Publication No.

GR-300EX-1/S1-1E

Service Manual
01

Rough Terrain Crane

GR-300EX-1/S1-1E

Model
GR-300EX-1
Applicable Serial No. 560678 --

ｃ
◯2005
PRINTED IN JAPAN
0505 K
 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 60°and
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 and 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 and 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 and according to instructions. Conduct function and
remounting and disassembling and 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 (－)
2.Remove source of heat, sparks, flame, impact,
terminal first. When connecting terminals,
friction or electricity including internal combustion
connect minus (－) 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 GR-300EX-1 rough terrain crane, its repair, checks
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.

KAGAWA, JAPAN

ISA04-001601

Spec. No. Applicable serial No.

GR-300E-1-00201

GR-300E-1-00202 560678--

GR-300E-1-00203

2. Separate service manual

Separate Service Manual Information No.
General Cautions SA01-01-2E

Overload Prevention Device (AML-L B) W301-0213E

Multiplex Data Transmitter W303-0255E
Torque Converter
W561-0081E
Transmission
Driving Axle W563-0081E

Please note that, for product improvement, some changes may have been
incorporated in the machine that are not covered in this manual.

1 WA04-1700E
 Foreword

3. Outline of specifications
Spec. No.
Item GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)
No. of boom sections 4

No. of jib stages 2 Not Fitted

Single top Option

Main winch Fitted

Auxiliary winch Fitted Not Fitted

Winch brake Automatic brake (Neutral brake)

Winch
Visual-type – Option
Drum rotation
Main *1 Option Option
indicator
Touch-type
Auxiliary Option Option –

Weight Counterweight Fitted Not Fitted

Overload Prevention Device (AML) AML-L B

Auto. stop solenoid valve energizing type Normally energized

AML external indicator lamp Fitted

AML external buzzer Fitted –

Oil cooler Fitted

Emergency engine stop system Fitted –

Reversing steering Fitted –

Air conditioner Option

Emergency steering Fitted Option

Steering pump warning lamp Fitted –

Over-unwinding prevention Option –

Outrigger control box (Both sides of carrier) Option –

Engine model Cummins QSB5.9 – 30TAA

Tires 445 / 95R 25 177E

[*1] : Drum indicator for Europe

Applicable serial No. Option
560678 – 714 Visible type
560715 – Touch type

2 WA04-1700E
 Foreword

4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km
1 0.1 0.001 0.03937 0.00328 1 1.6093
10 1 0.01 0.3937 0.03281 0.6214 1
1000 100 1 39.37 3.281
25.4 2.54 0.0254 1 0.08333
304.8 30.48 0.3048 12 1

Area
2 2 2 2 2
square millimeter, mm square centimeter, cm square meter, m square inch, in square foot, ft
1 0.01 0.000001 0.00155
100 1 0.0001 0.155 0.001076
1000000 10000 1 1550 10.764
645.2 6.452 0.000645 1 0.006944
92903 929.03 0.0929 144 1

Volume
cubic
centimeter, 3 3 3 gallon, 3
cubic meter, m cubic inch, in cubic foot, ft cubic inch, in liter, lit, L
3
cm , cc gal
1 0.000001 0.0610 0.0000353 1 231 3.785
1000000 1 61024 35.31 0.004329 1 0.01639
16.39 0.0000164 1 0.000579 0.2642 61.02 1
28320 0.02832 1728 1

Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
1 0.001 0.03527 0.0022
1000 1 35.27 2.205 0.001 0.001102
28.349 0.02835 1 0.0625 0.00002835 0.00003125
453.592 0.4536 16 1 0.0004536 0.0005
1000000 1000 35274 2205 1 1.102
907185 907.2 32000 2000 0.9072 1

Pressure
2 2
Pa kPa MPa kgf/cm lbf/in , psi
-3 -6 -5 -5
1 1×10 1×10 1.01972×10 14.5×10
3 -3 -2 -2
1×10 1 1×10 1.01972×10 14.5×10
6 3
1×10 1X10 1 1.01972×10 14.5×10
4 -2
9.80665×10 9.80665×10 9.80665×10 1 14.22
6895 6.895 0.006895 0.07031 1

3 WA04-1700E
 Foreword

Torque, moment
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
in-lbf
-2 -1 -3
1 1×10 1.01972×10 1.01972×10 0.00737 0.0885
2 -1
1×10 1 1.01972×10 1.01972×10 0.7376 8.851
-2 -2
9.80665 9.80665×10 1 1×10 0.0723 0.868
2 2
9.80665×10 9.80665 1×10 1 7.233 86.8
135.58 1.3558 13.83 0.1383 1 12
11.3 0.113 1.1525 0.01153 0.08333 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 =(9×t°C +160)/5

Force
N kgf lbf
-1 -1
1 1.01972X10 2.24809X10
9.80665 1 2.20461
4.44822 0.45359 1

4 WA04-1700E
 GROUP INDEX

B Hydraulic Power Generating System

C Outrigger System

D Swing System

E Boom Elevating System

F Winch System

G Boom Telescoping System

H Safety System

K Cab

L Control System

S Steering System

T Brake System

U Suspension System

Y Data, Adjustment and Checks

Z System Diagrams
5 WA04-1700E
 Foreword

5. Contents
Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

General

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

A

Hydraulic Power Generating System

Hydraulic Power Generating System B-1

Hydraulic Pump
B-2
(Double Variable Displacement Pump)
Hydraulic Pump
B-3
(Double Gear Pump)
Hydraulic Pump
B-4
(Gear Pump, Emergency Steering)

Hydraulic Valve (Emergency Steering) B-5

Pressure Reducing Valve

B-6 -
(Emergency Steering)
Solenoid Control Valve
B-7
(Outrigger, Suspension)

Rotary Joint B-8

B
Hydraulic Pilot Control Valve
B-9
(Elevating, Telescoping, Winch)

Sequence Valve (Pilot Pressure) B-10

Solenoid Valve(Pilot Pressure) B-11

Check valve (Gauge Isolator) B-12

6 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Outrigger System

Outrigger System C-1

Jack Cylinder C-2

Pilot Check Valve

C-3
(Jack Cylinder Retracting Prevention)

Extension Cylinder C-4

C (UCHIDA) C-5

Solenoid Valve (Slide/Jack) (TOKIMEC) C-6

(NACHI) C-7

Check Valve
C-8
(Outrigger Extending Prevention)

Outrigger Operation Box C-9 -

Swing System

Swing System D-1

Swing Ass’y D-2

D Hydraulic Pilot Control Valve (Swing) D-3

Hydraulic Motor (Swing) D-4

Swing Speed Reducer D-5

Boom Elevating System

Elevating System E-1

E Elevating Cylinder E-2

Counterbalance Valve (Elevating) E-3

7 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Winch system

Winch System F-1

Winch F-2
F
Hydraulic Motor and
F-3
Counterbalance Valve (Winch)

Hydraulic Valve (Winch Brake Release) F-4

Boom Telescoping system

Telescoping System G-1

Boom (Four-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

Overload prevention Device (AML) Refer to separate manual W301-0213E

Boom Length and Angle Detector H-2

H
Outrigger Extension Length Detector H-3

Solenoid Valve (Auto Stop) H-4

8 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Cab

Crane Cab Glass K-1

Air Conditioner (Option) K-2

K
Hydraulic Motor
K-3
(Air conditioner, Option)
Solenoid Valve
K-4
(Air conditioner, Option)

Control System

Control System L-1

Remote Control Valve (Lever) L-2

Remote Control Valve (Pedal) L-3

Shuttle Valve (Lever, Pedal) L-4

L
Solenoid Valve
L-5 -
(Boom Telescoping/Aux. Hoist)
Solenoid Control Relief Valve
L-6
(Elevating Slow Stop)

Accelerator Sensor L-7

Solenoid Valve (Air) L-8

Electrical System

Multiplex Data Transmitter (MDT) Refer to separate manual W303-0254E

N

Driving Power Transmission System

Torque Converter and Transmission Refer to separate manual W561-0081E

R Driving Axle Refer to separate manual W563-0081E

9 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Steering System

Steering System S-1

Priority Valve S-2

Orbitrol S-3

S Steering Cylinder S-4

Solenoid Valve (Steering Mode) S-5

Pilot Check Valve

S-6
(Steering Mode)
Solenoid Valve
S-7 -
(Reverse Steering) (Option)

Brake System

Brake System T-1

Brake (Service Brake) T-2

Brake Valve T-3

Booster (Brake) T-4

T
Air Dryer T-5

Brake (Parking Brake) T-6

Brake Chamber T-7

Solenoid Valve (Air) T-8

Suspension System

Suspension System U-1

U Suspension Lock Cylinder U-2

Pilot Check Valve

U-3
(Spring Lock Cylinder)

10 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Suspension System

Solenoid Valve
U U-4
(Spring Lock Check Release)

Data, Adjustment and Checks

Hydraulic Pressure Setting Table Y-1

Air Pressure Setting Table Y-2

Air Bleeding Procedure Y-3

Electric Switch Adjustment Y-4

Y
Adjustment and Checks Y-5

Mass Table Y-6

Specifications Y-7

Boom Connecting Pin and Thread Size

Y-8
Table

System Diagrams

Hydraulic Circuit Z-1

Torque Converter Circuit Z-2

Brake Circuit (Pneumatic Circuit) Z-3

Electric Circuit (AML, Crane) Z-4

Z
Electric Circuit (MDT, Carrier / Upper) Z-5

Electric Circuit (MDT, Carrier / Lower) Z-6

11 WA04-1700E
 Foreword

Spec. No.
Chapter Section GR-300E-1-00201 GR-300E-1-00202 GR-300E-1-00203
2M2D 2M2D 1M1D
(Europe) (General Export) (General Export)

Location of Installation

Location of Hydraulic Parts (Upper) Z-7

Location of Hydraulic Parts (Lower) Z-8

Location of Air Parts Z-9

Location of Electric Parts (Inside cab) Z-10

Location of Electric Parts

Z-11
(Swing Table, Boom)
Location of Electric Parts
Z-12
(Relay Assembly / Upper)

Location of Electric Parts (Lower) Z-13

Location of Electric Parts

Z-14
(Box Assembly / Lower)

Z
Harness Diagrams

Harness (Connector No.) Z-15

Harness (Inside Cab) Z-16

Harness (Swing Table, Left) Z-17

Harness (Swing Table, Right) Z-18

Harness (Boom) Z-19

Harness (AML, Upper) Z-20

Harness (Overwind) Z-21

Harness (Lower, Main) Z-22

Harness (Lower, Electric Governor) Z-23

12 WA04-1700E
 B B

Hydraulic Power Generating System

Contents

B-1 Hydraulic Power Generating B-6 Pressure Reducing Valve

System.................................... 1 (Emergency steering) ............19

1. General..................................................... 1 1. Structure ................................................. 19

B-2 Hydraulic Pump (Double Variable B-7 Solenoid Control Valve

Displacement Pump) ............... 4 (Outrigger, Suspension)........20

1. Structure ................................................... 4 1. Structure ................................................. 20

2. Theory of operating of regulator section.. 10

B-8 Rotary Joint ....................................33
3. Air bleeding procedure............................ 12
1. Structure ................................................. 33
1.1 General view .............................................33
B-3 Hydraulic Pump 1.2 Port size table .........................................35
(Double Gear Pump).............. 13 1.3 Swivel joint (Hydraulics • pneumatics) ......36
1.4 Swivel joint (Heated water) .......................38
1. Structure ................................................. 13
2. Slip ring................................................... 39
2. Air bleeding procedure............................ 15 2.1 General view .............................................39
2.2 Harness • connector..................................40
2.3 Maintenance of Ring and Brush ...............40
B-4 Hydraulic Pump (Gear Pump,
Emergency Steering) (Option) .. 16
B-9 Hydraulic Pilot Control Valve
1. Structure ................................................. 16 (Elevating, Telescoping, Winch) ...41

1. Structure ................................................. 41
B-5 Hydraulic Valve (Emergency
Steering) (Option) ...................... 17

1. Structure ................................................. 17

i
B-10 Sequence Valve (Pilot Pressure) .. 52

1. Structure ................................................. 52

B-11 Solenoid Valve (Pilot Pressure) .... 55

1. Structure ................................................. 55

B-12 Check Valve (Gauge lsolator) ....... 57

1. Structure ................................................. 57

ii
B-1 B-1
Hydraulic Power Generating System

B-1 Hydraulic Power Generating System

1. General

Hydraulic Circuit for Carrier

[NOTICE] 3. The double gear pump supplies oil to the circuits

If the machine is not equipped with the optional of outrigger,spring lock, steering, pilot pressure,
emergency steering, two points "A" are directly optional air conditioner and swing.
joined and four portions "*1" are plugged.
4. The gear pump and the hydraulic valve in the
1. The hydraulic power for this crane is generated by emergency steering circuit are optional. They
the double variable displacement pump, double are provided for the case when the double gear
gear pump, and optional gear pump for the pump malfunctions.
emergency steering circuit.

2. The double variable displacement pump supplies

oil to the circuits of elevating, telescoping, main
winch, and auxiliary winch. This double variable
displacement pump is driven only when the PTO
switch is turned on.

1 WB02-0330E
B-1 B-1
Hydraulic Power Generating System

Hydraulic Circuit for Crane

[NOTICE] auxiliary winch). When the PTO switch is turned

If the machine is not equipped with the optional air on, the solenoid valve for automatic stop is shifted,
conditioner, two points "B" are directly joined. For making the condition of this circuit onloaded.
the crane “IMID” without the auxiliary winch, five
points “*2” are plugged. 2. The pressurized oil delivered through the P1 port

Circuits for elevating, telescoping, main and auxiliary of the rotary joint is supplied to the circuits for the
winches main winch and the auxiliary winch.
The pressurized oil delivered through the P2 port
1. The hydraulic oil provided from the pumps is is provided to the circuits for elevating and
controlled (onloaded/unloaded) by the solenoid telescoping. This oil, however, is supplied to the
valve for automatic stop. This solenoid valve for circuits for the main winch and the auxiliary winch
automatic stop is switched by the AML output to while neither elevating nor telescoping operation
control the vent ports of the relief valve (elevating, is done.
telescoping) and the relief valve (main winch,

2 WB02-0330E
B-1 . B-1 .
Hydraulic Power Generating System

Circuit for pilot pressure, air conditioner(option)

1. The pressurized oil delivered through the P3 port

of the rotary joint is supplied to these circuits.
Pressurized oil reduced by the sequence valve is
supplied to the circuit for the pilot pressure.

2. The pilot pressure is supplied to the swing brake

release circuit, main winch brake release circuit,
auxiliary winch brake release circuit, and pilot
circuits for crane operations.

3. The pressurized oil delivered through the

sequence valve is supplied to the circuit for the air
conditioner(option).

3 WB02-0330E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

B-2 Hydraulic Pump (Double Variable Displacement 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
This pump is a variable displacement piston pump.
The angle of the swash plate is controlled by the regulator.

4 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

Main body

Apply adhesive (No. 1305N of Threebond make)

808 535 789 732 532 548 214 702 792 534 724 901 954 719 124 151 152 113 406 710
531
953

886

717
Apply (Sealub L101)
to the oil seal surface 406
circumferential

774
111

824
261

127
123
710
251
490 212 211 153 156 157 314 312 466 114 885 313 141 467 271 401 262
725 728
Valve plate for counter clockwise rotation Valve plate for clockwise rotation
IW101-0270E01

111.Drive shaft (F) 212.Swash plate 490.Plug 732.O-ring

113.Drive shaft (R) 214.Tilting bush 531.Tilting pin 774.Oil seal
114.Spline coupling 251.Support 532.Servo piston 789.Backup ring
123.Roller bearing 261.Seal cover (F) 534.Stopper (L) 792.Backup ring
124.Needle bearing 262.Seal cover (R) 535.Stopper (S) 808.Nut
127.Bearing spacer 271.Pump casing 548.Feed back pin 824.Snap ring
141.Cylinder block 312.Valve block 702.O-ring 885.Valve plate pin
151.Piston 313.Valve plate (R) 710.O-ring 886.Spring pin
152.Shoe 314.Valve plate (L) 717.O-ring 901.Eye bolt
153.Set plate 401.Hex. socket head bolt 719.O-ring 953.Hex. socket set screw
156.Spherical bush 406.Hex. socket head bolt 724.O-ring 954.Set screw
157.Cylinder spring 466.Plug 725.O-ring 981.Name plate
211.Shoe plate 467.Plug 728.O-ring 983.Pin

Thread size and tightening torque

Tightening torque Tightening torque

Sign / Port Thread size Sign / Port Thread size
N-m ft-lbf N-m ft-lbf
401 M16 240 177 531,532 M20x1.5 240 177
406 M6 12 8.8 808 M16 130 96
466 G1/4 36 26.5
467 G1/2 110 81
490 NPTF1/16 8.8 6.5

5 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

Enlarged view of the main body (the left side)

Apply (Shealub L101)

to the oil seal surface circumferential Apply adhesive (No. 1305N of Threebond make)

808 535 789 732 532 548 214 702 792 534 724
531

953

886

717

406

774
111

824
261
127
123
710
251
490 212 211 153 156 157 314 312
Valve plate for counter clockwise rotation
IW101-0270E02

6 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

Enlarged view of the main body (the right side)

901 954 719 124 151 152 113 406 710

466 114 885 313 141 467 271 401 262

725 728
Valve plate for clockwise rotation
IW101-0270E03

7 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

Regulator

962

412

801 924 627 701 624 651 652 621 496 887

728 625 402 629 724

IW101-012004

8 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

413 496 897 601

755

614

708

611

View Z IW101-012006

402.Hex. socket head bolt 614.Center plug 651.Sleeve 755.O-ring

412.Hex. socket head bolt 621.Compensator piston 652.Spool 801.Nut
413.Hex. socket head bolt 624.Spring seat 701.O-ring 887.Pin
496.Plug 625.Compensator spring 708.O-ring 897.Pin
601.Casing 627.Spring seat 724.O-ring 924.Hex. socket set screw
611.Feedback lever 629.Spring case 728.O-ring 962.Steel ball

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
402 M6 12 8.8
412,413 M8 29 24.1
496 NPTF1/16 8.8 6.5
614 G1/4 36 26.5
801 M8 17 12.5

9 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

2. Theory of operating of regulator section

10 W101-0272E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

Hydraulic oil (P) from the pump flows to areas A When the pump pressure is below a certain level,
and B shown in Figs. 1 and 2 via the path in the the spool does not move because the leftward
regulator casing. force of the compensation piston on the spool is
The oil also flows to small-diameter end H of the less than the pressure of the compensation spring.
servo piston. In this situation, the seating area C closes and the
The oil flowing to area A applies leftward pressure seating area E opens. Therefore the oil at the
to the compensation piston. servo piston’s large-diameter end G flows out

11 W101-0272E
B-2 . B-2 .
Hydraulic Pump (Double Variable Displacement Pump)

from the port D to the drain line via the spool.

Then the servo piston’s large-diameter end G is
pushed by the pressure exerted on the
small-diameter end H, to stay in the maximum
discharge rate position.
When the pump pressure exceeds the 1st turning
point (P1 in Fig. 3), the leftward force of the
compensation piston on the spool overcomes the
pressure of the compensation spring and the
spool is moved to the left. As a result, seating
area E closes, and seating area C opens. The
hydraulic oil in area B flows to the servo piston’s
large-diameter end G via the port D pushing the
servo piston to the right decreasing the discharge 3. Air bleeding procedure
flow rate. The rightward movement of the servo
Refer to “Air Bleeding Procedure” in chapter Y.
piston is transferred to the feedback lever via the
fulcrum J . The feedback lever revolves around
the pin on the top of the fulcrum plug. A pin (A) is
inserted in both the end of the feedback lever and
the hole of the sleeve. When the feedback lever
revolves, the sleeve moves to the left, and seating
areas C and E open where the Hydraulic powers
of the small and large-diameter ends of the servo
piston are balanced. When the pump pressure
decreases, the compensation spring pushes back
the spool, causing seating area C to close and
seating area E to open. The hydraulic oil at the
servo piston’s large-diameter end G is discharged
into the drain line, causing the servo piston to
move the left, increasing the discharge rate. The
movement of the servo piston is transferred to the
sleeve via the feedback lever, and seating areas
C and E open or close so that the servo piston,
under the pressures on both ends, follows the
movement of the spool.
As explained above, the discharge rate of the
pump is controlled by the balance of pressure on
the spool, the pressure setting compensation
spring, and the balance of pressure on the large
and small-diameter ends of the servo piston. The
maximum and minimum discharge rates are set
by adjustment screws 954 and 953, respectively.
The 1st turning point is set by the adjustment
screws. Gradients of the pressure discharge lines
are determined by the spring constant.
366-533-50001 △
0

366-540-20000 △
0

12 W101-0272E
B-3 B-3
Hydraulic Pump (Double Gear Pump)

B-3 Hydraulic Pump (Double Gear 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 2 3

IW101-013001

1.Gear pump assy 2.Connecting section 3.Gear pump assy

13 W101-0131E
B-3 B-3
Hydraulic Pump (Double Gear Pump)

Gear pump assy-1

13 18 19 17 16 2 8,9 1 7 3

6,10

12

3 14 2 15
IW101-013002

1.Body 7.Side plate 12.O-ring 16.Dowel pin

2.Bearing box 8.Backup ring 13.Drive gear 17.Oil seal
3.Bearing box 9.Rubber string 14.Driven gear 18.Oil seal
6.Front cover 10.Hex. socket head bolt 15.Rear cover 19.Retaining ring

Connecting section-2
2 1 4

IW101-013004

1.Coupling 2.O-ring 3.Dowel pin 4.Hex. socket head bolt

14 W101-0131E
B-3 . B-3 .
Hydraulic Pump (Double Gear Pump)

Gear pump assy-3

13 16 2 8,9 1 7 3

6,10

12

3 14 2 15
IW101-013003

1.Body 7.Side plate 12.O-ring 16.Dowel pin

2.Bearing box 8.Backup ring 13.Drive gear
3.Bearing box 9.Rubber string 14.Driven gear
6.Front cover 10.Hex. socket head bolt 15.Rear cover

2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

366-533-00000 △
0

366-519-00000 △
0

15 W101-0131E
B-4 . B-4 .
Hydraulic Pump (Gear Pump, Emergency Steering) (Option)

B-4 Hydraulic Pump (Gear Pump, Emergency Steering) (Option)

[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

25 3 21 12 5 11 22 2

A B

C-C C
23 13 21 1 4 22 32 31

IW101-014001

1.Front cover 5.Side plate 21.Bush (front cover) 31.Hex. socket head bolt
2.Body 11.Gasket 22.Bush (body) 32.Plain washer
3.Drive gear 12.Gasket 23.Retaining ring
4.Driven gear 13.Oil seal 25.Steel ball

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G3/4 62 - 75 46 - 56

D G1/4 24 - 29 17 - 22

31 M10 48 - 51 35 - 38

366-535-20000 △
2

16 W101-0142E
B-5 B-5
Hydraulic Valve (Emergency Steering)

B-5 Hydraulic Valve (Emergency Steering)

[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
T

B
P2 P3

The arrow in Figure shows the flow of the oil P1

A
at the emergency pump operation. IW123-016001

10

Z Z
P3 P1

Y Y
b

X X
P2
a

IW123-016101
9 9

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P3 G1/2 98 72

P2, T G3/4 167 123

Mounting screw M10 23 - 27 17 - 20

17 W123-0161E
B-5 . B-5 .
Hydraulic Valve (Emergency Steering) (Option)

Section X-X a
P2 8

7
2
b
Check valve C

IW123-0161E04

Section Y-Y 12 11 6 3 7 8

Check valve B

1 2 7 8 4 9 IW123-0161E03

d
Section Z-Z
P3 P1

Check valve A

2 5 7 8 IW123-0161E02

1.Body 4.Spring 7.O-ring 10.Plug

2.Poppet 5.Spring 8.Plug 11.O-ring
3.Spool 6.Spring 9.Plug 12.O-ring
366-470-30000 △
0

18 W123-0161E
B-6 . B-6 .
Pressure Reducing Valve (Emergency steering)

B-6 Pressure Reducing Valve (Emergency steering)

[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
P

A1

DR A2
IW120-0120E01

(*1)

A1

DR A2

10 9 8 7 6 5 4 3 2 1
IW120-0120E02

(*1) : Apply the thread locking agent (LOCTITE 270 or the equivalent)

1.Body 4.Sleeve 7.Spacer 10.Plug

2.Spool 5.Filter 8.O-ring
3.O-ring 6.O-ring 9.Spring
Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P G1/2 98 72
A1 G3/8 49 36
A2, Dr G1/4 29.4 22

366-054-90000 △
1

19 W120-0121E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

B-7 Solenoid Control Valve (Outrigger, Suspension)

[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

20 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Connector

+- (+) : Red
(-) : Blue

IW121-0542E01

1.Body assy (outrigger) 15.T cover assy 22.Nut 100.Plug

2.Body assy (suspension) 20.Name plate assy 23.Spring washer
10.P cover assy 21.Stud bolt 30.Tandem plate assy

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P, T G1 196 145
A1, B1, A2, B2 G3/4 167 123
C G1/2 98 72
G, E1, E2 G1/4 29 22

21 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Body assy (outrigger)

(illustrated as 1 on page 21)

1.Body
2.Spool
3.Plug
4.Not equipped
5.Not equipped
6.O-ring
7.O-ring 11
8.O-ring
9.Distance piece
10.Plug
11.Pilot cover assy
13.O-ring 7

13
3

5 1

4 8

6 10

IW112-011005

22 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Pilot cover assy (illustrated as 11 on page 22)

Note: Apply LOCTITE 242 (thread locking agent) to the threaded section of the orifice (12).

16 8 2 3 14

1.Cover
2.Spool
3.Spring
4.Spring seat 10
5.Spring
6.O-ring 7
7.O-ring
8.O-ring
11
9.O-ring
10.Plug
11.Plug
12
12.Orifice
13.Hex. socket head bolt
14.Hex. socket head bolt
15 5
15.Hex. socket head bolt
16.Solenoid (DC24V) 13 1

4 9 6
IW112-011007

23 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Body assy (suspension)

(illustrated as 2 on page 21)

1.Body
2.Spool
3.Plug 12
4.Not equipped
5.Not equipped
6.O-ring
7.O-ring
8.O-ring 7
9.Distance piece
10.Plug
11.Pilot cover assy 9
12.Cover assy

5 1

4 8

6 10

11

IW112-011006

24 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Pilot cover assy (illustrated as 11 on page 24)

Note: Apply LOCTITE 242 (thread locking agent) to the threaded section of the orifice (12).
16 8 2 3 14

1.Cover
2.Spool
3.Spring
10
4.Spring seat
5.Spring
6.O-ring 7
7.O-ring
8.O-ring 11
9.O-ring
10.Plug
11.Plug 12
12.Orifice
13.Hex. socket head bolt
15 5
14.Hex. socket head bolt
15.Hex. socket head bolt
16.Solenoid (DC24V) 13 1

4 9 6
IW112-011007

Cover Ass’y (illustrated as 12 on page 24)

1
1.Cover
2.Spring seat
3
3.Spring
4.O-ring
5.O-ring 4
6.Hex. socket head bolt

6 2
IW112-011008

25 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

P cover assy
(illustrated as 10 on page 21)

A
1

10

13

A
IW112-011012

26 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Cross section of the reducing valve and the relief valve along the line A-A illustrated on page 26

14

16

15

7 12 18 17

19 5

A-A
IW112-011003

27 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

1.Cover 6.O-ring 11.------ 16.Orifice

2.Spool 7.O-ring 12.Plug 17.Spring seat
3.Spring seat 8.O-ring 13.Distance piece 18.Hex. socket set screw
4.Spring 9.O-ring 14.Relief valve 19.Nut
5.Plug 10.O-ring 15.Plug

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
5 - 30 - 37 22 - 27

14 - 78 58

16 *1 M6 2.4 - 2.9 1.5 - 2.0

19 M8 10 - 15 7 - 11

*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.

Relief valve (illustrated as 14 on page 27)

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

T
IW112-011004

1.Body 5.Adjuster screw 9.Shim 13.Backup ring

2.Plunger 6.Nut 10.O-ring 14.Cap
3.Body 7.Spring 11.O-ring
4.Poppet 8.Spring 12.O-ring

28 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

T cover assy
(illustrated as 15 on page 21)

8 7

A
IW112-011013

29 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

Cross section of the flow control valve along the line A-A illustrated on page 29

6 4 2 A-A
IW112-011009

30 W112-0112E
B-7 B-7
Solenoid Control Valve (Outrigger, Suspension)

1.Cover 3.Plug 5.Flow control valve 7.Plug

2.O-ring 4.Plug 6.Orifice 8.Orifice

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
5 - 78 58

6 *2 M10 24 -29 17 - 22

8 *2 M5 3–4 2.5 - 3.0

*2: Apply LOCTITE 241 (thread locking agent) to threaded sections.

