 W123-0173E
G-7. G-7.
Hydraulic Valve
Solenoid valve assy
Connector
(+): Red
(-): Blue
IW121-0542E01
T1 3
A P B
T T
T2 12 9 1 15 8 7 11 2
IW121-025003

2.Plug 8.Square ring 12.Solenoid
Tightening torque
N-m kgf-m ft-lbf
2 - 44 - 49 4.5 - 5 32.5 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
366-497-50000 ٌ
1
366-463-10000 ٌ
1
33 W123-0173E
H
Safety System
Contents
H
H-1 Safety System .................................. 1 H-3 Outrigger Extension Length
Detector ....................................8
1. General ...................................................... 1
1.1 Pressure sensor ......................................... 1 1. Structure and function................................ 8
1.2 Boom length and angle detector ................ 1
1.3 Outrigger extension width detector............. 1 2. Disassembly .............................................. 9
1.4 Other detectors and switches..................... 1
1.5 AML (Load moment indicator) main body .. 1 3. Reassembly............................................. 10
1.6 Overwind cutout (Anti-twoblock) device ..... 1
1.7 Solenoid valve ............................................ 1
H-4 Solenoid Valve (Auto Stop) ...........12
2. Description of system ................................ 1
1. Structure .................................................. 12
1.1 (GR series : --546171)
H-2 Boom Length and Angle (GT series: --475379) .........................12
Detector.................................... 2 1.2 (GR series: 546172--)
(GT series: 475380--) .........................13
1.Structure and function.................................... 2
2. Solenoid valve assy................................. 14
2. Disassembly and reassembly .................... 4
2.1 Removing the cord ..................................... 4
2.2 Installing the cord ....................................... 4
2.3 Replacing spiral spring ............................... 6
2.4 Disassembling the potentiometer
(for boom length detector).................... 6
2.5 Reassembling potentiometer...................... 7
2.6 Replacing the boom angle detector ........... 7
3. Adjustment................................................. 7
i
H-1. H-1.
Safety System
H-1 Safety System 1.6 Overwind cutout (Anti-twoblock) device

1. General The anti-twoblock device prevents damage to the
crane that would be caused by pulling the hook
1.1 Pressure sensor
block pulled hard into the boom head. When the
1. A retraction pressure sensor and an extension hook block approaches the boom head, single top
pressure sensor are incorporated in the elevating or jib, the overwind cutout device sends a signal
cylinders. to AML, which then stops any further crane action
toward the critical condition.
2. They convert the elevation pressure into the
electric signal and transmit it to AML (Load 1.7 Solenoid valve
moment indicator) main body, making the limiter
calculate the total moment created by the lifted 1. If AML malfunctions or if the actual moment
load and the mass of the boom. reaches 100% of the rated moment or the hook
block is over-hoisted, an electric signal (auto.
1.2 Boom length and angle detector stop) is sent from AML main body to this valve.
The Boom length and angle detector is installed 2. When the solenoid valve is deenergizied, this
on the boom side, and uses the potentiometer solenoid valve contents the vent line of the relief
inside the detector to convert the extended boom valve mounted on the hydraulic pilot control valve
length and the angle of the boom relative to the to the tank. The solenoid valve by allowing the
ground into an electric signal that is transmitted to pressurized oil from the pump to escape through
AML main body. the relief valve to the tank, therefore the crane
operation stops.
1.3 Outrigger extension width detector
It is installed on the rear end of the outrigger outer

2. Description of system
case. The potentiometer in the detector converts
Refer to the repair manual of AML-L.
the outrigger extension width into the electric
signal and transmits it to AML main body.
1.4 Other detectors and switches
The outer detectors and switches convert the

crane operation modes and working conditions
into an electric signal that is transmitted to AML
main body.
1.5 AML (Load moment indicator) main body
1. AML main body calculates the moment being

generated on the crane based on signals from the
pressure sensor and the Boom length and angle
detector.
2. The calculation result is compared with the rated

moment and,when it reaches 90% and 100% of
the rating, AML sends alarm and auto. stop
signals, respectively, to prevent the crane from
being overloaded.
1 WH02-0081E
H-2 H-2
Boom Length and Angle Detector
H-2 Boom Length and Angle Detector

[NOTICE]
1.Structure and function

rotation is reduced by the reduction gear,which in
1. The boom length and angle detector consists of a
turn rotates the shaft of the potentiometer.
recoil spring, cord, reduction gear, potentiometer
(for boom length detection), and boom angle 3. The electric resistance of the potentiometer shaft
detector. varies proportional to the reduction of the shaft
rotation,and the change in electric resistance is
2. The cord wound on the drum is unwound and
transmitted to the AML main body to detect the
rewound by the recoil spring after the extension
boom length.
and retraction of the boom.The resultant drum
2 W305-0453E
H-2 H-2
1.Plate 16.Spring 31.Pin terminal 46.Cable

2.Case 17.Cover 32.Nut 47.Holder
3.Drum assy 18.Clip 33.Washer 48.Terminal
4.Slip ring assy 19.Support 34.Screw 49.Terminal
5.Contact assy 20.Clamp 35.Bolt 50.Angle detector
6.Contact assy 21.Cord guide 36.Bolt 51.Plug
7.Bearing case 22.Collar 37.Screw 52.Collar
8.Bearing 23.Packing 38.Screw 53.Bolt
9.Retaining ring 24.Packing 39.Screw 54.Spring washer
10.Retaining ring 25.Packing 40.Screw 55.Plain washer
11.Speed reducer 26.Connector 41.Screw 56.Bolt
12. -------- 27.Connector 42.Screw 57.Plain washer
13.Gear 28.Cord lock 43.Set screw 58.Spring washer
14.Bracket 29.Screw 44.Nut 59.Clip
15.Potentiometer 30.Pin terminal 45.Rubber bush 60.Collar
Potentiometer Resistance : 5000 ± 750ȍ

(for boom length detection) Electric turning angle : 347-352°
Mechanical turning angle : 360°,
continuous rotation
Potentiometer Resistance : 1000±200䎃
(for boom angle detection) Electric angle : 120 ± 1.8°
Electric Symbol
[NOTICE]
About the connector applicable to serial No.(Spec. No.) up to 437648. 437648 (GT-550E-1)
437572 (GT-600-1)
475370 (GT-700E-1, GT-800-1)
545760 (GR-600-1, GR-700E-1, GR-800-1)
3 W305-0453E
H-2 H-2
Drum assy
2. Disassembly and reassembly
2.1 Removing the cord
1. Remove the connector and the cord lock from the

end of the cord. Wind up the cord on the drum Plate
slowly until no tension of the spiral spring is
applied on the cord.
2. Loosen the clamp and remove the cover (2 place).
3. Disconnect the cable, potentiometer and angle

detector from the terminal, and remove the cover Nut IW305-0230E04
and the cable together.
4. Loosen the set screw and remove the gear. Then 7. Remove the slip ring assy from the drum assy.
remove the screw and detach the speed reducer. Then remove the solder that bonds the slip ring
and the cord.
[NOTICE]
Remove the speed reducer straight upward. Do not Slip ring assy
twist it while removing. Slip ring assy
5. Remove the retaining ring and bolt, and separate Core wire
the case from the drum assembly. Cord
[NOTICE]
Shield wire
Put match marks on the case and the plate to
identify the direction for removing the sub-cord. IW305-0230E05
Retaining ring
Case 8. Detach the whole old cord from the drum assy.
2.2 Installing the cord
1. Wind a yellow tape around the new cord as a

Bolt
0-marker.
Sub-cord
Plate
Match marks
IW305-0230E03
6. Remove the nut and separate the drum assy from

2. Pass the new cord through the hole of the drum
the plate.
assy. Solder it on the slip ring assy.
[NOTICE]
Attach the cord core wire to the inner slip ring.
Attach the shield wire to the outer slip ring.
Completely insulate the soldered section.
4 W305-0453E
H-2 H-2
Core wire original position after it is rotated a quarter turn by

Cord
finger and released. If it is not returned, loosen the
bolt and adjust the position of the bracket.
Shield wire
[NOTICE]
Drum assy
Vinyl tube If the potentiometer is faulty, replace it referring to
IW305-0230E07 the "Replacing the potentiometer (boom length
detector)" described later.
3. Install the slip ring assy so that the cord is not 10. Fix the gear in the notched section of the speed
slackened. reducer shaft using a set screw. Apply thread
locking agent to the set screw.
4. Wind the new cord around the drum assy while
taking up slack in the cord. When the 0-marker on Tightening torque :
the 8.83 m (29.0ft) point of the cord shows on the 1.18 N-m (0.12kgf-m) {0.87ft-lbf}
drum, wind the cord 13 turns more and fix it with
gummed tape to prevent slackening. 11.Take out the new cord from the guide hole of the
cord reel and draw it out completely. Then wind it
[NOTICE] again the drum. When the 0-marker comes to the
Wind the cord around the drum assy clockwise as edge of the cord guide, fix the cord there as
seen from the slip ring. shown in the figure.
0-marker
Slip ring
Gummed tape
IW305-0230E09
Gummed tape
IW305-0230E08 12. Applied voltage DC 5V to the potentiometer (for
boom length detector) as shown in the figure and
turn the gear using a screwdriver until the output
5. Insert the shaft of the drum assy into the boss
voltage between the red and white terminals is 0.5
hole of the plate and fix it with a nut.
± 0.06 V. Then fix the gear using a set screw.
6. Put the case over the drum assy, leading the Apply thread-locking agent to the set screw.
sub-cord outside through the hole of the case and
Tightening torque :
the cord end outside through the opening of the
1.18N-m (0.12kgf-m) {0.87ft-lbf }
cord guide.
Screwdriver
7. Secure the case and the plate with a bolt and Gear B
attach the retaining ring. Gear A Set screw
Bracket
8. Apply sealant agent thinly on the bottom of the Spring
speed reducer. Then install the speed reducer on
the case. White
Red +
9. Inset the gear on the shaft of the speed reducer. - Tester
Black
Loosen the set screw on the potentiometer side to - Applied
+ voltage
allow both gears to idle.
IW305-0230E10
Check that the gear is spring-returned to the
5 W305-0453E
H-2 H-2
13. Draw out the cord slightly from the drum and 2.4 Disassembling the potentiometer
make sure that the resistance between the red (for boom length detector)
and white terminals increases smoothly. [NOTICE]
14. Connect the cable to the terminals for the If both the cord and spiral spring are faulty, remove
the detector assy from the boom.
potentiometer and angle detector.
If only the potentiometer is faulty, it is not necessary
15. Attach the cover. to remove the detector.
16. Pull the cable to eliminate slack, and tighten the 1. Loosen the 2 clamps and remove the bolt and
clamp. (2 places) cover.
17. Install the cord lock on the cord end and install 2. Disconnect the lead wire terminals (3 pieces) and
the lead wires and the connector close to the cord cable terminal from the potentiometer, and
end. Completely insulate the soldered remove the potentiometer together with the
connections. bracket.
8.5 m (27.9ft) [NOTICE]

0.08 m
ft) (0.26ft) Before replacement, disconnect the wiring to the
(0.8
m boom angle detector from the pin terminal section to
0.25
disconnect the lead wires (red and black) from the
Cord lock boom angle detector.
0-marker
Wind HI-BOND tape for
Connector waterproofing and then Gear
wind insulating tape.
Spring
Yellow
Cord Bracket

White Lead wire
IW305-0230E11
Lead wire
18. Check for conduction and shortcircuit between Potentiometer Black

the terminals of the sub-cord connector and the Red
cord connector. To boom angle detector

Pin terminal
IW305-0230E13
Sub-cord Cord
3. Remove the gear and the spring, and detach the

IW305-0230E12
potentiometer from the bracket.
4. Remove the connector and the cord lock from the

2.3 Replacing spiral spring end of the cord. Wind up the cord on the drum
slowly until no tension of the spring is applied on
[NOTICE]
the cord.
If the spiral spring is broken, replace the whole
drum assy. For removing and installing the spring,
refer to the "Removing the cord" and "Installing the
cord" above mentioned.
6 W305-0453E
H-2. H-2.
2.5 Reassembling potentiometer 2.6 Replacing the boom angle detector
1. Install a new potentiometer. Disconnect the lead wires to the boom angle
detector from the pin terminal section, and replace
[NOTICE]
the boom angle detector assy.
To avoid exposing the potentiometer to high
temperature for a long time, solder the
potentiometer terminal and the lead wires quickly.
3. Adjustment
Fix the potentiometer terminal including the lead
wires to the bracket using insulating sealant.
1. Adjust the cord lock so that the 0-marker on the
cord is on the edge of the cord guide when the
Recommended sealant: Shin-Etsu Silicone
boom is fully retracted.
KE45RTV (Shin-Etsu Chemicals Industry)
Bracket
0-marker Cord lock

Potentiometer Insulating sealant IW305-0230E16
IW305-0230E14
2. Adjust the boom length display of the AML.

2. Loosen the set screws on the reducer side and (Refer to the repair manual of the AML.)
potentiometer side to allow both gears to idle.
Check that the gear on the potentiometer side is
spring-returned to the original position after it is
rotated a quarter turn by finger and released. If it
is not returned, loosen the bolt and adjust the
position of the bracket.
Gear B
Gear A Bracket
Spring
Bolt
IW305-0230E15
3. Fix the gear in the notched section of the speed

reducer shaft using a set screw. Apply thread
locking agent to the set screw.
Tightening torque :
1.18N-m (0.12kgf-m) {0.87ft-lbf}
4. Follow the same procedure as described in the

step 12. and below of the "Installing the cord"
section. 361-322-80000 ٌ
0
7 W305-0453E
H-3 H-3
Outrigger Extension Length Detector
H-3 Outrigger Extension Length Detector

[NOTICE] 3. The consequent rotation of the drum drives the
There is a case that the appearance and so on potentiometer shaft through gears which reduce
differ from the parts for this machine. Although there the speed to 5/6.
is not so much difference in functions and
disassembly procedures, make sure of the serial 4. The rotation of the shaft causes a proportional
number of this machine and the part sales unit
described in the parts catalog before starting change in the electrical resistance of the
disassembling operations. potentiometer. This change is supplied by the
multiplex data transmission (MDT) system to the
1. Structure and function AML (Load Moment Indicator) unit for detection of
the outrigger extension length.
1. The detector consists of the following major
components: a spiral spring, wire, and 5. When the wire is reeled out, the gears,
potentiometer. potentiometer, and potentiometer brush either
rotate or move.
2. The wire wound around the drum is unwound or
rewound by the action of the spiral spring as the
cylinder extends or retracts.
Potentiometer
Electric symbols 1 B Black 0V
3 R Red +5V (Power supply)
2 W White Out put
IW305-0250E01
Use silicon sealant to seal

the part that is shaded.
1 2 3 4 5 6 7 8
15
16
9
10
11 12 13 14 20 17
19
Power supply (Red)
0V (Black)
18
Output (White) IW305-0350E01
8 W305-0351E
H-3 H-3
1. Base plate 6. Nut 11. Screw 16. Screw

2. Drum assembly 7. Potentiometer 12. Set screw 17. Clamp
3. Case 8. Cover 13. Screw 18. Connector
4. Packing 9. Shaft 14. Gear•B 19. Cable
5. Gear•A 10. Bolt 15. Bracket 20. Entangling prevention fitting
Specification 2. Remove screw and loosen clamp to remove

cover.
Item Specifications Cover
Gear ratio 6/5 Screw Clamp Cable
Resistance: 2kȍ ± 5%
Potentiometer Mechanical rotating
angle: 360°
IW305-0250E03
2. Disassembly
3. Remove screw and remove potentiometer and
1. Move the entangling prevention fitting to the zero gear together with bracket.
point mark of the wire (yellow tape position), and
Potentiometer
fix it. And, wind up the wire to the drum up to the
zero point mark position. Gear
[NOTICE] Bracket
If the entire wire is rolled in the drum with the
Screw
potentiometer placed to the drum, the potentiometer
will be damaged.
Entangling IW305-0250E04
prevention
fitting
4. Remove screw to remove case .
Case
L1
L2 IW305-0350E02
Screw
L1: 0.08m(0.26ft)
L2: 0.48m(1.56ft)
IW305-0250E05
9 W305-0351E
H-3 H-3
3. Reassembly
5. Remove bolt and separate drum assembly and
base plate. 1. Put a zero marker on a new wire by winding a
Drum assembly yellow tape on it. Then tie an auxiliary string of
about 1.0 m (3.3 ft) in length to the terminal of the
wire.
Zero marker (yellow tape)

Aux. string
Drum side
Base plate
L4
Approx.
L3
1m (3.3ft)
IW305-0251E10
L3 : 3.24 m (10.63ft)
L4 : 0.08m (0.26ft)
Bolt
2. Wind the wire round drum assembly until the
IW305-0250E06
yellow tape position. Then wind it three additional
turns an secure the wire with a packing tape to
6. Remove the wire from the drum assembly.
prevent it from getting loose.
[NOTICE]
The wire winding direction should be clockwise as
viewed from the shaft end.
Gear side
Gummed tape
IW305-0251E11
3. Mount base plate on drum assembly with bolt.
Drum assembly
Base plate
Bolt
IW305-0250E06
10 W305-0351E
H-3. H-3.
4. Apply grease (Molyspeed Grease No.0) to the When replacing the potentiometer with a new one,
bearing of case and put the case over drum mount it onto the bracket, then solder the cable to
assembly. In this time, lead the end of the the potentiometer terminal.
auxiliary string out through the opening of the cord
[NOTICE]
guide.
Case Finish soldering the wire to the potentiometer
terminal as quick as possible (max. 5 seconds) to
minimize undesirable heat transmission to the
potentiometer.
Scrwe
Apply insulation sealant to the terminal of the
potentiometer.
Recommended sealant: Shin-Etsu Chemical’s
IW305-0250E05
Shin-Etsu Silicon KE45TRV
5. Secure case on base plate with screw. 8. Slightly draw out the wire from the drum. Check to
verify that the resistance between B and W
6. Draw out the wire from the guide window of the
decreases smoothly.
reel. After the wire has been extended to the
0-point mark (yellow tape), secure the wire to the 9. Mount cover, while positioning clamp on the
case with gummed tape. opposite side of the potentiometer.
7. Rotate gear•A of the potentiometer by hand. At the Cover

position where the resistance between B and W is Screw Clamp Cable
170 ± 30ȍ, mesh gears•A and B, and install the
potentiometer.
Gear • A
Gear • B
IW305-0250E03
10. Pull cable to take up the slack and then tighten

clamp.
11.Tighten the clamp after pulling the cable and

removing loosening.
12.Remove the auxiliary string from the wire edge.

IW305-0350E03
[NOTICE]
Potentiometer Detach and store the entangling prevention fitting
1 B Black 0V after installing the length detector in an actual
3 R Red +5V (Power supply) machine.
2 W White Out put
IW305-0250E01
361-319-40000 ٌ
0
11 W305-0251E
H-4 H-4
Solenoid Valve (Auto Stop)
H-4 Solenoid Valve (Auto Stop)
[NOTICE]
1. Structure
1.1 (GR series : --546171) (GT series: --475379)
1.Body
2.Distance piece
3.Filter element
4.Plug
5.Plug
6.O-ring
7.O-ring
8.Solenoid valve assy
T1
8 1 5 6 3 2 7 4 IW121-0540E03
Tightening torque
N-m kgf-m ft-lbf
A, B, T G1/4 29.4 3 22
4 G3/8 30 - 37 3 - 3.8 22.1 - 27.3
T1 M5 6.9 – 8.9 0.7 - 0.9 5.1 – 6.5
12 W121-0545E
H-4 H-4
1.2 (GR series: 546172--) (GT series: 475380--)
1.Body
2.Retainer
3.Filter element
4.Plug
5. Solenoid valve assy
6.Name plate
7.Screw
Tightening torque
N-m kgf-m ft-lbf
A, B, T G1/4 29.4 3 22
2 G1/4 6.9 - 8.8 0.7 - 0.9 5.1 - 6.5
T1 M5 6.9 - 8.9 0.7 - 0.9 5.1 – 6.5
13 W121-0545E
H-4. H-4.
2. Solenoid valve assy
Connector
(+): Red
(-): Blue
IW121-0542E01
T1 3
A P B
T T
T2 12 9 1 15 8 7 11 2
IW121-025003

2.Plug 8.Square ring 12.Solenoid (DC24V)
Tightening torque
N-m kgf-m ft-lbf
2 - 44 - 49 4.5 - 5 32.5 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
366-460-80000 ٌ
2
14 W121-0545E
K
Cab
Contents
K-1 Crane Cab Glass .............................. 1 7. Condenser Assy ...................................... 18
1. Glass replacement procedure.................... 1 8. Electric..................................................... 19

8.1 Electric circuit............................................19
2. Bonding the joint between windshield glass 8.2 Main harness A .........................................20
and roof glass................................. 2 8.3 Main harness B .........................................21 K
9. Important points for assembly (Layout) ... 22
K-2 Air Conditioner................................. 3 9.1 Evacuation ................................................22
9.2 Charging with refrigerant...........................22
1. Component parts ....................................... 3 9.3 Check for gas leakage and amount of
refrigerant charge ...............................23
2. Introduction to air conditioning................... 4 9.4 Heated water circuit ..................................23
2.1 Principle of air conditioning ........................ 4 9.5 Run-in operation .......................................23
9.6 Bolt size and tightening torque .................23
3. Basic refrigeration cycle............................. 5
3.1 Structure ..................................................... 5 10. How to charge air conditioner gas ........... 24
3.2 Conditions for air conditioning equipment .. 6 10.1 Charging gas in automatic operation ........24
3.3 Refrigerant.................................................. 7 10.2 How to charge air conditioner gas ............26
3.4 Refrigeration cycle of a car air conditioner. 8 10.3 How to check air conditioner.....................28
3.5 Comparison with a household air conditioner
............................................................. 8 11 Diagnosis table ........................................ 29
3.6 Receiver functions...................................... 9 11.1 Car air conditioner system diagnosis
3.7 Reheat method ......................................... 10 table I (Refrigeration circuit)................29
3.8 Components ............................................. 11 11.2 Car air conditioner system diagnosis
table II (External causes other than
4. Layout ..................................................... 13 insufficient cooling and abnormal
4.1 Overall layout............................................ 13 pressure).............................................32
4.2 Overall layout............................................ 14 11.3 Car air conditioner system diagnosis
4.3 Evaporator section ................................... 15 table III (Electrical system)..................34
11.4 Car air conditioner system diagnosis
5. Compressor Assy..................................... 16 table IV (Electronic thermo system)....36
6. Evaporator Assy....................................... 17
i
12. Compressor ............................................. 38
12.1 Compressor abnormal sound diagnosis chart
........................................................... 38
12.2 Compressor diagnosis chart (1/2) ............ 39
13. Troubleshooting ....................................... 41
14. Control table ............................................ 47
K-3 Hydraulic Motor (Air Conditioner)

(Option) .................................. 48
1. Structure .................................................. 48
K-4 Solenoid Valve (Air Conditioner)

(Option) (--475376)................. 50
1. Structure .................................................. 50
K-5 Solenoid Valve (Air Conditioner)

(Option) (475377--)................. 52
1. Structure .................................................. 52
ii
K-1 K-1
Crane Cab Glass
K-1 Crane Cab Glass 6. Let the primer C coated surfaces dry for more
1. Glass replacement procedure than 15 minutes.
Follow the procedure described below to replace 7. Clean and degrease the bonding surfaces of the
the fixed windshield window glass, roof glass, new glass with a gauze soaked with white
front right window glass (quarter window glass) gasoline or acetone.
and rear right window glass of the crane cab. Leave it more than 1 minute to dry.
1. Remove the glass to replace and the adhesive [NOTICE]

from the cab body, and clean the window opening Shake the primer bottle well and then apply the
surfaces. primer with a brush. While making sure that there is
no portion left uncoated or blurred, apply the primer
2. Fit a trim all around the glass bonding frame of the evenly.
cab body. Prevent the primer coated surfaces from any
[NOTICE] contact with hand, brush hairs, dust, water drops,
etc.
Make adjustments so that the glass and the rubber
dam of the trim will make even contact with each The primer deposited on a surface other than the
other. glass bonding surfaces should be immediately
wiped away with a cloth soaked with white gasoline.
3. Temporarily set a new glass on the cab, attach
pieces of masking tape across the glass and 8. Apply 5 to 20μm (0.0002 to 0.0008 inch) thick coat
frame in more than two places to mark their of primer B to the non-ceramic coated portion on
relative positions, and then remove the glass. the outer circumference of the new glass.
(Example) Roof glass • Primer B:
AR Primer for glass (black)
Cemedine Co., Ltd.
Apply
[15 mm (0.59 in)]
Ceramic coating
4. Clean and degrease the glass bonding surfaces of

the cab body with a new gauze soaked with white
Glass
gasoline or acetone. Wait for more than a minute IW587-0011E01
to let them dry.

9. Let the primer B coated surfaces dry for more
[NOTICE] than 15 minutes.
Shake the primer bottle well and then apply the
primer with a brush, while making sure that there is [NOTICE]
no portion left uncoated. Apply the POS seal to the cab interior side of the
Prevent the primer coated surfaces from any molding, to a point inner than the center.
contact with hand, brush hairs, dust, water drops,
etc. 10. Apply the POS Seal (Cemedine product) to the
The primer deposited on a surface other than the glass fitting groove of the molding.
glass bonding surfaces should be immediately
wiped away with a cloth soaked with white gasoline.
5. Apply a 5 to 20μm (0.0002 to 0.0008 inch) thick
coat of primer C to the glass bonding surfaces of
the cab body.
• Primer C:
AR Primer for cab (clear)
Cemedine Co., Ltd.
1 W587-0011E
K-1. K-1.
Crane Cab Glass
[NOTICE] 14. Set and press the new glass against the cab
Wipe away any excessive adhesive. while aligning the marks (masking tape pieces
put in Step 3) on the glass with those on the cab
11. Fit the molding on the circumference of the new body.
glass and bond its end joint with an instant
aneous adhesive.
2. Bonding the joint between windshield

[NOTICE]
glass and roof glass
Apply the adhesive so that its cross sectional form
is as shown in the figure by shaping it with a 1. Bond 50 mm (1.95 in) wide pieces of masking
spatula.
tape to places 1 to 2 mm (0.039 to 0.078 in) away
For a portion where there is a clearance between
from the edges of windshield glass and roof glass.
the glass and rubber dam, apply the adhesive to a
bead height of more than 5 mm (0.2 in).
2. Remove the rubber dam backing paper.
ٟInstall the glass in less than 30 minutes after
application of the adhesive. 3. Install and press the new glass while aligning the
marks with those on the cab body.
12. After installing the trim on the glass bonding
portion frame of the cab body, apply the adhesive 4. Secure the windshield glass and roof glass on the
to the glass bonding surfaces. cab body with an adhesive tape.
• Adhesive:
5. Fill the space between the windshield glass and
S-511A [Black paste to use when room
roof glass with the adhesive (cemedine’s S-511A
temperature is higher than 15°C (59°F)]
or S-511F-1) and reshape it with a spatula so that
S-511F-1 [Black paste to use when room
it will be flush with the glass.
temperature is lower than 15°C (59°F)]
Cemedine Co., Ltd. [NOTICE]
After the glass has been bonded, allow a curing
period of more than two hours. Don’t move the
glass.
After the glass has been bonded, secure the glass
on the cab body with a rubber tape or elastic cord,
or by other suitable means.
Unit : mm (1mm = 0.039 in) 6. Remove the masking tapes and wipe away
13. Remove the rubber dam backing paper. excessive adhesive using white gasoline or
(Refer to the figure.) acetone.
[NOTICE]
ٟWhen the glass installed, press it only once. Do not
press it repeatedly (This can form air bubbles).
Excess adhesive must be wiped away with a
spatula and white gasoline.
Unit : mm (1mm = 0.039 in)
2 W587-0011E
K-2 K-2
Air Conditioner
K-2 Air Conditioner
[NOTICE]
1. Component parts
1.Air conditioner assy 11.Compressor assy 17.Washer 24.Bush

2.Box assy 12.Harness 18.Nut 25.Bush
3.Air distributor 13.Pulley 19.V-belt 904.Pump assy
4.Harness 14.Bolt and washer 21.Suction hose 905.Control panel assy
5.Drain hose 15.Washer 22.Discharge hose 906.Condenser assy
6.Outlet grill 16.Bolt and washer 23.Liquid hose
3 W701-0162E
K-2 K-2
Air Conditioner
(Absorbing heat from surroundings.)

2. Introduction to air conditioning Vaporization
[NOTICE]
Liquid Vapor
This section explains the fundamentals of the car
air conditioner. Difficult concepts and special
mechanisms have been omitted where possible, Condensation
(Radiating heat of vapor outward.)
and only contents which focus on the basic
functions have been included. IS701-0010E0
2.1 Principle of air conditioning

5. A compressor is needed to compress the vapor,
1. When alcohol is applied to your skin, it feels cool, and a condenser is needed to absorb heat from it.
and when your garden is watered in the
summertime, you also feel cooler air. This is
because when alcohol or water vaporizes, it
absorbs heat (known as latent heat) from its
surroundings. As a liquid (such as alcohol and
water) changes into a vapor (such as alcohol
vapor and water vapor), it requires heat
(evaporation heat). The substance surrounding
the liquid is cooled as heat is absorbed from it.
2. This natural phenomenon explains in brief the

principle of the air conditioning that is used when
we need to lower the temperature in the cab.
3. However, if the vaporized liquid used for cooling is

simply disposed of into the air, it must be
constantly replenished with more liquid. As this is
not practical, in the actual cooling system the
vapor is cooled and returned to liquid form
(condensed).
4. To condense the vapor, it is necessary to absorb

heat from it. At this time if the vapor is
compressed to higher pressure, condensation will
take place relatively easily.
4 W701-0162E
K-2 K-2
Air Conditioner
3. Basic refrigeration cycle

2. Compressor
This component absorbs the gaseous refrigerant
3.1 Structure
that was vaporized in the evaporator, and
An ordinary air conditioner circulates a volatile compresses it to higher pressure so that it can be
liquid (called a refrigerant) that is contained in more easily liquefied in the condenser.
piping. In this piping, the refrigerant is repeatedly
3. Condenser
vaporized and condensed.
In this component, the high-temperature
This device is made up of the following
high-pressure refrigerant gas that was
components.
compressed by the compressor is cooled and
1. Evaporator liquefied.
In this component, the refrigerant vaporizes and
4. Expansion valve
absorbs heat from around the pipes, thus cooling
This is a kind of throttle valve which functions as a
the room.
barrier to keep the inside of the evaporator at low
pressure. It sprays the high-pressure liquid
refrigerant from the condenser into the evaporator
through a tiny opening, forming a low-pressure
low-temperature mist that is can easily and rapidly
vaporize.
5 W701-0162E
K-2 K-2
Air Conditioner
3.2 Conditions for air conditioning equipment
The conditions required for a high-performance air conditioner are the following.
Refrigerant vaporizes at the lowest temperature possible.
Refrigerant liquefies easily.
The largest possible quantity of refrigerant vaporizes in the evaporator.
1. When we look at the conditions of the refrigerant 5. If the amount of refrigerant is insufficient, it
within the refrigeration cycle, we find that the completely evaporates in the middle as it passes
refrigerant which was compressed by the through the evaporator. This results in degraded
compressor becomes a high-temperature performance of the evaporator.
high-pressure gas.
6. On the other hand, if there is too much refrigerant,
2. The refrigerant next enters the condenser, where it cannot vaporize in the evaporator, and some
it is cooled and changed from gas to liquid form as remains in liquid form when it enters the
it passes through. All of the refrigerant must be compressor. If this occurs, there is the possibility
changed to liquid form when it reaches the that compressing liquid instead of vapor will
condenser outlet. If the condenser cooling is damage the compressor.
insufficient, some refrigerant remains in gas form,
7. For these reasons, the amount of refrigerant must
and will result in degraded cooling performance.
be adjusted according to meet a variety of
3. When the liquid refrigerant passes through the conditions.
expansion valve, it is atomized.
8. The purpose of the air conditioner is to provide a
The expansion valve is also known as a throttle
comfortable environment not only by lowering the
valve. It sprays the high-pressure liquid through a
cab temperature, but also by reducing the
small nozzle to create a refrigerant mist. This
humidity. This is accomplished by cooling the hot
allows the refrigerant to vaporize easily.
air in the cab, and condensing the moisture in it
4. In the evaporator, the refrigerant mist absorbs when it passes the evaporator.
heat from the cab and vaporizes rapidly. By the
9. In this way, the moisture in the air is removed,
time it reaches the evaporator outlet, the
reducing the humidity. The water droplets that
refrigerant has been completely transformed to a
adhere to the fins are led to the outside of the
vapor.
vehicle through a hose.
6 W701-0162E
K-2 K-2
Air Conditioner
3.3 Refrigerant
2. As shown in the figure below, the refrigerant
1. The substance that circulates through the HFC134a remains in liquid form at relatively high
refrigeration cycle, and functions to transmit heat, temperatures when it is strongly compressed.
is known as the refrigerant. In our air conditioning However, at low pressures it vaporizes at
system, HFC134a is used. It is a freon-based temperatures as low as 0°C (32°F) or
refrigerant, but does not contain chlorine. -10°C (14°F).
3. This means, for example, that if the refrigerant 6. If 60qC (140°F) is possible, HFC134a will become
vaporizes at 0°C (32°F), then the evaporator is a liquid at 60°C (140°F) if the pressure is
also at 0°C (32°F). The air that passes through approximately 1.7 MPa (17.3 kgf/cm2) (246.5 psi)
this evaporator should be cooled. or above. When the gaseous refrigerant is
compressed to 1.7 MPa (17.3 kgf/cm2) (246.5 psi)
4. If the pressure is reduced so that the refrigerant
(by the compressor), the gas temperature rises to
evaporates at -5°C (23°F), the evaporator is also
approximately 80°C (176°F).
maintained at -5°C (23°F). This results in the
formation of frost, which inhibits the flow of air 7. Therefore, the temperature of the gas as it enters
through the evaporator and prevents cooling. the condenser is 80°C (176°F). The curve above
shows that when the refrigerant gas is cooled by
5. The vaporized refrigerant must then be liquefied.
20°C (68°F), it becomes a liquid at approximately
However, it is impossible to obtain a temperature
60°C (140°F) by the time it reaches the condenser
as low as 40°C (104°F) in a hot summer
outlet.
environment.
7 W701-0162E
K-2 K-2
Air Conditioner
3.4 Refrigeration cycle of a car air conditioner 2. Compared with the basic refrigeration cycle
described earlier, this cycle has an expansion
1. The refrigeration cycle of a car air conditioner
valve with a different construction, and adds a
comprises a compressor, condenser, receiver,
receiver.
expansion valve, and evaporator. The refrigerant
circulates within this cycle, with the heat in the cab 3. To increase the cooling capacity of an air
being absorbed by the evaporator and radiated conditioner, the largest possible amount of
outside the vehicle by the condenser, cooling the refrigerant must be vaporized inside the
cab. evaporator. The refrigerant must also be
completely vaporized when it reaches the
evaporator outlet.
3.5 Comparison with a household air conditioner
1. Larger temperature variation