Flow control valve (illustrated as 5 on page 30)

*1

10 5 10 11 6 11 2 7 1 8 4 9 3

IW112-0112E01

1.Body 4.Spring 7.O-ring 10.Backup ring

2.Piston 5.O-ring 8.O-ring 11.Backup ring
3.Plug 6.O-ring 9.O-ring

[NOTICE](*1)
TR-300XL-4 : there is O-ring
TR-450XL-4, TR-500XL-4 : there is not O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 - 51 - 58 69 - 58

3 - 87 - 108 118 - 147

31 W112-0112E
B-7 . B-7 .
Solenoid Control Valve (Outrigger, Suspension)

Tandem plate assy

(illustrated as 30 on page 21)

1.Plate
2.O-ring
3.O-ring 2
4.O-ring
5.Distance piece

IW112-011011

367-407-30000 △
0

366-465-80000 △
3

32 W112-0112E
B-8 B-8
Rotary Joint

B-8 Rotary Joint

[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

(F)mark FRONT 6

8
A

W1 B
7 W2

2 DR
T
P2

P4
P1
16 P3
P5
P7
P6
A3
A1
A2

P2 P1
P4 P7
T

W1
W2
A3
DR
P6
A2 P3
P5

A1
IW181-0380E01

33 W181-0380E
B-8 B-8
Rotary Joint

3 14
9,10
11,12 15

14
View A View B IW181-0380E02

1.… 6.Slip ring assy 11.Bolt 16. Swivel joint assy

2.Swivel joint assy 7.Bolt 12.Spring washer
3.Plate 8.Bolt 13.…
4.… 9.Hex. socket head bolt 14.Plug
5.… 10.Spring washer 15.Plug

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m tf-:lbf
*1
7 M10 43 - 49 32 - 36
*1
8 M12 54 - 66 40 - 49
*1
9 M6 6.6 - 8 5-6
*1
11 M10 18 - 22 13 - 16

*1：Apply LOCTITE242 to threaded sections.

34 W181-0380E
B-8 B-8
Rotary Joint

1.2 Port size table

port circuit remarks port size

P1 Winch G1
Elevating
P2 Telescoping G1

Steering
P3 Air conditioner G1/2

P4 Steering left G1/2

P5 Steering right G1/2

P6 Option G3/8

P7 Swing G1/2

T Tank Ф50

DR Drain G1/2

A1 Air suppy G3/8

A2 Service blake Primary G3/8

A3 Service blake Secondary G3/8

W1 Heater IN Ф13

W2 Heater OUT Ф13

35 W181-0380E
B-8 B-8
Rotary Joint

1.3 Swivel joint (Hydraulics • pneumatics)

M8

3
6
5
10
4
A

B
D

9
E
C 14

F
G
H
9 M
7
I 2

J K
8

D X E
1
H
C B

X1 X4

X2 X3 13
A F
X I
M G
11 J K

IW181-0380E03

36 W181-0380E
B-8 B-8
Rotary Joint

[NOTICE]
Before seal parts are installed in seal grooves of the body 2, remove oils and fats from seal grooves
completely. (To prevent the seal parts from turning with the core 1)
Before apply the silicon grease (NOK UNISILKON L 205) on faces X2, X3 and X4 of the body 2 and on side
X1 of the core 1 shown in view X.

1.Core 5.O-ring 9.Ring seal 13.Pulg

2.Body 6.O-ring 10.Hex. socket head bolt 14.Ring seal
3.Cover 7.O-ring 11.Plug
4.Plate 8.Ring seal 12. --------------------------

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft - lbf
*1
10 M8 30 - 34 22 - 25

*1：Apply LOCTITE242 to threaded sections.

37 W181-0380E
B-8 B-8
Rotary Joint

1.4 Swivel joint (Heated water)

1
A
5
2 B

4
6
3
IW181-028004

[NOTICE]
Before seal parts are installed in seal grooves of the core 3, remove oils and fats from seal grooves
completely. (To prevent the seal parts from turning with the body 4)
Before install plain bearings 5 and 6 into the core 3, apply Molybdenum Grease No.2 to inner and outer
surfaces of the bearing 5 and upper and lower surfaces of the bearing 6.

1.Packing 3.Core 5.Plain bearing 7.Retaining ring

2.O-ring 4.Body 6.Plain bearing

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft - lbf
A
R1/4 22 - 25 16 - 18.5
(INLET)
B
R1/4 22 - 25 16 - 18.5
(OUTLET)

38 W181-0380E
B-8 B-8
Rotary Joint

2. Slip ring

2.1 General view

1.Brush
2.Potentiometer assy
3.Bearing
4.Spacer
5.Brush
6.Base
7.Shaft
8.Gear
9.Gear
10.Bolt
11.Spring pin
12.Nut
13.Potentiometer
14.Pole
15.Ring

39 W181-0380E
B-8 . B-8 .
Rotary Joint

2.2 Harness • Connector

2.3 Maintenance of Ring and Brush

[NOTICE]
Maintenance-free from grease job of the contacts.
Never apply grease to contacts between rings and
brushes, rings for the upper power circuits (6
circuits) and disk type rings for the lower weak
signal circuits (20 circuits).

These slip-rings adopt carbon brushes on the

power and weak signal circuits.

These slip-rings have enough operating durability

with self-lubricating carbon materials. Therefore
grease job is not necessary like metal contacts.

346-307-11000 △
6

40 W181-0380E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

B-9 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

[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

P1 C1 b1 C2 b2 P2 b3 b4

C3

T1 Vent B1 A1 a1 B2 A2 a2 T2 Vent B3 A3 a3 B4 A4 a4
IW134-018001

41 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

C1 C2

Vent

Vent

(down) (down) (extending) (lowering)

b3,b4
b1 b2
b3 b4

B1 B2 T2 B3 B4

T1
C3
P2

A1 A2 A3 A4

a1 a2 a3 a4
a3,a4
Aux. winch Main winch Telescoping Elevating
(up) (up) (retracting) (raising)

P1
IW134-0180E02

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 22

A3,B3,A4,B4 G3/4 167 123

P1,P2,A1,B1,A2,B2 G1 196 145

42 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

Cross section of whole body

B A

Aux. winch

Main winch

Telescoping

Elevating

B A
18 17
IW134-0180E03

43 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

11
8
1
10

C C
Aux. winch

D D
Main winch
9
10
14
E E
13
2

F F
12 Telescoping
3

G G
Elevating

4 7 16
A-A IW134-0180E04

44 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

Aux. winch

Main winch

Telescoping

Elevating

5 15 6
B-B
IW134-0180E05

1.Winch selector valve 6.O-ring 11.Overload relief valve 16.Eye bolt

2.Telescoping selector valve 7.Hex. socket head bolt 12.Overload relief valve 17.Plug
3.Elevating selector valve 8Main relief valve 13.Overload relief valve 18.O-ring
4.End cover 9.Main relief valve 14.Overload relief valve
5.O-ring 10.Hex. socket head bolt 15.Plug

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
7 M12 57 - 59 42 - 43
10 M10 44 - 49 32.5 - 36
15 - 10 - 12 7-9
17 G1/4 24.5 - 29.4 18 - 22

45 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

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

18 17 15 28 27 26 28 14 16,17

C-C (Aux. winch) IW134-0180E06

6 3 4 20 19 21 22 1 Overload relief valve

25,24,23,13 9 8 12,23,24,25

7 11 10

18 17 29 28 27 26 28 14 16,17

D-D (Main winch) IW134-0180E07

46 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

1 Main relief valve

18 17 15 28 27 26 5 28 14 16,17

E -E IW134-0180E08

1.Winch selector valve body 8.Return spring 16.Plug 24.Plain washer

2.Spool (main, winch) 9.Return spring 17.O-ring 25.Spring washer
3.Spool (aux. winch) 10.Spring seat 18.Spring retainer 26.Plug
4.Flow control valve 11.Spool end 19.Check valve 27.O-ring
(main winch), (aux. winch) 12.Pilot cover 20.Spring 28.Plug
5.Flow control valve (junction) 13.Pilot cover 21.Plug 29.Spring
6.O-ring 14.Orifice 22.O-ring
7.Spring seat 15.Spring 23.Hex. socket head bolt

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
M27×1.5 78 - 88 58 - 65
(Main winch), (Aux. winch)
1
11* - 18 - 20 13 - 14
2
14* M6 5-6 3.5 - 4.5
16 M33 98 - 118 72 - 87
18 - 98 - 118 72 - 87
21 - 78.5 - 88.3 58 - 65
23 M8 27.5 - 29.4 20 - 22
26 G 3/8 39.2 - 49 29 - 36
28 NPT 1/16 10 - 12 7-9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

47 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

Telescoping selector valve

Overload relief valve

8 9 2 17 24 23 25 26 1 Overload relief valve

(Boom extending)
(Boom retracting)
7 6

12,13,27,28 11 3 4 5 10,13,27,28

11 18,19 21 20 22 14 15 16 18,19

F - F (Telescoping) IW134-0180E09

1.Telescoping selector valve 7.Spool end 14.Steel ball 21.Spring

body 8.Hex. socket set screw 15.O-ring 22.Plug
2.Spool (telescoping) 9.Steel ball 16.Plug 23.Check valve
3.Spring seat 10.Pilot cover 17.Flow control valve 24.Spring
4.Return spring 11.O-ring 18.Plug 25.Plug
5.Return spring 12.Pilot cover 19.O-ring 26.O-ring
6.Spring seat 13.Hex. socket head bolt 20.Orifice 27.Plain washer
28.Spring washer

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
M27×1.5 78 - 88 58 -65
(Telescoping)
1
7* - 18 - 20 13 - 14
1
8* M8 12 - 14 8.5 - 10
13 M8 27.5 - 29.4 20 - 22
1
16* - 18 - 20 13 - 14
18 M33 98 - 118 72 - 87
2
20* M6 5-6 3.5 - 4.5
25 - 78.5 - 88.3 58 - 65
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

48 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)
Elevating selector valve

Overload relief valve

8 9 20 21 20 21 2 1

7 6

12,13, 22,23 11 3 4 5 10,13, 22,23

11 15,16 18 17 19 14 15,16

G -G (Elevating) IW134-0180E10

1.Elevating selector valve body 7.Spool end 13.Hex. socket head bolt 19.Plug
2.Spool (elevating) 8.Hex. socket set screw 14.Flow control valve (elevating) 20.Plug
3.Spring seat 9.Steel ball 15.Plug 21.O-ring
4.Return spring 10.Pilot cover 16.O-ring 22.Plain washer
5.Return spring 11.O-ring 17.Orifice 23.Spring washer
6.Spring seat 12.Pilot cover 18.Spring (flow control valve)

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
M27×1.5 78 - 88 58 - 65
（Elevating）
1
7* - 18 - 20 13 - 14
1
8* M8 12 - 14 8.5 - 10
13 M8 27.5 - 29.4 20 - 22
15 M33 98 - 118 72 - 87
2
17* M6 5-6 3.5 - 4.5
20 G3/4 78.5 - 88.3 58 - 65
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

49 W134-0181E
B-9 B-9
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 - 28.4 - 30.4 21 - 22.4
10 M14×1 18.6 - 20.6 13.7 - 15.2
13 M14×1 18.6 - 20.6 13.7 - 15.2
14 - 38.2 - 40.2 28.2 - 29.6

50 W134-0181E
B-9 . B-9 .
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

Overload relief valve

(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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 - 18.6 - 20.6 13.7 - 15.2
8 M27×1.5 78.5 - 88.3 58 - 65
13 M14×1 18.6 - 20.6 13.7 - 15.2
14 M14×1 18.6 - 20.6 13.7 - 15.2

366-497-00000 △
0

51 W134-0181E
B-1 0 B-1 0
Sequence Valve (Pilot Pressure)

B-10 Sequence Valve (Pilot Pressure)

[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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P, V G1/2 98 72
Dr G3/8 49 36
Pi, G G1/4 29.4 22

52 W122-0113E
B-1 0 B-1 0
Sequence Valve (Pilot Pressure)

Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)

1.Body
2.Filter
3.Filter retainer 5
4.Back pressure regulating valve
5.Pressure reducing valve
6.Hex. socket head bolt
7.Plug
8.O-ring
9.Plug 4
A-A 1 2 3
IW122-0112E01

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
3 G1/2 9.81 - 11.8 7.2 - 8.7
6 M6 9.81 - 10.8 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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 M24×1.5 58.8 – 68.6 43.4 – 50.6

53 W122-0113E
B-1 0 . B-1 0 .
Sequence Valve (Pilot Pressure)

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

54 W122-0113E
B-1 1 B-1 1
Solenoid Valve (Pilot Pressure)

B-11 Solenoid Valve (Pilot Pressure)

[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

A2 A1

T
P
IW121-067001

701
Connector

IW121-0671E01

171

T
A2 A1

P
101.Casing
171.Hex. socket head bolt
701.Solenoid valve (DC24V)

101 T1 IW121-067002

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P,T,A1,A2 G1/4 34 - 38 25 - 28
171 M5 6-8 4.5 - 6
T1 M8 26 - 32 20 - 24

55 W121-0672E
B-1 1 . B-1 1 .
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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
802 M6 6.9 - 7.9 5.1 - 5.8

367-401-00000 △
0

56 W121-0672E
B-1 2 . B-1 2 .
Check Valve (Gauge Isolator)

B-12 Check Valve (Gauge Isolator)

[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

Hydraulic symbols
P' S

P1 P2 P3 IW116-012001

7 8 1 2 5 4 3 6

P1 P2 P3 IW116-012002

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P2, P3, P’ G 1/4 29.4 22

S G 3/8 49.0 36

Mounting bolt M8 13 - 15 9.6 - 11.0

1. Body 3. Poppet 5. O-ring 7. Plug

2. Plug 4. Spring 6. Screw 8. O-ring

366-251-20000 △
0

57 W116-0122E
 C C
Outrigger System

Contents

C-1 Outrigger System............................. 1 C-7 Solenoid Valve (Slide/Jack)

(NACHI) .....................................8
1. General..................................................... 1
1. Structure ................................................... 8

C-2 Jack Cylinder.................................... 3

C-8 Check Valve (Outrigger Extending
1. Structure ................................................... 3 Prevention) ...............................9

1. Structure ................................................... 9
C-3 Pilot check Valve (Jack Cylinder
Retracting Prevention) ............ 4
C-9 Outrigger Operation Box ...............10
1. Structure ................................................... 4
1. Structure ................................................. 10

C-4 Extension Cylinder .......................... 5 2. Connector diagram.................................. 11

1. Structure ................................................... 5 3. Specifications .......................................... 11

3.1 General ..................................................... 11
3.2 Bipolar toggle switch ................................. 11
C-5 Solenoid Valve (Slide/Jack) 3.3 Monopolar toggle switch ........................... 11
(UCHIDA) .................................. 6 3.4 Push switch ............................................... 11
3.5 Diode......................................................... 11
1. Structure ................................................... 6 3.6 Lamp assembly......................................... 11

C-6 Solenoid Valve (Slide/Jack)

(TOKIMEC) ............................... 7

1. Structure ................................................... 7

i
C-1 C-1
Outrigger System

C-1 Outrigger System

1. General
Hydraulic Circuit for Outrigger

1. The outrigger controls use the solenoid control 4. During outrigger retraction, the pressure oil
valve to select between extension or retraction for passes through the solenoid control valve and
each cylinder. The solenoid valve selects between pilot check valve, and operates on the retraction
operation of the extension cylinder and the jack side of the extension and jack cylinders. Only the
cylinder. circuit of the cylinder selected by the solenoid
valve retracts.
2. During outrigger extension, the pressure oil from
the pump passes through the solenoid control 5. The maximum puressure in the outrigger hydraulic
valve and solenoid valve to enter the cylinders. circuit is regulated by the relief valve.

3. At this time, back pressure is generated in the

return oil by the pilot check valve. The return oil
then passes through the solenoid control valve
and returns to the tank.

1 WC02-0270E
C-1 . C-1 .
Outrigger System

Electric Circuit (Relay RF3, Solenoid Valve)

1. The solenoid valve (extending/retracting) and the

four solenoid valves (slide/jack) are switched
according to the outputs from the multiplex data
transmitter (lower). The outputs to the four
solenoid valves (slide/jack) are transmitted via the
relay RF3.

2 WC02-0270E
C-2 . C-2 .
Jack Cylinder

C-2 Jack Cylinder

[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.Cylinder 6.O-ring 11.O-ring 16.------

2.Spring pin 7.Backup ring 12.Damper ring 17.Bolt
3.Piston 8.Plain bearing 13.Packing 18.Spring washer
4.Packing 9.Rod 14.Backup ring
5.Backup ring 10.Rod cover assy 15.Dust seal

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
17 M10 22 - 25 16 - 18

360-337-80000 △
4

3 W151-0260E
C-3 . C-3 .
Pilot Check Valve (Jack Cylinder Retracting Prevention)

C-3 Pilot check Valve (Jack Cylinder Retracting Prevention)

[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
9
A B
C D

C D
IW115-023001

5 4 10 6 7,8

A B 1
IW115-023002

1.Valve body 4.Valve 7.O-ring 10.Seat

2.Plug 5.Spring 8.Backup ring
3.O-ring 6.Piston 9.O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A G1/4 29.4 22

B G1/4 29.4 22
Mounting
M10 43 - 49 32 - 36
bolt 366-250-30000 △
0

4 W115-0232E
C-4 . C-4 .
Extension Cylinder

C-4 Extension Cylinder

[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.Cylinder 4.Piston 7.O-ring 10.Dust seal

2.Nut 5.Rod 8.Packing
3.Seal ring 6.Rod cover 9.Backup ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A, B, C G3/8 49 36

D, E G1/4 29.4 22

2 M20 176 - 196 130 - 145

360-420-60000 △
1

5 W153-0080E
C-5 . C-5 .
Solenoid Valve (Slide/Jack) (UCHIDA)

C-5 Solenoid Valve (Slide/Jack) (UCHIDA)

[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
Connector

(+): Red
AB
+- (-): Blue

PT
IW121-026001 IW121-0542E01

T2

A P B
T T

11 9 7 3 8 15 1
IW121-026003

1.Body 7.Spring seat 9.O-ring 12.Solenoid (24V DC)

3.Spool 8.Square ring 11.Spring 15.Hex. socket head bolt

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
15 M5 6.9 - 8.9 5.1 - 6.5

T1 - 3.9 - 4.9 2.9 - 3.6

T2 - 38.3 - 41.2 28.3 - 30.4

366-478-90000 △
1

6 W121-0263E
C-6 . C-6 .
Solenoid Valve (Slide/Jack) (TOKIMEC)

C-6 Solenoid Valve (Slide/Jack) (TOKIMEC)

[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
Connector

(+): Red
AB
+- (-): Black

PT
IW121-026001 IW121-0542E01

12

T P T

A B

1 2 3 4 5 6 7 8 9 10 11
IW121-027001

Note: Install the centering washer (10) with its slit directed toward the body (7).

1.Nut 4.Solenoid coil (24V DC) 7.Body 10.Centering washer

2.O-ring 5.Packing 8.O-ring 11.Spring
3.Solenoid core (24V DC) 6.O-ring 9.Spool 12.Spring pin

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 - 8.8 - 10.8 6.5 - 8

3 - 18 - 22 13.3 - 16.2

Mounting bolt M5 6.9 - 7.8 5-6

366-465-40000 △
1

7 W121-0273E
C-7 . C-7 .
Solenoid Valve (Slide/Jack) (NACHI)

C-7 Solenoid Valve (Slide/Jack) (NACHI)

[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
Connector

(+): White
AB
+- (-): Black

PT
IW121-026001 IW121-0542E01

10 16

T T

A B

7 14 8 9 6 15 4 3 13 2 1
IW121-028001

1.Body 6.Spring 10.Solenoid coil (24V DC) 16.O-ring

2.Spool 7.Nut 13.O-ring
3.Retainer 8.Rod 14.O-ring
4.Retainer 9.Solenoid guide (24V DC) 15.O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
7 - 5-7 3.7 - 5.1

Mounting bolt M5 6-8 4.4 - 5.9

366-457-31000 △
1

8 W121-0283E
C-8 . C-8 .
Check Valve (Outrigger Extending Prevention)

C-8 Check Valve (Outrigger Extending Prevention)

[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

P1

C B

P2
IW116-011001

1 6 5 7 4 3 8 9 10 2 11,12

P1

B C

P2
IW116-011002

1.Body 4.Spring 7.Valve 10.O-ring

2.Cover 5.Stopper 8.Spring 11.Hex. socket head bolt
3.Valve 6.Stop ring 9.Stopper 12.Spring washer

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P1 G1/2 98 72

P2 G1/2 98 72

366-245-40000 △
0

9 W116-0112E
C-9 C-9
Outrigger Operation Box

C-9 Outrigger Operation Box

[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
[NOTICE]
The illustration below shows the left side of the vehicle.
For the controls on the right side, the arrangement of the switches are different.

3 4 5

trol
Outrigger con
RR
1 12 RF
Extension
6

Retraction
11
2
ON
10 Slide

OFF
LR
Jack LF

B W R G
9 8 7
Y Br L Gr
O Sb P

View from end of connector

IW326-0180E01

1.Box assy 5.Lamp assy 9.Push switch (RF) 12.Toggle switch

2.Gromment 6.Push switch (accelerator) 10.Toggle switch (slide/jack) (extension/retraction)
3.Push switch (RF) 7.Toggle switch (lights) 11.Push switch (all)
4.Push switch (RR) 8.Push switch (LR)

10 W326-0180E
C-9 . C-9 .
Outrigger Operation Box

2. Connector diagram

NO 6
COM
1.25WG
*1
10
2 Slide
1
0.75 Gr 3 *1
24V 1.0A or 10mA
0.75 R 1A N
12
24V 30mA 5
0.75 Sb 4
24V 1.5A Jack
24V 1.5A 0.75 L 6 2 Ext.
Power 0.75 P 1
24V supply
0.75 G 1.25O 3
24V 1.5A N
0.75 Y 5
24V 1.5A 0.75 Br 4
24V 1.5A Ret.
0.75 W 6
24V 1.5A
0.75 O
24V 10mA
0.75 B 11
1.25GB
NO
COM
3A 3A
NO
COM
9
*1 : point of contact (toggle switch) NO
2 2 COM
1 1 NO
3
5
3
5
COM
8 3
4 4 NO
6 6 COM
3
retraction extention 2
jack slide
7 4
IW326-0180E02

3. Specifications
3.4 Push switch
3.1 General Current capacity: Resistance load 10 A
Power voltage: DC20V ~ 30V lnducatance load 4 A
Service temp. range: -25° ~ +70°C
3.5 Diode
3.2 Bipolar toggle switch 12-diode sect.: Average rectified current: 3A
Current capacity: Resistance load 20 A Peak inverse voltage: 600V
lnducatance load 10 A
1-diode sect. : Average rectified current: 1A
Contact connection resistance: Peak inverse voltage: 600V
10mΩ or less (initial)
3.6 Lamp assembly
3.3 Monopolar toggle switch Rating: 24V, 3W
Current capacity: Lamp load 2 A

Contact connection resistance: [NOTICE]

10mΩ or less (initial) Coat the full surface of all diodes (13 total) with
ThreeBond #2901 or equivalent product.
347-314-21000 △
1

347-314-22000 △
1

11 W326-0180E
 D
Swing System D

Contents

D-1 Swing System................................... 1 5. Installation of hydraulic motor.................. 16

1. General..................................................... 1

D-2 Swing Assembly .............................. 3

1. Structure ................................................... 3

2. Swing bearing mounting bolt..................... 4

2.1 Bearing Inner ring bolts .............................. 4
2.2 Bearing outer ring bolts .............................. 5

D-3 Hydraulic Pilot Control Valve

(Swing) ..................................... 6

1. Structure ................................................... 6

D-4 Hydraulic Motor (Swing)................ 12

1. Structure ................................................. 12

D-5 Swing Speed Reducer ................... 14

1. Structure ................................................. 14

2. Removing of hydraulic motor .................. 15

3. Disassembly of reducer .......................... 15

4. Assembly of reducer ............................... 16

i
D-1 D-1
Swing System

D-1 Swing System

1. General
Hydraulic Circuit for Swing

Remote Control Pressure Vent, Swing Free, Swing Brake Release

[NOTICE]
1. The swing operation is controlled by the hydraulic
The remote control valve and the hydraulic pilot
control valve are connected at the two points having pilot method. The pilot pressure from the remote
the same symbols such as "a5" and "b5". control valve controls the hydraulic pilot control
valve.

1 WD02-0280E
D-1 . D-1 .
Swing System

2. The maximum pressure in the swing circuit is 5. Circuit for swing brake release
regulated by the relief valve. In case of sudden In this hydraulic circuit, the solenoid valve (swing
stoppage of swing movement, the overload relief brake release) controls the pilot pressure to the
valve (high pressure) in the circuit with unusually brake release port of the hydraulic motor for swing
high pressure operates to protect the hydraulic operation.
motor for swing operation.
6. Circuit for remote control pressure vent
3. Circuit for free swing In this hydraulic circuit, the solenoid valve (remote
In this hydraulic circuit, the solenoid valve (swing control pressure vent) controls the pilot pressure
free) and the swing relief proportional control to the remote control valve.
valve control the vent ports of the two overload
relief valves (high pressure). As the set pressure
of the swing relief proportional control valve is low,
the overload relief valve (high pressure) in the
circuit with internal pressure higher than the set
pressure is activated at low pressure. The
overload relief valve (high pressure) is activated at
low pressure only when the swing control lever is
located at the neutral position.

4. Circuit for swing automatic stop

The right swing proportional control valve, the left
swing proportional control valve and the swing
relief proportional control valve serve to
automatically stop the swing movement. These
valves control the swing operation according to
the output from the AML. The swing relief
proportional control valve automatically stops the
swing movement only when the swing free/lock
selector switch is set to “FREE” side.

2 WD02-0280E
D-2 D-2
Swing Assembly

D-2 Swing Assembly

[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.Bolt
2.Plain washer

FRONT

Swing motor

Swing speed reducer

1, 2

Swing bearing

IW514-0260E01

[NOTICE]
Apply torque control agent to the threaded sections of the bolts.
Place the high-strength plain washer orienting its chamfer to the underhead fillet as shown below.

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1 M18 372 - 412 274 - 304

3 W514-0260E
D-2 D-2
Swing Assembly

2. Swing bearing mounting bolt

2.1 Bearing Inner ring bolts

3,2 3,2

FRONT

4,5

6,7 (S) mark

S
6,7

1,2
3,2 3,2 IW514-0260E02

1.Bolt (L=122mm) 5.Plain washer

2.Pain washer 6.Bolt
3.Bolt (L=110mm) 7.Spring washer
4.Bolt

[NOTICE] Thread size and tightening torque

Install the bearing inner ring with the "S" mark Thread Tightening torque
facing the rear of the carrier. Sign / port
size N-m ft-lbf
Apply torque control agent to the threaded sections
of the bolts. 1
(44 points)
Place the high-strength plain washer orienting its M22 628 - 672 463 - 496
chamfer to the underhead fillet as shown below. 3
(4 points)
4
M10 42 - 49 31 - 36
(6 points)
*1
6 M12 74 - 82 54.5 – 60.5

*1:Apply THREE BOND 1305 (thread locking

agent) to threaded sections.