The temperature in the cab is greatly influenced
by the outside air temperature. The cab
temperature is very high, especially when the
vehicle is parked under the burning sun.
This means:
The required amount of refrigerant within the cycle
varies greatly.
8 W701-0162E
K-2 K-2
Air Conditioner
2. Large variations in compressor speed

3. There are two types of receivers – block joint type
The compressor of a household air conditioner is
and union type. The difference is the means of
maintained at a constant motor speed. The
connecting the pipes.
compressor in a car air conditioner is driven by
the engine, and its speed varies largely. Block joint type Union type
This means: IN OUT
IN Sight glass
The amount of refrigerant circulating in the cycle
varies greatly. OUT
Desiccant
Tube
Strainer Dryer
Desiccant
Strainer
IW701-0110E08
In addition to temporarily storing the refrigerant,

the receiver also functions to separate gas and
liquid refrigerant.
3. For these reasons, the expansion valve is not a
simple throttle valve, but automatically adjusts the 4. Depending on the outside air conditions, not all of
flow in response to changes in the compressor the refrigerant may be liquefied when it is cooled
speed and cooling load, in order to always by the condenser.
maintain the optimal amount of refrigerant in the If refrigerant gas is sent to the expansion valve, it
cycle. will degrade the cooling capacity.
For this purpose, a receiver is installed to
temporarily store excess refrigerant. 5. Inside the receiver, liquid refrigerant is stored in
the lower part, while gas refrigerant is stored in
4. In an actual air conditioning system, various the upper part. Because the receiver exit pipe
controllers to adjust temperature and airflow are takes only liquid refrigerant from the bottom, the
included to keep the inside of the cab comfortable. gas and liquid are kept separated.
3.6 Receiver functions
1. The receiver is installed between the condenser

and the expansion valve. It temporarily stores the Gas refrigerant
refrigerant after it has been liquefied by the Liquid refrigerant
condenser, so that the refrigerant can be supplied
as needed to the evaporator according to the
cooling load.
2. Inside the receiver is a strainer and a desiccant, IW701-0110E09
which remove dust and moisture from the cooling

cycle.
If moisture enters the cycle, it will cause corrosion
of functioning parts, and will freeze in the hole of
the expansion valve, inhibiting the flow of
refrigerant.
9 W701-0162E
K-2 K-2
Air Conditioner
3.7 Reheat method
1. The air which cools (or heats) the cab is taken in

from outside (or inside) by a blower motor, and
then passes through the cooler unit and heater
unit before being blown out from each of the ducts.
The temperature control type at this time is the
reheat method.
Reheating type
Evaporator Heater core

IW701-0110E10
10 W701-0162E
K-2 K-2
Air Conditioner
3.8 Components
6 7 3
R/ F 1
HOT
D E F COOL
A/ C
MODE
O N
OFF
4
5
LCD panel Air circulation inside cab

8
13 COOL HOT Outside-cab air supply
12 11 10 Min. Max.
Cool Hot
Face Face and foot Foot
The current volume
The current temperature
IW701-0160E14
Switches Sign on the LCD panel

1.Power switch 8.Sign of air supply selection
2.Air conditioner switch 9.Sign of air conditioner operation (Snow-shaped sign)
3.Inside/outside air selector switch 10.Sign of air flow volume
4.Air flow switches 11.Sign of air temperature
5.Temperature control switches 12.Sign of air blowing direction
6.Air outlet changeover switch 13.Sign of the defroster switch
7.Defroster switch
11 W701-0162E
K-2 K-2
Air Conditioner
WARNING Air outlet changeover switch

While the engine and the air conditioner are This switch is used to select the air blowing
running, be sure not to touch the rotating direction. As it is pressed, the direction changes
objects (fan belt, condenser fan, etc). Face Face and foot Foot in sequence
repeatedly.
[NOTICE] The current direction is shown on the display.
ٟOperate the air conditioner after starting the engine. Defroster switch
Before stopping the engine, turn off the power
This switch is used to set the air flow coming out
switch of the air conditioner.
of the defroster.
ٟDo not place an obstructive object at the front of the
louvers. To cancel the defroster mode, press this switch
ٟThe compressor of the air conditioner stops during again or press the air outlet changeover switch.
outrigger operation and suspension lock operation. The air flows will come out in the direction last
selected.
Power switch
While the defroster is used, the corresponding
As this switch is pressed, the power to the air sign is shown on the display.
conditioner is turned on or off repeatedly.
While the switch is on, signs are shown on the
liquid crystal display.
Air conditioner switch

This switch is used to start up the compressor and
to activate the cooling/dehumidification function.
As it is pressed, it is turned on or off repeatedly.
While the switch is on, the snow-shaped sign
appears on the display.
Inside/outside air selector switch

This switch is used to select air supply between
outside-cab air supply and air circulation inside
cab.
As it is pressed, the air supply changes between
outside-cab air supply and air circulation inside
cab repeatedly.
The current air supply is shown on the display.
Air flow switches

These switches are used to select air flow volume
among four steps.
The current volume is shown on the display.
Temperature control switches

These switches are used to adjust the
temperature of the air from the air conditioner
among eight steps.
The current temperature is shown by the bargraph
on the display.
12 W701-0162E
K-2 K-2 K-2
Air Conditioner
4. Layout
4.1 Overall layout
345-107-61000 7
ٌ
13 W701-0162E 13
K-2 K-2 K-2
Air Conditioner
4.2 Overall layout
345-107-63000 7
ٌ
14 W701-0162E 14
K-2 K-2 K-2
Air Conditioner
4.3 Evaporator section
345-107-12000 4
ٌ
15 W701-0162E 15
K-2 K-2
Air Conditioner
5. Compressor Assy
16 W701-0162E
K-2 K-2 K-2
Air Conditioner
6. Evaporator Assy
17 W701-0162E 17
K-2 K-2 K-2
Air Conditioner
7. Condenser Assy
18 W701-0162E 18
K-2 K-2 K-2
Air Conditioner
8. Electric
8.1 Electric circuit
19 W701-0162E 363-205-60030 0
ٌ 19
K-2 K-2 K-2
Air Conditioner
8.2 Main harness A
20 W701-0162E 20
K-2 K-2 K-2
Air Conditioner
8.3 Main harness B
21 W701-0162E 21
K-2 K-2
Air Conditioner
9. Important points for assembly

(Layout)
9.1 Evacuation
[NOTICE]
If moisture and air are not fully eliminated from the
cycle, they will cause problems such as cooling
trouble and clogs in the cycle.
1. Evacuate by applying vacuum to the high- and

low-pressure service valves. Continue applying
vacuum for at least 10 minutes after the pressure
reaches 101 kPa (1.03 kgf/cm2) (14.6 psi).
2. Airleakage check
After evacuation is completed, leave for 5 minutes
or longer, and then check that there are no
abnormal gauge readings (pressure increases).
9.2 Charging with refrigerant
CAUTION
Never inject refrigerant from the high-pressure
side while the cycle is operating. This is
extremely dangerous; the refrigerant will flow in
reverse, and the gas can or hose may rupture.
[NOTICE]
Never inject liquid refrigerant from the low-pressure
side, regardless of whether the cycle is operating or
not. This will harm the compressor.
1. Injecting liquid
Be sure to inject from the high-pressure side,
without operating the cycle.
(1100 g or 2.42 lb)
2. Injecting gas (additional charge)

Inject gas from the low-pressure side while
operating the cycle.
22 W701-0162E
K-2 K-2
Air Conditioner
9.3 Check for gas leakage and amount of 9.5 Run-in operation
refrigerant charge
Operate the A/C for 5 minutes or more under the
[NOTICE] conditions below to perform the initial run-in
Never check using a halide-torch type leak detector. operation.
Engine speed :Idle
1. Insert refrigerant in gas form until the gauge
(High-speed starting is especially prohibited.)
pressure reads 98 kPa (1kgf/cm2) (14.2 psi). Then
Temp. control :Max. cool
use a leak tester and check for leaks.
Blower :Hi
[NOTICE]
9.6 Bolt size and tightening torque
An excess or insufficient amount of refrigerant can
result in the following trouble.
Excess amount: Cooling trouble resulting from Bolt Tightening torque
operation of the pressure switch
N•m kgf-m ft•lbf
Insufficient amount: Cooling trouble or malfunction
resulting from compressor lubrication failure Compressor
24.5 - 29.4 2.5 - 3 18.1 - 21.7
installation
2. When the sight glass bubbles disappear, control Idle pulley center
31.4 - 47.1 3.2 - 4.8 23.2 - 34.7
the refrigerant to +100 - 200 g. bolt
(Conditions)
Doors : Open
Blower : Hi
Engine speed : Idle
A/C switch : ON
Proper amount of refrigerant
Temp. control : Max. cool
9.4 Heated water circuit
1. When connecting the heated water piping, be Refrigerant lack

(Bubbles are visible)
careful not to incorrectly assemble the IN and
OUT piping. Sight glass
IW701-0160E12
2. In order to prevent damage resulting from freezing

of the water inside the heated water circuit, in the
wintertime use antifreeze in a concentration
appropriate for the outside temperature.
3. The pressure which is applied to the heated water

circuit heater core is 196 kPa (2kgf/cm2) (28.4 psi)
or less when the circuit is in use. However the
usual pressure is 98 kPa (1kgf/cm2) (14.2 psi) or
less.
23 W701-0162E
K-2 K-2
Air Conditioner
10. How to charge air conditioner gas

10.1 Charging gas in automatic operation
㩷
㩷
㩷
㩷
㩷
㩷 Gas charging unit (Reference)
㩷
㩷
㩷
㩷
㩷
㩷
㩷
24 W701-0162E
K-2 K-2
Air Conditioner
Jigs
Flow
Procedure Safety point and
No.
tools
1 Plug the power supply cord of the main unit.
2 Connect the coupler of the high-pressure side (red hose) and the Be careful to the
low-pressure side with the compressor main body sequentially. scaffold
Purge residual pressure before connecting because the
connection of coupler becomes firm if there is residual pressure in
the unit.
(Usually it has been performed at work end. Refer to Flow No.14.)
54453 Attach all freon cans. (6 cans) Be careful that gas

Tighten as it is though the gas leaks a little when attaching. liquor does not splash
4 Turn ON the automatic gas sweep switch. (to increase degree of
vacuum)
(If the gas is insufficient, turning OFF is allowed.)
5 Set the time switch to "20 minutes".
(Set to longer period if there is a time.)
6 Turn the power switch to the automatic side. (starts vacuum)
7 Vacuum operation is finished when the buzzer sounds 15-20
minutes later. Starts gas charging.
8 Engine start is allowed when buzzer sound stops. (Turn ON the air Make sure to check
conditioner switch.) surroundings
(Keep idling for at least 10 minutes --- specified by DENSO.)
9 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
10 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 rpm
The blowing temperature must be in the graphic chart value.
(Refer to the graphic chart.)
(Near the outside air temperature scale in the gauge is a standard
pressure.)
11 Stop the engine Pull out the key
12 Wait for two minutes until pressure falls, and detach the Be careful to the
high-pressure side and low-pressure side quick couplers. scaffold
13 Test gas leakage. (for all hose connections) Be careful to the Gas
(Check the gas leakage from the lower side because the freon is scaffold leak
heavier than air.) tester
Compressor: 2 places
Compressor charge coupler: 2 places
Receiver: 2 places
Condenser Assy: 2 places
Main body of air conditioner: 2 places
Pressure switch hose connections : 1 place
11 places in total
14 Detach the empty gas can, and purge pressure in the hose.
1) Set the timer knob to the vacuum side.
2) Set the power switch to the automatic or manual.
3) Turn OFF the power switch when the high/low-pressure gauge
indicates approx. "0" pressure-value after a few seconds.
15 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.
25 W701-0162E
K-2 K-2
Air Conditioner
10.2 How to charge air conditioner gas

Flow Jigs and
Procedure Safety point
No. tools
1 Plug the power supply cord of the main unit.
2 Connect the coupler of the high-pressure side (red hose) and the Be careful to the
low-pressure side with the compressor main body sequentially. scaffold
Purge residual pressure before connecting because the
connection of coupler becomes firm if there is residual pressure in
the unit.
(Usually it has been performed at work end. Refer to Flow No.16.)
3 Attach one freon can. Be careful that gas

(Put the blind caps to the couplers which gas-can has not been liquor does not splash
attached.)
Tighten as it is though the gas leaks a little when attaching.
4 Set the time switch to the position of gas replenishment.
5 Turns the power switch to the manual side. (with 3 seconds
automatic air purge)
6 Start the engine. Make sure to check
- Engine speed: Idling surroundings
- Temperature control: Maximum cool
- Blower: Lo-Hi
7 Check the condition of bubble in the sight glass. (Check whether Make sure to check
the bubble disappears.) surroundings
8 Turn OFF the power switch when the gas disappears from the Be careful to the
remainder gas sight glass of the main unit. scaffold
9 Detach the empty gas can, and attach another gas can. Be careful that gas
liquor does not splash
10 Turns the power switch to the manual side. (with 3 seconds
automatic air purge)
- Repeat Flow No.7 until the bubble disappears.
(The charging amount should be 200g㫧50g after the bubble
disappears.)
11 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
12 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 rpm
The blowing temperature must be in the graphic chart value.
(Refer to the graphic chart.)
(Near the outside air temperature scale in the gauge is a standard
pressure.)
13 Stop the engine Pull out the key
14 Wait for two minutes until pressure falls, and detach the Be careful to the
high-pressure side and low-pressure side quick couplers. scaffold
15 Test gas leakage. (for all hose connections) Be careful to the Gas
(Check the gas leakage from the lower side because the freon is scaffold leak
heavier than air.) tester
Compressor: 2 places
Compressor charge coupler: 2 places
Receiver: 2 places
Condenser Assy: 2 places
Main body of air conditioner: 2 places
Pressure switch hose connections : 1 place
11 places in total
16 Detach the empty gas can, and purge pressure in the hose.
26 W701-0162E
K-2 K-2
Air Conditioner
Flow Jigs and