4 W514-0260E
D-2 . D-2 .
Swing Assembly

2.2 Bearing outer ring bolts

1.Bolt (L=125mm)
2.Plain washer (50points)
3.Nut (5points)
4.Reamer bolt (L=145mm)
5.Bolt (L=145mm)
6.Plain washer (2points)

[NOTICE]
Apply torque control agent to the threaded sections Thread size and tightening torque
of the bolts.
Place the high-strength plain washer orienting its Thread Tightening torque
chamfer to the underhead fillet as shown below. Sign / port
size N-m ft-lbf
1
(39 points)
4 627.2 –
M22 463 - 495
(6 points) 671.3
5
(2 points)

343-008-10000 △
0
347-623-23000 △
1
342-311-60000 △
0

5 W514-0260E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

D-3 Hydraulic Pilot Control Valve (Swing)

[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

(+):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

6 W134-0123E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P, R G1 200 - 240 145 - 174

AM, BM G3/4 150 - 180 108 - 130

G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 25 - 28

Dr G1/4 34 - 38 25 - 28

7 W134-0123E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

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

8 W134-0123E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

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

9 W134-0123E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

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

10 W134-0123E
D-3 . D-3 .
Hydraulic Pilot Control Valve (Swing)

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)

Thread size and tightening torque

Tightening torque
Sing / port Thread size
N-m ft-lbf
151 R1/4 20 - 24 14 - 17

152, 252 NPTF1/16 6-8 4.5 - 6

211 *1 M8 16 - 18 12 - 13

251 *1 M5 3.5 - 4.5 2.5 - 3.5

253 G1/4 34 - 38 25 - 28

261 M22 39 - 49 29 - 36

351, 352, 353 M6 10.5 - 13.5 8 - 10

401 M24 58 - 70 43 - 51

450 M10 14.5 - 17.5 10.5 - 12.5

551 M33 190 - 210 140 - 155

552 M24 120 - 140 88 - 103

641 G1/8 8 - 10 6-7

701 M30 110 - 130 81 - 96

702 M22 39 - 49 29 - 36

703 M27 69 - 79 51 - 58

706 M22 39 - 49 29 - 36

*1: Apply LOCTITE 241 (thread locking agent) to threaded sections.

366-461-30000 △
1

366-489-70000 △
0

11 W134-0123E
D-4 D-4
Hydraulic Motor (Swing)

D-4 Hydraulic Motor (Swing)

[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

12 W102-0530E
D-4 . D-4 .
Hydraulic Motor (Swing)

31.Housing 36.Retaining ring 41.Ring 46.Distance pieace

32.Rotary group 37.Plate (inner disc) 42.O-ring 47.Plug assy
33.Sshaft 38.Plate (outer disc) 43.O-ring
34.Cover 39.Retaining ring 44.O-ring
35.Piston 40.Oil seal 45.Spring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P G1/4 29 22

A, B G3/4 167 123

R G3/8 49 36

366-631-50000 △
2

13 W102-0530E
D-5 D-5
Swing Speed Reducer

D-5 Swing Speed Reducer

[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. This reducer is two-stage planetary-gear speed reducing mechanism.

2. The rotation power of the hydraulic motor is transmitted in the following order.
Motor output shaft Sun gear(1) planetary gear(18) carrier-A(20) Sun gear(22)
Planetary gear(7) carrier-B(26) reducer output shaft(13)

14 W511-0271E
D-5 D-5
Swing Speed Reducer

1.Sun gear 8.Plate 15.Plug 22.Sun gear

2.Bolt 9.King pin (B) 16.Seal washer 23.Hex. socket plug
3.Spring washer 10.Ball bearing 17.Needle bearing 24.Snap ring
4.Plate 11.Retainer (A) 18.Planetary gear 25.Oil seal
5.Casing 12.Roller bearing 19.Plate 26.Carrier (B)
6.Needle bearing 13.Output shaft 20.Carrier (A) 27.Name plate
7.Planetary gear 14.Spacer 21.King pin (A) 28.Rivet

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
2 M8 23.5 – 27.5 17.5 - 20

15 G1/2 245 - 274 181 - 202

2. Removing of hydraulic motor 3. Disassembly of reducer

[NOTICE] [NOTICE]
After fixing the swing frame, remove the hydraulic Disassembly and assembly should be always
motor and the reducer to prevent the swing frame performed in a clean place caring dust and so on.
from self-rotating. Careful work is necessary.
Do not beat and lever to prevent burrs and
1. Before disassembly, mark to each mating surface breakages that cause impossible assembly and
performance deteriorations.
2. Drain oil from the hydraulic motor and the reducer.
1. Take out parts from sun gear(1) to carrier-B(26).
3. After removing bolts(2) (eight places) securing the
hydraulic motor, remove the motor by using [NOTICE]
pulling-out screw (2-M8) on the motor flange. King pins(9), (21) are fitted by shrinkage fitting,
space(14) is fitted by caulking.

2. Remove snap ring(24), and remove output

shaft(13) from casing (5) by using a press.

15 W511-0271E
D-5 . D-5 .
Swing Speed Reducer

4. Assembly of reducer 5. Installation of hydraulic motor

1. Press-fit retainer(11) and roller bearing(12) to 1. Tighten hydraulic motor by bolt(2).
output shaft(13).
[NOTICE]
[NOTICE] Apply THREE BOND 1215 on the mating surface
Apply lithium type grease between retainer(11) and between the hydraulic motor casing and the swing
roller bearing (12). reducer.

2. Press-fit oil seal(25) into casing(5). 2. Supply gear oil into the reducer via plug(15).
3
(about 1.6L (97.6 in ))
[NOTICE]
Apply lithium type grease on the inner of oil
seal(25).

3. Install output shaft (13) in casing (5).

4. Press-fit ball bearing(10) into output shaft(13),

and fix it with snap ring(24).

5. Hereafter, assemble carrier B(26) to sun gear(1)

in reverse order of "Disassemly of reducer."

[NOTICE]
Confirm sun gear(1) turns lightly by your hand.
Secure clearance X=0.2 to 2.1mm (0.008 to 0.083
in) and Y=0.1 to 2.45 mm (0.004 to 0.096 in) shown
in figure of previous page when mounting the
hydraulic motor.

360-814-51000 △
0

16 W511-0271E
 E
Boom Elevating System
E

Contents

E-1 Elevating System ............................. 1

1. General..................................................... 1

E-2 Elevating Cylinder............................ 3

1. Structure ................................................... 3

E-3 Counterbalance Valve (Elevating) .. 5

1. Structure ................................................... 5

2. Function.................................................... 7
2.1 When control valve is at the neutral
position ................................................. 7
2.2 While actuator is being pushed up ............. 7
2.3 While actuator descends ............................ 7

i
E -1 E -1
Elevating System

E-1 Elevating System

1. General
Hydraulic Circuit for Boom Elevating

Remote Control Pressure Vent

1 WE02-0280E
E -1 . E -1 .
Elevating System

[NOTICE] 3. Circuit for boom elevating slow stop

The solenoid control relief valve and the hydraulic The boom raising proportional control valve and
pilot control valve are connected at the two points the boom lowering proportional control valve
having the same symbols such as "a1" and "b1".
make the boom elevating movement stop slowly.
These valves control the boom elevating
1. The boom elevating operation is controlled by the
operation according to the output from the AML.
hydraulic pilot method. The pilot pressure from
either the remote control valve (boom elevating 4. Circuit for remote control pressure vent
control lever) or the remote control valve (boom In this hydraulic circuit, the solenoid valve
elevating control pedal) controls the hydraulic pilot (remote control pressure vent) controls the pilot
control valve. pressure to the remote control valve for boom
elevating control lever and the remote control
2. The maximum pressure in the elevating hydraulic
valve for boom elevating control pedal.
circuit is regulated by the relief valve (elevating,
telescoping). The maximum pressure in the
boom lowering circuit is regulated by the overload
relief valve activated at low pressure to prevent
the boom from hunting.

2 WE02-0280E
E -2 E -2
Elevating Cylinder

E-2 Elevating Cylinder

[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

3 W155-0250E
E -2 . E -2 .
Elevating Cylinder

36 4,5 4,6 7,40 35 38 12 13,14 15,16

1 2 3 8 9 10 11 39 34 IW155-0250E02

1.Cylinder 11.O-ring 21.O-ring 31.Spring washer

2.Spring pin 12.Damper ring 22.Fitting 32.Counter balance valve assy
3.Plain bearing 13.Packing 23.O-ring 33.Fitting
4.Packing 14.Backup ring 24.Pipe 34.O-ring
5.Backup ring 15.Dust seal 25.Pipe 35.Orifice
6.Backup ring 16.Retaining ring 26.T-fitting 36.Grease nipple
7.O-ring 17. ----------------- 27.Pipe 37.Pipe
8.Piston 18. ----------------- 28.Clamp assy 38.O-ring
9.Rod assy 19.Support 29.Sleeve 39.Head cover
10.Rod cover assy 20.Fitting 30.Bolt 40.Backup ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A G3/4 108 - 123 80 - 90

B G1/2 54 - 64 40 - 47

C, D G3/8 25 - 30 18.5 - 22.0

30 M8 23.5 – 27.4 17.3 - 20.2

360-274-10000 △
0

4 W155-0250E
E -3 E -3
Counterbalance Valve (Elevating)

E-3 Counterbalance Valve (Elevating)

[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
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

5 W119-0212E
E -3 E -3
Counterbalance Valve (Elevating)

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A G3/4 167 123

P.P G3/8 49 36

2-1 - 177 - 196 130 - 145

2-15 - 127 - 147 94 - 108

3-1 - 108 - 127 80 - 94

3-7 - 59 - 78 43 - 58

Mounting bolt M8 24 - 27 17 - 20

6 W119-0212E
E -3 . E -3 .
Counterbalance Valve (Elevating)

2. Function

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 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. 366-051-70000 △
2

7 W119-0212E
 F
Winch System

F
Contents

F-1 Winch System .................................. 1 4.7 Taking planetary gear-2[107] out ..............16
4.8 Taking counterbalance valve out ..............16
1. General (2M2D) ........................................ 1 4.9 Taking rear flange[401] out. ......................17
4.10 Taking out those parts attached to rear
2. General (1M1D) ........................................ 3 flange[401] ..........................................18
4.11 Disassembling internal
counterbalance valve..........................19
F-2 Winch ................................................ 5 4.12 Disassembling counterbalance valve
section.................................................19
1. Structure ................................................... 5 4.13 Disassembling hydraulic motor .................20
1.1 General view............................................... 5 4.14 Taking spring[214] out of
1.2 Reducer ...................................................... 6 cylinder block[204] ..............................22
4.15 Taking out pivot[267] .................................22
4.16 Taking out tapered roller bearing ..............23
F-3 Hydraulic Motor and 4.17 Disassembling spindle[102] ......................23
Counterbalance Valve ............. 7 4.18 Taking angular ball bearing out .................24
4.19 Taking out those parts attached to
1. Structure ................................................... 7 spindle[102]. .......................................24
1.1 Hydraulic symbol ........................................ 7 4.20 Primal washing..........................................25
1.2 General view............................................... 7 4.21 Final washing ............................................25
1.3 Hydraulic motor assy.................................. 8
5. Maintenance standards ........................... 26
2. Description of operation .......................... 10 5.1 Seal ...........................................................26
2.1 Mechanical brake ..................................... 10 5.2 Maintenance standards for parts subject
2.2 Counterbalance valve................................11 to wear ................................................26

3. Troubleshooting ...................................... 13 6. Assembly ................................................ 28

6.1 Preparation................................................28
4. Disassembly procedure of motor............. 14 6.2 General suggestion for work .....................28
4.1 Washing hydraulic motor .......................... 14
4.2 Mounting hydraulic motor ......................... 14
4.3 Draining gear oil ....................................... 14
4.4 Taking cover[113] out ............................... 15
4.5 Taking sun gear-1[104] out....................... 15
4.6 Taking carrier assy out ............................. 15

i
7. Assembly procedure ............................... 28
7.1 Assembling hub[101]................................ 29
7.2 Assembling spindle[102] .......................... 30
7.3 Assembling hydraulic motor parts ............ 31
7.4 Assembling shaft[202] .............................. 31
7.5 Clearance adjustment for angular ball
bearing ............................................... 32
7.6 Clearance adjustment for tapered roller
bearing ............................................... 33

8. Performance confirmation test ................ 34

8.1 Required measurement instruments ........ 34
8.2 Test procedure.......................................... 34

9. Classifications of clearance
adjustment parts .......................... 35

F-4 Hydraulic Valve

(Winch Brake Release).......... 36

1. Structure ................................................. 36

ii
F-1 F-1
Winch System

F-1 Winch System

1. General (2M2D)
Hydraulic Circuit for Winch (2M2D)

1 WF02-0330E
F-1 F-1
Winch System

Boom Telescoping / Auxiliary Winch

Remote Control Pressure Vent

[NOTICE] auxiliary winch employs a similar hoist-down

The remote control valve and the solenoid valve are circuit.
connected to the hydraulic pilot control valve at the
points having the same symbols such as "a2", "a3", 4. Circuit for boom telescoping/auxiliary winch
"b2", and "b3". In this hydraulic circuit, the two solenoid valves
(boom telescoping/auxiliary winch) switch the pilot
1. The main winch is controlled by the hydraulic pilot
circuit from the remote control valve (boom
method. The pilot pressure from the remote
telescoping/auxiliary winch control lever) to the
control valve (main winch control lever) controls
hydraulic pilot control valve to either the boom
the hydraulic pilot control valve. The auxiliary
telescoping pilot circuit or the auxiliary winch pilot
winch employs a similar hydraulic pilot method.
circuit.
2. The maximum pressure in the main and auxiliary
5. Circuit for remote control pressure vent
winch hydraulic circuits is regulated by the relief
In this hydraulic circuit, the solenoid valve (remote
valve (main winch, auxiliary winch).
control pressure vent) controls the pilot pressure
3. The overload relief valve (down) regulates the to the remote control valve (main winch), the
maximum pressure in the hoist-down circuit for remote control valve (boom telescoping/auxiliary
the main winch. This valve suppresses the surge winch control lever), the hydraulic valve (main
pressure that may occur in a sudden hoist-down winch brake release), and the hydraulic valve
operation so as to assure a smooth hoist-down (auxiliary winch brake release).
movement. In case of sudden stoppage of
hoist-down movement, the relief valve integrated
in the counterbalance valve operates to protect
the hydraulic motor for the main winch. The

2 WF02-0330E
F-1 F-1
Winch System

2. General (1M1D)
Hydraulic Circuit for Winch (1M1D)

3 WF02-0330E
F-1. F-1.
Winch System

Remote Control Pressure Vent

[NOTICE] 3. The overload relief valve (down) regulates the

The remote control valve and the hydraulic pilot maximum pressure in the hoist-down circuit for
control valve are connected at the two points having the main winch. This valve suppresses the surge
the same symbols such as "a2" and "b2". For a
pressure that may occur in a sudden hoist-down
"1M1D"-specification crane without the auxiliary
winch, seven portions "*2" are plugged. operation so as to assure a smooth hoist-down
movement. In case of sudden stoppage of
1. The main winch is controlled by the hydraulic pilot hoist-down movement, the relief valve integrated
method. The pilot pressure from the remote in the counterbalance valve operates to protect
control valve (main winch control lever) controls the hydraulic motor for the main winch.
the hydraulic pilot control valve.
4. Circuit for remote control pressure vent
2. The maximum pressure in the main winch In this hydraulic circuit, the solenoid valve (remote
hydraulic circuit is regulated by the relief valve control pressure vent) controls the pilot pressure
(main winch, auxiliary winch). to the remote control valve (main winch) and the
hydraulic valve (main winch brake release).

4 WF02-0330E
F-2 F-2
Winch

F-2 Winch

[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

1.Motor assy 3.Support 5.Hexagon socket head bolt 7.Ball bearing

2.Drum 4.Support 6.Retaining ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B G1 97 - 119 71.5 - 88

Oil filler and drain port G3/8 49 - 68.6 36 - 50.5

Oil level port G1/8 9.85 - 14.75 7 - 11

5*1 M16 264.8 - 284.4 195 - 210

Mounting bolt M20 431.2 - 470.4 318 - 347

*1: Apply THREE-BOND 1305 to threaded sections.

5 W526-0340E
F-2. F-2.
Winch

1.2 Reducer

101.Hub 110.Thrust collar 2 125.Ring 138.Floating seal

102.Spindle 111.Thrust plate 127.Needle roller bearing 139.Plug
103.Carrier 112.Thrust collar 3 128.Needle roller bearing 140.Bolt
104.Sun gear 1 113.Cover 129.Inner ring 141.Steel ball
105.Planetary gear 1 114.Coupling 130.Retaining ring 202.Shaft
106.Sun gear 2 117.Washer 131.Retaining ring
107. Planetary gear 2 121.Collar 132.Parallel pin
108.Pin 122.Retaining ring 135.O-ring
109.Thrust collar 1 124.Ball bearing 137.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
139 G3/8 48.99 - 68.61 36.1 - 50.6

140 M10 48.09 - 67.71 35.5 - 50

[NOTICE]
Once disassembled, sealing parts (O-ring, Oil seal, Floating seal) should be replaced with new ones even
though no damage is observed.
Do not take off Pin[108], Parallel pin[132] from Carrier[103].
360-735-40000 △
0

6 W526-0340E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

F-3 Hydraulic Motor and Counterbalance Valve

[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 Hydraulic symbol
E :Pilot port (for brake release)
F :Air bleeding port
P1 :Pressure check port
P2 :Pressure check port
P3 :Pressure check port
D :Drain port

1.2 General view

7 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
D G1/2 78.5-117.7 58-87
E, F G1/4 24.5-34.3 18-25
P1, P2, P3 R1/4 24.5-34.3 18-25
T1 M16 212.8-291.2 157-214.8

1.3 Hydraulic motor assy

8 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

101.Hub 137.O-ring 216.Mating plate 316.O-ring

102.Spindle 138.Floating seal 217.Mating Plate 317.O-ring
103.Carrier 139.Plug 219.Collar 318.O-ring
104.Sun gear 1 140.Bolt 232.Oil seal 319.O-ring
105.Planetary gear 1 141.Steel ball 235.O-ring 320.Hexagon socket head bolt
106.Sun gear 2 142.Parallel pin 239.O-ring 321.Hexagon socket head bolt
107.Planetary gear 2 143.O-ring 245.Retaining ring 322.Washer
108.Pin 144.O-ring 249.Tapered roller bearing 323.O-ring
109.Thrust collar 1 146.Plug 250.Tapered roller bearing 401.Rear flange
110.Thrust collar 2 147.O-ring 251.Needle roller 421.Plug
111.Thrust plate 148.Plug 267.Pivot 438.O-ring
112.Thrust collar 3 149.O-ring 271.Parallel pin 441.Parallel pin
113.Cover 202.Shaft 301.Body 443.Hexagon socket head bolt
114.Coupling 203.Swash plate 302.Spool 446.Hexagon socket plug
117.Washer 204.Cylinder block 303.Spool 454.Hexagon socket plug
121.Collar 205.Piston 304.Plug 464.Plug
122.Retaining ring 206.Shoe 305.Orifice 465.O-ring
124.Ball bearing 207.Retainer plate 306.Stopper 468.Steel ball
125.Ring 208.Thrust ball 307.Cover 469.Plug
127.Needle roller bearing 209.Timing plate 308.Plug 470.O-ring
128.Needle roller bearing 210.Washer 309.Plug 471.Spool
129.Inner ring 211.Washer 310.Spring 480.Orifice
130.Retaining ring 212.Piston 311.Spring 483.Plug
131.Retaining ring 213.Spring 313.Valve
132.Parallel pin 214.Spring 314.Plug
135.O-ring 215.Friction plate 315.Spring

9 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
139 G3/8 48.99 - 68.61 36.1 - 50.6
140 M10 48.09 - 67.71 35.5 - 50
146 G1/8 9.85 - 14.75 7.3 - 10.9
148 G1/4 24.5 - 34.3 18 - 25.3
308 M30 122.5 - 171.5 90.4 - 126.5
309 M24 98.191 - 117.8 72.4 - 86.9
314 G1/8 9.85 - 14.75 7.3 - 10.9
320 M10 48.09 - 67.71 35.5 - 50
321 M10 48.09 - 67.71 35.5 - 50
421 G3/8 48.99 - 68.61 36.1 - 50.6
464 G1/2 78.6 - 117.6 58 - 86.7

2. Description of operation

2.1 Mechanical brake

Brakes are released Brakes in operation

Pilot pressure

Friction plate

Spring Piston Steel plate IW102-0560E05

10 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

2.2 Counterbalance valve

Description of operation (pattern diagrams)

11 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

Counterbalance valve assy

12 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

3. Troubleshooting
Symptom 1 Symptom 2 Probable cause Remedy
Low relief set pressure Set Pressure correctly
Pressure does
Faulty pump
not go up Repair as necessary
Faulty selecter valve
Winch motor Faulty brake release pump Repair brake release pump or selecter
does not or selecter valve valve
rotate
Pressure goes Faulty hydraulic motor Repair as necessary
up Damaged gear (speed
Replace hydraulic motor
reducer)
Excessive overload Reduce load
Hydrulic oil Scratches on mating Correct with the grindstone and paper,
leaks from the surface etc.
mating surface. Loosened bolt Retighten.
Hydrulic oil Loosened plug Retighten
leaks from the
case Cracked by flying stone Replace hydraulic motor
Hydrulic oil Hydrulic oil Abnormally worn and
leakage leaks from the seizure on sliding surface Replace hydraulic motor
reducer seal Damaged o-ring
Loosened bolt Retighten
From hydraulic Damaged o-ring O ring exchange
motor
Correct with the grindstone and paper,
Flaw of sealing surface
etc.
Leakage of the Decreased volume
hydraulic oil efficiency of hydraulic Replace hydraulic motor
increases motor
Winch motor Brake release pressure
is rotated by does not come off Cleaning of orifice (as adapted)
load during Mechanical completely
operating brake has not
Damaged spring Replace spring
acted
Replace friction plate and other party
Worn friction plate
plate
Lack gear oil Replenish gear oil up to proper amount
Surface temperature of Pitching in bearing Replace hydraulic motor
reducer case is high
Hydraulic oil leakage into
Exchange of oil seals
gear case
Pump does not operate
Discharge of
Speed does correctly
the pump is Repair or replace pump
not go out Excessive outside leakage
lack
from hydraulic pump
Excessive outside leakage
Replace hydraulic motor
from hydraulic motor
From hydraulic Damaged hydraulic motor
Replace hydraulic motor
Noise motor or reducer
From piping piping vibration Piping is clamped

13 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4. Disassembly procedure of motor

4.1 Washing hydraulic motor

1. Fasten 2 eyebolts to spindle[102].

[NOTICE]
Fasten 2 eyebolts in the screw holes on spindle
[102]. Chose two holes which is located opposite to
the other to keep good balance.

2. Hook wire to eyebolts, lift up hydraulic motor by

crane, and carry it to washing tank.

3. Wash each part of hydraulic motor with brush.

[NOTICE]
Mud and sand is stuck in the gap between
hub[101] and spindle[102] (floating seal portion ).
Take special care for washing this portion.

4.2 Mounting hydraulic motor

1. While matching screw holes of hub[101] to screw

holes of hydraulic motor workbench, carefully
mount the hydraulic motor in the mounting hole of
hydraulic motor workbench.

4.3 Draining gear oil

[NOTICE]
If disassembly is limited to counterbalance valve,
proceed to (4.8).
If disassembly is limited to rear flange, proceed to
(4.9).

1. Turn hydraulic motor to the reduction gear side

up.

2. Loosen up 2 Plugs[139].

[NOTICE]
Put a receptacle under hydraulic motor workbench
for draining gear oil.

3. Turn hydraulic motor slowly and drain gear

oil.(Turn motor side up)

14 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.4 Taking cover[113] out

1. Turn hydraulic motor to the reduction gear side

up.

2. Loosen up 8 hexagon socket head screws[140].

3. Tighten up 2 eyebolts to the thread holes for oil

where plug[139] which had been taken away.

4. Hook wire to 2 eyebolts, and lift up cover[113]

slowly by crane

[NOTICE]
When cover[113] does not come out easily, do not
lift it up forcefully. Instead, tap the cover[113] with
plastic hummer, and make the cover[113] even.

5. Take o-ring[135] out from cover[113]

[NOTICE]
Do not reuse removed o-ring[135].

4.5 Taking sun gear-1[104] out

1. Snatch sun gear-1[104] and take it out.

2. Remove steel ball[141] from sun gear[104]

3. Take out washer[117] between planetary

gear-1[105] and carrier[103].

4.6 Taking carrier assy out

1. Taking carrier assy out from hub[101].

2. Taking coupling[114] out from shaft[102].

3. Disassembly work of carrier assy.

4. Take retaining ring[130] from Pin[108].

[NOTICE]
Retaining ring[130] may pop off, and may cause
injury.

5. Take out thrust collar-2[110], planetary

gear-1[105], needle roller bearing[127], thrust
collar-2[110] out from pin[108].

[NOTICE]
Do not take off pin[108] and parallel pin[132] from
carrier[103].

15 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

6. Take retaining ring[131] out from retaining ring

groove on sun gear-2[106]

7. Take sun gear-2[106] out from carrier[103]

4.7 Taking planetary gear-2[107] out

1. Loosen up hexagon head bolt[140], and take

thrust collar[111] out.

2. Take out planetary gear-2[107] and needle roller

bearing[128] out from shaft portion of
spindle[102].

3. Take inner race[129] out from shaft portion of

spindle[102].

4. Take thrust collar-3[112] out from shaft portion of

spindle[102].

5. Take thrust collar-1[109] out from spindle[102]

4.8 Taking counterbalance valve out

1. Turn hydraulic motor to the motor side up

[NOTICE]
The following procedure is for performing whole
disassembly work easily. loosen plugs until they
are to be turned by hand.
If disassembly of the counterbalance valve is not
necessary, do not loosen plugs and proceed to (5.).

2. Loosen Plug[308].

3. Loosen Plug[309].

16 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4. Loosen hexagon socket head bolt[321]

5. Take out hexagon socket head bolt[320].

4.9 Taking rear flange[401] out.

1. Take out hexagon socket head bolt[443].

2. Take rear flange[401] out from spindle[102].

[NOTICE]
Hold rear flange[401] with both hands, and lift it up
straight slowly and carefully. Forceful attempt or
banging by hummer may cause damage on
timing plate[209] from falling off.

3. Take parallel pin[142] out from spindle[102].

4. Take out o-ring[143] and [144] from spindle[102].

[NOTICE]
Do not reuse removed o-ring[143] and [144].

17 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.10 Taking out those parts attached to rear

flange[401]

1. Place and set rear flange on working table such

that the side which has been faced with spindle
[102] faces up.

2. Take out spring[213].

3. Take timing plate[209] out from rear flange[401].

[NOTICE]
Do not damage the timing plate[209], which is
precisely manufactured and extremely important for
the hydraulic motor’s performance.
Timing plate[209] may be attached to rear flange
firmly due to working oil.
In such case, use bar with fat side. Insert fat side of
the bar into the gap between timing plate[209] and
rear flange[401]. Then, lift up timing plate [209]
softly by using the bar as lever. Do not use sharp
edged or pointed tool such as screwdrivers instead
of flat bar.

4. Take parallel pin[441] out from rear flange[401].

5. Take out tapered roller bearing[250] and collar

[219] from rear flange[401].

[NOTICE]
Orifice[480], steel ball[468] and flange plug[469] do
not exchange single goods.

18 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.11 Disassembling internal counterbalance

valve

1. Remove hexagone socket head bolt[321], and

take out cover[307].

2. Take out spring[310] and [315], stopper[306],

orifice [305] and spool[302] in the order.

[NOTICE]
Do not damage the surface of spool[302], which is
precisely manufactured and extremely important for
the hydraulic motor’s performance.
Do not put garbage in orifice
Spool[305] and body[301] are clearance
adjustment parts.
If replacement is necessary, replace them together.

3. Remove plug[309] and take out spring[311] and

valve[313].

[NOTICE]
Do not damage the surface of valve[313], which is
precisely manufactured and extremely important for
the hydraulic motor’s performance.

4. Remove plug[308] and take out spool[303].

[NOTICE]
Do not damage the surface of spool[303], which is
precisely manufactured and extremely important for
the hydraulic motor’s performance.
Spool[303] and body[301] are clearance
adjustment parts.
If replacement is necessary, replace them together.

4.12 Disassembling counterbalance valve

section

[NOTICE]
Abrupt injection of compressed air may cause
piston[212] pop out. Use protection such as
protection cover to avoid body injury.

1. Apply compressed air to the entrance of the oil

path to counterbalance valve of spindle[102] to
take out piston[212] from spindle[102].

19 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

2. Remove o-ring[235] and [239] from piston[212].

[NOTICE]
Do not reuse removed o-ring[235] and [239].

4.13 Disassembling hydraulic motor

[NOTICE]
Rotate hydraulic motor workbench so that hydraulic
motor takes horizontal position. Use a receptacle to
collect working oil from motor case.

1. Take out tapered roller bearing[250] from shaft

[202].

2. Fasten M8 eyebolt in the screw hole on

shaft[202].

3. Hold eyebolt by hands and rotate it about 90

degree. Swash plate[203] will be taken apart from
spindle[102] by this procedure..

[NOTICE]
In the above process, pivot[267] will be dropped
because pivot[267] will be sticking to swash
plate[203].