Procedure Safety point
No. tools
1) Set the timer knob to the vacuum side.
2) Set the power switch to the automatic or manual.
3) Turn OFF the power switch when the high/low-pressure gauge
indicates approx. "0" pressure-value after a few seconds.
17 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.
27 W701-0162E
K-2 K-2
Air Conditioner
10.3 How to check air conditioner

Jigs
Flow
Procedure Check point and
No.
tools
1 Illumination lamp check (for control panel)
1) The lamp lights with the working lamp switch ON. (Two lamps
Lights both 2 lamps.
on upper and lower of center in the panel.)
2) The lamp turns off with the working lamp switch OFF.
2 Cooler temperature control switch. (Check with blower "HI".)
1) The cooler operates by setting to "COOL". (With maximum Must be a cold blow
cooling.)
(The cooler will be hard to operate if the ambient temperature is
low. The checking becomes easy when raising the cabin
temperature to about 25°C.)
2) The cooler stops by setting to "OFF". Must be a natural blow.
3 Heater temperature control switch (Check with blower "HI" and
engine speed maximum.)
1) Warm blow must come with maximum. Must be a warm blow
2) The heater stops by setting to "OFF". Must be a natural blow.
4
1) The blower stops by setting to "OFF".
There must be a change in
2) LO: Low, ME: Medium, and HI: High
three levels
5 Mode selector switch
1) Left position: Blows down from the duct.
2) Right position: Blows down from the windshield.
6 Electric fan for condenser
1) Must synchronize with the compressor.
7
Cooler performance check
Refer to the graphic chart in the instruction manual which is for
charging an air conditioner gas.
- Blower switch is HI.
- Temperature control is maximum COOL.
- Engine speed is MAX.
- All doors are opened. (All closes in winter.)
- Tmperature of air inhalation vent must be 25-35 °C.
(The standard of temperatures fluctuate is about 10-17°C.)
* Raise the cabin temperature with the heater as much as
Check with your hand in the
possible in the winter.
winter.
(Check with your hand that the cold blow is
Avoid performing in the low
output.---Compressor must be operating.)
ambient temperature period
as much as possible.
28 W701-0162E
K-2 K-2
Air Conditioner
11 Diagnosis table
11.1 Car air conditioner system diagnosis table I (Refrigeration circuit)
A/C system Status explanation Measures (specific
Phenomenon explanation to Diagnosis result (phenomenon of
trouble of A/C system Possible cause part name and
consider other factors principal cause)
phenomenon pressure repair method)
Bubble does not appear easily to
sight glass when dripping water on
Discharge
Sight glass is transparent with liquid condenser.
Refrigerant overcharge refrigerant up to
refrigerant. Liquid level in sight glass does not proper amount.
fall even if about two seconds have
passed since A/C OFF.
Install packing or
Hot air of condenser outlet
Pressure at high When idling, pressure at high There is a spot where hot air rubber sheet to a
Insufficient air and radiator outlet air
pressure side is pressure side is high. enters in front of condenser. part where hot air
cooling. flows in front of condenser.
high hits.
Deflate from circuit
Much air contaminates in and fill refrigerant.
----------------------------- --------------------------------
refrigeration circuit. Replace receiver
drier (R/D).
Dirt or blocking in condenser fin. ------------------------------ Wash condenser.
Ventilation to condenser is bad. Replace
Air volume of condenser fan is few. Condenser fan failure.
condenser fan.
Pressure at high pressure side Blocking in high-pressure Remove blocked
rises immediately after A/C ON. circuit between COMP. and foreign object, or
High pressure is
Bubbles appear in sight glass. R/D. replace part.
No cooling high, and low --------------------------------
(High pressure side is uncertain for
pressure is low.
vehicle with charge valve following
R/D.)
Both pressures at Gas leakage from piping Check joint
high pressure side Oil blots to the piping and parts. joint and parts. looseness and
Bubbles appear in sight glass.
and low pressure Gas detector detects. re-tighten, or
Insufficient side are low. replace part.
cooling. TXV adjustment failure TXV readjustment
Bubbles appear in sight glass, then (reduced too much), or gas or replace.
------------------------------
it changes transparently. leakage in therms sensor
tube.
29 W701-0162E
K-2 K-2
Air Conditioner

Remove blocked
foreign object, or
------------------------------ TXV failure (blocking)
replace TXV and
R/D.
Will not get cold when driving
Replace R/D.
continuously, and repeats getting Freezing of TXV by
Both high Bubble appears in sight glass, then cold after a while. Blow air volume contamination of water.
Insufficient and fill refrigerant.
pressure and low it changes transparently. does not change.
cooling.
pressure low. Evaporator dirt and
Wash or replace.
blocking.
Seal the joint with
Air leakage between cooling
No air blow or air volume is few. repair tape or
unit and heater unit.
packing agent.
Blower electric circuit or Check and repair
blower motor failure. circuit, or replace.
High pressure is High-pressure side and
Compressor discharge Repair or replace
No cooling. low, and low low-pressure side will be balanced ------------------------------
failure. compressor.
pressure is high. after stopping compressor.
Improve contact of
therms sensor
TXV therms sensor tube part. Correct heat
Low-pressure piping is abnormally ------------------------------ contacts to piping, or heat insulation.
Insufficient Low pressure is
cold and frosting. (refrigerant insulation failure. Replace therms
cooling. high.
returning) sensor tube
fixation clip.
TXV adjustment failure Readjust or
-------------------------------
(raise too much) replace TXV.
Insufficient
cooling. (Normal Blowing air volume changes Evaporator is frosting. Thermistor Check thermistor,
cooling at gradually. When A/C is OFF, and is not cold. If louver blowing Turning OFF temperature of thermo amp., and
--------------------
beginning, and blower is ON, much water is temperature gets cold enough, thermostat has lowered. mechanical
gradually reduce drained from drain hose. compressor will be OFF tentatively. thermo.
cooling later.)
30 W701-0162E
K-2 K-2
Air Conditioner

Check that thermo
Evaporator is frosting. Thermistor Installation position failure of therms sensor is in
is not cold. If louver blowing thermo therms sensor proper position.
---------------- Blowing air volume changes temperature gets cold enough, (thermistor and mechanical Move it to proper
gradually. When A/C is OFF, and compressor will be OFF tentatively. thermo capillary). position in case of
blower is ON, much water is NG.
Insufficient drained from drain hose. Evaporator is frosting. Thermistor
Check thermo
cooling. (Normal is cold. If louver blowing Thermistor or thermo amp.
---------------- system wiring, or
cooling at temperature gets cold enough, failure (will not turn OFF).
replace parts.
beginning, and compressor will not be OFF.
gradually reduce Seal with repair
cooling later.) Gas leakage from
---------------- tape or packing
evaporator case.
Air volume is small from the agent.
Evaporator frost formation.
beginning. Gas leakage from joint of
Affix packing
---------------- heater unit and evaporator
again.
unit.
---------------- Air volume does not decrease. Freezing of TXV Water intrusion in circuit.
and fill refrigerant.
Outside air intrusions to Adjust inside and
------------------------------------ inside, though inside outside air switch
circulation. dumper.
Warmed with heater. (Water
Check and adjust
valve adjustment failure or
Blowing temperature is high and it ------------------------------------- water valve and air
leakage, and air mix dumper
does not get cold (refrigeration mix dumper.
does not close completely.)
circuit is normal).
Check thermostat.
Insufficient (Check mechanical
Normal Thermostat operating
cooling. ------------------------------------- thermo, thermistor,
temperature failure.
thermo amp., and
thermo VR.)
Air volume is few and does not get Wash or replace
------------------------------------- Blocking of evaporator fin.
cold, though blowing temperature is evaporator.
cold. Blower motor revolution is Check and replace
slow. blower motor.
-------------------------------------
Blocking of blower
Check and repair.
inhalation vent.
31 W701-0162E
K-2 K-2
Air Conditioner
11.2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure)
Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Water leak is Cooling unit Leaks at normal operation. Water leak from cooling Drain hose for blocking, bend, or Install drain hose, grommets,
found. case. coming off failure. and heat insulators
Delivery valve blocking, bend, appropriately, or replace case
coming off, or opening at end. and failed components.
Blocking in outlet under case.
Crack under case.
Noise sounds. Inside cabin. Gas leakage sound is ------------------------------- Gas leakage between Seal with packing or packing
heard. evaporator unit and blower material.
motor heater unit.
Something is heard from ------------------------------- Abnormal sound from motor or Replace the one with large
blower motor fan relation. bearing. sound.
------------------------------- Foreign object intrusion in fan Remove foreign object.
case.
Refrigerant gas sound ------------------------------- Gas vibration sound (flow sound Remove interference between
(sound 'Goooo!') is heard. or pulse sound) refrigeration piping and vehicle
frame or hood, if there is.
Something is heard from Whistle sound. ------------------------------- Replace parts for the one with
TXV relation (whistle sound large whistle sound.
or gas flow sound). Gas flow sound Gas flow sound may be Check refrigerant level, and
generated at insufficient charge refrigerant.
refrigerant or at air/refrigerant
mixed condition.
------------------------------- Gas flow sound is generated
somewhat, and check sound
level, then replace if it is noisy.
Engine room side Sound is generated when ------------------------------- Clutch bearing or idle pulley Replace bearing and idle
compressor and bearing is failure. pulley. Longevity will be
electromagnetic clutch are shortened if belt is
OFF. over-tensioned.
------------------------------- Loosening of idle pulley Re-tighten screw.
mounting nut.
Sound is generated when ------------------------------- Compressor noise failure. Repair or replace in case of
compressor starts. failure.
32 W701-0162E
K-2 K-2
Air Conditioner
Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Noise sounds. Engine room side Sound is generated when -------------------------------- Vibration or slip by belt Tension belt, replace, or
compressor starts. looseness (continuous sound re-tighten screw.
'Quuuu!'). Screw looseness
failure.
Sound is generated from -------------------------------- Motor-fan shaft shaking, bearing Repair or replace.
radiator fan and condenser breakdown, fan damage, or
fan. fan/shroud come in contact.
Sound is generated from -------------------------------- Dropout of fixed bolt, looseness, Tighten appropriately, or
parts installation section or damage of brackets. replace brackets.
(shaking when touching).
Vehicle Condenser unit Condenser is set in front of Blocking in condenser fin. -------------------------------- Wash condenser fin.
overheats radiator. Revolution of condenser fan Condenser fan failure. Replace condenser fan motor.
easily. is slow.
High-pressure is high. (High Same cause as refrigeration Same measures as
pressure is high at idling.) circuit system-I. (Hot air flows in refrigeration circuit system-I
condenser.)
Vehicle Vehicle side Trouble around radiator. Blocking in radiator fin. Wash or replace radiator fin.
overheats -------------------------------- Dirt inside radiator. Check and replace.
easily. Radiator filler cap failure.
Water pump failure.
Blocking in water thermo.
Radiator coolant is -------------------------------- Check leakage and replenish,
shortage. or replace radiator.
Fan belt and water pump -------------------------------- Adjust belt tension or replace
belt are slippage. belts.
Revolution of radiator Radiator fan failure. Replace
cooling fan is slow, or
slippage.
Engine Vehicle side Engine revolution adjusting -------------------------------- Raising idling speed too much or Adjust idling speed to a
(revolutions) is device overheat. regulated value, and adjust
overrun. engine. Take measures for
overheat.
Smells Cooling unit -------------------------------- -------------------------------- Smoke of Tabaco, dust, and Wash evaporator.
unpleasant. mold, etc. are adhered or
deposited to the evaporator fin.
33 W701-0162E
K-2 K-2
Air Conditioner
11.3 Car air conditioner system diagnosis table III (Electrical system)
Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
1) Neither Check of fuse -------------------------------- No fuse blowing -------------------------------- Measures from diagnosis
compressor clutch blowing. (normal). of 2) and 4).
nor blower motor -------------------------------- Fuse blowing. Short-circuit of compressor clutch Repair
operate. or blower motor system wiring.
2) Only Connect battery Clutch does not suck. ---------------------------- Clutch failure. Replace
compressor clutch directly to clutch Clutch does suck. Clutch does suck. Either of thermo amp., pressure Check and replace parts.
does not suck. terminal. Short-circuit both ends SW, or thermistor is failure.
(Others are of thermo amp. bypass Clutch does not suck. 0 (zero) V Check parts, and repair or
operating.) connector, pressure SW, Check voltage of Either of clutch relay signal replace parts.
and thermistor. clutch relay connector. circuit or vehicle side electronic
control amplifier is failure.
Clutch does not suck. Approx. 12V Check parts, and repair or
Check voltage of Either of clutch relay or clutch replace parts.
clutch relay connector. power circuit (disconnection) is
failure.
3) Compressor Remove thermistor Clutch does not suck. ---------------------------- Thermistor failure. Replace
clutch suction does from thermo amp. Clutch does suck. Clutch does not suck. Thermo amp. failure. Replace
not stop. Remove thermo amp. Clutch does suck. Clutch relay contact failure. Replace
power supply connector.
4) Only blower Connect battery Blower motor does not ---------------------------- Blower motor failure. Replace
motor does not directly to "+" work.
work. terminal of blower Blower motor works. Blower motor works. Blower switch failure. Replace
motor. Connect L.M.H of blower Blower motor does not Blower system cords Repair
switch directly to battery work. disconnection.
terminal. Rresistor failure. Replace
5) Condenser fan Connect battery Fan motor does not work. ---------------------------- Fan motor failure. Replace
motor does not directly to "+" Fan motor works. 0 (zero) V Signal circuit is open, and thermo Check parts, and repair or
work. terminal of fan Check voltage of amp. failure. replace parts.
motor. condenser fan relay Approx. 12V Condenser fan relay contact Check parts, and repair or
connector. failure or fan motor power circuit replace parts.
open.
6) Compressor Check air gap. -------------------------------- ----------------------------- Air gap is large. Adjust air gap.
clutch slips.
34 W701-0162E
K-2 K-2
Air Conditioner
Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
6) Compressor Measure clutch -------------------------------- ---------------------------- Clutch suction voltage is low (7V Repair or replace parts.
clutch slips. suction voltage. or less).
Try to turn -------------------------------- ---------------------------- Compressor shaft does not turn Repair or replce parts.
compressor shaft smoothly.
manually.
35 W701-0162E
K-2 K-2
Air Conditioner
11.4 Car air conditioner system diagnosis table IV (Electronic thermo system)
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Compressor Check thermistor. Measure resistance of Resistance is small. Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. (Abnormal if resistance is
ON. about 7kǡ or less.)
Resistance is about 2kǡ Thermistor is normal. ----------------------------
(25͠).
Check thermo Turn OFF thermo volume. Compressor clutch is turned Thermo volume is Replace thermo volume.
volume. OFF. short-circuited.
Check relay Remove connector of Compressor clutch cannot be Relay contact joining. Replace relay or thermo amp.
contact and thermistor. turned OFF. (Stayed ON) Thermo amp. failure.
thermo amp.
Compressor Check thermistor. Measure resistance of Resistance is about 7kǡ or Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. more.
OFF. Check thermo Measure resistance of thermo Resistance is п (infinity). Thermo volume is Replace thermo volume.
volume. volume terminal. disconnected.
Check relay Detach connector of thermistor, Compressor clutch cannot be Relay contact joining. Replace relay or thermo amp.
contact and and short-circuit thermo amp. turned ON. Thermo amp. failure.
thermo amp. side connector.
Compressor Check thermo Check conduction in thermo Tester indicator changes if Contact failure in thermo Replace thermo switch.
clutch does switch. volume terminal. applying shock to thermo switch.
chattering. volume.
Tester indicator does not Thermo switch is normal. ----------------------------
change even if applying
shock to thermo volume.
Check thermo Remove thermistor, and When applying shock to Soldering failure (or, Replace thermo amp.
amp. short-circuit thermo amp. side thermo amp., compressor caulking failure) in thermo
connector. clutch does chattering. amp.
Check contact Twist connectors. Compressor clutch does Connector failure. Repair connector.
condition in wiring chattering.
connector.
Insufficient Replaces Gets cold normally. Thermistor failure. Deterioration of thermistor. Replace thermistor.
cooling. (Clutch thermistor with
works ON and new one.
OFF.)
36 W701-0162E
K-2 K-2
Air Conditioner
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp. internal Replace thermo amp.
cooling. (Clutch thermistor with not change. failure.
works ON and new one.
OFF.) Check installation Positioned correctly. -------------------------------- Thermistor failure. Replace thermistor.
condition of Incorrect position or comes off. -------------------------------- -------------------------------- Install thermistor in correct
thermistor. position.
Insufficient Refer to other -------------------------------- -------------------------------- -------------------------------- --------------------------------
cooling. (Clutch diagnosis tables.
stayed ON) (Excluding the
cause of
electronic thermo
system.)
37 W701-0162E
K-2 K-2 K-2
Air Conditioner
12. Compressor
12.1 Compressor abnormal sound diagnosis chart
38 W701-0162E 38
K-2 K-2 K-2
Air Conditioner
12.2 Compressor diagnosis chart (1/2)
39 W701-0162E 39
K-2 K-2 K-2
Air Conditioner
Compressor diagnosis chart (2/2)
40 W701-0162E 40
K-2 K-2
Air Conditioner
13. Troubleshooting
41 W701-0162E
K-2 K-2
Air Conditioner
42 W701-0162E
K-2 K-2
Air Conditioner
43 W701-0162E
K-2 K-2
Air Conditioner
44 W701-0162E
K-2 K-2
Air Conditioner
45 W701-0162E
K-2 K-2
Air Conditioner
46 W701-0162E
K-2. K-2. K-2.
Air Conditioner
14. Control table
Input Output
Input from Panel LCD display on panel
ON/OFF Blowout mode In/outside A/C switch In/outside air
M/A Blowout mode Air blow mode Relay
Switch change switch air switch mode
㪠㪥㪧㪬㪫㪆㪦㪬㪫㪧㪬㪫
ON
B/L
ON
OFF
OFF
FOOT
VENT
Lo Hi
A/C sign
M1 M2
B/L
DEF
Eva sensor
clutch
FACE
FOOT
Fresh air
䇭䇭
䇭䇭
䇭䇭
䇭䇭
䇭䇭
For air mix
Temp. UP switch
DEF mode switch
䇭䇭
Air blow UP switch
㪚㪦㪥㪫㪩㪦㪣
Circulated air
For inside and
Temp. DOWN switch