4. Lift up eyebolt, take out roter parts (shaft[202],

swash plate[203], cylinder block[204], piston [205],
shoe[206], retainer plate[207], thrust ball[208]
etc.) from spindle[102].

20 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

5. Take piston kit (piston[205] and shoe[206]) and

retainer plate[207] out from cylinder block[204].

[NOTICE]
On this process, hold retainer plate[207] by a hand
and lift it up together with piston assy.
Do not change the arrangement of piston kit to
keep good performance.
Cylinder block[204] and piston kit(piston[205] and
shoe[206]) make a minimum unit. (Cylinder
block[204] and piston[205] are clearance
adjustment parts.) If replacement is necessary,
replace them together.

6. Take piston kit out of Retainer plate[207]

7. Take thrust ball[208] out of cylinder block[204].

8. Take Washer[211] out of cylinder block[204].

9. Take out Needle roller[251] from cylinder block

[204].

21 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.14 Taking spring[214] out of cylinder block[204]

1. Set cylinder block[204] on press table

[NOTICE]
Spring[214] should be removed only when
replacement is necessary.
Set Holder(Ⅰ) to the center of Washer[210] to
avoid giving damage on cylinder block[204] on this
process.
Use protection such as vinyl sheet to prevent the
sliding surface of cylinder block[204] from getting
damaged.

2. Set Holder ( ) to the center of Washer[210].

Pressing down Holder ( ). Then, take off
retaining ring[245] from cylinder block[204].
Use retaining ring pliers for this work.

[NOTICE]
Abrupt release of the press cylinder may cause pop
out of the spring[214] and may result in injury.
Release press cylinder slowly.

3. Release press cylinder slowly until spring[214]

lose backing up force.

4. Take out retaining ring[245], washer[210],

spring[214] and washer[210] from cylinder
block[204].

4.15 Taking out pivot[267]

1. Take out Pivot[267], parallel pin[271] and outer

race of tapered roller bearing[249] from spindle
[102].

22 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.16 Taking out tapered roller bearing

[NOTICE]
Tapered roller bearing should be removed only
when replacement is necessary.

1. Set Holder( ) on press table, and place

shaft[202] as is illustrated.

2. Press down shaft[202] by pushing the one end,

and remove tapered roller bearing[249]

[NOTICE]
Do not reuse removed tapered roller bearing.

4.17 Disassembling spindle[102]

1. Mount press tool(Ⅳ) on spindle[102]. Press

spindle[102] down to hub[101] by tightening up
equally placed 4 bolts, which fix spindle[102] to
hydraulic motor workbench. (See the illustration
on page 26.)

Tightening torque: 78±20 N-m

(57.5 ± 14.7 ft-lbf)

2. Turn hydraulic motor to the reduction gear side up

3. Take off retaining ring[122] from spindle[102] by

retaining ring pliers.

4. Turn hydraulic motor to the motor side up.

5. Take press tool( ) away from spindle[102].

6. Attach 2 eyebolts to the thread holes on spindle

[102].

7. Hook wire to 2 eyebolts, and hoist spindle[102]

slowly.
Take out spindle[102] from hub[101].

[NOTICE]
Floating seal[138] and oil seal[232] will come off
with spindle[102].

23 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.18 Taking angular ball bearing out

1. Take floating seal[138] out from hub[101].

[NOTICE]
Do not reuse removed floating seal[138]

2. Attach 2 eyebolts on hub[101]

3. Remove 2 bolts fixing hub[101] on hydraulic

motor workbench.

4. Hook wire to 2 eyebolts. Hoist and move hub[101]

out of hydraulic motor workbench.

4.19 Taking out those parts attached to

spindle[102].

1. Take floating seal[138] out of spindle[102]

2. Remove oil seal[232] from spindle[102]. Use

Screwdriver and Hand hammer.

[NOTICE]
Do not reuse removed floating seal[138] or oil
seal[232].

24 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

4.20 Primal washing

1. Hub[101], spindle[102], cover[108] and rear

flange[201] are distinguished from other parts
which are called inner parts here after.

2. Set and wash hub[101], spindle[102], cover[108]

and rear flange[201] in Washing tank.

[NOTICE]
Remove mud and sand elaborately.
Combustible liquids such as kerosene are often
used for washing parts. They can get ignited easily,
and may cause fire and injury. Be careful for the
handling.
Brushing or wiping parts having dried and
hardened mad or sand on may create scratches.
Soak those parts into washing liquid before
washing.

3. Set inner parts in a receptacle having washing

liquid in it. Wash the parts.

4.21 Final washing

1. Set inner parts in a receptacle having washing

liquid in it. Rotating parts slowly, wash every
portion. Rinse the washed parts.

2. Blow off washing liquid by compressed air. Wipe

off the remaining liquid by clean cloth and dry
parts.

[NOTICE]
After drying, coat the parts with oil to prevent them
from rusting.

25 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

5. Maintenance standards
Follow this procedure for disassembling and inspecting inner parts of hydraulic motor. Handle inner parts
carefully. Do not give any damage especially on sealing surfaces and sliding surfaces.

5.1 Seal

Once disassembled, all sealing parts should be replaced with new ones even though no damage is observed.

5.2 Maintenance standards for parts subject to wear

1. Replace all parts which shows severe damage.

2. Replace parts showing the following appearance or symptom (1mm = 0.03937 in)
Parts Maintenance Replacement
Parts Name Appearance / Symptom
No. standards standards
[101] Hub • Severe damage
• Pitting on teeth of ring gear ―― ――
• Abnormal wear such as scuffing

[102] Spindle • Severe damage Diametric Diametric

clearance clearance
• Abnormal wear such as scuffing
22–36 μm 100 μm
[103] Carrier assy • Flaking on Pin[108]
―― ――
etc. • Abnormal wear such as scuffing

[104] Sun gear1 • Pitting on gear teeth

[106] Sun gear2 • Flaking on rolling surface of bearing
―― ――
[105] Planetary gear1
[107] Planetary gear2

[109] Thrust collar1 • Sign of seizure such as severe color

[110] Thrust collar2 change
[111] Thrust plate • Abnormal wear on sliding surface ―― ――
[112] Thrust collar3 washer
[117]

[114] Coupling • Abnormal wear of spline

―― ――

[122] Retaining ring • Sign of seizure such as severe

color change ―― ――
• Abnormal wear on sliding surface
[124] angular ball bearing • dents or flaking on rolling surface of
bearing race
―― ――
• Uneven wear

[127] Needle roller bearing • Pitting on needle roller

―― ――
[128] • Abnormal wear on roller cage
[129] Inner ring • Flaking on rolling surface of bearing
―― ――

26 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

Parts Maintenance Replacement

Parts Name Appearance / Symptom
No. standards standards
Rear flange kit • Severe scar on sliding surfaces of
[401] Rear flange both spool[471] and spool hole Diametric Diametric
• Abnormal clearance between spool clearance clearance
[471] Spool hole and spool[471] 6-26 μm 43 μm
• Severe scar on outer dia.
• Uneven waer on outer dia.
[202] Shaft • Abnormal wear on oil seal [232]
sealing surface ―― ――
• Abnormal wear of spline

[203] Swash plate • Sign of seizure ―― ――

[204] Cylinder block • Abnormal wear of spline
• Abnormal wear in cylinder bore
• Severe scar or uneven wear on
―― ――
sliding surface
Piston assy • Abnormal axial clearance between Axial clearance Axial clearance
[205] Piston piston[205] and shoe [206] 0.05 mm 0.15 mm
[206] Shoe • Abnormal or uneven wear of
shoe[206]

[207] Retainer plate • Transform

• Uneven wear on retaining shoe[206]
surface ―― ――
• Uneven wear on sliding surface to
thrust ball[208]

[208] Thrust ball • Uneven wear on sliding surface ―― ――

[209] Timing plate • Sign of seizure or uneven wear ―― ――
[215] Friction plate • Uneven wear of lining Braking torque Braking torque
[216] Mating plate • Low braking torque 928 N-m 668 N-m
[217] Mating plate • Sign of seizure (665 ft-lbf) (493 ft-lbf)

[212] Piston • Severe scar on outer dia. ―― ――

[249] Tapered roller bearing • Dents or flaking on race
[250] • Flaking on roller and cage ―― ――
• Uneven wear
[301] Body • Severe scar on sliding surfaces of
[302] Spool both spool [302], [303] and spool
[303] Spool hole.
• Abnormal clearance between spool ―― ――
and spool hole.
• Uneven wear on outer dia.
• Severe scar on outer dia.

27 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

6. Assembly 7. Assembly procedure

Assembly procedure is reverse way to disassembly [NOTICE]
procedure basically. Some parts are required clearance adjustment.
Before start assembling, make sure if the following
6.1 Preparation parts are replaced or not.

Provide workbenches, tools and equipments same 1. Parts required clearance adjustment for angular
as disassembly preparation. ball bearing
hub[101], spindle[102], collar[121] and angular ball
6.2 General suggestion for work bearing[124]
1. Pay the same attention and caution paid for 2. Parts required clearance adjustment for tapered
general suggestions for disassembly on section 2. roller bearing
2. Before assembling, make sure assembled parts spindle[102], shaft[202], rear flange[401], tapered
are clean and have no burrs or dents. If burrs or roller bearing[249] and [250]
dents are observed, remove them with oilstone. [NOTICE]
3. Replace o-ring, oil seal and floating seal to the If any of above listed parts is replaced, perform
clearance adjustment by following the each
new parts. procedure. If not, it may result in malfunction, poor
performance or short serving term (short life) of
4. Remove adhesive from thread holes on shaft
hydraulic motor.
portion on spindle[102] by using tap for
M10(P=1.5) thread. Keep the thread hole dry and
clean by using cleaning liquid and air blow. Do not
reuse hexagon head bolt[140].

5. Use caution for not damaging o-ring, oil seal and

floating seal on assembling. Apply small amount of
lithium grease for smooth assembling

6. Apply clean working oil (NAS standard 9 or less) to

hydraulic motor parts and valves before
assembling.

7. Do not use fabric gloves at assembling to prevent

fiber pieces from coming in to hydraulic motor and
valves.

8. Bolts and plugs should be tightened at the torque

given in 1-2 tightening torque table on page 10.

9. Plug all ports to prevent hydraulic motor from

being contaminated after assembly.

10. The photographs and drawings contained in this

manual describe standard model. The assembly
procedure is still same even though product is
different from the standard model.

28 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

7.1 Assembling hub[101]

1. Set hub[101] on press table.
2. Place angular ball bearing[124] on hub[101] and
set press tool( ) on outer race of angular ball
bearing[124]. press tool( ) is guided by inner
diameter of angular ball bearing[124]. Press the
press tool( ) down till stopped.
3. Insert ring[125] into ring groove on hub[101].
4. Put collar[121] on outer race of angular ball
bearing[124]
5. Insert angular ball bearing[124] in hub[101] by
following the procedure 2.
[NOTICE]
Do not assemble angular ball bearing[124] in wrong
way. angular ball bearing has direction.

6. Tighten up 2 eyebolts in the screw holes on

hub[101].
7. Hook wire to 2 eyebolts. Hoist and set hub[101],
on hydraulic motor workbench.
[NOTICE]
While matching screw holes of hub[101] to screw
holes of hydraulic motor workbench, carefully place
hub[101] in mounting hole.

8. Mount hub[101] on hydraulic motor workbench by

fastening more than two hexagon socket head
screws. Chose locations where one is located
opposite to the other
[NOTICE]
Tighten up bolts securely. Failing to do so could
result in injury caused by hydraulic motor falling off
when it is turned up side down.

9. Apply grease thinly on the o-ring of floating

seal[138]. Insert floating seal[138] into floating seal
housing on hub[101]
[NOTICE]
Remove o-ring from floating seal[138] to apply
grease thinly and evenly.
Set F/S installation tool( ), floating seal[138], and
F/S installation tool( ) in the order. Press in F/S
installation tool( ) until it reaches F/S installation
tool( ). Take away the installation tools. Check that
seal surface of the installed floating seal [138] is
placed evenly within 1 mm against hub[101] end
face.

29 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

7.2 Assembling spindle[102]

1. Apply grease thinly on the o-ring of floating

seal[138]. Insert floating seal[138] into floating
seal housing on spindle[102].

[NOTICE]
Set F/S installation tool( ), floating seal[138], and
F/S installation tool( ) in the order. Press in F/S
installation tool( ) until it reaches F/S installation
tool( ). Take away the installation tools. Check that
seal surface of the installed floating seal [138] is
placed evenly within 1 mm against spindle[102] end
face.

2. Tighten up 2 eyebolts for fuck up

3. Hook wire to 2 eyebolts. Hoist and insert spindle

[102] into hub[101].

[NOTICE]
If any of hub[101], spindle[102], collar[121], or
angular ball bearing[124] is replaced, go to 4. If not,
go to 5.

4. Perform clearance adjustment for angular ball

bearing[124]. Refer to “Clearance adjustment for
angular ball bearing[124]”.

5. Mount press tool( ) on spindle. Press spindle

[102] down to hub[101] by tightening up equally
placed 4 bolts, which fix spindle[102] to hydraulic
motor workbench. (See the illustration on page
26.)
Tightening torque: 49±9.8 N-m
(36±7 ft-lbf)

6. Turn the assembly to the reduction gear side up

7. Insert retaining ring[122] into retaining ring groove

on spindle[102].

8. Turn the assembly to the motor side up.

9. Take Press tool( ) away from spindle[102].

30 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

7.3 Assembling hydraulic motor parts

1. Press fit oil seal[232] into spindle[102] by press

tool( ) and plastic hummer.

[NOTICE]
Apply lithium grease on seal lip on fitting oil
seal[232].
oil seal has direction to be fit.

2. Insert outer race of tapered roller bearing[249] into

spindle[102]

3. Insert parallel pin[271] into pin hole of spindle

[102]

4. Apply lithium grease to rounded surface of Pivot

[267], and set onto the mounted parallel pin[271]

5. Apply working oil to sliding surface of piston kit.

Insert it into piston hole on spindle[102].

7.4 Assembling shaft[202]

[NOTICE]
Wear thick leather gloves for handling heated
tapered roller bearing. Failing to do so may result in
injury.

1. Set tapered roller bearing[249] in heater and keep

it at 100±10°C (212±50°F) for 10 min.
Press fit tapered roller bearing[249] on to shaft
[202]

31 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

7.5 Clearance adjustment for angular

ball bearing

[NOTICE]
If any of hub[101], spindle[102], angular ball
bearing[124] or collar[121] is replaced, perform
clearance adjustment by selecting specially sized
and classified retaining ring[122]. If not, it may result
in fatal accident as well as malfunction, poor
performance or short serving term (short life) of
hydraulic motor.
If the above mentioned parts is not replaced, this
clearance adjustment procedure is not necessarily.
The following is the clearance adjustment
procedure for angular ball bearing[124]

1. Set Bearing preload adjuster on spindle[102].

Fasten Special nut at 108N-m (80ft-lbf) and then
loosen. Fasten Special nut again at specified
torque for preload.
Tightening torque: 75.5±20 N-m
(55.7±14.7 ft-lbf)

2. Measure the distance between end face of

angular ball bearing[124] and retaining ring
groove wall. (Distance “C” in the illustration left)
Measure at equally spaced 4 angular locations
through measurement holes on Bearing preload
adjuster, and obtain the average

3. Select retaining ring[122] which has the closest

thickness to the distance “C” out of 9
classifications. (See classification table)

4. Loosen Special nut, and take away Bearing

preload adjuster from spindle[102].

5. Turn the assembly to the motor side up.

6. Place press toolⅣ on spindle[102]. Press spindle

[102] to hub[101] by tightening equally spaced 4
bolts specified below at specified tightening
torque.
Bolt : M16 (P2.0) ×180 mm (7.09 in)
Tightening torque: 49±9.8 N-m
(36±7 ft-lbf)

7. Turn the assembly to the reduction gear side up

8. Insert retaining ring selected in process③to

retaining ring groove

32 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

7.6 Clearance adjustment for tapered

roller bearing

[NOTICE]
If any of spindle[102], rear flange[401], shaft[202],
tapered roller bearing,[249] or [250] is replaced,
perform clearance adjustment by selecting specially
sized and classified collar[219]. If not, it may result
in malfunction, poor performance or short serving
term (short life) of hydraulic motor.
If the above mentioned parts is not replaced, this
clearance adjustment procedure is not necessarily.
The following is the clearance adjustment
procedure for tapered roller bearing[249], and [250].

1. Place flat plate which has constant thickness(“D”

mm) on spindle[102]. Measure the distance
between end face of tapered roller bearing[250]
and the flat plate(“E”). Measure at equally spaced
4 angular locations, and obtain the average.

2. Measure the depth of the housing hole for tapered

roller bearing[250](“F”). Measure at equally
spaced 4 angular locations, and obtain the
average.

3. Thickness(“G”) of collar[219] is obtained by the

following equation.

“G” = “F” - “D” - “E” + (0.045 to 0.09) (mm)

[ “G” = “F” - “D” - “E” + (0.0018 to 0.0036) (in) ]

4. Select the classification of collar[219], which

satisfies the above equation, out of the 12
classifications. (See classification table.)

5. Insert selected collar[219] to housing hole for

tapered roller bearing on rear flange[401].

33 W102-0560E
F-3 F-3
Hydraulic Motor and Counterbalance Valve

8. Performance confirmation test

After reassembling hydraulic motor, conduct performance confirmation tests by following procedure.

8.1 Required measurement instruments

1 Pressure gauge (for up to 4.9Mpa (710psi)) 2

3
2 Cylinder (for up to 5L (305 in )) 1

3 Stop watch 1

8.2 Test procedure

• Mount hydraulic motor on flame of machine, and connect pipe and
Mounting /
1 hose.
piping
• Wire rope should not be attached, for the performance confirmation
test (No-load drive)
• Attach pressure gauge, and connect pipe and hose to measure the
amount of drain of hydraulic motor.

Revolution Pressure Direction Time

Pre-test
2 No-load drive At least 1 min.
operation Left and Right
30 rpm pressure each

Performance
3
confirmation test

Actuate hydraulic motor for warming up working oil as well as hydraulic motor
1 • working oil 45-55 °C (113-131 °F)
• temperature on the surface of Hub 40-60 °C (104-140 °F)

Confirmation test Conduct the following test

standards －1) Drive pressure (entrance pressure minus exit pressure)is less than
2 2.45MPa (355psi) at output revolution 30rpm.
3
2) The amount of hydraulic motor is less than 0.5L/min (30.5 in /min)
at output revolution 30rpm.

GOOD NO GOOD

Disassemble and
Attach wire rope
Investigate

34 W102-0560E
F-3. F-3.
Hydraulic Motor and Counterbalance Valve

9. Classifications of clearance adjustment parts

35 W102-0560E
F-4. F-4.
Hydraulic Valve (Winch Brake Release)

F-4 Hydraulic Valve (Winch Brake Release)

[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
B

Dr AC P.P
IW123-0300E02

1 6 3
T B

P.P

AC Dr
4 5 2
IW123-0300E01

1.Valve body 3.Plug 5.Spring

2.Spool 4.Plug 6.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
AC, B, Dr, T, P.P G1/4 29.4 22

367-406-50000 △
0

36 W123-0300E
 G
Boom Telescoping System

Contents G
G-1 Telescoping System ........................ 1 4.4 Installing slide plates onto sides of
rear end...............................................12
1. General..................................................... 1
5. Adjustment .............................................. 12
2. Description of telescoping system (Refer to 5.1 Adjusting clearance for the boom.................12
the circuit diagram in Chapter Z.)... 3
2.1 Extension circuit ......................................... 3 6. Test .................................................... 14
2.2 Retraction circuit......................................... 3 6.1 Operation test ...........................................14
6.2 Boom lateral warp test ..............................14
3. Boom telescoping mechanism .................. 4 6.3 Other functional test..................................14
3.1 Extension.................................................... 4
3.2 Retraction ................................................... 5
G-3 Jib .................................................15

G-2 Boom (Four-Section Boom) ............ 6 1. Structure ................................................. 15

1.1 Location of Jib...........................................15
1. Structure ................................................... 6 1.2 Jib main body............................................16

2. Disassembly ............................................. 9
2.1 Removing the 2nd boom section................ 9 G-4 Telescoping Cylinder .....................18
2.2 Removing the 3rd boom section............... 10
2.3 Removing the top boom section................11 1. Structure ................................................. 18

3. Check .....................................................11
3.1 Boom .........................................................11 G-5 Counterbalance Valve
3.2 Slide plate..................................................11 (Telescoping) .........................20
3.3 Sheave ......................................................11
3.4 Boom telescoping wire rope ......................11 1. Structure ................................................. 20

4. Reassembly............................................ 12 2. Function .................................................. 21

4.1 Greasing ................................................... 12 2.1 When control valve is at the
4.2 Install anti-buckling bolts for telescoping neutral position ...................................21
cylinder ............................................... 12 2.2 While actuator is being pushed up............21
4.3 Installing lower slide plates....................... 12 2.3 While actuator descends...........................21

i
G-6 Hose Reel ....................................... 22

1. Structure ................................................. 22

2. Mounting................................................. 23

3. Disassembly ........................................... 23

4. Reassembly............................................ 24

G-7 Hydraulic Valve .............................. 25

1. Structure ................................................. 25

ii
G -1 G -1
Telescoping System

G-1 Telescoping System

1. General

Hydraulic Circuit for Boom Telescoping (2M2D)

1 WG02-0440E
G -1 G -1
Telescoping System

Remote Control Pressure Vent

Top Cylinder Select

[NOTICE] telescoping/auxiliary winch control lever) to the

The solenoid valve and the hydraulic pilot control hydraulic pilot control valve to either the boom
valve are connected at the two points having the telescoping pilot circuit or the auxiliary winch pilot
same symbols such as "a4" and "b4".
circuit.

1. The telescoping operation is controlled by the 4. Circuit for remote control pressure vent
hydraulic pilot method. The pilot pressure from the In this hydraulic circuit, the solenoid valve (remote
remote control valve (boom telescoping/auxiliary control pressure vent) controls the pilot pressure
winch control lever) or the remote control valve to the remote control valve (boom
(boom telescoping control pedal) controls the telescoping/auxiliary winch control lever) and the
hydraulic pilot control valve. remote control valve (boom telescoping control
pedal).
2. The maximum pressure in the boom telescoping
hydraulic circuits is regulated by the relief valve 5. Circuit for top cylinder select
(elevating, telescoping). In this hydraulic circuit, the solenoid valve (top
cylinder select) controls the hydraulic valve which
3. Circuit for boom telescoping/auxiliary winch
delivers the pressurized oil from the hydraulic pilot
In this hydraulic circuit, the two solenoid valves
control valve to the No.1 cylinder circuit or the
(boom telescoping/auxiliary winch) switch the pilot
No.2 cylinder circuit.
circuit from the remote control valve (boom

2 WG02-0440E
G -1 G -1
Telescoping System

2. Description of telescoping system (Refer to the circuit diagram in Chapter Z.)

Sheave at the head of the 3rd boom section Top boom section retraction wire rope

Top boom section extension wire rope Fix at the head of the 2nd boom section Fix at the rear end of the top boom section
Adjuster and sheave on the Sheave at the rear end of the
head of the 2nd boom section 3rd boom section

Top boom 3rd boom 2nd boom Base boom

Fold at the rear end of the 3rd boom section

IWG02-0440E02

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

3 WG02-0440E
G -1 G -1
Telescoping System

3. Boom telescoping mechanism WT

Balance of force : F3 = 4 × = 2WT
2
3.1 Extension
Equation of workload : W T × E4 = F3 ×E3
1. 2nd boom section
E3
Extended by No.1 cylinder ∴E4 = F3 ×
WT
(L1: No.1 cylinder stroke)
E3
2nd boom section travel (E2)=L1 = 2WT ×
WT
2. 3rd boom section = 2E3
Extended by No.2 cylinder
(L2: No.2 cylinder stroke)
Top boom section travel (E4) = 2L2
3rd boom section travel (E3)=L2

3. Top boom section

Extended by the wire rope mechanism that
synchronizes with the extension of 3rd boom
section
F3
3rd boom

WT WT WT WT
2 2 2 2

E4 Top
boom

Top boom

WT

2nd boom 2nd boom

3rd boom

2nd boom
. IWG02-0440E03

E4 : top boom section travel

E3 : 3rd boom section travel
F3 : 3rd boom section force
W T : Top boom section weight

4 WG02-0440E
G -1 . G -1 .
Telescoping System

3.2 Retraction 2. 3rd boom section

Retracted by No.2 cylinder
1. Top boom section
3rd boom section travel (R3) = L2
Retracted by the wire rope mechanism that
synchronizes with the retraction of 3rd boom 3. 2nd boom section
section. Retraction by No.1 cylinder
2nd boom section travel (R2) = L1
2nd boom
F3 R3=L2
3rd boom 3rd boom

WT WT WT WT
2 2 2 2

2nd
boom

R4

WT WT
2 2
Top boom

Top
boom
IWG02-0440E04

R4 : Top boom section travel

R3 : 3rd boom section travel
(=L2: No.2 cylinder stroke)
F3 : 3rd boom section force
(=No.2 cylinder force)
W T : Top boom section weight
WT
Balance of force : F3 = 4 × = 2WT
2
Equation of workload : W T × R4 = F3 × R3
R3
∴R 4 = F3 ×
WT
R3
= 2WT ×
WT

= 2R3 = 2L2

Top boom section travel (R4) = 2L2

5 WG02-0440E
G -2 G -2 G -2
Boom (Four-Section Boom)

G-2 Boom (Four-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

6 W536-0910E 6
G -2 G -2 G -2
Boom (Four-Section Boom) Applicable serial No. △
3 ：560713 --

7 W536-0910E 7
G -2 G -2
Boom (Four-Section Boom)

1.Base boom section 29.Spring washer 57.Retainer (R) 85.Pin

2.Second boom section 30.Plate 58.Pin 86.Plain washer
3.Third boom section 31.Pin 59.Split pin 87. ----------
4.Top boom section 32.Plate 60.Slide plate 88.Slide plate
5.Plate 33.Slide plate 61.Retainer 89.Hexagon socket head bolt
6.Nut 34.Plate 62.Slide plate 90.Shim
7.Tooth washer 35.Set screw 63.Pate 91.Shim
8.Sheave assy 36.Nut 64.Plate 92.Support assy
9.Pin 37.Pin 65.Retainer (L) 93.Pin
10.Snap pin 38.Split pin 66.Retainer (R) 94.Retaining ring
11.Pin 39.Retainer 67.Slide plate 95.Slide plate
12.Spacer 40.Bolt 68.Plate 96.Pin
13.Bolt 41.Adjuster assy 69.Plate 97.Pin
14.Nut 42.Spacer 70.Retainer (L) 98.Plain bearing
15. ---------- 43.Pin 71.Retainer (R) 99.Set screw
16.Plate 44.Sheave assy 72.Bolt 100.Bolt
17.Pin 45.Guide 73.Spring washer 101.Spacer
18.Grease nipple 46.Bolt 74.Guide 102.Pin
19.Wire rope 47.Spring washer 75.Bolt 103. ----------
20.Nut 48.Bolt 76.Pin 104. ----------
21.Nut 49.Retainer 77.Spacer 105.Plain washer
22.Plug 50.Slide plate 78.Sheave assy 106.Pin
23.Grease nipple 51.Plate 79.Bolt 107.Bolt
24.Wire rope 52.Plate 80.Plaine washer 108.Bolt
25.Nut 53.Slide plate 81.Slide plate 109.Bolt
26.Bolt 54.Plate 82.Hexagon socket head bolt 110. ----------
27. ---------- 55.Plate 83.Plate 111. ----------
28.Bolt 56.Retainer (L) 84.Plate 112. ----------

342-019-10000 △
4

8 W536-0910E
G -2 G -2
Boom (Four-Section Boom)

2. Disassembly 6. Pull out the connecting pin that connects the base
The procedure to remove the 2nd boom section and boom section and the No. 1 telescoping cylinder
further sections as an assembly is described below. by removing the retaining ring. Then loosen the
nut and remove the bolt.
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.

Wind up the wire rope on the drum.

3. Swing the boom to place where there is enough

clearance, then lower the boom to 0° and stop the
engine.

4. Remove the wiring connector, loosen the wiring

clip and secure the cable end using a tape at the
cable guide (a) located closest to the cord reel.

7. After removing the slide plate on the top of the

base boom section head, pull out the 2nd boom
section by approx. 1 m (3.281 ft).
And removing the slide plate.

8. While lifting up the 2nd boom section slightly,

remove the retainer from the bottom of the base
boom section head.

5. Remove the high-pressure hoses (2 pieces) and

the hose leading to the hose reel from the
telescoping cylinder.
[NOTICE]
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.

9. Lift up and pull out the 2nd boom section using a

crane, and place it on a level platform.

9 W536-0910E
G -2 G -2
Boom (Four-Section Boom)

2.2 Removing the 3rd boom section 8. Remove the sheave assy from the 3rd boom
section head.
1. Remove the hose (1 piece) that connects the No.1
telescoping cylinder and No.2 telescoping
cylinder.

2. Remove the support assy of the No.1 telescoping

cylinder located at the rear end of the 3rd boom
section by loosening the bolt.

9. Fix the end of wire rope to the top boom section

with the string etc.
3. Lift up and retain the No.1 telescoping cylinder
10. Remove the adjuster assy from the 2nd boom
using a crane.
section by loosening the bolt, fix to the 3rd boom
4. After removing the retaining ring, remove the section with the string etc.
connecting pin that connects the 2nd boom
section and the No.1 telescoping cylinder.

5. Lift up and pull out the No.1 telescoping cylinder

using a crane.

6. Remove the connecting pin that connects the

No.2 telescoping cylinder and the 2nd boom
section.
Then loosen the nut and remove the bolt. 11. Lift up and retain the No.1 telescoping cylinder
using a crane.
Next, remove the connecting pin that connects the
3rd boom section and the No.2 telescoping
cylinder.

12. Lift up and pull out the No.2 telescoping cylinder

using a crane.

13. After removing the slide plate on the top of the

2nd boom section head, pull out the 3rd boom
section by approx. 1m (3.281ft).
And removing the slide plate.

14. While lifting up the 3rd boom section slightly,

7. Remove the end of wire rope for the top boom
remove the retainer from the bottom of the 2nd
section extension located on the top of the 2nd
boom section head.
boom section head by loosening the nut.
15. Lift up and pull out the 3rd boom section using a
[NOTICE]
crane, and place it on a level platform.
Before loosening the nut, measure the length of the
wire rope protrusion (L1) as a guide for reassembly.

10 W536-0910E
G -2 G -2
Boom (Four-Section Boom)

2.3 Removing the top boom section 3. Check

1. Remove the guides (on both side of the rear end
3.1 Boom
of the 3rd boom section) by loosening the bolt 1,
and remove the pin 1 and sheave assy by Check the boom for twist, deformation, wrap, and
looseing the bolt 2. cracks.

3.2 Slide plate

Check the slide plates for cracks and wear, and

replace when these conditions are excessive.

3.3 Sheave

Check the sheaves for damage, deformation and

wear, and replace them when these conditions are
excessive.

3.4 Boom telescoping wire rope

Wire rope in the condition described below must not

be used.

• Deformation or corrosion

• Kinking

• 10% or more broken wire (filler wires excluded) in

one lay of the wire rope

• diameter reduction exceeding 7% of the nominal

2. Remove the pin 2 from the rear end of the top diameter.
boom section by loosening the bolt 3 and remove
the wire ropes for top boom section retraction. • Evidence of any heat damage from any cause.

3. After removing the slide plate on the top of the 3rd

boom section head, pull out the top boom section
by approx. 1m (3.281ft).
And removing the slide plate.

4. While lifting up the top boom section slightly,

remove the retainer from the bottom of the 3rd
boom section head.

5. Lift up and pull out the top boom section using a

crane, and place it on a level platform.

[NOTICE]
Pull out the extending and retracting wire rope on
the top boom section together.

11 W536-0910E
G -2 G -2
Boom (Four-Section Boom)

4. Reassembly 5. Adjustment

4.1 Greasing 5.1 Adjusting clearance for the boom

• When installing unplated pins, apply grease 1. Lateral clearance at the bottom of the boom rear
beforehand. end

• Apply TNR-2 Grease sufficienty to the sliding Place shims so that the total clearance
surfaces of the slide plates, the booms and (distributed to right and left) is 0.5 mm (0.02 in).
telescoping cylinders.
2. Upper clearance on boom rear end
4.2 Install anti-buckling bolts for telescoping Place shims that the lateral deviation of center is
cylinder
±1.5 mm (0.06 in), and vertical deviation is 3-5
B
Boom side mm (0.12-0.2 in).
A
Cylinder side E
D 3. Lateral clearance at boom head

Place shims so that the total clearance is 0.5 mm

(0.02 in) when the boom is 1 m (3.281 ft) longer
S than that of full retraction.
C
IW536-0680E12 4. Clearances over head of each boom section

1) Extend the boom fully and tighten the set screw

1. Connect the boom and telescoping cylinder using until no clearance between the pad and boom top
the pins A and B. face is left. Then return the screw for a quarter
2. Adjust the bolt C locked with nuts D and E so that turn and lock it with the nut 1.
it can be turned by hand and the clearance (S) is
2) Tighten the bolt until it lightly touches the retainer
0.5mm (0.02in) or less.(Apply thread locking
and lock it with the nut 2.
agent.)
Set screw Nut 1
[NOTICE]
Refer to normal insert directions of bolt•C shown on
[2.Disassembly]
Retainer
4.3 Installing lower slide plates
Nut 2
1. Apply thread locking agent to the bolt, tighten it
lightly and turn it in reverse for a quarter turn. Bolt

2. If the tip of the bolt protrudes beyond the bottom

of the retainer, scrape it off with a grinder.
IW536-0630E14

4.4 Installing slide plates onto sides of rear end

5. Vertical clearance for the boom head.
Apply thread locking agent to the bolt, tighten it
lightly and turn it in reverse for a quarter turn. Place shim so that the difference of right and left
size (X) is 2 mm (0.08 in) or less, when the boom
is 1 m (3.281 ft) longer than that of full retraction.

12 W536-0910E
G -2 G -2
Boom (Four-Section Boom)

6. 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

IW536-0910E12

7. Adjusting the bolt on the bottom of base boom

section head.

[NOTICE]
This adjustment is applied to only
serial No.560678- 560712

Fix the support so that the size[H] is 0.5 mm (0.02

in), and lock the bolt with a nut while it is lightly
pressed against the support.

Place shims so that the size[ ] is 5-6 mm

(0.2-0.24 in).

13 W536-0910E
G -2 . G -2 .
Boom (Four-Section Boom)

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]
･Crane levelness : ± 6' max.
･Boom length : Full extension
･Boom elevation : Maximum
･Boom direction : Over-front, Over-rear,
Over-right, Over-left
･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 150mm (5.9 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
450mm (17.7 in).
When the displacement is more than the specified
limit, readjust the shim.

14 W536-0910E
G -3 G -3 G -3
Jib

G-3 Jib
1. Structure
1.1 Location of Jib

1.Jib assy 2 7.Plate 13.Set screw 19.Support

2.Bar 8.Support 14.Nut 20.Bar
3.Plate 9.Support assy 15.Pin assy 21.Pin
4.Support 10.Support 16.Plate 22.Plate
5.Support 11.Plate 17.Grease nipple 23.Support
6.Support 12.Plate 18.Stopper 342-216-61000 △
1

15 W537-0160E 15
G -3 G -3 G -3
Jib

1.2 Jib main body

16 W537-0160E 16
G -3 . G -3 .
Jib

1.Stopper 14.Retaining ring 27.Pin 40.Pin

2.Jib 2 15.Pin 28.Snap pin 41.Bolt
3.Jib 1 16.Snap pin 29.Plate 42.Spring washer
4.Support 17.Slide plate 30.Link 43.Sheave assy
5. --------------- 18.Shim 31.Stopper 44.Plate
6.Pin 19.Shim 32.Plain washer 45.Pin
7.Snap pin 20.Plate 33.Pin 46.Plain washer
8.Sheave assy 21.Bolt 34.Split pin 47.Plate
9.Pin 22.Spring washer 35.Spacer 48.Bolt
10.Retaining ring 23.Roller assy 36.Spacer 49.Plate
11.Grease nipple 24.Spacer 37.Spacer 50.Cushion
12.Roller assy 25.Stopper 38.Guide assy 51.Plate
13.Pin 26.Roller assy 39.Spacer

342-216-61100 △
0

17 W537-0160E
G -4 G -4
Telescoping Cylinder

G-4 Telescoping Cylinder

[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

IW157-0390E01

1. No.1 cylinder
2. No.2 cylinder
3. Hose

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A G3/4 108 - 123 80 - 90

B, C G1/2 54 - 64 40 - 47

18 W157-0420E
G -4 . G -4 .
Telescoping Cylinder

*1

1 2 3 4 5 6 19 5 7 8 9 10 11 12 13 14 15 16 17 18

IW157-0880E02

1.Plug 9.Cylinder 17.Plain bearing

2.Spring pin 10.Rod 18.Dust seal
3.Nut 11.O-ring 19.Backup ring
4.Piston 12.Rod cover assy
5.Backup ring 13.Support
6.Packing 14.Damper ring
7.Plain bearing 15.Packing
8.O-ring 16.Backup ring

*1: Face the notch or the lip toward the pressurized side.

360-178-70000 △
1

360-178-80000 △
0

19 W157-0420E
G -5 G -5
Counterbalance Valve (Telescoping)

G-5 Counterbalance Valve (Telescoping)

[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
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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
6 - 29 - 49 22 - 36
7 - 1 - 1.2 0.7 - 0.9
11 - 56 - 62 41 - 46
18 - 78 - 98 58 - 72
20 - 1 - 1.2 0.7 - 0.9
M M6x1 - -

20 W119-0222E
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

21 W119-0222E
G -6 G -6
Hose Reel

G-6 Hose Reel

[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.Reel 8.Spring washer 15.Case 22.Set screw

2.Ball bearing 9.Shaft 16.Plate 23.O-ring
3.Retaining ring 10.Seal ring 17.Aux. spring 24.Oil seal
4.Seal ring 11.Bolt 18.Rubber 25.Retaining ring
5.Buckup ring 12.Spring washer 19. ---------------- 26.Plate
6.Ball bearing 13. ------------------ 20.Spacer
7.Nut 14.Spring 21.Oil seal

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
T1 G1/2 98 72
T2 G1/2 53.9 - 63.7 40 - 47
T3 M12 36 - 40 26.5 - 29.5

22 W183-0230E
G -6 G -6
Hose Reel

2. Mounting 5. Retry from the first step of the above procedure

when L is out of 7.1 to 7.6 m (23.3-24.9 ft).
1. Install the hose reel on the specified place. Mount Increase and decrease the number of pre-wind-up,
the hose reel on the swing frame, and connect the from eight(8) to ten(10) turns, in the step 3.
hose to the telescoping cylinder at A position.
Record the hose length between A and B pisitions
(or make a mark on B position of the hose). 3. Disassembly

Telescoping cylinder

Hose reel

B IW183-0230E01 [NOTICE]
This process is very dangerous. Take extreme
caution in executing it to secure safety.
2. Disconnect the hose from A on the telescoping
cylinder, and wrap the hose on the reel. 1. Remove set screw(22) and retaining ring(3), and
remove spacer(20).
3. To accumulate the spring force, manually rotate
the whole reel from eight(8) to ten(10) turns where 2. Remove nuts(7), and remove reel(1).
take-up force of the reel is zero(0). Pull out the
3. Fix shaft(9) in a vise with the reel(1) mounting
hose from the reel until the reel can not turn
side up.
further: the inner spring of the reel is in closed fit.
After that, the reel can wind up the hose from one 4. Before loosening bolts(11) from shaft(9) to remove
(1) to one and a half (1.5) turns. the case assy, install protection plates using
mounting holes as shown to avoid spring(14)
4. In this condition, pre-wind-up force is sufficient
flying out.
when L is within 7.1 to 7.6 m (23.3-24.9 ft).
Connect the hose to A of the telescoping cylinder.
L=7.1 to 7.6 m (23.3-24.9 ft)
Telescoping cylinder stroke: 7.1m (23.3 ft)

Hose reel

B A

L
IW183-0230E02

23 W183-0230E
G -6 . G -6 .
Hose Reel

5. Take out spring(14) from case(15) by following

procedures to change spring(14) with new one.

First step, remove the protection plates from

case(15). Second step, fix case(15) in a
sufficiently wide space. Tie one end of a sufficient
wire length to inner end of spring(14), and pull the
other end of the wire by hand to take out
spring(14).
5. Apply THREE BOND 1401 on the thread of
bolts(11), and securing spring(14) to shaft(9) by
4. Reassembly
bolts(11).
1. Apply grease(IDEMITU Daphone Eponex SR2) on
6. Remove vice pliers from the out side of spring(14),
seal ring(10), and then insert seal ring(10) into
and place auxiliary spring(17) and plate(16). Stock
case(15).
vice pliers on the heel side of spring(14) are
2. Install case(15) into shaft(9). removed and the plate spring supplementary(17)
and (16) are put. And, install spring(14) to
3. Remove the sring holder which secures the case(15) with bolts(11) coated by THREE BOND
spring(14), holding spring(14) with vice pliers. 1401. After installing, finish bolt(11) heads
waterproof with THREE BOND 4101.
[NOTICE]
If the spring recoils, it may hurt personnel. Be sure 7. After removing the other vice plier and protection
to clamp it securely with vice pliers.
plates, apply grease on the upper of spring(14).
Clamp with vice pliers, paying attention to the
installation orientation of the spring. 8. Install groove rubber(18) into case(15).

9. Install seal ring(4), backup ring(5), and O-ring(23)

into shaft(9). After installing, apply grease lightly
on the shaft.

10. Apply grease(IDEMITU Daphone Eponex SR2)

into clearance between ball bearings(2),and (6)
and oil seals(21),and (24), and then adhesive on
the mateing surface between reel(1) and groove
rubber(18). Insert reel(1) into shaft(9). Apply
adhesive on the mateing surface between reel(1)
and groove rubber(18).

11. Fix reel 1 and case(15) together with nuts(7).

12. Insert spacer(20) into shaft(9) and fix spacer(20)

4. After applying grease on the bottom of spring(14), with retaining ring(3), and then lock spacer(20) by
insert spring(14) into case(15) and then install screw(22) applyed with THREE BOND 1401.
protection plates.

24 W183-0230E
G -7 G -7
Hydraulic Valve

G-7 Hydraulic Valve

[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

PP

P C T Dr
IW123-017001

PP

Dr
C P T

IW123-017002

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, C, T G3/4 167 123

PP, Dr G1/4 29.4 22

25 W123-0172E
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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
Mounting bolt
M5 7 5
(for solenoid valve.6)

26 W123-0172E
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

1.Body 7.Spring seat 11.Spring

2.Plug 8.Square ring 12.Solenoid
3.Spool 9.O-ring 15.Hexagon socket head bolt

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
2 - 44 - 49 32.5 - 36
15 M5 6.9 - 8.9 5 - 6.5
T1 - 39 - 49 28.8 - 36
T2 - 4.4 - 5.4 3.3 - 4

366-497-50000 △
1

366-463-10000 △
1

27 W123-0172E
 H
Safety System

Contents

H-1 Safety System .................................. 1 H-3 Outrigger Extension Length H

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

H-2 Boom Length and Angle Detector .. 2

1.Structure and function................................... 2

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 into the boom head. When the hook block
1. A retraction pressure sensor and an extension approaches the boom head, single top or jib, the
pressure sensor are incorporated in the elevating overwind cutout device sends a signal to AML,
cylinders. 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 WH02-0080E
H-2 H-2
Boom Length and Angle Detector

H-2 Boom Length and Angle Detector

[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 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 W305-0480E
H-2 H-2
Boom Length and Angle Detector

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 ± 750Ω

(for boom length detection) Electric turning angle : 347-352°
Mechanical turning angle : 360°,
continuous rotation
Potentiometer Resistance : 1000±200Ω
(for boom angle detection) Electric angle : 120 ± 1.8°

Electric Symbol

[NOTICE]
About the connector applicable to serial No. up to JA0217. JA0217 (GT-250C-1)
560819 (TR-300XL-4, GR-300EX-1)

3 W305-0480E
H-2 H-2
Boom Length and Angle Detector

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 W305-0480E
H-2 H-2
Boom Length and Angle Detector

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 : 1.18 N-m {0.87ft-lbf}
the 6.59 m (21.6ft) point of the cord shows on the
drum, wind the cord 7 turns more and fix it with 11.Take out the new cord from the guide hole of the
gummed tape to prevent slackening. cord reel and draw it out completely. Then wind it
again the drum. When the 0-marker comes to the
[NOTICE] edge of the cord guide, fix the cord there as
Wind the cord around the drum assy clockwise as shown in the figure.
seen from the slip ring.
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
5. Insert the shaft of the drum assy into the boss
turn the gear using a screwdriver until the output
hole of the plate and fix it with a nut.
voltage between the red and white terminals is 0.5
6. Put the case over the drum assy, leading the ± 0.06 V. Then fix the gear using a set screw.
sub-cord outside through the hole of the case and Apply thread-locking agent to the set screw.
the cord end outside through the opening of the
Tightening torque : 1.18N-m {0.87ft-lbf }
cord guide.
Screwdriver
7. Secure the case and the plate with a bolt and Gear B
Gear A Set screw
attach the retaining ring.
Bracket
8. Apply sealant agent thinly on the bottom of the Spring
speed reducer. Then install the speed reducer on
the case. White
Red +
- Tester
9. Inset the gear on the shaft of the speed reducer. Black
- Applied
Loosen the set screw on the potentiometer side to + voltage
allow both gears to idle. IW305-0230E10
Check that the gear is spring-returned to the

5 W305-0480E
H-2 H-2
Boom Length and Angle Detector

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.

[NOTICE]
Before replacement, disconnect the wiring to the
boom angle detector from the pin terminal section to
disconnect the lead wires (red and black) from the
boom angle detector.

Gear

Spring

Bracket

Lead wire

18. Check for conduction and shortcircuit between Potentiometer Black

Red
the terminals of the sub-cord connector and the
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.
2.5 Reassembling potentiometer To avoid exposing the potentiometer to high
temperature for a long time, solder the
1. Install a new potentiometer. potentiometer terminal and the lead wires quickly.

[NOTICE]

6 W305-0480E
H-2. H-2.
Boom Length and Angle Detector

Fix the potentiometer terminal including the lead 3. Adjustment

wires to the bracket using insulating sealant.
1. Adjust the cord lock so that the 0-marker on the
Recommended sealant: Shin-Etsu Silicone cord is on the edge of the cord guide when the
KE45RTV (Shin-Etsu Chemicals Industry) boom is fully retracted.

Bracket

Potentiometer Insulating sealant 0-marker Cord lock

IW305-0230E14 IW305-0230E16

2. Loosen the set screws on the reducer side and 2. Adjust the boom length display of the AML.
potentiometer side to allow both gears to idle. (Refer to the repair manual of the AML.)
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 {0.87ft-lbf}

4. Follow the same procedure as described in the

step 12. and below of the "Installing the cord"
section.

2.6 Replacing the boom angle detector

Disconnect the lead wires to the boom angle

detector from the pin terminal section, and replace
the boom angle detector assy.
361-317-70000 △
1

361-323-30000 △
0

7 W305-0480E
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

10

17

19
18 0V (Black)

11 12 13 14 Power supply (Red)

IW305-0251E02
Output (White)

8 W305-0251E
H-3 H-3
Outrigger Extension Length Detector

1. Base plate 6. Nut 11. Screw 16. Screw

2. Drum assy 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

Specification 4. Remove screw to remove case .

Item Specifications Case

Gear ratio 6/5

Resistance: 2kΩ ± 5%
Potentiometer Mechanical rotating Screw

angle: 360°

IW305-0250E05

2. Disassembly
1. Get the wire slowly rewound round the drum until 5. Remove bolt and separate drum assy and base
the power spring loses its power. plate.

2. Remove screw and loosen clamp to remove

cover.

Cover

Screw Clamp Cable

IW305-0250E03

3. Remove screw and remove potentiometer and

gear together with bracket.
6. Remove the wire from the drum assy.
Potentiometer

Gear

Bracket

Screw

IW305-0250E04

9 W305-0251E
H-3 H-3
Outrigger Extension Length Detector

3. Reassembly 4. Apply grease (Molyspeed Grease No.0) to the

bearing of case and put the case over drum assy.
1. Put a zero marker on a new wire by winding a In this time, lead the end of the auxiliary string out
yellow tape on it. Then tie an auxiliary string of through the opening of the cord guide.
about 1.0 m (3.3 ft) in length to the terminal of the Case

wire.

Zero marker (yellow tape)

Aux. string
Drum side Scrwe

L4
Approx.
L3
1m (3.3ft) IW305-0250E05

IW305-0251E10
L3 : 2.72 m (8.9ft) 5. Secure case on base plate with screw.
L4 : 0.08m (0.26ft)
6. Draw out the wire from the guide window of the
2. Wind the wire round drum assy until the yellow reel. After the wire has been extended to the
tape position. Then wind it three additional turns 0-point mark (yellow tape), secure the wire to the
an secure the wire with a packing tape to prevent case with gummed tape.
it from getting loose.
7. Rotate gear•A of the potentiometer by hand. At the
[NOTICE] position where the resistance between B and W is
The wire winding direction should be clockwise as 200 ± 30Ω, mesh gears•A and B, and install the
viewed from the shaft end. potentiometer.
Gear B
Gear A

Gear side

Gummed tape

IW305-0251E11

3. Mount base plate on drum assy with bolt.

IW305-0250E09

Potentiometer
1 B Black 0V
3 R Red +5V (Power supply)
2 W White Out put
IW305-0250E01

10 W305-0251E
H-3 . H-3 .
Outrigger Extension Length Detector

When replacing the potentiometer with a new one,

mount it onto the bracket, then solder the cable to
the potentiometer terminal.

[NOTICE]
Finish soldering the wire to the potentiometer
terminal as quick as possible (max. 5 seconds) to
minimize undesirable heat transmission to the
potentiometer.
Apply insulation sealant to the terminal of the
potentiometer.
Recommended sealant: Shin-Etsu Chemical’s
Shin-Etsu Silicon KE45TRV

8. Slightly draw out the wire from the drum. Check to

verify that the resistance between B and W
decreases smoothly.

9. Mount cover, while positioning clamp on the

opposite side of the potentiometer.

Cover

Screw Clamp Cable

IW305-0250E03

10. Pull cable to take up the slack and then tighten

clamp.

361-318-00000 △
0

11 W305-0251E
H-4 H-4
Solenoid Valve (Auto Stop)

H-4 Solenoid Valve (Auto Stop)

[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.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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B, T G1/4 29.4 22
4 G3/8 30 - 37 22.1 - 27.3
T1 M5 7–9 5 – 6.5

12 W121-0543E
H-4 . H-4 .
Solenoid Valve (Auto Stop)

Solenoid valve assy

1.Body
2.Plug Connector
4.Spool

+-
7.Spring seat (+): Red
8.Square ring (-): Blue
9.O-ring
11.Spring
IW121-0542E01
12.Solenoid (DC24V)

2
T2 T1

A P B
T T

12 11 9 7 4 8 1
IW121-0540E04

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
2 - 44 - 49 32 - 36
T1 - 39 - 49 29 - 36
T2 - 4.4 – 5.4 3-4

366-460-80000 △
1

13 W121-0543E
 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 Construction ............................................... 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 table I
3.7 Reheat method ......................................... 10 (Refrigeration circuit) ..........................29
3.8 Components ..............................................11 11.2 Car air conditioner system diagnosis table II
(External causes other than insufficient
4. Layout .................................................... 13 cooling and abnormal pressure) .........32
4.1 Overall layout............................................ 13 11.3 Car air conditioner system diagnosis table III
4.2 Overall layout............................................ 14 (Electrical system) ..............................34
4.3 Evaporator section ................................... 15 11.4 Car air conditioner system diagnosis table IV
(Electronic thermo system) .................36
5. Compressor Assy....................................... 16

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) .................................. 50

1. Structure ................................................. 50

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

while aligning the marks (masking tape pieces put

[NOTICE]
in Step 3) on the glass with those on the cab body.
Wipe away any excessive adhesive.

11. Fit the molding on the circumference of the new

glass and bond its end joint with an instant
aneous adhesive.

2. Bonding the joint between windshield

glass and roof glass

[NOTICE] 1. Bond 50 mm (1.95 in) wide pieces of masking

Apply the adhesive so that its cross sectional form tape to places 1 to 2 mm (0.039 to 0.078 in) away
is as shown in the figure by shaping it with a from the edges of windshield glass and roof glass.
spatula.
For a portion where there is a clearance between 2. Remove the rubber dam backing paper.
the glass and rubber dam, apply the adhesive to a
bead height of more than 5 mm (0.2 in). 3. Install and press the new glass while aligning the
◆Install the glass in less than 30 minutes after marks with those on the cab body.
application of the adhesive.
4. Secure the windshield glass and roof glass on the
12. After installing the trim on the glass bonding cab body with an adhesive tape.
portion frame of the cab body, apply the adhesive
5. Fill the space between the windshield glass and
to the glass bonding surfaces.
roof glass with the adhesive (cemedine’s S-511A
• Adhesive:
or S-511F-1) and reshape it with a spatula so that
S-511A [Black paste to use when room
it will be flush with the glass.
temperature is higher than 15°C (59°F)]
S-511F-1 [Black paste to use when room [NOTICE]
temperature is lower than 15°C (59°F)] After the glass has been bonded, allow a curing
Cemedine Co., Ltd. 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.

6. Remove the masking tapes and wipe away

excessive adhesive using white gasoline or
Unit : mm (1mm = 0.039 in) acetone.

13. Remove the rubber dam backing paper.

(Refer to the figure.)

[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)
14. Set and press the new glass against the cab

2 W587-0011E
K-2 K-2
Air Conditioner

K-2 Air Conditioner

[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. 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 W701-0190E
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 W701-0190E
K-2 K-2
Air Conditioner

3. Basic refrigeration cycle

2. Compressor
This component absorbs the gaseous refrigerant
3.1 Construction
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 W701-0190E
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 W701-0190E
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 60°C (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 (246.5 psi) or above.
this evaporator should be cooled. When the gaseous refrigerant is compressed to
1.7 MPa (246.5 psi) (by the compressor), the gas
4. If the pressure is reduced so that the refrigerant
temperature rises to approximately 80°C (176°F).
evaporates at -5°C (23°F), the evaporator is also
maintained at -5°C (23°F). This results in the 7. Therefore, the temperature of the gas as it enters
formation of frost, which inhibits the flow of air the condenser is 80°C (176°F). The curve above
through the evaporator and prevents cooling. shows that when the refrigerant gas is cooled by
20°C (68°F), it becomes a liquid at approximately
5. The vaporized refrigerant must then be liquefied.
60°C (140°F) by the time it reaches the condenser
However, it is impossible to obtain a temperature
outlet.
as low as 40°C (104°F) in a hot summer
environment.

7 W701-0190E
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 W701-0190E
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.

IW701-0110E09
2. Inside the receiver is a strainer and a desiccant,
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 W701-0190E
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 W701-0190E
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 W701-0190E
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.

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4. Layout
4.1 Overall layout

345-109-41000 △
1

13 W701-0190E 13
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Air Conditioner

4.2 Overall layout

345-109-43000 △
1

14 W701-0190E 14
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Air Conditioner

4.3 Evaporator section

15 W701-0190E 15
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Air Conditioner

5. Compressor Assy

16 W701-0190E
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Air Conditioner

6. Evaporator Assy

17 W701-0190E 17
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Air Conditioner

7. Condenser Assy

18 W701-0190E 18
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Air Conditioner

8. Electric
8.1 Electric circuit

363-205-60030 △
0

19 W701-0190E 19
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Air Conditioner

8.2 Main harness A

20 W701-0190E 20
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Air Conditioner

8.3 Main harness B

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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 (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.

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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 98.1 kPa (14.2 psi). Then use a
Temp. control :Max. cool
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 ft•lbf
Insufficient amount: Cooling trouble or malfunction
resulting from compressor lubrication failure Compressor installation 24.5 - 29.4 18.1 – 21.7
Idle pulley center bolt 31.4 - 47.1 23.2 – 34.7
2. When the sight glass bubbles disappear, control
the refrigerant to +100 - 200 g.
(Conditions)
Doors : Open
Blower : Hi
Engine speed : Idle Proper amount of refrigerant
A/C switch : ON
Temp. control : Max. cool

9.4 Heated water circuit Refrigerant lack

(Bubbles are visible)
1. When connecting the heated water piping, be
Sight glass
careful not to incorrectly assemble the IN and IW701-0160E12

OUT piping.

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 (28.4 psi) or less
when the circuit is in use. However the usual
pressure is 98 kPa (14.2 psi) or less.