Temp. control display
For water pump
For compressor
Air blow DOWN switch

outside air mode
For blowout mode
䇭 Circulated air
䇭䇭 Fresh air
䌃䌏䌏䌌 FACE Circulated COOL MAX
Initial settings (first power ON) - ON - - - - - - - - - - - - - ON OFF OFF OFF ON OFF ON OFF OFF OFF ON 䊷 OFF
䌍䌁䌘 position ait position (display one bar)
Operates Bar increases
COOL㸢WARM OFF ON OFF - - - - - - - - - - - - - - - - - - - - - - - - - -
to WARM from left
Air mix M/A control
Operates Bar decreases
WARM㸢COOL OFF OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - -
to COOL from right
FACE mode OFF - - ON OFF 㸠㸠 - - - - - - - - FACE pos. - ON OFF 㸠㸠 - - - - - - - - - -
Blowout mode M/A B/L mode OFF - - OFF ON OFF 㸠 - - - - - - - - 䌂䋯䌌 pos. - OFF ON OFF 㸠 - - - - - - - - - -
control FOOT mode OFF - - OFF 㸠 ON OFF - - - - - - - - 䌆䌏䌏䌔 pos. - OFF 㸠 ON OFF - - - - - - - - - -
DEF mode OFF - - OFF 㸠㸠 ON - - - - - - - - 䌄䌅䌆 pos. - OFF 㸠㸠 ON - - - - - - - - - -
Inside and outside Circulated air mode OFF - - - - - - - - ON OFF - - - - - Circ. air - - - - ON OFF - - - - - - - -
air M/A control Fresh air mode OFF - - - - - - - - OFF ON - - - - - Fresh air - - - - OFF ON - - - - - - - -
Lo OFF - - - - - - - - - - - - - - - - - - - - ON OFF 㸠㸠 - - - -
Opera Opera
Blower amplifier M1 OFF - - - - - - - - - - - - - - - - - - - - OFF ON OFF 㸠 - - - -
-tes to -tes to
control M2 OFF - - - - - - - - - - - - - - - - - - - - OFF 㸠 ON OFF - - - -
䌈䌉䌌䌏
Hi OFF - - - - - - - - - - - - - - - - - - - - OFF 㸠㸠 ON - - - -
Thermo operation OFF - - - - - - - - - - 䌏䌎䌏䌆䌆 Note1 - - - - - - - - - - - - - ON - Note1 -
Compressor clutch
Frost formation detection OFF - - - - - - - - - - 䌏䌎䌏䌆䌆 Note2 - - - - - - - - - - - - - ON - Note2 -
control
Status before turning OFF is held.

Fretting prevention OFF - - - - - - - - - - - - - - - - - - - - - - OFF OFF ON ON - - Note3 -
Bars displayed on LCD Water pump relay Eight bars
OFF - - - - - - - - - - - - - - - - - - - - - - - - - - - - ON
Water pump relay are eight. ON display
control Bars displayed on LCD Water pump relay Seven or less
OFF - - - - - - - - - - - - - - - - - - - - - - - - - - - - OFF
are seven or less. OFF bars display
A/C ON signal
Signal output at A/C ON OFF - - - - - - - - - - 䌏䌎䌏䌆䌆 - - - - - - - - - - - - - - ON - ON -
output
Blinking of HOT
Air mix M/A OFF ON - - - - - - - - - - - - - 䌏䌆䌆 - - - - - - - - - - - - - - -
sign
Abnormality
Open circuit Blowout mode Blinking of human
of M/A and its OFF ON - - - - - - - - - - - - - - 䌏䌆䌆 - - - - - - - - - - -
detection M/A character sign
I/O circuit
In/outside air Blinking
OFF ON - - - - - - - - - - - - - - - 䌏䌆䌆 - - - - - - - - - - - -
Abnormal detection mode M/A in/outside air
and subsequent Abnormality
Open or Blinking
control of sensors
short-circuit Eva sensor OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - - of A/C - OFF -
and their
detection sign
input circuits
Between
Abnormality of operation panel Blinking of bar
OFF ON - - - - - - - - - - - - - OFF OFF OFF - - - - - - - - - - - OFF OFF
communication and control display "Frame"
amplifier
䇭䇭Note 1. OFF temperature: 4-6㷄(39.2-42.8°F), ON temperature: 5.5-8.5㷄(41.9-47.3°F)

䇭䇭Note 2. Timer set temperature:6-10㷄(42.8-50°F), Timer cancellation temperature:6-12㷄(42.8-53.6°F), Count up time: 10±1 minutes, Timer reset temperature: 7-13㷄(44.6-55.4°F)
䇭䇭Note 3. When compressor clutch is never turned ON after power ON of vehicle main key, also when compressor clutch is turned ON only once when air blow M2 or higher continues for five minutes. This control is cleared by main key power OFF in the vehicle,
and starts the control again by turning it ON. Compressor clutch ON time: 1±0.6 seconds
47 W701-0162E 47
K-3 K-3
Hydraulic Motor (Air Conditioner) (Option)
K-3 Hydraulic Motor (Air Conditioner) (Option)
[NOTICE]
1. Structure
2 16 12 1 8 11 A 10 4 B 3
24 19
A B
9 13 15 IW102-037001
48 W102-0371E
K-3. K-3.
Hydraulic Motor (Air Conditioner) (Option)
5 7 6 14 25 20 21 22
A B
Dr
23
24
19
IW102-037002 IW102-037003
1.Casing 8.Tapered roller bearing 15.Spring washer 22.Spring

2.Drive shaft 9.Tapered roller bearing 16.Key (7×7×30) 23.Spring retainer
3.Pintle 10.Timing pin 17.----- 24.O-ring
4.Cylinder block 11.Timing ring 18.----- 25.O-ring
5.Piston 12.Oil seal 19.Plug
6.Piston ring 13.O-ring 20.Seat
7.Pistonring retainer 14.Hex. socket head bolt 21.Steel ball 5/16
366-634-40003 ٌ
0
366-634-40002 ٌ
0
366-634-40001 ٌ
0
49 W102-0371E
K-4 K-4
Solenoid Valve (Air Conditioner) (Option) (--475376)
K-4 Solenoid Valve (Air Conditioner) (Option) (--475376)

[NOTICE]
1. Structure
b f
b f 1
P A
T1
a T B
e
P
B
A
T
IW121-076001 IW121-076002
1.Solenoid valve assy 2.Body
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/2 98 10 72
T1 M5 6.8 - 8.9 0.7 - 0.9 5.1 - 6.5
50 W121-0763E
K-4. K-4.
Solenoid Valve (Air Conditioner) (Option) (--475376)
Solenoid valve assy
Connector

(+): Red
(-): Blue
IW121-0542E01
T1 9 21 9
A P B
T T
T2 159 157 156 1 15 113 60 71 4

IW121-076003
1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V)

4.Plug 21.Spool 113.Square ring 159.O-ring
9.O-ring 60.Spring seat 156.O-ring
Tightening torque
N-m kgf-m ft-lbf
4 - 44 - 49 4.5 - 5 32 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
367-401-70000 ٌ
0
51 W121-0763E
K-5 K-5
Solenoid Valve (Air Conditioner) (Option) (475377--)
K-5 Solenoid Valve (Air Conditioner) (Option) (475377--)

[NOTICE]
1. Structure
1. Solenoid valve assy 2. Body 3. Orifice
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/2 98 10 72
T1 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
52 W121-0951E
K-5. K-5.
Solenoid Valve (Air Conditioner) (Option) (475377--)
Solenoid valve assy
Connector
(+): Red
(-): Blue
IW121-0542E01
T1 9 21 9
A P B
T T
T2 159 157 156 1 15 113 60 71 4

IW121-076003
1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V)

4.Plug 21.Spool 113.Square ring 159.O-ring
9.O-ring 60.Spring seat 156.O-ring
Tightening torque
N-m kgf-m ft-lbf
4 - 44 - 49 4.5 - 5 32 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
367-415-00000 ٌ
0
53 W121-0951E
L
Control System
Contents
L-1 Control System ................................ 1
1. Crane control devices ................................ 1
L-2 Remote Control Valve (Lever)......... 3
1. Structure .................................................... 3 L
L-3 Remote Control Valve (Pedal)......... 6
1. Structure .................................................... 6
L-4 Shuttle Valve (Lever / Pedal) ........... 9
1. Structure .................................................... 9
L-5 Solenoid Valve (Boom Telescoping

/ Aux. Winch).......................... 10
1. Structure .................................................. 10
L-6 Solenoid Control Relief Valve

(Elevating Slow Stop)............ 12
1. Structure .................................................. 12
i
L-1 L-1
Control System
L-1 Control System

1. Crane control devices
1.Engine trouble warning lamp 8.Boom telescoping operation 16.Swing free/lock selector 25.Starter switch
2.Counterweight mounting/ indicator lamp switch 26.Accelerator lock knob
dismounting position indicator 9.Auxiliary hoist operation 17.Boom telescoping/auxiliary 27.Outrigger controls (option)
lamp (option) indicator lamp hoist control selector switch 28. Cigarette lighter
3.AML cancellation warning lamp 10.Telescoping mode II indicator 18.Boom telescoping mode I/II 29. Ashtray
4.Jib lock indicator lamp lamp selector switch 30. Bubble level (option)
5.Hydraulic oil pressure 122qF 11.Telescoping mode I indicator 19.Load moment indicator (AML) 31. Boom elevating control lever
(50͠) indicator lamp lamp 20.Auxiliary winch indicator lamp 32. Main hoist control lever
6.Hydraulic oil pressure 185qF 12.Engine stop switch 21.Winch selector switch 33. Accelerator pedal
(85͠) warning lamp 13.Low noise mode switch 22.Anti-twoblock disable switch 34. Lever stand unlock lever
7.Outrigger control non-neutral 14.Front wiper switch 23.AML override switch
position lamp (option) 15.Front washer switch 24.Swing brake switch
1 WL01-0160E
L-1. L-1.
Control System
35.Boom telescoping/auxiliary 43.Roof washer switch telescoping switch 60.External warning lamps
hoist control lever 44.Roof wiper switch 51. Jib state switch 61.Jib lock pin switch
36.Head/end boom extension 45.Flood lamp switch 52. Jib removed indicator lamp 62.Jib mounting/stowing switch
switch 46.Oil cooler switch 53. Air conditioner control panel 63.Jib mounting/stowing
37.Horn switch 47.Outrigger state emergency (option) operationality indicator lamp
38.Swing control lever register switch 54. Cab lamp
39.Boom telescoping control 48.Outrigger state emergency 55.Seat
pedal register indicator lamp 56.Fan switch (option)
40.Boom elevating control pedal 49.2nd boom emergency 57.AML override key switch
41.Power window switch telescoping switch 58.Swing lock lever
42.Oil reservoir 50.3rd/4th/top boom emergency 59.Power window close switch
2 WL01-0160E
L-2 L-2
Remote Control Valve (Lever)
L-2 Remote Control Valve (Lever)

[NOTICE]
1. Structure
TP
1 2 3 4
IW135-013001
A A
455
247
T
P
171
172
101
PORTS 1䋧㩷㪉 PORTS 3䋧㩷㪋
A 123 A
103
IW135-0130E02
3 W135-0133E
L-2 L-2
Cross section along the line A-A
501
402
445
454
453
452
481 411
212
401
211
213
214
T 215
216
217 161
241
131 P
221
201
PORTS 1•3 PORTS 2•4 122

125
111
A-A
IW135-0130E03
101.Casing 171.Bolt 216.Spring seat 445.Hexagon socket head bolt

103.Casing 172.Nut 217.Washer 452.Disc
111.Port plate 201.Spool 221.Spring 453.Cam shaft
122.O-ring 211.Plug 241.Spring 454.Set screw
123.O-ring 212.Push rod 247.Spring pin 455.Bush
125.Hexagon socket head bolt 213.Seal 401.Upper cover 481.Hexagon socket head bolt
131.Bush 214.O-ring 402.Lever 501.Boot
161.Plug 215.Washer 411.Set screw
4 W135-0133E
L-2. L-2.
Tightening torque
N-m kgf-m ft-lbf
P, T G1/4 34 - 38 3.5 - 3.9 25 - 28
PORTS 1, 2, 3, 4 G1/4 34 - 38 3.5 - 3.9 25 - 28
125 M8 27 - 31 2.8 - 3.2 20 - 23
161 R1/4 20 - 24 2 - 2.4 14 - 17
172 M8 16 - 18 1.6 - 1.8 12 - 13
411 M12 27 - 31 2.8 - 3.2 20 - 23
445 M8 27 - 31 2.8 - 3.2 20 - 23
454 *1 M8 16 - 18 1.6 - 1.8 12 - 13
481 M6 11 - 13 1.1 - 1.3 8 - 9.4
366-349-20000 ٌ
0
5 W135-0133E
L-3 L-3
Remote Control Valve (Pedal)
L-3 Remote Control Valve (Pedal)

[NOTICE]
1. Structure
T P
[NOTICE]
This structure shows the
triple-bank valve.
The structure of the double-bank
valve is similar to the triple-bank
valve.
1 2 3 4 5 6
IW135-015001
323
315
A 431
414
262
263
T
115
P
272 273
1,2 3,4 5,6 102

101 103 A IW135-015002
6 W135-0153E
L-3 L-3
Section A-A
501 413 472 473 420
471
214
210
271
202
201
212
311
324
T
335
217
P
313
251
261
301 2,4,6
1,3,5 IW135-015003
101
101.Casing 214.Push rod 273.Nut 413.Cam shaft

102.Casing 217.Shim 301.Spool 414.Bush
103.Casing 251.RO plug 311.Spring seat 420.Cam
115.Plate 261.O-ring 313.Washer 431.Block
201.Cover 262.O-ring 315.Iock nut 471.Ball
202.Plug 263.O-ring 323.Iever 472.Set screw
210.Seal 271.Hexagon Socket head bolt 324.Spring 473.Hexagon socket head
335.Spring bolt
212.O-ring 272.Hexagon Socket head bolt
501.Boot
7 W135-0153E
L-3. L-3.
Tightening torque
N-m kgf-m ft-lbf
272 M8 19.1 - 22.1 1.95 - 2.35 14.1 - 16.3
271 M6 8.7 - 8.9 0.89 - 0.91 6.4 - 6.6
251 G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
315 M12 56.3 - 61.3 5.7 - 6.3 41.5 - 45.2
5.9 - 7.9 0.6 - 0.8 4.4 - 5.8
472 M6
Apply LOCTITE 241
473 M8 15.2 - 18.2 1.55 - 1.85 11.2 - 13.4
P, T G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
Port 1,2,3,4,5,6 G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
366-380-60000 ٌ
1
366-377-50000 ٌ
3
8 W135-0153E
L-4. L-4.
Shuttle Valve (Lever/Pedal)
L-4 Shuttle Valve (Lever / Pedal)

[NOTICE]
1. Structure
c d
e f
a b
IW128-011001
c d d(c)
2
f(e)
1
a b b(a)
IW128-011002
1.Body 2.Joint 3.O-ring 4.Steel ball
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/4 29.4 3 22
c, d G1/4 29.4 3 22
2 G3/8 49 5 36
366-236-90000 ٌ
1
9 W128-0113E
L-5 L-5
Solenoid Valve (Boom Telescoping/Aux. Winch)
L-5 Solenoid Valve (Boom Telescoping / Aux. Winch)

[NOTICE]
1. Structure
H F G D B C
E T A
IW121-031001
Connector
(+): Red
(-): Black
IW121-0542E01
10 W121-0314E
L-5. L-5.
Solenoid Valve (Boom Telescoping/Aux. Winch)
Cross section along the line X-X
3 1 14 16
B (F) D (H)
C (G)
11
T T
8
A (E)
4 16 7 15
X-X
IW121-031003
Note: Apply LOCTITE 262 (thread locking agent) to the threaded section of the seat (1).
1.Seat 5.Solenoid (DC24V) 11.Plain washer 16.Plug

2.Spring 7.Sleeve 13.Steel ball
3.Body 8.Stopper 14.Steel ball
4.Spool 10.Hexagon socket head bolt 15.O-ring
Tightening torque
N-m kgf-m ft-lbf
A, B, C, D G1/4 29.4 3 22
E, F, G, H G1/4 29.4 3 22
T G1/4 29.4 3 22
366-481-30000 ٌ
1
11 W121-0314E
L-6 L-6
Solenoid Control Relief Valve (Elevating Slow Stop)
L-6 Solenoid Control Relief Valve (Elevating Slow Stop)

[NOTICE]
1. Structure
601
171
151
A2 A1
101.Casing P2 P1
151.Plug
601.Proportional reducing valve
101 T1 IW136-0250E01
Tightening torque
N-m kgf-m ft-lbf
P1, P2, T, A1, A2 G1/4 34 - 38 3.5 - 3.9 25 - 28
151 R1/16 6-8 0.6 - 0.8 4-6
171 M5 6-8 0.6 - 0.8 4-6
T1 M8 26 - 32 3.7 - 3.3 20 - 24
12 W136-0252E
L-6. L-6.
Solenoid Control Relief Valve (Elevating Slow Stop)
Proportional Reducing Valve
351 311 326 324 331
P A T
312 361 362 363 861 325 801 802
IW136-0250E02
311.Spool 326.Retaining ring 362.O-ring 861.O-ring

312.Sleeve 331.Spring seat 363.O-ring
324.Spring 351.Orifice 801.Proportional reducing valve
325.C-ring 361.O-ring 802.Seal nut
Tightening torque
N-m kgf-m ft-lbf
351 M3 0.5 - 0.7 0.05 - 0.07 0.37 - 0.52
802 M6 6.9 - 7.9 0.7 - 0.8 5.1 – 5.8
367-301-50000 ٌ
0
13 W136-0252E
Y
Data, Adjustment and Checks
Contents
Y-1 Hydraulic Pressure Setting Table... 1 Y-3 Electric Switch Adjustment .............7
1. 3rd / top boom full retraction detection

Y-2 Air Bleeding Procedure ................... 2 switch (L7)...................................... 7
1. Starting pump............................................. 2 2. 2nd boom full retraction detection

1.1 Before starting the engine .......................... 2 limit switch (L8) .............................. 7
1.2 Shakedown of the pump............................. 2
3. Jib stowed detection proximity
2. Accelerator circuit ...................................... 3 switch (CS10)................................. 7
3. Swing circuit............................................... 3 4. Jib lock pin retraction detection

3.1 Swing motor................................................ 3 switch (L1)...................................... 8
3.2 Swing hydraulic pilot control valve ............. 3
5. Main winch drum rotation proximity
4. Winch circuit (main and aux.) .................... 4 switch (CS13) (option) ................... 8
4.1 Winch motor ............................................... 4
4.2 Winch counterbalance valve ...................... 4 6. Aux. winch drum rotation detection
4.3 Winch brake................................................ 4 proximity switch (CS14) (option) .... 8
5. Jib lock pin and jib offset cylinder .............. 5 7. Swing dead angle detection
proximity switch (CS11) ................. 8
6. Hydraulic pilot circuit.................................. 5
6.1 Swing.......................................................... 5 8. Swing brake holding detection
6.2 Elevating..................................................... 5 switch (CS23)................................. 9
6.3 Telescoping................................................. 5
6.4 Winch (main and aux.) ............................... 5 9. Control lever stand position detection
switch (swing control and boom
7. Oil cooler motor ......................................... 6 telescoping/aux. hoist) (L16).......... 9
8. Air condition motor (option)........................ 6 10. Counterweight stowing position detection

switch 1 (CS24) and
9. Dolly circuit ................................................ 6 switch 2 (CS25)............................ 10
9.1 Elevating..................................................... 6
Y
9.2 Swing free and swing brake ....................... 6
i
11. Front jack full retraction detection
switch(S087) ................................ 11
Y-4 Check (Crane Operation)............... 12
1. Hoisting.................................................... 12
2. Jib ..................................................... 12
3. Detection of contact of the front jack

with ground................................... 12
4. Setup the outrigger emergency ............... 12
5. Upper outrigger operation (option):

It becomes possible when
connecting PTO and becoming
the crane work possible. .............. 12
6. Alarms ..................................................... 13
7. Adjustment procedure of front jack overload

detector switch (S660) ................. 14
Y-5 Adjustment and Checks ................ 15
1. Engine speed adjustment procedure ....... 15

1.1 Speed control ........................................... 15
1.2 Accelerator pedal ..................................... 17
1.3 Engine speed............................................ 17
2. Adjusting boom telescoping wire ropes ... 18
Y-6 Oils and Grease Table ................... 22
Y-7 Mass Table ..................................... 23
Y-8 Boom Connecting Pin and Thread

Size Table............................... 24
ii
Y- 1 . Y-1. Y-1.
Hydraulic Pressure Setting Table
Y-1 Hydraulic Pressure Setting Table
345-803-81500 1
ٌ
1 WY02-0810E 1
Y- 2 Y-2
Air Bleeding Procedure
Y-2 Air Bleeding Procedure 3. Start the engine, warm up the engine, and then
turn ON the PTO switch with the engine running at
1. Starting pump idling speed (600±50 min-1) to shakedown the
pump for approx. 10 minutes.
1.1 Before starting the engine
4. After the shakedown is finished, turn OFF the
Make sure that PTO switch and stop the engine.
• PTO switch (in the carrier driver’s cab) is turned
2) Others
OFF.
• After the shakedown of the pump, do not let the
• The oil cooler is not functioning (due to the
engine speed exceed the middle range (1000
hydraulic oil temperature below 50°C (122°F)).
min-1) if you bleed the cylinders.
1.2 Shakedown of the pump When you try to raise the oil temperature in
order to adjust the hydraulic pressure, make
Make sure that the crane cab cooler (option) is not sure that there is no bubbles caused by the
working before starting shakedown. bleeding in the tank.
1) Main pump (Piston pump) • After disassembling the suction section for
repair, bleed it following the above procedure.
1. Fill the hydraulic tank fully with hydraulic oil. • When pressurizing the tank, do not let the
pressure exceed 15 kpa (0.15 kgf/cm2) (2.2
2. Loosen the air bleeder plug and remove the hose
psi) .
joint of L1 shown below with the engine stopped.
• Place all the control levers in neutral position.
When oil begins to flow through the air bleeder
Secure the outriggers with the lock pins.
plug hole, tigthten the air bleeder plug and the
hose joint of L1.
2 WY05-1751E
Y- 2 Y-2
2. Accelerator circuit 3. Swing circuit

1. Bleed the accelerator circuit by depressing the 3.1 Swing motor
accelerator pedal in the crane operator’s cab
repeatedly with the carrier engine stopped. (there [NOTICE]
are three bleeding points.) Do not load the motor before bleeding.
Bleed the swing motor by following either (1), (2) or (3).
2. After bleeding, check that the oil level in the
(1) Pour the hydraulic oil through the drain port into
reserve tank in the cab is between the marks
the casing until the oil flows out.
indicating the allowable lowest and highest levels.
(2) Perform the right or left swing operation slowly
3. After bleeding, depress the accelerator pedal for approx. one minute.
gradually and make sure that the engine (3) Set the swing brake switch to ON. Perform the
functions smoothly at all engine speeds from right or left swing operation and keep the swing
idling to maximum speed. If not, repeat bleeding circuit hydraulic pressure at approx. 4.9MPa (50
kgf/cm2) (710 psi) for approx. 30 seconds.
and accelerator adjustment.
Engine speed:
Maximum [1890 min-1(rpm)]
AC1 Bleeding plug
AC2 Bleeding plug
Top view of rotary joint
3.2 Swing hydraulic pilot control valve
Bleeding plug Set the PTO switch and the swing brake switch to
ON, and set the engine speed to the maximum
(1890 min-1). Repeat the rapid swing operation to
Operation ass'y, accelerator (on the carrier frame) the right or the left until no more air bubbles come
IWY05-0740E02 out of the air bleeder screw.
3 WY05-1751E
Y- 2 Y-2
4. Winch circuit (main and aux.) 4.3 Winch brake
Bleed the chamber as follows:

[NOTICE]
Bleed the main and auxiliary winch circuits by [NOTICE]
following the procedures below. The procedures
After assembling pipings, do not perform hoisting
are common to the both circuits.
operation until the winch brakes are bled.
1. When assembling pipings, Plug the hoist-down

port by stopping up the piping between the main
valve and motor.
(Apply plugs to the point close to the main valve
and point close to the motor.)
[NOTICE]
Thereafter, do not perform hoist-up operation
neither by the main nor aux. winch until the winch
brakes are bled.
2. Discharge oil through the winch brake bleeder

plug by hoist-down operation to bleed the winch
brake.
• Keep the engine idling.
• Shift the lever fully to the hoist-down side.
• Bleeding is completed when no air bubbles
come out of the plug.
4.1 Winch motor
3. After completing bleeding of the winch brakes,
[NOTICE] remove the plugs on the pipings and restore the
Do not load the motor before bleeding. pipings.
Bleed the winch motor by following.
(1) After assembling pipings, pour the hydraulic oil

through the drain port into the casing until the oil
flows out.
4.2 Winch counterbalance valve
Repeat the slow hoist-up and slow hoist-down

operations, while increasing the engine speed
gradually to the maximum (1890 min-1) until no
more air bubbles come out of the air bleeder screw.
4 WY05-1751E
Y- 2 Y-2
5. Jib lock pin and jib offset cylinder 6. Hydraulic pilot circuit
[NOTICE] 6.1 Swing
Bleed the jib lock pin, jib offset cylinder as follows.
Set the hydraulic oil temperature to 50oC (122°F) or
(1) Start the engine, turn the PTO switch on, and higher, set the PTO switch and the swing brake
-1
raise the engine speed to approx. 1890 min . switch to ON, let the engine idle, and move the
swing control lever fully to the right-swing side.
(2) Attach a hose to the bleeder screw (A).and
Keep the above conditions for 20 seconds or more
loosen the bleeder screw. In this condition, repeat
for bleeding. Proceed the same steps by moving the
the rapid jibset operation to the retract or the
swing control lever to the left-swing side.
extend until no more air bubbles come out of the
air bleeder screw. 6.2 Elevating
Air bleeder plug
Pull out the connector of the AML vent solenoid. Set
the hydraulic oil temperature to 50°C (122°F) or
higher, set the PTO switch to ON, let the engine idle,
and move the boom elevating control lever fully to
the boom lowering side. Keep the above conditions
for 20 seconds or more for bleeding. Proceed the
(A) (B) same steps by moving the boom elevating control
Jib lock pin
lever to the boom raising side.
Air bleeder plug

6.3 Telescoping

and move the boom telescoping control lever fully to
(C) (D) the retraction side. Keep the above conditions for 20
seconds or more for bleeding. Proceed the same
Jib offset cylinder steps by moving the boom telescoping control lever
IWY05-0580E02
to the boom extension side.
6.4 Winch (main and aux.)

[NOTICE]
Bleed in the order of bleeder screws, (A), (B), (C) [NOTICE]
and (D).
Bleed the main and auxiliary winch circuits by
following the procedures below. The procedures
(3) After air-bleeding is over, fasten the bleeder are common to the both circuits.
screw and remove the hose.
and move the hoist control lever fully to the hoist-up
side. Keep the above conditions for 20 seconds or
more for bleeding. Proceed the same steps by
moving the hoist control lever to the hoist-down
side.
5 WY05-1751E
Y- 2 . Y-2.
7. Oil cooler motor

Pour the hydraulic oil through the drain port into the
casing until the oil flows out.
8. Air condition motor (option)

Pour the hydraulic oil through the drain port into the
casing until the oil flows out.
9. Dolly circuit
[NOTICE]
During crane operation and normal traveling, never
set the levers to the positions for dolly traveling.
9.1 Elevating
9.2 Swing free and swing brake
345-803-82000 ٌ
1
345-803-80500 ٌ
0
6 WY05-1751E
Y- 3 Y-3
Electric Switch Adjustment
Y-3 Electric Switch Adjustment
1. 3rd / top boom full retraction detection

switch (L7)
Adjust the switch position so that its contact is
shifted (opened/closed) when the top boom section
is extended/retracted beyond the position where it is
5-8 mm (0.2-0.31 in) longer than its fully retracted
length.
343-625-82000 ٌ
3
3. Jib stowed detection

proximity switch (CS10)
Adjust the switch position so that the dimension A
becomes 4 mm (0.16 in) with the jib stowed.
(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).
343-625-82000 ٌ
3
2. 2nd boom full retraction

detection switch (L8)
Adjust the switch position so that its contact is
shifted (opened/closed) when the 2nd boom section
343-537-02000 ٌ
2
is extended/retracted beyond the position where it is
2-3 mm (0.08-0.12 in) longer than its fully retracted
length.

7 WY04-1151E
Y- 3 Y-3
4. Jib lock pin retraction

detection switch (L1)
becomes 30.5 mm (1.2 in) with the switch in
free position.

344-925-80000 ٌ
2
6. Aux. winch drum rotation detection

proximity switch (CS14) (option)
Follow the same procedure as that in MAIN WINCH
DRUM ROTATION DETECTION PROXIMITY
SWITCH (CS13). 344-904-62000 ٌ
1
7. Swing dead angle detection proximity

switch (CS11)
becomes 1.5 - 3mm (0.06 - 0.12 in) with the switch
stowed.

343-537-02000 ٌ
2
5. Main winch drum rotation proximity

switch (CS13) (option)
becomes 2.5±0.5 mm (0.1±0.02 in).

349-516-30000 ٌ
1
8 WY04-1151E
Y- 3 Y-3
8. Swing brake holding detection switch

(CS23)
bocomes 2 mm (0.08 in)

343-537-02000 ٌ
2
9. Control lever stand position detection

switch (swing control and boom
telescoping/aux. hoist) (L16)
Before the adjustments below, tilt the lever stand by
the angle of 16°. Squeeze the switch upward and
secure it temporarily where its contact is shifted
(opened/closed). Then, lower the switch by 1 mm 343-224-71000 ٌ
5
(0.039 in) from the temporary secured position and

secure it. (A rotation of the switch mounting nut
makes the switch move upward or downward by
approx. 1 mm (0.039 in) ).