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10. How to charge air conditioner gas

10.1 Charging gas in automatic operation

Gas charging unit (Reference)

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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.14.)

3 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.

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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±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

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Flow Jigs and

Procedure Safety point
No. tools
16 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.
17 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.

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10.3 How to check air conditioner

Jigs
Flow
Procedure Safety 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.

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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.

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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)
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
Deflate from circuit
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.)

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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)
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.
Deflate from circuit
---------------- 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.

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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.

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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.

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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.

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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.

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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 7kΩ or less.)
Resistance is about 2kΩ Thermistor is normal. ----------------------------
(25℃).
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 7kΩ or Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. more.
OFF. Check thermo Measure resistance of thermo Resistance is ∞ (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.)

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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 W701-0190E
K-2 K-2 K-2
Air Conditioner

12. Compressor
12.1 Compressor abnormal sound diagnosis chart

38 W701-0190E 38
K-2 K-2 K-2
Air Conditioner

12.2 Compressor diagnosis chart (1/2)

39 W701-0190E 39
K-2 K-2 K-2
Air Conditioner

Compressor diagnosis chart (2/2)

40 W701-0190E 40
K-2 K-2
Air Conditioner

13.Troubleshooting

41 W701-0190E
K-2 K-2
Air Conditioner

42 W701-0190E
K-2 K-2
Air Conditioner

43 W701-0190E
K-2 K-2
Air Conditioner

44 W701-0190E
K-2 K-2
Air Conditioner

45 W701-0190E
K-2 K-2
Air Conditioner

46 W701-0190E
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

Air blow DOWN switch

Temp. control display

Temp. DOWN switch
Switch change switch air switch mode

Air blow UP switch

DEF mode switch
INPUT/OUTPUT

Temp. UP switch

For blowout mode

Eva sensor

outside air mode

For water pump

For compressor
A/C sign
For inside and

Circulated air
　 Circulated air
FOOT
VENT

For air mix

OFF

OFF
ON

ON
B/L

Fresh air
FOOT
FACE

clutch
　　 Fresh air

DEF
B/L
Lo M1 M2 Hi

　　

　　

　　
　　

　　
　　
CONTROL

ＣＯＯＬ FACE Circulated COOL MAX

Initial settings (first power ON) - ON - - - - - - - - - - - - - ON OFF OFF OFF ON OFF ON OFF OFF OFF ON ー OFF
ＭＡＸ position ait position (display one bar)
Operates Bar increases
COOL→WARM OFF ON OFF - - - - - - - - - - - - - - - - - - - - - - - - - -
to WARM from left
Air mix M/A control
Operates Bar decreases
WARM→COOL OFF OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - -
to COOL from right
FACE mode OFF - - ON OFF ← ← - - - - - - - - FACE pos. - ON OFF ← ← - - - - - - - - - -
Blowout mode M/A B/L mode OFF - - OFF ON OFF ← - - - - - - - - Ｂ／Ｌ pos. - OFF ON OFF ← - - - - - - - - - -
control FOOT mode OFF - - OFF ← ON OFF - - - - - - - - ＦＯＯＴ pos. - OFF ← ON OFF - - - - - - - - - -
Status before turning OFF is held.

DEF mode OFF - - OFF ← ← ON - - - - - - - - ＤＥＦ pos. - OFF ← ← 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 ← ← - - - -
M1 Opera Opera
Blower amplifier OFF - - - - - - - - - - - - - - - - - - - - OFF ON OFF ← - - - -
-tes to -tes to
control M2 OFF - - - - - - - - - - - - - - - - - - - - OFF ← ON OFF - - - -
ＨＩ ＬＯ
Hi OFF - - - - - - - - - - - - - - - - - - - - OFF ← ← ON - - - -
Thermo operation OFF - - - - - - - - - - ＯＮ ＯＦＦ Note1 - - - - - - - - - - - - - ON - Note1 -
Compressor clutch
Frost formation detection OFF - - - - - - - - - - ＯＮ ＯＦＦ Note2 - - - - - - - - - - - - - ON - Note2 -
control
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 - - - - - - - - - - ＯＮ ＯＦＦ - - - - - - - - - - - - - - ON - ON -
output
Blinking of HOT
Air mix M/A OFF ON - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - - - - - -
sign
Abnormality
Open circuit Blowout mode Blinking of human
of M/A and its OFF ON - - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - -
detection M/A character sign
I/O circuit
In/outside air Blinking
OFF ON - - - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - - -
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

　　Note 1. OFF temperature: 4-6℃(39.2-42.8°F), ON temperature: 5.5-8.5℃(41.9-47.3°F)

　　Note 2. Timer set temperature:6-10℃(42.8-50°F), Timer cancellation temperature:6-12℃(42.8-53.6°F), Count up time: 10±1 minutes, Timer reset temperature: 7-13℃(44.6-55.4°F)
　　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 W701-0190E 47
K-3 K-3
Hydraulic Motor (Air Conditioner) (Option)

K-3 Hydraulic Motor (Air Conditioner) (Option)

[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

2 16 12 1 8 11 A 10 4 B 3

24 19

A B

9 13 15 IW102-037001

48 W102-0370E
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.Steel ball 5/16

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.Spring

360-634-40001 △
0

49 W102-0370E
K-4 K-4
Solenoid Valve (Air Conditioner) (Option)

K-4 Solenoid Valve (Air Conditioner) (Option)

[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

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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7-8 5-6

50 W121-0762E
K-4 . K-4 .
Solenoid Valve (Air Conditioner) (Option)

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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
4 - 23 - 28 17 - 21
15 M5 7-8 5-6
T1 - 38 - 41 28 - 30
T2 - 4–5 3-4

367-401-70000 △
0

51 W121-0762E
 L
Control System

Contents

L-1 Control System ................................ 1 L-7 Accelerator Sensor ........................15

1. General of hydraulic pilot system (2M2D) . 1 1. Structure ................................................. 15

2. General of hydraulic pilot system (1M1D) . 2 2. Adjustment .............................................. 15

3. General of pneumatic control devices ....... 3

L-8 Solenoid Valve (Air) .......................16 L
L-2 Remote Control Valve (Lever)......... 4 1. Structure ................................................. 16

1. Structure ................................................... 4

L-3 Remote Control Valve (Pedal)......... 7

1. Structure ................................................... 7

L-4 Shuttle Valve (Lever / Pedal)......... 10

1. Structure ................................................. 10

L-5 Solenoid Valve (Boom Telescoping

/ Aux. Winch).......................... 11

1. Structure ..................................................11

L-6 Solenoid Control Relief Valve

(Elevating Slow Stop)............ 13

1. Structure ................................................. 13

i
L-1 L-1
Control System

L-1 Control System

1. General of hydraulic pilot system (2M2D)

Hydraulic Pilot Circuit (2M2D)

1 WL02-0070E
L-1 L-1
Control System

2. General of hydraulic pilot system (1M1D)

Hydraulic Pilot Circuit (1M1D)

2 WL02-0070E
L-1. L-1.
Control System

3. General of pneumatic control devices

Pneumatic Circuit

3 WL02-0070E
L-2 L-2
Remote Control Valve (Lever)

L-2 Remote Control Valve (Lever)

[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
TP

1 2 3 4
IW135-013001

A A

455

247
T

P
171
172

101

PORTS 1＆ 2 PORTS 3＆ 4

A 123 A
103
IW135-0130E02

4 W135-0132E
L-2 L-2
Remote Control Valve (Lever)

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.Hex. 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.Hex. socket head bolt 213.Seal 401.Upper cover 481.Hex. socket head bolt
131.Bush 214.O-ring 402.Lever 501.Boot
161.Plug 215.Washer 411.Set screw

5 W135-0132E
L-2. L-2.
Remote Control Valve (Lever)

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T G1/4 34 - 38 25 - 28

PORTS 1, 2, 3, 4 G1/4 34 - 38 25 - 28

125 M8 27 - 31 20 - 23

161 R1/4 20 - 24 14 - 17

172 M8 16 - 18 12 - 13

411 M12 27 - 31 20 - 23

445 M8 27 - 31 20 - 23

454 *1 M8 16 - 18 12 - 13

481 M6 11 - 13 8 - 9.4

*1: Apply LOCTITE 241 (thread locking agent) to threaded sections.

366-349-20000 △
0

6 W135-0132E
L-3 L-3
Remote Control Valve (Pedal)

L-3 Remote Control Valve (Pedal)

[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
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

7 W135-0152E
L-3 L-3
Remote Control Valve (Pedal)

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.Hex.Socket head bolt 324.Spring 473.Hex. socket head bole
212.O-ring 272.Hex.Socket head bolt 335.Spring 501.Boot

8 W135-0152E
L-3. L-3.
Remote Control Valve (Pedal)

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
272 M8 19.1 - 22.1 14.1 - 16.3
271 M6 8.7 - 8.9 6.4 - 6.6
251 G1/4 27.4 - 31.4 20.2 - 23.2
315 M12 56.3 - 61.3 41.5 - 45.2
5.9 - 7.9 4.4 - 5.8
472 M6
Apply LOCTITE 241
473 M8 15.2 - 18.2 11.2 - 13.4
P, T G1/4 27.4 - 31.4 20.2 - 23.2
Port 1,2,3,4,5,6 G1/4 27.4 - 31.4 20.2 - 23.2

366-380-60000 △
0

366-377-50000 △
2

9 W135-0152E
L-4. L-4.
Shuttle Valve (Lever/Pedal)

L-4 Shuttle Valve (Lever / Pedal)

[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
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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
a, b, e, f G1/4 29.4 22

c, d G1/4 24 - 29 18 - 22

2 G3/8 49 36

366-236-90000 △
1

10 W128-0112E
L-5 L-5
Solenoid Valve (Boom Telescoping/Aux. W inch)

L-5 Solenoid Valve (Boom Telescoping / Aux. W inch)

[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

H F G D B C

E T A
IW121-031001

Connector

+-
(+): Red
(-): Black

IW121-0542E01

11 W121-0313E
L-5. L-5.
Solenoid Valve (Boom Telescoping/Aux. W inch)

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.Hex. socket head bolt 15.O-ring
Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B, C, D G1/4 29.4 22

E, F, G, H G1/4 29.4 22

T G1/4 29.4 22

366-481-30000 △
1

12 W121-0313E
L-6 L-6
Solenoid Control Relief Valve (Elevating Slow Stop)

L-6 Solenoid Control Relief Valve (Elevating Slow Stop)

[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
601

171

151

A2 A1

101.Casing P2 P1
151.Plug
171.Hex. socket head bolt
601.Proportional reducing valve

101 T1 IW136-0250E01

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P2, T, A1, A2 G1/4 34 - 38 25 - 28
151 R1/16 6-8 4-6
171 M5 6-8 4-6
T1 M8 26 - 32 20 - 24

13 W136-0251E
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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
351 M3 0.5 - 0.7 0.37 - 0.52
802 M6 6.9 - 7.9 5.1 – 5.8

367-301-50000 △
0

14 W136-0251E
L-7. L-7.
Accelerator Sensor

L-7 Accelerator Sensor

[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.Sensor 7.Lever 13.Pin 21.Bolt

2.Machine screw 8.Support 14.Spring 22.Nut
3.Spring washer 9.Plain washer 17.Bolt
4.Switch assy 10.Spring 18.Spring washer
5.Link 11.Pin 19.Bolt
6.Lever 12.Split pin 20.Nut

2. Adjustment
Refer to “Adjustment and checks” in chapter Y.

347-112-62000 △
2

15 W322-0130E
L-8 L-8
Solenoid Valve (Air)

L-8 Solenoid Valve (Air)

[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

OUT

＋
ー
Diode
GP 15M IN
EXH
IW210-0022E01

4 3 2 1 18,19
5

6
8
9
10

11
12 20
IN
11
13 T1
14 15 16 17

IN
EXH

OUT

IW210-0022E02

16 W210-0022E
L-8. L-8.
Solenoid Valve (Air)

1.Core 6.Coil assy (DC24V) 11.O-ring 16.Cover

2.O-ring 7.----------- 12.Valve seat 17.Filter
3.Case 8.Rod 13.Valve 18.Packing
4.Spring 9.Coil cover 14.Bady 19.Packing holder
5.Plunger 10.O-ring 15.Spring 20.Plug

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22

T1 M8x1.25 8 - 12 6-9

366-459-70000 △
4

17 W210-0022E
 S
Steering System

Contents

S-1 Steering System............................... 1 S-6 Pilot Check Valve

(Steering Mode)........................10
1. General..................................................... 1
1. Structure ................................................. 10

S-2 Priority Valve .................................... 2

S-7 Solenoid Valve
1. Structure ................................................... 2 (Reverse Steering, Option)......11

2. Function.................................................... 2 1. Structure ................................................. 11

3. Principle of operation ................................ 3

3.1 Neutral state ............................................... 3
3.2 Right steering ............................................. 3
3.3 Right steering to the end ............................ 3

S-3 Orbitrol.............................................. 4

1. Structure ................................................... 4

2. Function.................................................... 7 S

S-4 Steering Cylinder ............................. 8

1. Structure ................................................... 8

S-5 Solenoid Valve (Steering Mode) ..... 9

1. Structure ................................................... 9

366-418-40000 △
1

i
S -1 . S -1 .
Steering System

S-1 Steering System

1. General
Hydraulic Circuit for Steering

Layout of Steering Cylinders 1. The steering wheel is coupled with the orbitrol.
(Right steering)
2. The orbitrol, together with the priority valve,
supplies the steering cylinders with oil at the rate
corresponding to the rotational speed of the
steering wheel. Surplus oil is supplied to the
swing circuit.

3. The solenoid valve (steering mode) is switched

according to the outputs from the multiplex data
transmitter (lower).

4. The maximum pressure in the steering hydraulic

circuit is regulated by the relief valve in the priority
valve. The emergency steering can be provided to
the steering system as an option. (Refer to the
"Hydraulic Circuit for Carrier" in the "Hydraulic
[NOTICE] Power Generating System" for detailed
Two "*R"s and two "*L"s of the two front steering information.)
cylinders represent the right steering port and the
left steering port respectively.

1 WS02-0100E
S -2 S -2
Priority Valve

S-2 Priority Valve

[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
LS CF EF

P IW126-003001

6 9 12 13 10 14 11 7 8 3 2 1
P

LS

16 15
17 16 EF CF IW126-0060E01

1.Housing 7.Ring 11.Valve seat 15.Plug

2.Spool 8.Screen 12.O-ring 16.O-ring
3.Spring 9.Screw 13.Guide 17.Plug
6.Body 10.Spring 14.Popet

Thread size and tightening torque 2. Function

Sign / Tightening torque This valve allows the hydraulic oil to flow to the
Thread size Orbitrol only in the flow rate required by the
Port N-m ft-lbf
T, LS 7/16 - 20UNF - 2B 20 - 24 15 - 18 steering operation, and all the excess oil to flow to
P, EF 1•1/16 -12UN - 2B 78 - 88 58 - 65 other actuators.
CF 3/4 - 16UNF - 2B 54 - 66 40 - 48

2 W126-0060E
S -2 . S -2 .
Priority Valve

3. Principle of operation

NEUTRAL RIGHT STEERING

The above figure is for illustrating the principle. The construction of the actual machine may differ from the figure.

3.1 Neutral state 3.2 Right steering

While the engine is standing still, spool 2 in the When the steering wheel is turned clockwise, the
priority valve is pushed to the left end by spring 3, hydraulic oil routes inside the Orbitrol are
fully opening port CF and fully closing port EF. switched over, causing the oil entering through
When the engine is started, the hydraulic oil port P of the Orbitrol to flow through orifice C1.
delivered from the hydraulic pump flows through Then, the pressures across orifice C1 are
port P and port CF of the priority valve to port P of transferred to pressure chambers A and B. The
the Orbitrol. As the hydraulic pressure in circuit CF spool is moved until the pressure difference (P5 –
rises in this way, pressure P5 in pressure P6) becomes balanced by spring 3.
chamber A of the priority valve also rises. At this
time, pressure chamber B is connected to the tank 3.3 Right steering to the end
line via port LS and port T of the Orbitrol, and When the steering cylinder piston is moved to the
when the pressure difference (P5 – P6) between stroke end, the relief valve in the priority valve
chamber A and chamber B rises to overcome the actuates, producing oil flow through orifice C2 in
force of spring 3, the spool moves towards right line LS of the priority valve. The pressure
until port EF becomes almost fully opened, and difference across C2 is transferred to pressure
port CF becomes slightly open. The spool remains chambers A and B and the spool is further moved
stable in this position, and the pump delivery oil towards right until it becomes stable with port CF
mostly flows through port EF. slightly open, and route EF almost fully open.

366-114-20000 △
0

3 W126-0060E
S -3 S -3
Orbitrol

S-3 Orbitrol
[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

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T, L, R 3/4-16UNF-2B 54 - 66 40 - 48
LS 7/16-20UNF 20 - 24 15 - 18
T1 3/8-16UNC 43 - 49 32 - 36

4 W184-0012E
S -3 S -3
Orbitrol

Cross section

Star

13

A NG OK
IW184-001003 IW184-001006 IW184-0010E05

26 25 4 2
T P
18

21

22

14 5

20

19

16 17 13 10 11 12 8 24 7 23 3 1

A- A
IW184-001004

5 W184-0012E
S -3 S -3
Orbitrol

[NOTICE]
Orient the star of the rotor set (4), drive (8) and pin (13) as shown in the "OK" figure.

1.Screw 8.Drive 16.Race bearing 22.Seal gland bushing

2.Retainer screw assy 10.Housing 17.Thrust needle 23.O-ring
3.End cap 11.Sleeve 18.O-ring 24.O-ring
4.Rotor set 12.Spool 19.Oil seal 25.Adapter screw
5.Spacer 13.Pin 20.Dust seal 26.Ball
7.Spacer plate 14.Centering spring 21.Retaining ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
1, 2 - 22.6 17

6 W184-0012E
S -3 . S -3 .
Orbitrol

2. Function
Spool
The machine is equipped with a load-sensing type Housing B Sleeve Drive
orbitrol consisting of the following main C
D
components:

1. Housing
The housing has five piping ports: P, T, R, L and
LS.

2. Spool and sleeve

Spool is splined to the steering wheel, and serves
to switch over hydraulic circuits by its relative
position to sleeve.
Spool and sleeve are mechanically connected at
two positions, as shown in section B-B and C Rotor set D
Spring
section C-C. B
Pin
In section B-B, spring is installed in the recess
grooves in spool and sleeve, so that while the IW184-001007

steering wheel is stationary, spool and sleeve are

kept in the neutral position relative to each other
as shown in section B-B by the force of spring. In
the area around section C-C, spool, sleeve and
drive are connected by pin. Here, sleeve and drive
are connected by pin without clearance, but spool
has oval holes in which pin can move through
small angles.

3. Drive
The drive serves to transmit the motion of the star
of rotor set to sleeve through pin.

4. Rotor set
This consists of a ring possessing seven internal
teeth and a star internally in mesh with the ring,
possessing six teeth.

366-316-40000 △
1

366-352-70001 △
1

7 W184-0012E
S -4 . S -4 .
Steering Cylinder

S-4 Steering Cylinder

[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.Cylinder 6.O-ring 11.Packing 16.Boot

2.Split pin 7.Rod 12.Backup ring 17.Clip
3.Nut 8.Rod cover 13.Dust seal
4.Piston 9.O-ring 14.Plain bearing
5.Plain bearing 10.Damper ring 15.Clip

*1: Face the notch or the lip toward the pressurized side.

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A G1/2 98 72
B G3/8 49 36
C, D Rc1/8 9 -12 6.5 - 9 360-619-20000 △
3
360-619-30000 △
3

8 W160-0030E
S -5 . S -5 .
Solenoid Valve (Steering Mode)

S-5 Solenoid Valve (Steering Mode)

[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

AB Connector
(+):White

PT
+- (-):Black

IW121-030001 IW121-0542E01

10 16

T T

A B

7 14 8 9 6 15 4 3 13 2 1
IW121-030002

1.Body 6.Spring 10.Solenoid coil (DC24V) 16.O-ring

2.Spool 7.Nut 13.O-ring
3.Retainer 8.Rod 14.O-ring
4.Retainer 9.Solenoid guide (DC24V) 15.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
7 - 5-7 3.5 - 5
Mounting bolt M5 6-8 4.5 - 6

366-468-21000 △
0

9 W121-0302E
S -6 . S -6 .
Pilot Check Valve (Steering Mode)

S-6 Pilot Check Valve (Steering Mode)

[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

P T B A
IW115-025001

A B

7 11 2 1 6 10 4 5 8 3
IW115-025002

1.Valve body 4.Piston 7.Spring seat 11.O-ring

2.Needle valve 5.Valve seat 8.Spring
3.Check valve 6.Rod 10.O-ring

366-245-50000 △
1

10 W115-0251E
S -7 . S -7 .
Solenoid Valve (Reverse Steering, Option)

S-7 Solenoid Valve (Reverse Steering, Option)

[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
Connector

+-
(+): White
AB (-): Black

PT
IW121-0890E02 IW121-0542E01

1.Body 7.Spring 13.Coil case 19.O-ring

2.Plug 8.Nut 14.Coil yoke 20.O-ring
3.Spool 9. -------------- 15.Connector packing 21.Connector
4.Retainer 10.Rod 16.Screw 22.Bolt
5.Retainer 11.Solenoid guide 17.O-ring
6.Spacer 12.Solenoid coil 18.O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
8 - 7 - 10 5.1 - 7.4
11 - 55 - 65 40.6 - 47.9
Mounting bolt M6 10 - 13 7.4 - 9.6
366-418-40000 △
1

11 W121-0890E
 T
Brake System

Contents

T-1 Brake System ................................... 1 2.4 Operation under piping rupture ................. 11

1. General..................................................... 1 3. Dismouting and remounting .................... 11

4. Disassembly............................................ 11
T-2 Brake (Service Brake)...................... 2 4.1 Disassembly of the mount plate................12
4.2 Disassembly of the body...........................12
1. Structure and function ............................... 2
1.1 Principle of operation.................................. 3 5. Cleaning and checking ............................ 13
5.1 Cleaning ....................................................13
2. Checking the pad assy.............................. 3 5.2 Checking ...................................................14

3. Checking the disc plate............................. 3 6. Reassembly ............................................ 14

6.1 Reassembly of the secondary side...........14
4. Replacing the pad assy............................. 4 6.2 Reassembly of the primary side ...............14
6.3 Reassembly of the mount plate ................16
5. Disassembly ............................................. 5
7. Test .................................................... 16
6. Washing and checking .............................. 5 7.1 Air leakage through supply valve and
6.1 Washing...................................................... 5 exhaust valve ......................................16
6.2 Checking..................................................... 5 7.2 Air leakage in other parts ..........................16
7.3 Operation test ...........................................16
7. Reassembly.............................................. 6 7.4 Performance test.......................................16
T
8. Maintenance standards............................. 6 8. Maintenance standards ........................... 17
8.1 600-hour check .........................................17
8.2 2000-hour or 1-year check........................17
T-3 Brake Valve ...................................... 7

1. Structure and function ............................... 7 T-4 Booster (Brake) ..............................18

2. Description of operation ............................ 9 1. Structure ................................................. 18

2.1 Generation of air pressure.......................... 9
2.2 Stabilization of air pressure ........................ 9 2. Function .................................................. 19
2.3 Release of air pressure ............................ 10 2.1 Air cylinder ................................................19

i
 2.2 Oil cylinder................................................ 19 5.2 Disassembly of cartridge...........................34

3. Operation of cylinder............................... 20 6. Reassembly ............................................ 36

3.1 Booster not in operation ........................... 20 6.1 Cartridge (lower) .......................................36
3.2 Booster in operation ................................. 20 6.2 Tapping......................................................37
3.3 Brakes are released ................................. 20 6.3 Cartridge (upper).......................................37

4. Removing of booster............................... 20 7. Troubleshooting ...................................... 38

5. Disassembly ........................................... 21
5.1 Disassembly of cylinder............................ 21 T-6 Brake (Parking Brake)....................41

6. Check .................................................... 22 1. Structure and function ............................. 41

6.1 Rubber parts............................................. 22
6.2 Air cylinder................................................ 22 2. Replacing pad ......................................... 42
6.3 Oil cylinder................................................ 22
3. Remounting............................................. 43
7. Reassembly............................................ 23 3.1 Connecting parking brake to
spring chamber ...................................43
8. Test .................................................... 24 3.2 Adjusting parking brake clearance............43
8.1 Testing equipment .................................... 24
8.2 Performance diagram............................... 24 4. Check .................................................... 44
8.3 Test method .............................................. 24

9. Maintenance standards........................... 25 T-7 Brake Chamber...............................45

9.1 Daily check ............................................... 25
9.2 2000-hours or one year check.................. 25 1. Structure ................................................. 45
9.3 Maintenance standards ............................ 25
2. Function .................................................. 46

T-5 Air Dryer ......................................... 26 3. Disassembly............................................ 46

1. Structure ................................................. 26 4. Cleaning and checking ............................ 47

4.1 Cleaning ....................................................47
2. Function.................................................. 30 4.2 Checking ...................................................47
2.1 Dehumidification ....................................... 30
2.2 Regeneration ............................................ 31 5. Reassembly ............................................ 48
2.3 Intake position .......................................... 32
2.4 Release position ....................................... 32 6. Test .................................................... 48
6.1 Air leak test ...............................................48
3. Precautions for handling ......................... 33
7. Maintenance standards ........................... 48
4. Maintenance and inspections.................. 33 7.1 2000-hour or 1-year check........................48
4.1 Daily inspection ........................................ 33
4.2 Inspection and part replacement every 1
year or 100,000 km (62140mi) of driving . 34 T-8 Solenoid Valve (Air) .......................49

5. Disassembly ........................................... 34 1. Structure ................................................. 49

5.1 Removing DU-3 ........................................ 34

ii
T-1. T-1.
Brake System

T-1 Brake System

1. General

Brake Circuit (air over hydraulic brake)

1 WT02-0100E
T-2 T-2
Brake (Service Brake)

T-2 Brake (Service Brake)

[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 and function

The clearance between the pad assy and the disc
The brake system employs an opposed piston plate are maintained constant by means of the
type disc brake, using one each pad assy on both piston seals.
sides of each disc plate to pinch it between them,
Although 4-piston type and 6-piston type brakes
as shown here.
are used in the crane, the service procedures and
The disc plate turns together with the wheel, and
the maintenance standards for the two types are
pads are incorporated in a torque plate which is
identical. In the following explanation, the 4-piston
fixed to the knuckle.
type is mainly explained.
The torque plate incorporates pistons to force the
pad assy onto the disc plate to brake its motion.

1. Torque plate 6. Torque pin (smaller) 11. Piston plug 16. Backup ring
2. Bleeder valve 7. Pad assy 12. Cap seal 17. Bolt
3. Bolt 8. Pad assy 13. Piston 18. Cap bolt
4. Torque pin (larger) 9. Cap bolt 14. Scraper ring 19. Cap
5. O-ring 10. Cover plate 15. Piston seal 21. Backup ring

2 W577-0021E
T-2 T-2
Brake (Service Brake)

1.1 Principle of operation The simple check method of pad assy is shown as
follows:
1. When hydraulic pressure is applied Check the pad thickness by inserting a check gauge
as shown below in the check holes in the torque
The pistons exert force to the pad assy by plate.

0
6 -0.5
deforming the piston seals. (Fig. 2)
5
0.
R

C
0.
61.5±0.2

5
80 IW577-0021E01
(Unit: mm) (1mm=0.039inch)

[NOTICE]
When one of the pad assy is found to have worn to
the use limit, all the other ones are also worn to the
same limit in most cases.
Replace the pad assy for the right and the left
2. When hydraulic pressure is removed wheels or even for all the four wheels
simultaneously.
The seals recover the original shape to push the Thickness of the brake lining of the Pad assy
pistons back, creating clearance between the disc Thickness of the brake lining
plate and the pad assy. (Fig. 3 ) New parts 14 mm (0.56in)
Use limit 4 mm (0.16in)

The regular check is necessary to prevent from

deteriorating brake function and from the brake
damage since the thickness of the brake lining
exceeding the limit results in serious damage.

Check gauge

3. When pad assy wears

The piston displacement distance increases

beyond the seal deformation limit, and the pistons Replace the pad assy when this
slip relative to the seals, but when the hydraulic distance becomes zero.
Piston
pressure is removed, the pistons are pulled back Back plate Pad assy
Brake lining
by the seals through the same distance as before Disc plate IW577-0190E02

the occurance of wear, giving the same

clearances.