9 WY04-1151E
Y- 3 Y-3
10. Counterweight stowing position

[NOTICE]
detection switch 1 (CS24) and Bring the switch 1 close from the D direction to the
switch 2 (CS25) plate 1, move it 1-2 mm (0.04-0.08 in) further from
the position which changes into turning ON in the
[Condition] direction of the plate 1, and fix it.
Bring the switch 2 close from the C direction to the
• Boom: Full retraction
plate 1, move it 1-2 mm (0.04-0.08 in) further from
Horizontal the position which changes into turning ON in the
Rear position direction of the plate 1, and fix it.
• Counterweight: Dismount all from swing table
Adjust it at the swing position where the shift at the

center of ĭ70 and ĭ74 becomes a right and left
distribution with the counterweight dismounted.
333-716-80000 ٌ
4
333-716-80000 ٌ
4

becomes 4 mm (0.16 in)
(It is possible to adjust it by placing an acrylic
board or vinyl chloride board.)
(*1): Apply the screw locking agent (Three-Bond 1401
or the equivalent)
10 WY04-1151E
Y- 3 . Y-3.
11. Front jack full retraction detection

switch(S087)
1. Adjust the switch position so that the dimension A
becomes 2 mm (0.08 in)
(*): Apply the screw locking agent

(Tree-Bond 1401 or the equivalent)
2. Extend the cylinder so that dimension L may

become 15-25 mm (0.6-1.0 in), and adjust for the
switch to operate while it extends 2 mm (0.08 in)
further from that state.
[NOTICE]
Confirm the indicator lamp is turned off, when the
cylinder is fully retracting.
Indicator lamp
Front panel (Inside carrier cab)

IW04-0490E07
This switch is a detection switch to light the

indicator lamp for warning the driver in the carrier
cab when the front jack has extended in the state of
traveling.
(Be careful about not lighting this indicator lamp
when the crane work has been selected with the
crane/carrier operation select switch in the carrier
cab.)
346-720-81000 ٌ
0
11 WY04-1151E
Y- 4 Y-4
Check (Crane Operation)
Y-4 Check (Crane Operation) seconds after the jack float touches the ground.
Make sure that the front jack indicative symbol on
1. Hoisting the AML is highlighted in this situation.
[Condition]
• Load :None 4. Setup the outrigger emergency
• Engine speed :Approx.600 min-1 to medium speed
1. Turn ON the switch of the panel on upper right in
the cab.
[Procedure]
1. Shift the boom telescoping lever to full stroke first. 2. Confirm the indicator is lighting.
Indicator
2. Make sure that the main winch moves slowly
ON
while the auxilialy winch lever is slightly operated.
3. Make sure that the main winch does not move

while the auxilialy winch lever is operated to full
stroke. OFF
2. Jib IWY04-0510E02
1. Make sure that overwinding cut-out 3. Confirm the extending width can be set manually
device(anti-two block function) does not work with AML regardless of the extending width. (same
during the jib set status is registered. to all outriggers)
2. Check the jib lock indicator lamp.

• Make sure that the lamp is lit when the jib slides 5. Upper outrigger operation (option):
out of the center support on the boom. It becomes possible when
connecting PTO and becoming
Lamp is lit the crane work possible.
JIB LOCK
IWY04-0510E01
1. Confirm an individual operation performs correctly,
and in addition, confirm the following.
• After the jib is stowed, make sure that the lamp
• All operation extending: Only four outriggers
is not lit.
operate.
• All operation retracting: Four outriggers and
3. Detection of contact of the front jack front jack operate.
with ground
2. O/R switch non-neutral position lamp must light if
1. Set the crane on outriggers before extending the either Ext./Ret. selection swich or Jack/Slide
front jack. selection switch is actuated.
Stop front jack operation just before the front jack
touches the ground, and slightly retract the front Lamp is lit
jack.
2. Confirm the front jack indicative symbol on the IWY04-0510E03
AML is not highlight in this situation.

3. After the status of O/R is registered with AML,
3. Extend the front jack again.
confirm the status of AML bocomes on-tire if
Continue extending operation for more than 4
retracting O/R or F/J.
12 WY05-1891E
Y- 4 Y-4
6. Alarms Applicable serial No. ٌ

5 㧦437273 --, 475326 --
Type of
Item Sound Checking procedure
alarm
• Buzzer sounds ten seconds later if either Ext./Ret.
O/R switch • 2300Hz selection switch or Jack/Slide selection switch is actuated
Electric
non-neutral position • continous and none of O/R button is operated.
buzzer
alarm Piiii • When any O/R button is operated within ten seconds,
buzzer sounds again after counting ten seconds.
• 280Hz Raise the moment to 100% while the AML is activated
Moment limit detected Electric
• continous (Intermittent sound is output when the moment exceeds
by AML buzzer
buzz 90%)
• 2300Hz Activate the overwind (two-block) detector switch for each
Overwind(Two-block) Electric
• continous main winch and auxiliary winch by hoisting up the
alarm buzzer
ding-dong corresponding winch.
Making the internal pressure for the front jack extension
Front jack overload circuit 18.6MPa [3500psi (245kgf/cm2)].
Horn • 415Hz
alarm (Checking this alarm is not necessary because it is output
only when the front jack is overloaded.)
Actuate the P.T.O., and turn OFF the swing brake switch
(on right side of AML) to put into the state that the crane
can be operated.
1. Disconnect the connector of the accumulator pressure
detection switch.
2. Operate the swing brake lever to confirm that
• Buzzer sounds if the lever in the dolly side, and
A. • Buzzer dose not sound if the lever in the crane side.
Swing brake lever
position detection
buzzer
Cab Crane side

Dolly buzzer
• Intermittent
Electric Puu···· Puu···
Swing brake lever Dolly side
buzzer Proximity switch
(B910) IWY04-0510E04
3. Reconnect the connector of step 1 after confirming the

step 2.
5
Adjust the lever in the above figure to the crane side,
(Carrier
side) and disconnect the connector of proximity swtch.
B. (Buzzer will not sound because the pressure of
Swing brake accumulator is high.)
accumulator low
4. Turn ON the swing brake switch. Confirm the
pressure warning
accumulator pressure becomes low, and the buzzer
buzzer
sounds.
5. Turn OFF the swing brake switch, and confirm the
buzzer stops sounding one minute later.
6. Reconnect the connector of step 3.
13 WY05-1891E
Y- 4 . Y-4.
7. Adjustment procedure of front jack

overload detector switch (S660)
࡮Adjustment is not necessary for TT-800XXL-1 with
serial No. 475366 --, GT-700E-1 with serial No.
475366 --, TT-600XL-1 with serial No. 437515--,
GT-900XL-1 and GT-800E-1.
1. Remove the cap of front jack overload detector

switch installed to the front jack head, and loosen
the lock nut.
2. Tighten the adjusting screw one turn clockwise.
3. Tighten the lock nut so that the adjusting screw

should not turn.
4. Mark the adjusting screw with while point for

identification.
Front jack overload detector switch

Adjustment screw
A
Remove a cap
Lock nut FRONT

Look at the front jack head.
View A (Front jack is located in the
cover of toolbox at the right
of carrier cab.)
IWY04-0510E05
[NOTICE]
Raises the setting pressure 2700psi (18.6MPa)
(190kgf/cm2) to 3500psi (24MPa) (245kgf/cm2) by
this adjustment when the vehicle is delivered.
345-801-03000 ٌ
5
14 WY05-1891E
Y- 5 Y-5
Adjustment and Checks
Y-5 Adjustment and Checks

1. Engine speed adjustment procedure
1.1 Speed control operating the transmission interlock because of

exceeding the idling range if voltage E1 becomes
1. Apply grease to the rotating part and the sliding
1.0V or more.
area.
Potentiometer
2. Set the crane/carrier operation select switch in the Output voltage ratio 50% position
carrier cab to “1” carrier side, turn the PTO switch
OFF, and start the engine.
Plate H
(Never set the crane/carrier operation select
switch to “2” crane side before adjusting this
because the engine speed will rise rapidly.)
3. Install the potentiometer as shown in the above

detail drawing. Pull the return spring about 10 mm
(0.394 in), and fix the link to the idling position.
Marking(*1)
Connect the connector of potentiometer, and Wiring side
measure the voltage E1 between white and black
Potentiometer Detail IWY05-0730E02
wires on the potentiometer side by using the
measurement jig.
Adjust the idling position with bolt B to become (*1): Confirm the mark on the potentiometer shank is
E1=0.70-0.80V, and seal the bolt B. turning in the direction of wiring side and the
Adjust the voltage at idling as becoming 14-16% plate H is installed in parallel to the mark.
for applied voltage of 5.0V between red and black
wires.
Be careful about not engaging of PTO by
15 WY05-1760E
Y- 5 Y-5
Output voltage ratio 䋨䋦䋩

90
70
50
10
-45 0 +22.5 +45
Electrical travel 䋨䉙䋩
Potentiometer output characteristics
IWY05-0730E03
4. Adjust the rod length with nut D so that the gap C

of the cylinder rod and the pin may have the play
of 2-3 mm (0.08-0.12 in) at all retracting the
cylinder rod manually.
(The dead band of pedal depressing is decreased
by compressing the hydraulic oil in piping with this
play.)
5. Adjust the bolt F so that the return spring length J

may become 21±1 mm (0.82±0.04 in) longer
compared with the free length.
(The free length is 78 mm (3.1 in) in the drawing
value.)
Confirm the lever E completely returns to the
idling position by operating the accelerator pedal
which is in the crane cab.
6. Set the crane/carrier operation select switch in the

carrier cab to “2” crane side, and turn the PTO
switch ON to engage PTO.
Confirm the idling speed is 600±50 min-1.
(The idling speed is controlled with the computer
on the engine side, and do not readjust it with bolt
B.)
7. Adjust the maximum engine speed is 1890 min-1

with bolt G and seal the bolt G.
8. Confirm the length of spring does not exceed the

maximum use length when adjusting the
maximum engine speed.
337-113-10000 ٌ
1
16 WY05-1760E
Y- 5 Y-5
1.2 Accelerator pedal

Bolt B Knob
Lever E
Spring
Accelerator pedal
Cylinder rod
End D
65
Bolt C
H 5 mm
8
75-1 n)
H=1 .9-7.3 i
(6
IWY05-0730E04
1. Remove the spring. 9. Depress the pedal unit the maximum engine
speed reaches maximum with no-load, apply the
2. Adjust height H of the pedal to 175-185 mm
bolt C to the pedal, screw in the bolt one turn from
(6.9-7.3 in) with the end D and cylinder rod.
that state, and lock the bolt with nut.
3. Screw the knob fully.
1.3 Engine speed
4. Screw the bolt B and fix it immediately before the
pedal begins to move. Engine speed
Item
(min-1)
At this time, confirm the poppet valve of master
600±50
cylinder is not closed. Idling
(set by the Maker)
(When pressing the pedal by the hand, confirm Max. 1890
the point which changes control force in a word, Accelerator
(Crane cab) Low- 1400±50
the poppet valve closes and pressure begins to noise mode
(set by the Maker)*2
rise.) 1800±50
At outrigger operating O/R
(set by the Maker)*3
5. Install the spring.
[NOTICE]
6. Remove the bolt C to facilitate the air bleeding. The maker setting revolution adjustment is
(To facilitate the air bleeding by increasing the unnecessary.
discharge volume from the master cylinder when
bleeding.)
7. Bleed the accelerator circuit surely.
8. Adjust IDL and MAX with the accelerator of the

343-316-10000 ٌ
1
carrier side. 345-800-63500 ٌ

7
17 WY05-1760E
Y- 5 Y-5
2. Adjusting boom telescoping wire ropes

1. With the boom fully retracted, tighten the nut-A until a tension is placed on the top boom section retraction
wire rope (to keep the boom fully retracted).
[NOTICE]
Loosen the sway stopper bolt
on the bottom of each boom
section until it is out of contact
with the support.
2. Tighten the four nut-B’s equally until the 4th boom section extends by 1-5 mm (0.04-0.2 in) from the 3rd
boom section.
3. Tighten the two nut-C’s equally until the top boom section extends by 1-5 mm (0.04-0.2 in) from the 4th
boom section.
18 WY05-1760E
Y- 5 Y-5
4. Tighten the nut-A until the top and 4th boom sections are fully retracted.
5. Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control lever and then retract
it fully. Check the boom is fully retracted.
NG OK
END
6. Check the tension of the two 4th boom section extension wire ropes.
7. When the wire rope is slack: 8. When the wire rope is tense:
7.1 Tighten the two nut-B’s by approx. a third turn equally.
7.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control
NG
lever and then retract it fully. Check the boom is fully retracted.
OK
END
19 WY05-1760E
Y- 5 Y-5
8. When the wire rope is tense:

8.1 Tighten nut-A by approx. a third turn.
8.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
NG OK
9. When only the 4th boom section is not fully retracted: END
9.1 Tighten two nut-C’s by approx. a third turn equally.
9.2 Extend the boom by 200-300mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
OK
END
20 WY05-1760E
Y- 5 . Y-5.
10. Adjust the sway stopper bolt for the each boom
section.
[NOTICE]
Refer to “Adjusting the bolt on the bottom of each
boom section head” in chapter G.
345-800-62500 ٌ
1
21 WY05-1760E
Y- 6 . Y-6.
Oils and Grease Table
Y-6 Oils and Grease Table

Item Quantity : L (gal) Remarks
Hydraulic oil 920 (243) TADANO Hydraulic Oil LL

Mobil Gear 632 (or 600XP_320)
Swing ass’y 3.8 (1.0) ISO VG 320
API Service Class GL-3
Gear oil Mobil Gear 629
Main 6.1 (1.61)
Winch ass’y ISO VG 150
Aux. 6.1 (1.61) API Service Class GL-3
Hydraulic oil (for axle) 0.6 (0.16) Daphne Super Hydro 22WR
Grease 1 (0.26) Daphne Coronex Grease EP No.2
Fuel 378 (100) Light Oil (JIS K 2204 2)
*Applicable to machine equipped with an air conditioner inside its crane operator’s cab.
1. Turn the battery main switch to ON in Carrier cab.

Then shift the temperature adjust switch fully toward HOT side in crane operator’s cab.
2. Press the air conditioner shutdown switch and then start the engine.
3. Bleed the circuit from the engine via the radiator to the rotary joint completely.
4. Bleed the circuit (5 minutes) with the 1st step of the wind volume and the air conditioner switch turned ON.
(Engine speed : idling)
5. Check the cooling water level after bleeding.
345-803-81000 ٌ
0
22 WY01-1501E
Y- 7 . Y-7.
Mass Table
Y-7 Mass Table

Spec. No.
Part Name GT-900-1-90102
2M2D
(North America)
Boom assy (including telescoping
11470kg (25290lb)
cylinder, jib-1 and jib-2)
Telescoping cylinder (No.1) 790 kg (1740 lb)
Boom Telescoping cylinder (No.2) 880 kg (1940 lb)
Jib-1 560 kg (1230 lb)
Jib-2 280 kg (620 lb)
Elevating cylinder 960 kg (2120 lb)

Swing table assy
(excluding boom and elevating cylinder, swing 5150 kg (11360 lb)
bearing, counter weight)
Swing bearing 630 kg (1390 lb)
Swing speed reducer and swing motor 210 kg (460 lb)
Rotary joint 180 kg (400 lb)

Main winch assy
520 kg (1150 lb)
(including winch motor)
Winch Auxiliary winch assy
520 kg (1150 lb)
(including winch motor)
Winch motor (main/auxiliary) 70 kg (160 lb)
Counterweight (1) 2620 kg (5780 lb)

Weight
Counterweight (6) 1000 kg (2210 lb) × 2
23 WY01-1510E
Y- 8 . Y-8.
Boom Connecting Pin and Thread Side Table
Y-8 Boom Connecting Pin and Thread Size Table

(mm)
GR-550E-1- ,
GR-600-1- ,
GR-700E-1- ,
GR-800-1- ,
GT-550E-1- , GR-450-1- ,
Applicable spec. No
GT-600-1- , GR-500-1-
GT-700E-1- ,
GT-800-1- ,
GT-800E-1- ,
GT-900-1-
Part Name Diameter Thread size Diameter Thread size
Rod end pin ĭ120 M33×3.5 ĭ100 M30×3.5

Elevating cylinder
Base pin ĭ110 M30×3.5 ĭ90 M30×3.5
M18×2.5 M16×2.0
Boom base pin ĭ100 ĭ90
(Qty:4) (Qty:4)
(mm)
GT-250C-1- ,
Applicable spec. No. GT-350C-1- , TM-3500-1-
GS-300-1-
Rod end pin ĭ100 M30×3.5 ĭ100 -

Elevating cylinder
Base pin ĭ90 M30×3.5 ĭ90 M30×3.5
M18×2.5
Boom base pin ĭ100 ĭ100 M30×3.5
(Qty:4)
(mm)
TR-300-4- ,
Applicable spec. No GR-300E-1- , TL-300E-3-
GR-300-1-
Rod end pin ĭ100 M30×3.5 ĭ100 M30×3.5

Elevating cylinder
Base pin ĭ110 M30×3.5 ĭ100 M30×3.5
Boom base pin ĭ100 M30×3.5 ĭ100 M30×3.5
(mm)
TR-150-4-
Applicable spec. No TT-300-1-
GR-150-1-
Rod end pin ĭ90 M30×3.5 ĭ60 -