3. Checking the disc plate

2. Checking the pad assy
Check the disc plate for the thickness and
[NOTICE] damage. If it is excessively damaged or the
The brake caliper must be disassembled to check thickness is below 17.5 mm (0.689 in), replace the
the remained pad thickness. However, the check
disc plate. (Thickness of new disc plate: 20 mm
gauge may use to check.
(0.787 in))

3 W577-0021E
T-2 T-2
Brake (Service Brake)

4. Replacing the pad assy

7. Push in torque pin 4 in its hole after applying
When the thickness of the brake lining has grease to both. At this time, adjust the clearance
reduced to 4 mm (0.16 in) , replace the pad assy. between the disc plate and torque pin 4 to 1.5 - 3
mm (0.06 - 0.12 in).
1. Set the outriggers, and remove the tire. (To Check that the torque pin on the brake mounting
remove the brake assy as a unit, unscrew the 4 side is not protruding adove the mounting surface.
mounting bolts. When remounting it, tighten the
mounting bolts to 480 - 578N-m (355 - 427ft - lbf)).

2. Apply an 11mm box wrench on bleeder valve 2,

connect a transparent vinyl tube (Inside diameter :
7 - 7.5 mm (0.276 - 0.295 in)) to the bleeder valve,
and open the bleeder valve by turning the wrench.

3. Insert a piston return lever as shown below

between pad assy 7, 8 and the disc plate, and
push all pistons 13 fully home. Then, close
bleeder valve 2.
[NOTICE]
When tightening bolts 3 and 17, make sure the bolt
end is fully in the groove in torque pin.

8. Clamp torque pin 4 with bolt 3 (or 17).

Tightening torque of bolts 3 and 17: 49 - 54 N-m

(36.2 - 39.8 ft-lbf)

(Unit : mm) (1mm = 0.039inch)

4. Unscrew bolts 3 and 17 on the side of larger

torque pin 4 approx. 4 turns, and extract torque
pin 4 .

5. Remove pad assy 7, 8, and install new pad assy

in their places.
9. Bleed the brake circuits as explained in “Air
6. Check O-ring 5 of torque pin 4, and replace it if Bleeding Procedure” in Chapter Y.
damaged or defective otherwise.
10.Mount the tires.

Hub nut torque:

490 - 588 N-m (362 - 434 ft-lbf)

4 W577-0021E
T-2 T-2
Brake (Service Brake)

5. Disassembly 6. Washing and checking

6.1 Washing

CAUTION
Never use mineral oil.

Wash the metal parts in trichloroethylene or brake

fluid. After washing, blow air into the holes and
grooves in the torque plate and wipe off all
residual liquid with clean cloth.

6.2 Checking

1. Torque plate
Check the torque plate, and if it is damaged in the
areas indicated below, correct the surface with No.
180 sandpaper.
If the damage is beyond repair, replace the torque
plate.

1. Loosen bolts 3 and 17, extract torque pins 4 and

6, and remove pad assy 7 and 8.

2. Remove cover plate 10, push out piston plugs 11

and pistons 13 on the cover plate side. Pull out
pistons 13 on the opposite side.

3. Remove scraper rings 14. Remove piston seals 2. Pad assy

15 and backup rings 16 with a hooked wire. Replace the pad assy when its wear lining has
been worn to 4 mm (0.16 in) or less.

3. Piston
When the sliding surface is damaged, dented or
the plated layer has been worn, replace the
piston.

4. Torque pin
Replace the pin if the portion in contact with the
back plate of the pad assy is excessively worn.

5. Seal kit (Sealing parts)

Replace the seal kit (cap seal, scraper ring, piston
seal, and backup ring) once a year or once in
1000 hours.
In addition, be sure to replace them whenever
they are disassembled.

5 W577-0021E
T-2. T-2.
Brake (Service Brake)

7. Reassembly
[NOTICE]
1. Apply the rust preventive lubricant found in the For the installing procedure, see
“ Replacing the pad assy ” .
seal kit to piston seal 15, backup rings 16, pistons
13 and to the cylinder bores.
5. Install torque pins 4, 6, pad assy 7, 8, and bolts 3,
17.

[NOTICE] 6. After mounting the brake assy on the axle,

Take care to install the piston seal in the correct readjust the clearance between the torque pins
orientation. (See Fig.1) and the disc plate to 1.5 - 3.0 mm (0.06 - 0.12 in).
Be sure to install the pistons from the inner side of
the torque plate.
8. Maintenance standards
2. Install backup ring 16, piston seal 15 and scraper
ring 14 in this order in the grooves in the bore of
Item Maintenance standards
torque plate 1. Then push in piston 13.
6 month Check the worn thickness of the pads,
check and replace them if worn beyond the
use limit (thickness of wear material:
4 mm (0.16 in)).
When the liquid level in the reservoir
sinks to a warning level, through
leakage, pad wear, etc., the brake lamp
lights during traveling. Check for
leakage and pad wear immediately.
1000 hour Disassemble and check all the parts.
or Replace the sealing parts with a seal kit.
1 year
check

3. Apply the rust preventive lubricant to backup ring

21 and cap seal 12, and install them in the
grooves in piston plug 11. Then install piston plug
11 in torque plate 1 with the cap seal on the piston
side.

4. Thoroughly clean the mating surfaces of torque

plate 1 and cover plate 10, and install the cover
plate on the torque plate with bolts 9 (18) with the
stamped part number of the cover plate out.

Torque for bolts 9:

197 - 217 N-m (146 - 160 ft-lbf)
Torque for bolts 18:
291 - 320 N-m (215.2 - 236.8 ft-lbf)

6 W577-0021E
T-3 T-3
Brake Valve

T-3 Brake Valve

[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 and function It delivers air at pressures determined by the

position of the brake pedal to two systems, Even
This brake valve is a dual circuit rubber spring
when one of the systems fails, the other system
type brake valve for air brake systems.
remains operational to brake the vehicle.

46 45 16 26 T1
25
24
43 T2

42
23 19 T3
27 21
Primary side
22 20

3 15
Supply port Delivery port

18
17
1 4
9 5
10 40 14
Supply port 11 Secondary side

7
6
13
Delivery port
8
2
28,41 T4
12
Exhaust pot
36 34 37,38 T5 39 29 35 33 32 31 30
IW202-0010E01

7 W202-0013E
T-3 T-3
Brake Valve

1. Upper body 13.O-ring 25.Spring washer 37.Exhaust cover

2. Upper valve 14.O-ring 26.Nut 38.Screw and washer
3. Valve retainer 15.Return spring 27.O-ring 39.Exhaust check
4. Valve spring 16.Stem 28.Lower body 40.O-ring
5. Retainer 17.Inner spring 29.Lower valve 41.Bolt and washer
6. O-ring 18.Outer spring 30.Valve retainer 42.Mount plate
7. Special washer 19.Sleeve 31.Valve spring 43.Bolt and washer
8. Retaining ring 20.Stem washer 32.Retainer 44.－
9. O-ring 21.Piston 33.O-ring 45.Plunger boot
10. Retaining ring 22.Rubber spring 34.Special washer 46.Plunger
11. Spring 23.Spring seat 35.Retaining ring
12. Relay piston 24.Special washer 36.O-ring

Thread size and tightening torque

tightening torque
Sign / Port Thread size
N-m ft-lbf
T1 ― 3.9 - 6.9 2.9 - 5.1

T2 ― 8.8 - 13.7 6.5 - 10.1

T3 ― 3.9 - 6.9 2.9 - 5.1

T4 ― 3.9 - 6.9 2.9 - 5.1

T5 ― 1.3 - 2.5 1 - 1.8

Pipe port Rc 3/8 29.4 - 39.2 21.7 - 28.9

8 W202-0013E
T-3 T-3
Brake Valve

2. Description of operation 7. The lower valve moves further down, opening the
air inlet valve seat on the lower body. This allows
2.1 Generation of air pressure pressurized air from the secondary supply port to
flow through the delivery port into the brake
1. When the pedal is depressed, the depressing
chamber of the secondary system.
force is transmitted through the plunger, spring
seat, and rubber spring to the piston. The piston
moves down, compressing the return spring.

2. The discharge valve seat at the bottom of the

piston makes contact with the upper valve, closing
the discharge passage at the center.
Upper body
3. As the piston further compresses the return spring, Inlet valve sheet
it moves the upper valve, opening the air inlet
valve seat on the upper body. Relay piston

4. The pressurized air supplied from the primary

supply port flows through the delivery port to the
Discharge valve sheet
brake in the primary system.
Discharge air passage
Lower valve
Return spring Plunger IW202-0010E03

Spring sheet

Rubber spring 2.2 Stabilization of air pressure

Piston
1. When the pedal is depressed to a certain extent,
and kept stationary at that position, the air
pressure is stabilized at a level corresponding to
Inlet valve sheet
that pedal position as follows:

2. As the pedal is depressed, the discharge valve

closes and the inlet valve opens to deliver air to
Discharge valve sheet
the system.
Upper body
3. This air also exerts upward pressure on the
Upper valve
underside of piston.

4. With the pedal maintained at a certain depressed

IW202-0010E02 position, the air under piston pushes up piston by
compressing rubber spring above the piston.
5. On the other hand, as the primary system
becomes operational, part of its pressurized air 5. Piston , while keeping contact with upper valve,
flows through the passage in the upper body into rises until upper valve comes into contact with the
the space above the relay piston in the secondary inlet valve seat to stop the delivery of air.
system. This pushes the relay piston down.
6. Then, with the discharge valve seat in contact with
6. The discharge valve seat at the bottom of the upper valve, the air pressure remains stable.
relay piston comes into contact with the lower
valve, closing the discharge passage at the
center.

9 W202-0013E
T-3 T-3
Brake Valve

Rubber spring

Piston

Discharge valve sheet

Relay piston

Inlet valve sheet

Upper body

Upper valve Discharge valve sheet

Inlet valve sheet

Lower body Lower valve
IW202-0010E05
IW202-0010E04

7. In the secondary air system, relay piston lowers in 2.3 Release of air pressure
proportion to the air pressure in the primary
1. As the pedal is released, the plunger and piston
system to generate air pressure in the secondary
are pushed up by the return spring and by the
system. The generated pressure is also applied to
primary air pressure.
the underside of relay piston.
2. The discharge air seat at the bottom of the piston
8. As this pressure on the underside of relay piston
disengages from the upper valve, opening the
becomes balanced with the primary system
discharge passage at the center. This allows the
pressure applied on the top of the relay piston, it
primary system air pressure to be discharged from
is no more pushed down, but moves up while
the discharge port.
keeping contact with lower valve.
3. On the other hand, as the pressure in the primary
9. As lower valve comes into contact with the inlet
system drops, relay piston is pushed up by the
valve seat of lower body, the air supply through
secondary system air pressure and springs, and
the supply port is stopped.
the discharge valve seat at the bottom of relay
10. In this state, since the discharge valve seat is in piston disengages from lower valve to open the
contact with lower valve, the air pressure central discharge passage.
stabilizes.
4. Thus the secondary system pressure discharges
11. Thus, the pressure in the secondary system is into the discharge port.
kept stable at a level equal to that of the primary
system. Spring serves to minimize the pressure
difference between the two systems.

10 W202-0013E
T-3 T-3
Brake Valve

Return spring Plunger

Spring seat 2. Operation with only secondary system
Rubber spring When the primary brake system is damaged, no
Piston
air pressure is generated in the primary system,
so that no primary air pressure is available to work
on the relay piston for actuation of the secondary
Discharge valve seat system. However, in this case, depressing the
pedal further down brings the lower end of piston
Upper body
in contact with the top of relay piston, causing the
discharge valve seat of relay piston to directly
Spring
push lower valve to cause the secondary system
Relay piston
to operate in the same way as the primary system
Upper valve
in the normal state, generating air pressure,
stabilizing, and releasing it.
Discharge valve seat

Lower valve
IW202-0010E06

2.4 Operation under piping rupture

1. Operation with only primary system

Piston
When the secondary brake system is broken, the
primary system remains operational, because
relay piston separates it from the secondary
system. Relay piston

Lower valve
IW202-0010E08

3. Dismouting and remounting

1. Dismount the valve after immobilizing the vehicle
and discharging the compressed air from the
reservoir by opening the drain cock.
Relay piston
2. Tighten the pipe fitting: 29 - 39 N-m (21.4 - 28.8 ft-lbf)

4. Disassembly
[NOTICE]
IW202-0010E07 When disassembling, remove mud, dust, water etc.
from the outside surface to avoid their entry into the
interior.
Prior to disassembly, mark the joints to facilitate
correct reassembly.

11 W202-0013E
T-3 T-3
Brake Valve

Place the disassembled parts in neat order to Upper body Stem

facilitate reassembly.

4.1 Disassembly of the mount plate

1. Remove three bolts and washers, and remove

mount plate, plunger, and plunger boot.

Plunger Plunger boot

Bolt and washer

Mount plate Relay piston

IW202-0010E11

3. Unscrew nut at the top of piston, and remove

piston, return spring, relay piston, spring, and
stem.
IW202-0010E09

[NOTICE]
At this time, hold the piston to prevent it from being
4.2 Disassembly of the body popped out by the return spring.

1. Clamp the body in a vise, with lower body up; Nut

unscrew four bolts, and remove the lower body
Piston
assembly from upper body.

Lower body
Return spring
Bolt

Upper body
IW202-0010E10

2. Clamp a screwdriver in a vise, pass it through the

discharge passage of relay piston and place the
blade in the alit in the stem.

Relay piston

Stem

IW202-0010E12

12 W202-0013E
T-3 T-3
Brake Valve

4. Remove the O-ring from between the upper body

Retaining ring
and lower body. Clamp the lower body in a vise,
with the exhaust check facing up. Special washer

5. Unscrew the 4 screws, and remove the exhaust O-ring

cover and lower valve assy.
Retainer
Screw
Exhaust check
Valve spring
Exhaust cover
Valve retainer

Lower valve assy Upper valve

Lower body
Upper valve assy

IW202-0010E15

Retaining ring

O-ring Special washer

IW202-0010E13

O-ring

6. Remove retaining ring from the groove inside

Retainer
upper body, and take out the upper valve assy.
Valve spring
Upper body Retaining ring
Valve retainer

Lower valve
Upper valve assy
Lower valve assy
IW202-0010E16

Sleeve Stem washer

Spring Stem

IW202-0010E14
Stem assy
IW202-0010E17

7. Disassemble the upper valve assy lower valve 5. Cleaning and checking
assy and the stem assy.
5.1 Cleaning

1. Cleaning the rubber parts by wiping with a cloth

dampened with alcohol.

2. Wash all metal parts, except the mount plate, with

trichloroethylene or other suitable cleaning

13 W202-0013E
T-3 T-3
Brake Valve

agents. 2. Build the lower valve assy into lower body.

3. The mount plate incorporates an oilless alloy bush. 3. Install exhaust cover, and secure with screw and
Wash it with kerosene and dry it with compressed washers. Pack grease in the groove in the surface
air. of lower body which mates with upper body; install
O-ring coated with grease.
5.2 Checking
Screw
1. Check the parts for cracks, deformation, etc., and
check the sliding surfaces for dents; replace any Exhaust cover
faulty parts.

2. Examine the springs for corrosion, and replace if Lower valve assy
faulty. Lower body

6. Reassembly
[NOTICE]
Apply lithium base grease (Idemitsu Daphne
Coronex Grease EP2, or equivalent) to the valve O-ring
sliding surface, body sliding surface, and the relay IW202-0010E18

piston sliding surface.

When inserting O-rings, be sure to apply lithium
base grease to them, (Idemitsu Daphne Coronex 6.2 Reassembly of the primary side
Grease EP2) and fill the O-ring groove with grease
in advance. 1. Place the upper valve on the work bench with the
Apply lithium base grease containing MoS2 (bearing valve seat side down.
grease No.3 by Nippon Molybdenum, or equivalent)
to the sliding surfaces of the plunger, and to the 2. Install the valve retainer, valve spring, retainer
roller and fulcrums. with 2 O-rings, and special washer in sequence.
Secure these parts with the retaining ring.
6.1 Reassembly of the secondary side
[NOTICE]
1. Place lower valve on the work bench with the Apply grease to the O-ring.
valve seal side down; install valve retainer, valve
spring, retainer with O-rings, and special washer,
Retaining ring
and secure with retaining ring.
Retaining ring Special washer

Special washer O-ring

O-ring Retainer

Retainer Valve spring

Valve spring Valve retainer

Valve retainer Upper valve

Lower valve
Upper valve assy

Lower valve assy IW202-0010E15

IW202-0010E16

14 W202-0013E
T-3 T-3
Brake Valve

3. Insert the upper valve assy in upper body, and

secure with retaining ring.
Stem assy

Upper body Retaining ring

Relay piston

Upper valve assy

O-ring

Spring

IW202-0010E19

IW202-0010E20
4. Put the springs, stem washer, and sleeve onto the
stem, and tighten the sleeve.
6. Holding relay piston by hand to prevent it from
[NOTICE] being pushed loose by spring, apply the
Apply grease to the springs. screwdriver slit of stem to the blade of a
screwdriver clamped in a vise.
Sleeve Stem washer
Spring Stem Stem
Upper body

Stem assy
IW202-0010E17

5. Install O-rings and on relay piston; insert spring,

relay piston and the stem assy in this sequence
into upper valve previously placed in upper body.
Spring Relay piston
[NOTICE]
Be sure to apply grease amply to the O-ring and to
their sliding surfaces. IW202-0010E21

7. Install return spring, piston, rubber spring, spring

seat, special washer, and spring washer in this
sequence, and clamp them with nut.

15 W202-0013E
T-3 T-3
Brake Valve

Nut 7.1 Air leakage through supply valve and

Spring washer
exhaust valve

Special washer In the fully released state, the air leakage to the
Spring seat delivery port and the exhaust port combined
3 3
Spring seat should be less than 100 cm /min {6.1in /min}.
In the fully depressed state, the leakage to the
Piston exhaust port should also be less than 100
3 3
cm /min {6.1in /min}.
Return spring

7.2 Air leakage in other parts

Stem In the fully depressed state, there should be no
IW202-0010E22 leakage from the body, valve cap, and their joints.

7.3 Operation test

8. Clamp the upper body assy in a vise, put the
lower body assy on it, and clamp them with bolts Thrust the plunger speedily into the fully
and washers. depressed position, and then release speedily; the
delivery pressure should rise and fall smoothly.
Lower body
7.4 Performance test
Bolt
Depress the pedal slowly from the free state to the
fully depressed position, checking that the delivery
pressure changes smoothly, roughly tracing the
performance curve shown below.

Also check that when the upper delivery port

Upper body pressure is at 98.1 kPa {14.2psi}, the lower
IW202-0010E23
delivery port pressure is over 78.5 kPa {11.4psi}. If
these criteria are not met, the cause may be lack
of grease on sliding parts or weakened springs.
6.3 Reassembly of the mount plate
Performance curve
1. With the plunger boot on, install plunger in mount (Psi) (kPa) Max. travel 11.8mm (0.46in)
1015 690
plate, and clamp them to upper body with three
Delivery pressure

590
bolts and washers.
725 490
390
435 290
7. Test 200
145 98
[NOTICE] 0 0
1 2 3 4 5 6 7 8 9 10 11 12 (mm)
Test the brake valve for leaks and performance,
0 0.1 0.2 0.3 0.4 0.48 (in)
with a pressure gauge measuring up to 981 kPa
{142psi} or so connected to the delivery side, and Plunger travel
with the supply pressure adjust to 684 kPa {100psi}. IW202-0012E01

First, in the fully released state, make sure that the

delivery pressure is zero for both upper lower sides.
Then, check the following items for both upper and
lower sides.

16 W202-0013E
T-3. T-3.
Brake Valve

8. Maintenance standards

8.1 600-hour check

Disassemble the parts above the mount plate,

wash and check them. Replace defective parts,
and apply grease to the sliding surfaces.

8.2 2000-hour or 1-year check

Disassemble the valve, and clean all the parts.

Replace all rubber parts. Replace metal parts that
are scratched, worn, or otherwise damaged.
Execute all the tests specified.

366-010-00001 △
1
366-045-10000 △
0

17 W202-0013E
T-4 T-4
Booster (Brake)

T-4 Booster (Brake)

[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
33 34 11 10 9 8 7 6 13 12 32

Air
pressure 19 18 20 25-31 24 27 26

From oil reservoir

17
16 15

Output
fluid
Clearance stroke 1.6±0.5mm pressure

30 35 29 28

14

3 1 2 4 5 21 22 23 IW404-0030E01

Enlarged view of oil cylinder

11 10 9 8 7 6 13 12 32

19 18 20 25-31 24 27 26

From oil reservoir

17
16 15

Output
fluid
pressure
Clearance stroke 1.6±0.5 mm
(0.063±0.02 in)
30 35 29 28

14

5 21 22 23 IW404-0030E02

18 W404-0030E
T-4 T-4
Booster (Brake)

1.Air cylinder assy 10.Cup supporter B 19.Ring 28.Cap

2.Air piston assy 11.Stop ring 20.Piston push guide 29.O-ring
3.Piston cup 12.O-ring 21.Bolt 30.Bolt and washer
4.Return spring 13.O-ring 22.Spring washer 31.Gasket
5.Cover 14.Plug 23.Nut 32.Air breather
6.Bushing 15.Piston assy 24.Cylinder 33.Conector
7.Cup supporter A 16.Puressure cup 25.Nipple 34.O-ring
8.Secondary cup 17.Backup ring 26.Bleeder screw 35.Retern spring
9.Spacer 18.Piston pin 27.Bleeder screw cap

2. Function 2.2 Oil cylinder

1. Piston in oil cylinder is connected with air piston

1. The booster transmits fluid pressure, proportional
assy through piston push guide and piston pin.
to the air pressure (signal pressure) from the
brake valve, to the wheel cylinders, and as a 2. The ring prevents the piston pin from coming off.
result operates the disc brakes.
3. The brake fluid from the oil reservoir is fed
2. Main parts of the booster consist of the air and oil forcefully to the wheel cylindesr with the piston
cylinders. pushed out by air piston assy.
Brake pressure is maintained while piston comes
2.1 Air cylinder
in contact with piston push guide.
1. Air piston assy and return spring are built in the air
cylinder.

2. The atmospheric pressure always acts on the

return spring side of air piston assy, and the
compressed air from the air tank acts on the other
side.

Return spring Air piston assy

Air pressure

From oil reservoir

Output
fluid
Piston assy pressure

Piston push guide

Pin

Air cylinder Oil cylinder

IW404-0030E03

19 W404-0030E
T-4 T-4
Booster (Brake)

3. Operation of cylinder 3.3 Brakes are released

When the brake pedal is released, air piston assy,

3.1 Booster not in operation
piston push guide(20), and piston(15) are returned to
Air piston assy is pressed by return spring(4) to the the non-operating state by return springs(4)and(35),
left of air cylinder. and the brake is released.
When air piston assy is pushed to the left by return
spring(4), and piston(15) is pushed to the left by
return spring(35), the space between piston push
guide(20) and piston(15) occurs.
The brake fluid from the oil reservoir runs to the oil
cylinder room via the space between piston push
guide(20) and piston(15).

IW404-003006

4. Removing of booster
1. Fix the vehicle.
3.2 Booster in operation
2. After exhausting compressed air in the air tank,
Air piston assy is moved to the right with air pressure remove the booster.
generated by depressing brake pedal.
Piston push guide(20) connected to the push rod of
air piston assy moves to the right.The guide(20)
contacts with piston(15), and blocks off the central
hole, between the oil reservoir and the oil cylinder
chamber.
Fluid pressure in inverse proportion to the sectional
area of the air cylinder and the oil cylinder occurs in
the oil cylinder chamber.

IW404-003005

20 W404-0030E
T-4 T-4
Booster (Brake)

5. Disassembly

5.1 Disassembly of cylinder

33 34 11 10 9 8 7 6 13 12 32

Air
pressure 19 18 20 25-31 24 27 26

From oil reservoir

17
16 15

Output
fluid
Clearance stroke 1.6±0.5mm pressure

30 35 29 28

14

3 1 2 4 5 21 22 23 IW404-0030E01

1. Remove bolts and washers(30), and separate

cylinder(24) from the booster.

2. Place the booster with piston assy(15) upward on

the work bench. Move ring(19) under piston
assy(15), and remove piston pin(18).

3. Separate piston assy(15) and piston bushing

guide(20).

[NOTICE]
In removing air cylinder assy, return spring(4) may
fly out when bolt (21) and nut(23) are removed
because return spring(4) is compressed by about
235 N(52.8 lbf) force.

4. Remove bolt(21) and nut(23), and the separate air

cylinder assy(1) and cover(5).

21 W404-0030E
T-4 T-4
Booster (Brake)

6. Check

6.1 Rubber parts

1. Exchange wound, wear-out, or deteriorated parts

for new ones.

2. Exchange wound, wear-out, or deteriorated parts

for new ones.

6.2 Air cylinder

1. Sliding area
Exchange wound or remarkable wear-out parts in
the sliding area of the air piston assy for new
articles.
Exchange a little wound or wear-out on the push
rod of the air piston assy for new one.

2. Return spring
Exchange return springs for new ones when crack,
breakage, or exceeded useing limit of free length
in springs.
(1 mm = 0.03937 in)

Parts No. New ones (mm) Using limit (mm)

4 357 321

36 208 187

6.3 Oil cylinder

1. Sliding area
Exchange wound or remarkable wear-out parts in
the sliding area of the piston assy for new articles.

2. Seat
Exchange wound parts on the seat of piston assy
for new ones.

22 W404-0030E
T-4 T-4
Booster (Brake)

7. Reassembly

33 34 11 10 9 8 7 6 13 12 32

Air
pressure 19 18 20 25-31 24 27 26

From oil reservoir

17
16 15

Output
fluid
Clearance stroke 1.6±0.5mm pressure

30 35 29 28

14

3 1 2 4 5 21 22 23 IW404-0030E01

[NOTICE]
When assembling the air cylinder, apply proper Aapply proper quantity of (CCI Corporation CCI＃
quantity of silicon grease on the inner of air cylinder 20)grease on the outer of piston assy(15), pressure
assy(1), the outer of air piston assy(2), piston cup(16), backup ring(17), the inner of oil
cup(3), and O-ring(12). cylinder(24), and O-rings(13),(29).
When assembling the oil cylinder, apply proper
quantity of rubber grease（NIPPON GREASE
NIGLUBE RX-2）on the rod of air piston assy(2), the
bushing inner of cover(5), pressure cup(16),
secondary cup(8).

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m ft-lbf
1
M10 14.7-22.6 10.8-16.7
(for mounting booster)
14 - 20-29 14.8-21.4 Apply fluid sealant
21
M10 14.7-22.6 10.8-16.7
(for mounting booster)
26 - 6.9-12.7 5.1-9.4
28 - 63.7-73.5 47-54.2
28 Rc1/4 14.7-24.5 10.8-18.1
32 - 29-32 21.4-23.6 Apply fluid sealant
Apply THREEBOND
33 M22 29.4-39.2 21.7-28.9
TB1374
33 Rc3/8 29.4-39.2 21.7-28.9

23 W404-0030E
T-4 T-4
Booster (Brake)

8. Test

8.1 Testing equipment

Pressure gauge (1)
Brake valve
Air pressure
Service line
Cut valve
Pressure
regulating Air reservoir
valve
Pressure gauge (2)

Pressure gauge (3)

Air piping Wheel

cylinder
Fluid piping
IW404-0030E08

8.2 Performance diagram

12.5 +0.5
- 0.8 MPa
18
Oil cylinder output fluid pressure (MPa)

16
-2
14 (I kPa = 14.5×10 psi)
12 (I MPa = 14.5×10psi)
10
8
6
4
2
0 590
0 200 400 600 800
100 300 500 700 900
59kPa or less
Air cylinder input pressure (kPa) IW404-0030E07

8.3 Test method

Test items Test conditions Standards
Apply 11.8 MPa(1711 psi) of hydraulic pressure to the fluid piping, and
10 seconds
Fluid-tight test then measure times requiring pressure drop to 10.8 MPa(1566 psi) after
or over
the fluid piping is blocked off.
Apply 590 kPa(85.5 psi) of compressed air to the booster, and then
Air tightness test 39 kPa (5.7 psi)
measure a amount of pressure drop for 15 seconds after the compressed
when opening. or less
air source blocked off from the circuit.
Operation beginning Service line pressure when wheel cylinder pressure begins to rise when 29 - 49 kPa
pressure test brake-valve pedal is gradually depressed. (4.2-7.1 psi)
Operation test at full 11.7 - 13.0 MPa
Wheel cylinder pressure at service line pressure 590 kPa (85.5 psi).
load (1697-1885 psi)
Air tightness test at Measure a amount of pressure drop for 15 seconds under the service line 59kPa (8.6 psi)
full load blocked out from the operating state at the full load. or less
78.5 - 127.5 kPa
Residual pressure test Measure the wheel cylinder pressure when brake pedal is released.
(11.4-18.5 psi)

24 W404-0030E
T-4. T-4.
Booster (Brake)

9. Maintenance standards 9.2 2000-hours or one year check

Disassemble the booster, and inspect all aparts.