Elevating cylinder
Base pin ĭ90 M30×3.5 ĭ70 M24×3.0
Boom base pin ĭ90 M30×3.5 ĭ60 M10×1.5
24 WY01-1790E
Z
System Diagrams
Contents
Z-1 Hydraulic Circuit .............................. 1 Z-12 Harness (Boom) ..............................12
Z-2 Electric Circuit .................................. 2 Z-13 Harness (AML, Upper) ....................13
Z-3 Electric Circuit Z-14 Harness (Overwind)........................14

(Outrigger Operation, Option) ......... 3
Z-15 Harness (Lower)..............................15

Z-4 Location of Hydraulic Parts ............. 4
Z-16 Harness
Z-5 Location of Electric Parts (Upper)... 5 (Outrigger Operation, Option)........16
Z-6 Location of Electric Parts (Lower) .. 6
Z-7 Location of Electric Parts

(Outrigger Operation, Option) ......... 7
Z-8 Hydraulic, Electric, Carrier

Equipment Comparison Table......... 8
Z-9 Harness (Inside Cab)........................ 9
Z-10 Harness (Swing Table, Left)........... 10
Z-11 Harness (Swing Table, Right) ........ 11

Z
i
Z-1. Z-1. Z-1.
Hydraulic Circuit 1 㧦475377 - -
Z-1 Hydraulic Circuit
344-022-00000 1
ٌ
1 WZ01-2101E 1
Z-2. Z-2. Z-2.
Electric Circuit
Z-2 Electric Circuit
344-122-40000 1
2 WZ03-3861E 2
Z-3. Z-3. Z-3.
Electric Circuit (Outrigger operation, option)
Z-3 Electric Circuit (Outrigger Operation, Option)
3 WZ03-1841E 333-316-60010 0
ٌ 3
Z-4. Z-4. Z-4.
Location of Hydraulic Parts
Z-4 Location of Hydraulic Parts
4 WZ07-2030E 4
Z-5. Z-5. Z-5.
Location of Electric Parts (Upper)
Z-5 Location of Electric Parts (Upper)
5 WZ02-3611E 5
Z-6. Z-6. Z-6.
Location of Electric Parts (Lower) 2 㧦475334 --
Z-6 Location of Electric Parts (Lower)
[NOTICE]
For error of transmitter refer to Table 1,2,3,4.
Table 1 Light emitting diode display

Content of error LED1 LED2 LED3 LED4
There is no error. (Normal) OFF OFF Blinking 1 Blinking 2
The transmitter is abnormal.
ON ON ON ON
(self-diagnosis abnormality)
Reception open circuit ON OFF ON Blinking 2
The reception is abnormal. (data abnormality) OFF ON ON Blinking 2
Blinking 1: Blinking cycle is two(2) seconds.
Blinking 2: Blinking cycle is one(1) second.
Note: An abnormal reception is not detected in the transmitter type that doesn't have the receiver
capability.
Table 2 Self-diagnosis content list ٌ2:Abnormal-settling condition change at each cycle processing (The trouble correspondence by transmitter V type is reflected.)
Do output in abnormal
Item Content Watch time Abnormal-settling condition Normal return condition
circumstances
ROM sum check ROM sum check
An easy arithmetic operation is When power supply is turned on.
CPU check Each of three time retries is
done and the result is confirmed.
abnormal. OFF
Type check Type check Return if the check result
When power supply is turned on. returns normally.
RAM check R/W check of specific area RAM
At each cycle processing
䂦2: Each of six time retries is
The power supply voltage and abnormal. The output before abnormality
Voltage watch At each cycle processing
the reference voltage are checked. is maintained.
CPU exceptional When the exceptional handling is The first and one exceptional Reset (reboot) with software
CPU is working. generation is recognized as OFF
generation generated in CPU is done automatically.
abnormal.
Table 3 Reception abnormality check content list

Do output in abnormal
Item Content Watch time Abnormal-settling condition Normal return condition
circumstances
The data reception from AML is At each cycle When 700ms or more breaks off the reception of
Reception open circuit data.
checked. processing
(communication cycle: 200ms) The output before abnormality㩷 Return if the check result
When the sum error of receive data is detected. is maintained. returns normally.
The reception is abnormal. At each cycle
Sum check of receive data (The first and one exceptional generation is
(data abnormality) processing
recognized as abnormal.)
Table 4 Voltage watch

Make the following ranges a normal range in the voltage watch.
Watch voltage Normal range
24V power supply 13-40㩷 (V)
Power supply for potentiometer 4.5-5.5㩷 (V)
6 WZ02-1392E 6
Z-7. Z-7. Z-7.
Location of Electric Parts (Outrigger Operation, Option) 1 㧦475376 - -
Z-7 Location of Electric Parts (Outrigger Operation, Option)
333-316-60300 0
ٌ
333-316-60000 1
ٌ
7 WZ02-1401E 7
Z-8. Z-8. Z-8.
Hydraulic, Electric, Carrier Equipment Comparison Table
Z-8 Hydraulic, Electric, Carrier Equipment Comparison Table

No. Parts Name No. Parts Name No. Parts Name No. Parts Name
1 Oil tank 51 Pressure switch (PS10) 102 Bubble level (Illumination) 153 2nd boom section emergency telescoping switch (S2)
2 Oil filter 52 Remote control valve (pedal) 103 Relay ass’y 154 3rd/top boom section emergency telescoping switch (S1)
3 Oil filter 53 Hydraulic valve (winch brake release) 104 O/R switch non-neutral position alarm buzzer 155 Buzzer 4 (Two-blocking)
4 Hydraulic Pump (Crane A1, A2, A3, A4) 54 Oil filter 105 O/R switch non-neutral position lamp 156 Buzzer 3 (AML alarm)
5 ----- 55 Winch speed reducer 106 Crane relay ass’y (Lower) 157 Winch selector switch (S32)
6 Oil filter 56 Hydraulic motor (winch) 107 158 Oil cooler switch (S30)
7 Flow control valve 57 Counterbalance valve 108 159 Outrigger state emergency register switch (SK2)
8 Control cylinder (Accelerator) 58 Winch speed reducer 109 160 Boom telescoping/aux. hoist control selector switch (S13)
9 Master cylinder (Accelerator) 59 Hydraulic motor (winch) 110 Starter switch (SK3) 161 Telescoping mode I/II selector switch (S31)
10 Oil reservoir 60 Counterbalance valve 111 Power window switch (Outside cab) 162 Head-end boom switch (S7)
11 Rotary joint 61-1 Prevention valve (prevention of No.2 cylinder retraction while mode is selected) 112 Power window switch 163 Jib lock pin retraction detection switch (L1)
12 Sequence valve (Pilot pressure) 61-2 Hydraulic valve (top cylinder select) 113 Power window motor 164 Jib mounting/dismounting switch (S23)
12-1 Sequence valve 62 Oil filter 114 Front wiper motor 165 Jib lock pin switch (S24)
12-2 Reducing valve 63 Oil filter 115 Roof wiper motor 166 Jib state switch (SK4)
13 Solenoid control valve (Jib set and counterweight cylinder) 64 Hose real 116 Washer tank 167 Counterweight mounting/dismounting operation switch (S16)
14 Oil filter 65 Counterbalance valve 117 Engine stop switch (S21) 168 -----
15 Jib offset cylinder 66 Telescoping cylinder (No.2) 118 ----- 169 -----
16 Restriction 67 Counterbalance valve 119 Work lamp switch (SN1) 170 -----
17 Pilot check valve 68 Telescoping cylinder (No.1) 120 Front wiper switch (SN7) 171 Swing brake switch (S6)
18 Jib lock pin 69 Elevating cylinder 121 Front washer switch (SN9) 172 Drum rotation indicator switch (S9)(Option)
19 Restriction 70 Pressure sensor (SPS4) 122 Roof wiper switch (SN6) 173 Drum indicator (Main)(Option)
20 Pilot check valve 71 Pressure sensor (SPS3) 123 Roof washer switch (SN8) 174 Drum indicator (Aux.)(Option)
21 Counterweight cylinder 72 Restriction 124 Room lamp (10W) 175 Drum rotation detector switch (CS13) (Main)(Option)
22 Restriction 73 Select valve 125 Door switch 176 Drum rotation detector switch (CS14) (Aux.)(Option)
23 Pilot check valve 74 Counterbalance valve 126 Room lamp (10W) (Side of relay box) 177 Counterweight stowing position detection switch 1 (CS24)
24 Pilot check valve 75 Hydraulic pilot control valve (Elevating winch telescoping) 127 Fan switch (Option) 178 Counterweight stowing position detection switch 2 (CS25)
25 Counterweight cylinder 76 Hydraulic pilot control valve (Swing) 128 Fan motor (Option) 179 Swing brake holding detection switch (CS23)
26 Restriction 77 Oil filter 129 Cigarette lighter 180 AML-L C
27 Solenoid valve (Pilot pressure) 78 Oil filter 130 Air conditioner ass’y (option) 181 -----
28 Oil filter 79 Hydraulic motor (Swing) 131 Horn switch (SN2) 182 Revolving light switch (S015)
29 Restriction 80 Swing speed reducer 132 Horn 183 Light switch (S006)
30 Check valve 81 Select valve 133 Low noise mode switch 184 Crane/Carrier operation select switch (K043a, K044a)
31 Accumulator 82 Select valve 134 ----- 185 Starter switch (S002)
32 Check valve 83 Accumulator 135 Boom angle detector 186 Buzzer (Dolly)
33 Remote control valve (Lever) (Right side) 84 Restriction 136 Boom length detector 187 Main switch (S021)
34 Oil filter 85 Accumulator pressure detection switch (PS17) 137 Swing angle detector 1,2 188 Battery relay
35 Shuttle valve (Lever/Pedal) 86 Solenoid valve (Auto stop) 138 2nd boom section full retraction detection switch (L8) 189 Cooling-water residual quantity detection switch (S032)
36 Pressure switch (PS6) 87 Pressure sensor (SPS1) 140 3rd/top boom section full retraction detection switch (L7) 190 Crane/Carrier operation select switch (S013)
37 Oil filter 88 Check valve (gauge isolator) 141 Overwinding (two-blocking) detection switch (S4) 191 F/J overload detector switch (S660)
38 Oil filter 89 Hydraulic motor (air conditioner) (option) 142 Jib and single top overwindng (two-blocking) 192 F/J extension detector switch (S661)
39 Pressure switch (PS5) 90 Solenoid valve (air conditioner) (option) 143 Swing free/Lock selector switch (S14) 193 Transmitter type 2
40 Solenoid control relief valve (Elevating slow stop) 91 Check valve 144 Elevation slow stop cancel switch (S22) 194 O/R length detector (FR)
41 Restriction 92 Solenoid valve (oil cooler) 145 Swing stop cancel switch (S14) 195 O/R length detector (FL)
42 Pressure switch (PS1) 93 Check valve 146 Overwind cutout (anti two-block disable) switch 196 O/R length detector (RR)
43 Remote control valve (Lever) (Left side) 94 Hydraulic motor (oil cooler) 147 Jib stowed detection switch (CS10) 197 O/R length detector (RL)
44 Oil filter 95 Check valve 148 Swing dead angle detection switch (CS11) 198 Fuse(Touch-type winch drum indicator)(For main)(0.3A)(Option)
45 Solenoid valve (Boom telescoping/aux. hoist) 96 Thermo switch 50°C (122°F) 149 Swing control and boom telescoping/aux. hoist control 199 Fuse(Touch-type winch drum indicator)(For aux.)(0.3A)(Option)
46 Pressure switch (PS3) 97 Thermo switch 85°C (185°F) lever stand position detection switch (L16) 200 Connector(Visual-type winch drum indicator)(Option)
47 Restriction 98 Relief valve 150 Boom elevating control and hoist control lever stand 201 Connector(Visual-type winch drum indicator)(Option)
48 Restriction 99 Pressure switch (PS4) position detection switch (L11) 202 Connector(Touch-type winch drum indicator) (For control) (Option)
49 Pressure switch (PS2) 100 151 AML override switch (Outside cab) (SK1) 203 Winch drum indicator lamp(LED1 main, LED2 aux.)(Visual-type)(Opt. )
50 Pressure switch (PS9) 101 Outrigger controls 152 AML override switch (Inside cab) (S19)
8 WZ09-0211E 8
Z-9. Z-9. Z-9.
Harness (Inside Cab)
Z-9 Harness (Inside Cab)
343-537-01010 1
ٌ
9 WZ04-2770E 9
Z-10. Z-10. Applicable serial No. 5 㧦545473--,475342--,437295 --
ٌ 8 㧦545545--,475358--,437395 --
ٌ Z-10.
6 㧦545485--,475342--,437297 --
ٌ 9 㧦545813--,475375--,437601 --
ٌ
Harness (Swing Table Left)
7 㧦545520--,475349--,437378 --
ٌ
Z-10 Harness (Swing Table, Left)
343-529-92020 9
ٌ
10 WZ04-1114E 10
Z-11. Z-11. Z-11.
Harness (Swing Table, Right)
Z-11 Harness (Swing Table, Right)
343-537-02010 0
ٌ
11 WZ04-2790E 11
Z-12. Z-12. Z-12.
Harness (Boom)
Z-12 Harness (Boom)
1. Boom, base
2. Boom, top
343-530-22030 2
ٌ
343-530-32040 1
ٌ
12 WZ04-1311E 12
Z-13. Z-13. Z-13.
AML-LΤC (USA)
Harness (AML, Upper)
AML-LΤB (STD)
Z-13 Harness (AML, Upper)
343-625-71101 1
ٌ
13 WZ04-2251E 13
Z-14. Z-14. Z-14.
Harness (Overwind)
Z-14 Harness (Overwind)
343-724-40000 3
ٌ
343-724-40010 1
ٌ
344-721-83000 1
ٌ
343-723-61000 4
ٌ
14 WZ04-2320E 14
Z-15. Z-15. Z-15.
Harness (Lower) 1 㧦475388 - -
Z-15 Harness (Lower)
336-500-70100 1
ٌ
15 WZ04-2801E 15
Z-16. Z-16. Z-16.
Harness (Outrigger Operation, Option)
Z-16 Harness (Outrigger Operation, Option)
333-316-60020 0
ٌ
16 WZ04-1330E 16
Head Office Ko-34,Sinden-cho, Takamatsu, Japan
Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785
History of revision
1
2
3
4
5

Truck Crane 1: GT-900XL

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Truck Crane 1: GT-900XL

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Publication No.

1. Fundamental cautions fatal accidents, as there is a possibility that the

2.The oil cooler fan may rotate the moment the

1. Applicable spec. NO.

SPEC. NO. SERIAL. NO.

2. Separate service manual

No. of boom sections 5

No. of jib stages 2

Single top Option

Main winch Fitted

Auxiliary winch Fitted

Drum rotation indicator Touch-type (Option)

Weight Counterweight Removable type

Load moment indicator lamp AML- L C

Auto. stop solenoid valve energizing type Normally energized

AML external indicator lamp Fitted

Oil cooler Fitted

Air conditioner Option

Carrier model FAUN / KF90-4

Carrier type Left hand steering, 8×4

Engine model Mercedes - Benz OM460LA

gallon, gal cubic inch, in3 liter, lit, L

bar MPa kgf/cm2

N-m kgf-m ft-lbf

B Hydraulic Power Generating System

E Boom Elevating System

G Boom Telescoping System

Y Data, Adjustment and Checks

General Cautions Refer to separate service manual SA01-01-2E

Hydraulic Power Generating System

Hydraulic Power Generating System B-1

Hydraulic Pump B-2

Flow Control Valve B-3

Rotary Joint B-4

Hydraulic Pilot Control Valve

Sequence Valve (Pilot Pressure) B-6

Solenoid Valve (Pilot Pressure) B-7

Solenoid Control Valve (Jib Set and

B Pilot Check Valve (Jib Set) B-9

Solenoid Valve (Oil Cooler) B-10

Hydraulic Motor (Oil Cooler) B-11

Jib Lock pin B-12

Jib Offset Cylinder B-13

Counterweight Cylinder B-14

Pilot Check Valve B-15

Relief Valve B-16

Check Valve (Gauge Isolator) B-17

Swing System D-1

Swing Assembly D-2

Hydraulic Pilot Control Valve (Swing) D-3

Swing Speed Reducer D-5

Select Valve (Dolly) D-6

Boom Elevating System

Elevating System E-1

Elevating Cylinder E-2

E Counterbalance Valve (Elevating) E-3

Select Valve (Dolly) E-4

Winch System F-1

Hydraulic Motor (Winch) F-3

Hydraulic Valve (Winch Brake Release) F-5

Boom Telescoping system

Telescoping System G-1

Boom (Five-Section Boom) G-2