9.1 Daily check
Exchange all rubber parts and other damaged parts
1. Check the oil level of the oil reservoir tank. for new ones.
Examine according to test items.
2. Examine the liquid leakage around the oil cylinder.

9.3 Maintenance standards

Item Maintenance standards Limit Remarks

At 204mm (8 in)
Return spring force of piston 196±1.9 N (44±0.44 lbf) 156.9 N (35.2 lbf))
in spring height

0.05 mm (0.002 in)

Bending of push rod 0.15 mm (0.006 in) -
or less

Space between oil piston and 0.040 - 0.123 mm

0.20 mm (0.008 in) -
oil cylinder (0.0016 - 0.0048 in)

Fluid-tight:
Required times of pressure
10 seconds or over - -
drop from 11.8 MPa (1711 psi)
to 10.8 MPa (1566 psi).
At service line
Air tight at no-load: 39 kPa (5.7 psi)
- pressure 590 kPa
Pressure drop for 5 seconds or less
(85.5 psi).

98 kPa (14.2 psi)

Operation beginning pressure - -
or less

At service line
Operation at full load: Wheel 117 - 137 mm
- pressure 590 kPa
cylinder (4.6 - 5.4 in)
(85.5 psi).
At service line
Air tight at full load: 59 kPa (8.6 psi)
- pressure 590 kPa
Pressure drop for 15 seconds or less
(85.5 psi).

78.5 - 127.5 kPa

Residual pressure -
(11.4 - 18.5 psi)

360-629-80000 △
0

25 W404-0030E
T-5 T-5
Air Dryer

T-5 Air Dryer

[NOTICE] Air circuit diagram

There is a case that the appearance and so on
differ from the parts for this machine. Although there Purge chamber
is not so much difference in functions and Drying tube
disassembly procedures, make sure of the serial
number of this machine and the part sales unit
IN
described in the parts catalog before starting
disassembling operations. OUT
Drain valve
1. Structure Governor

Anload IW232-0040E01

48
Purge chamber
47
46 49
45
44
42
43
Desiccant
40
57
Oil separator filter 51
42
52 A
41
56
53
55
50
54
Check valve 34
35
OUT IN

37
6
38
5
36
9 4
14 3
8 7 Drain valve
1 11
10
12 13 12 15 16

IW232-0030E02
Drain

26 W232-0040E
T-5 T-5
Air Dryer

View A

58

To compressor
B B

59 Heater
2

C
A IW232-0040E02

27 W232-0040E
T-5 T-5
Air Dryer

Section B-B IN
33
32
30
31
28
29
25
27 26
23
17
19
22
18
24 21
20
2

OUT IW232-0040E03

IN
View C

61

60 Thermostat

63

62
39 OUT

C IW232-0040E04

28 W232-0040E
T-5 T-5
Air Dryer

1. Body 17. Piston 33. Cap nut 49. Screw and washer
2. Steel ball 18. O-ring 34. Check valve 50. Cover
3. Valve body 19. Special washer 35. Check valve spring 51. Oil separator filter
4. Valve spring 20. Governor valve 36. Check valve stopper 52. O-ring
5. Piston 21. Valve spring 37. O-ring 53. Hexagon socket head bolt
6. O-ring 22. O-ring 38. Retaining ring and washer
7. Valve 23. Exhaust stem spring 39. Plug 54. Gasket ring
8. Bolt and washer 24. Exhaust stem 40. Case 55. Gasket ring
9. O-ring 25. Adjusting screw 41. Filter plate 56. O-ring
10. Silencer case 26. Spring seat 42. Filter 57. Purge chamber
11. Silencer 27. Spring 43. Absorbent 58. Bolt and washer
12. Silencer plate 28. Spring seat 44. Filter plate 59. Heater
13. Retaining ring 29. Nut 45. Set spring 60. Thermostat
14. O-ring 30. Retaining ring 46. O-ring 61.Screw
15. Exhaust cover 31. Seat 47. Case cover 62. Cord clamp plate
16. Retaining ring 32. Plate 48. Check valve 63. Screw

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft - lbf
IN, OUT Rc 1/2 44 - 59 32.5 - 43.5

8 - 4-7 3-5

29 - 7-8 5-6

33 - 5-6 3.5 - 4.5

39 - 15 - 25 11 - 18

49 - 2-4 1.5 - 3

53 - 2-4 1.5 - 3

58 - 18 - 27 13 - 20.5

59 - 20 - 29 14.5 - 21.5

61 - 0.5 - 1 0.4 - 0.7

63 - 1 - 1.5 0.7 - 1.1

Mounting bolt M10 × 1.25 15 - 23 11 - 16.5

29 W232-0040E
T-5 T-5
Air Dryer

2. Function
2. The air flows through a filter which includes an oil
1. When the air pressure at the air dryer outlet port mist separator, which removes minute oil droplets
(air tank air pressure) reaches the specified and dust before the air enters the drying tube.
release pressure, this governor sends that
3. In the drying tube, the moisture in the air is
pressurized air to the control port, opening the air
removed by a desiccant that has a strong affinity
dryer drain valve.
for water.
2. When the air pressure at the air dryer outlet port
4. As the air proceeds from the bottom of the drying
has dropped to the specified intake pressure, the
tube to the top, it contacts a stronger desiccant,
pressurized air at the control port is released to
which further reduces the moisture. When the air
the atmosphere, closing the drain valve.
reaches the top of the drying tube, it is dry air.

2.1 Dehumidification 5. This dry air passes through the check valve and
purge chamber at the top of the drying tube, and
1. During the compressor load cycle, the air from the
is supplied to the governor chamber and main
compressor enters the air dryer inlet port. The
tank via the outlet port check valve.
compressed air is cooled down as it flows along
the body walls. This results in moisture and oil
accumulating at the bottom of the body.

Check valve
Purge chamber
Desiccant

Oil filter

Main tank

Outlet Inlet Compressor

Governor IW232-0030E06

30 W232-0040E
T-5 T-5
Air Dryer

2.2 Regeneration
4. In addition, because there is no feedback
1. When the air pressure in the system reaches the command to the compressor, the compressor
upper limit pressure of the governor, the governor continues to supply pressure. For this reason, this
control pressure passes through the control line pressure is also ejected from the dryer into the
and opens the drain valve atmosphere by the opening of the drain valve.

2. At this time, the air in the drying tube is released 5. When the load cycle begins again, a command
into the atmosphere. Because it is released from the governor closes the drain valve, and the
suddenly, the pressure in the drying tube cleans dehumidifying process starts.
the oil filter and ejects the oil and water
condensate into the atmosphere.

3. After the sudden decrease in pressure, the dry air

in the purge chamber passes through the orifice,
decompressing and expanding. It becomes
super-dry air, which flows backwards through the
drying tube, absorbing moisture from the
desiccant carrying it out into the atmosphere,
completing the regeneration of the desiccant.

Oriffice Check valve

Desiccant

Purge
chamber

Main tank

Outlet Inlet
Compressor

Silencer

Governor IW232-0030E07

31 W232-0040E
T-5 T-5
Air Dryer

2.3 Intake position 2.4 Release position

1. The pressurized air from the air dryer outlet port 1. When the outlet port air pressure (air tank air
(air tank pressurized air) travels through the pressure) increases, and the force acting on the
passage and acts on the bottom of the governor bottom of the governor piston becomes stronger
piston. than the force of the spring, the governor piston
moves toward the spring side.
2. When the air pressure is at or below the specified
pressure, the governor piston is kept pressed 2. The exhaust stem is closed by the governor valve,
down by the spring. and the control port air is cut off from the
atmosphere.
3. Under these conditions, the pressurized air in the
control port passes through the exhaust stem and 3. When the outlet port pressure increases further,
is released into the atmosphere. and reaches the release pressure, the governor
piston moves farther to the spring side, and the
governor valve is opened by the exhaust stem.

4. The pressurized air from the outlet port passes

through the governor valve, and is delivered from
Spring the control port to the top of the air dryer drain
Exhaust port valve, pressing the drain valve open.

Control port

Governor piston
Control port
Exhaust stem

From outlet port

IW232-0030E08
Governor valve

Direction of governor
piston movement
IW232-0030E09

5. The outlet port air pressure (air tank air pressure)

gradually decreases. When it drops to the intake
pressure, the governor piston is pressed back by
the spring.

6. This closes the governor valve. The exhaust stem

is disconnected from the governor valve, and the
control port pressurized air passes through the
exhaust stem to be released into the atmosphere.
This closes the drain valve.

32 W232-0040E
T-5 T-5
Air Dryer

3. Precautions for handling 4. Maintenance and inspections

WARNING WARNING
Never touch the desiccant with wet hands, or When performing inspections, use caution to
put the desiccant in your mouth. Doing so will prevent dirt from entering the eyes.
cause heating of the desiccant, and can result in
burns.
4.1 Daily inspection
[NOTICE]
1. Check for air leakage around the body, at pipe
Be certain to use the desiccant specified by
NABCO (part No. 41213640010), and replace it with openings, and other locations.
an amount that is within the specified range.
2. To check that the air dryer is operating normally,
Use of a desiccant other than that specified, or in
amounts less than those specified, will not only open the drain cock on the air tank, and check
reduce the moisture-absorption capability of the that there is no drainage.
dryer, but can lead to degradation and loss of the (A small amount of drainage may accumulate if
desiccant and can greatly increase the likelihood of the temperature around the air tank has
vehicle malfunctions.
decreased by more than 17°C (62.6°F)).
Be aware that the desiccant used in DU-3 is of a
different type than the desiccant used in DR-41, 3. In cases other than the above (drainage resulting
DR-42, and DU-4.
from temperature change), if a small amount of
Be sure to perform tapping when inserting the
drainage occurs, check the precautions for
desiccant.
handling again.
1. If the vehicle has been parked for several hours in
[NOTICE]
a cold location (-10°C (14°F) or below), wait at
If the desiccant becomes seeped in oil or other
least 10 minutes before driving after starting the substance, its ability to absorb moisture is
engine. (It takes time for the temperature to rise decreased. Because this greatly affects dryer
after the heater turns ON.) function, be sure to replace the desiccant if this
occurs.
2. Make sure that the unload time is 50 seconds or It is recommended that you replace the filter at the
longer. same time as the desiccant.
(If the regeneration process is not performed, the
moisture-removal capability of the desiccant is 4. If no abnormalities are found, disassemble the air
decreased, and the dryer function is lost.) dryer and check whether or not the desiccant is
seeped in oil or other impurities. If 1/5 or more of
3. During unloading, air is continuously discharged the total desiccant is seeped in such substances,
from the air dryer exhaust port. replace the desiccant.
This is normal, and is not a problem of air
leakage. [NOTICE]
◆Oil (liquid oil and carbonized oil) is contained in the
4. Replace the desiccant every 1 year or 100,000 km compressed air that enters the air dryer. This will
(62140mi) of travel, whichever occurs sooner. accumulate in the compressor and dryer piping, and
inside the dryer itself. Because this oil may burn, be
5. If drainage occurs from the air tank, disassemble sure to perform cleaning periodically.
the dryer, and replace the desiccant if 1/5 or more
5. Pay attention to the drainage from the air dryer
of the total desiccant is seeped in oil.
exhaust port. If an abnormal amount of oil is
(If the desiccant becomes seeped in oil, its ability
drained, inspect the compressor and take steps to
to absorb moisture is decreased. Because this
prevent increases in the amount of oil.
greatly affects dryer function, be sure to replace
the desiccant if this occurs.)

33 W232-0040E
T-5 T-5
Air Dryer

6. Use the on-board air pressure gauge to check that 5. Disassembly

the pressure governor is operating at the specified
pressure. Also check that there is no decrease in 5.1 Removing DU-3
pressure when the brakes are not in use.
1. Block the wheels without using the pneumatic
Governor switching pressure: circuit.

Refer to “Pressure regulator” in “Air puressure 2. Open the drain cock on the air tank. Discharge the
setting table” in chapter Y. air from the brake piping.

3. Disconnect the thermostat wiring.

4.2 Inspection and part replacement every 1
year or 100,000 km (62140mi) of 4. Disconnect all the wires (IN, OUT, CONTROL)
driving
from the air dryer.
1. Disassemble the air dryer. Replace the desiccant,
5. Loosen the three bolts to remove the UD-3.
oil filter, filter, and all rubber parts, regardless of
whether or not scratches or wear is visible on 5.2 Disassembly of cartridge
these parts.
1. Anchor the DU-3 body-1 in a vise. Unscrew the
2. Check that there are no abnormalities in the bolts and washers that fasten the purge chamber
piping and wiring. to the body, and remove the purge chamber.

[NOTICE] Case cover

Corrosion of metal parts can result in air leakage Purge chamber
when the corrosion falls off and becomes caught in Set spring Screws
the valves. and
These inspections and maintenance are to be washers
performed when either the travel distance or
installation time is reached, whichever occurs first. Purge chamber

Absorbent
3. Check all metal parts for corrosion. Repair or Bolts
replace them as necessary. and
washers

Body

IW232-0030E10

2. When the purge chamber is removed, cartridge

assy through containing the desiccant is exposed.
Directly remove the cartridge assy upward by
hand.

34 W232-0040E
T-5 T-5
Air Dryer

Case cover
CAUTION Purge chamber
Keep pressing on the case cover with your Set spring Screw
hand until all screws and washers have been and
Washer
removed.
The case cover can be extremely dangerous if
the set spring inside causes the cover to jump Purge chamber
up and strike a person in the face or other body Desiccant
part.

Bolt
3. Use your hand and press from above on the case and
Washer
cover attached to the desiccant case. At the same
time, use a Phillips screwdriver to unscrew and
remove the 4 screws and washers.

4. Remove set spring, filter plate B, filter, desiccant,

filter and filter plate A from above the case. Body

Purge chamber
Set IW232-0011E12
spring

6. Press the cover with your hand, and lift the case
Filter
Filter up to remove it. Remove the oil separator filter
plate B Absorbent that is inside.
Filter
Filter
plate A

IW232-0030E11

5. Use a 4 mm hex wrench to unscrew and remove

the 4 hexagon socket head bolts and washers.

35 W232-0040E
T-5 T-5
Air Dryer

6. Reassembly 3. Insert filter plate A and the filter into the case.
Insert the filter so that the soft surface is on top.
[NOTICE]
With the exception of rubber parts and the
Purge chamber
desiccant, wash all disassembled parts well with
clean oil and wipe off all adhering substances.

WARNING
Filter
Be certain to use the specified NABCO Filter
desiccant (41213640010). plate B Case
Absorbent
Use of a desiccant other than that specified is Desiccant
Filter
extremely dangerous. It can result in the
Filter
desiccant deteriorating and being lost, with plate A
pieces blocking the brake piping and preventing
normal brake operation.
The desiccant used is different than that used
for NABCO DR-41, DR-42, and DU-4. Be careful
not to use the wrong type.

6.1 Cartridge (lower)

1. Install the oil separator filter in the center of the

cover, and install the O-ring into the groove.
IW232-0030E13

Purge chamber
4. Insert the specified amount of desiccant.
3
The specified amount is 590 - 619 cm (36 -
3
37.8in ) [480g (1.06lb)]. Insert the entire bag of
Case desiccant that was purchased for use with the
Oil separator Absorbent repair kit.
filter

O-ring Hexagon soket

head bolts

Cover
DANGER
If less than the specified amount of desiccant
is used, the desiccant may deteriorate and be
lost, with pieces blocking the brake piping and
preventing normal brake operation. Be sure to
insert the specified amount.

5. Next insert the second filter, this time with the soft
surface on the bottom. Then place filter plate B in
IW232-0030E12 position and perform tapping.

2. Place the case in position, and use a 4 mm hex

wrench to tighten the hexagon socket head bolts
and washers.
Tightening torque: 2.0 - 3.9 N-m
(1.5 - 2.9 ft-lbf)

36 W232-0040E
T-5 T-5
Air Dryer

6.2 Tapping 6.3 Cartridge (upper)

[NOTICE]
DANGER Applying grease to the raised part of the check
When tapping is not performed, the desiccant valve will allow it to be inserted more easily.
may deteriorate and be lost, with pieces blocking Use NABCO grease (grease pack 45499030090,
the brake piping and preventing normal brake grease weight: approximately 10 g (0.022lb).
operation.
Be sure to follow the procedure below when 1. Fit the check valve into the case cover by
performing tapping.
pressing on the center bulge with your thumb.

[NOTICE] 2. Install the O-ring onto the case, then insert the set
When tapping, place 2, 3 sheets of shopcloth or spring. Tighten the screws and washers while
other soft cloth on top of one another at the tapping pressing down on the case cover with your hand.
location to prevent the cover from being scratched.
Tightening torque: 2.0 - 3.9 N-m

Check valve Case cover (1.5 - 2.9 ft-lbf)

purge chamber
Set spring Screws
and
washers
O-ring
Case

Filter plate Absorbent

Cover

IW232-0030E14

1. While pressing on filter plate B with both hands,

lift the entire case up approximately 10 cm (4in).

2. Next, gently tap the raised case against the

workbench. At this time, do not let go, and lower
your hands with the case.

3. Repeat steps 1 and 2 approximately 30 times.

Check that the position of filter plate B is 4 - 6 mm
(1.5 – 2.4in) below where it was initially. When this
is verified, the work is complete.

37 W232-0040E
T-5 T-5
Air Dryer

7. Troubleshooting
[NOTICE]
Be sure to perform daily inspections and periodic
maintenance, as described in 4. Maintenance and
Inspections.
If any of the below symptoms or malfunctions occur,
follow the remedy procedures listed below to
inspect and correct the problem

Symptom Probable cause Remedy

Condensate The amount of oil increase in the Replace the desiccant.

flows out from compressor is abnormally large. 1/5 or Also take steps to prevent the increase of oil.
the air tank. more of the desiccant is seeped in oil and
its ability to absorb moisture has
decreased.

Because the amount of desiccant is too Insert the specified amount of desiccant.
little, its ability to absorb moisture is 3
(Specified amount: 590 - 610 cm (36 - 37.2in ))
3

insufficient.

Because the type of desiccant is wrong, Insert the specified type of desiccant.
its ability to absorb moisture is insufficient. (Be aware that the type is different than that used
with DR-41, DR-42, and DU-4.)

The amount of air consumed is too large, Reduce the amount of air consumed in 1
and has exceeded the moisture-absorbing loading/unloading cycle.
capability range of the desiccant. {The maximum amount of air that can be
processed for moisture-removal is 93 L
[25gal(us)] /cycle.}

The drain valve is not opening, and Check the governor discharge pressure. If it
regeneration of the desiccant is not being differs from the specified value, adjust or replace
performed. the governor.
• Disassemble and inspect the valve operation
parts. Remove any foreign substances that are
found.
• If the drain valve is frozen, check for a open
circuit in the heater, thermostat failure, missing
wire, or other problem. Replace parts or
connect wires securely.

If the dryer inlet temperature is higher Make arrangement to reduce the inlet
than 60°C (140°F), moisture absorption temperature to less than 60 °C (140°F).
will be insufficient.

If the desiccant has not been replaced for Replace the desiccant every 1 year or 100,000
a long time, and 1/5 or more is seeped in km (62140mi) of travel, whichever occurs sooner.
oil, its ability to absorb moisture will
decrease.

38 W232-0040E
T-5 T-5
Air Dryer

Symptom Probable cause Remedy

Condensate If the purge time is too short, the Inspect the check valve and O-ring.
flows out from desiccant regeneration capability will be (Purge time should be approximately 35 seconds
the air tank. reduced. from 890 kPa (129psi) to 0 kPa (0psi).)

If the pressure in the purge chamber is Check the governor discharge pressure. If it is
too low, the desiccant regeneration different from the specified value, adjust or
capability will be reduced. replace the governor.

No condensate The drain valve is frozen and will not If there is an open circuit in the heater, replace
is discharged open. the heater.
from the (Check the continuity with a tester.)
exhaust port.
• If there is a thermostat failure, replace the
thermostat.
(Leave at 0°C (32°F) or less, then check the
continuity with a tester.)

• Check that no wires have been disconnected.

• If left for a long time in a cold environment, time

will be required for the temperature to rise
after the heater is turned ON.
(Approximately 15 - 20 minutes to rise -20°C -
0°C (-4°F - 32°F.)

If the governor discharge pressure is 490 Check the governor discharge pressure. If it
kPa (71psi) or less, the drain valve will not differs from the specified value, adjust or replace
open. the governor.

A foreign substance (carbonized oil) has Disassemble and inspect the valve operation
entered during the valve operation, parts. Remove any foreign substances that are
preventing valve operation. found.

Air leaks from The drain valve is frozen and will not If there is an open circuit in the heater, replace
the exhaust close. the heater.
port.
• If there is a thermostat failure, replace the
thermostat.

• Check that no wires have been disconnected.

• If left for a long time in a cold environment, time

will be required for the temperature to rise
after the heater is turned ON.

A foreign substance has been caught in Disassemble and inspect the valve, and remove
the valve, preventing it from sealing. any foreign substances. If the valve seal surface
is scratched, replace the valve component or
valve body.

39 W232-0040E
T-5. T-5.
Air Dryer

Symptom Probable cause Remedy

Main tank If the air dryer outlet check valve fails to Disassemble and inspect the air dryer outlet
pressure drops function, the air in the main tank flows check valve. If necessary, replace the check
abnormally backwards and out through the air dryer. valve.
when the
compressor is
unloaded.

368-704-10000 △
1

40 W232-0040E
T-6 T-6
Brake (Parking Brake)

T-6 Brake (Parking Brake)

[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 and function

The clearance of pad assy 6 and 7 is
Inner pad carrier 1 and outer pad carrier 2 are automatically adjusted by means of the
mounted to the mounting bracket by means of elastic-plastic property of retraction plates 4,
respective pad carrier bolts 3, and pad assy 6 and which must be replaced when the pads are
7 are mounted to the respective pad carriers with replaced.
special bolts integral with the pads and nuts 8.
Lever assy 10 is connected to inner pad carrier 1
with pivot seat 14, and lever assy 10 incorporates
trunnion 12 and spring support pin 19. Hand brake
bolt 11 is screwed into self lock nut 13 to serve as
an element in the actuating train for pad assy 6
and 7. Return spring 17 between inner pad carrier
1 and lever assy 10 serves to return lever assy
10.

1. Inner pad carrier 6. Pad assy 11. Hand brake bolt 16. Cotter pin
2. Outer pad carrier 7. Pad assy 12. Trunnion 17. Return spring
3. Pad carrier bolt 8. Nut 13. Self lock nut 18. Spring anchor
4. Retraction plate 9. Toothed lock washer 14. Pivot seat 19. Spring support pin
5. Tab washer 10. Lever assy 15. Pin

41 W577-0141E
T-6 T-6
Brake (Parking Brake)

2. Replacing pad
[NOTICE]
At this time, if the clearance between the pad and
WARNING the disc plate is too narrow to adjust, loosen the
hand brake bolt.
Be sure to immobilize the vehicle before starting
to work.
7. Set pad carrier 1 and 2 with new pads to the
mounting bracket, and install pad carrier bolts 3
CAUTION
together with new retraction plates 4 and tab
Make sure that the run out of the disk plate is
washers 5.
less than 0.15 mm (0.006 in) at the center of the
pad sliding surface.
8. Fold one tab of tab washers 5 to lock pad carrier
bolts 3.
[NOTICE]
The pads should preferably be replaced in a set of
two. If only fully worn one is replaced, the other one
would require replacement soon, and in this way,
the checking and changing intervals would become
short.

1. With the parking brake lever in the release

position and the brake chamber in the extension
sided stroke end, disconnect lever assy 10 from
the brake chamber push rod.

2. Move the parking brake lever to the braking

position to return the brake chamber push rod.

3. Loosen hand brake bolt 11 to free retraction plate

4.

4. Unfold the tab of tab washer 5, unscrew pad

carrier bolts 3 with a wrench, and remove them
together with retraction plate 4.

5. Remove one of the pad carriers from the

mounting bracket and replace the pad with a new
pad. To replace the pad, first, unscrew hexagon
nut 8 with a wrench and remove together with
toothed lock washer 9, and then, withdraw the
worn pad along the fixed bolt hole. Install a new
pad by reversing the procedure. Replace also the
toothed lock washer 9 and hexagon nut 8.

6. Replace the other pad similarly.

42 W577-0141E
T-6 T-6
Brake (Parking Brake)

3. Remounting

3.1 Connecting parking brake to spring chamber 3.2 Adjusting parking brake clearance

1. Adjust the clearance between the pad and the 1. Move the parking brake lever to the release
disc plate to approximately 0.15 mm (0.006 in) per position to bring the brake chamber into the
side with the hand brake bolt. extension side stroke end.

2. Move the lever to release the parking brake and 2. Screw the hand brake bolt in accordance with the
bring the brake chamber to the extension stroke pad wear, until the clearance between the pad
end, and connect the link to the lever by adjusting and the disc plate becomes approx. 0.15 mm
its position. Then, check the clearance between (0.006 in) per side.
the pad and the disc plate. It must be approx. 0.15 when it becomes impossible to adjust the
mm (0.006 in) per side. If the clearance is correct clearance by the hand brake bolt, readjust the
lock it with the jam nut. brake in accordance with the preceding paragraph,
“ 3.1 Connecting parking brake to spring
chamber ”

43 W577-0141E
T-6. T-6.
Brake (Parking Brake)

4. Check

WARNING
When the brake has been used as
emergency brake, adjust the pad clearance as
soon as the use is terminated.
When the clearance between the pad and
the disk plate is set to 0.15 mm (0.006 in)
per side before starting to use, the brake can
be used without adjusting the hand brake
bolt, until the pad wears approx. 2.0 mm
(0.079 in).
When the brake wears more, the trunnion
fouls the pivot seat to make the brake
ineffective, and at the same time, undue force
is applied to the pivot seat to break it. Adjust
the clearance in time.

1. The pad assy consists of a backing plate and

wear material, and they are 3.2 mm (0.126 in) and
10.5 mm (0.413 in) respectively in thickness when
new (total: 13.7 mm (0.539 in)).
Since change in thickness by wear changes the
stroke, adjust the hand brake bolt according to the
pad wear from time to time.

CAUTION
If the wearing condition is not regularly
checked, the inner and outer pad carriers
may foul the disk plate to damage it, making
its replacement necessary.

2. The use limit of the pad assy is considered to be

reached when the remaining thickness of the wear
material has become 3.8 mm (0.150 in), that is,
the total thickness has become 7 mm (0.276 in),
at any part.

44 W577-0141E
T-7 T-7
Brake Chamber

T-7 Brake Chamber

[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
Stroke
3 2 4 5

IW576-0020E01

7 1. Pressure plate
2. Non pressure plate
6 3. Diaphragm
4. Spring
5. Push rod
6. Clamp ring
A IW576-001002
7. Bolt
8. Nut
Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft - lbf
7, 8 － 9.8 - 14.7 7.2 - 10.8

45 W576-0022E
T-7 T-7
Brake Chamber

2. Function DANGER
Never attempt to disassemble without using the
1. When compressed air is introduced behind the special jig. Doing so is extremely dangerous.
diaphragm, it pushed the diaphragm, and the The spring is powerful. Be sure to use the
push rod to release the brake. special jig to pull the push rod out approximately
5 mm before disassembling.
2. When the compressed air is freed to the outside
air, the push rod is pushed back by a strong return
spring, puling the brake lever to effect the parking
brake. 3. Disassembly
[NOTICE]
Mark the clamp bolts, non-pressure plate, and
pressure plate with alignment marks before
disassembling, so that they can be aligned correctly
during reassembly.

Dimensions of special jig (sample) (Unit：mm) (1mm＝0.039in)

Rod
M12×1.25 M14×1.5
(0.77)
19.6

20 (0.8)
17 30 (1.2) 150 (5.9)
(0.67)
IW576-0021E01

Adapter
Thrust ball bearing
(1.97)
(0.94)
20
(0.8)

28
(1.1)

50
(0.59)24
15

9
100 (3.94) (0.35)
IW576-0021E02

46 W576-0022E
T-7 T-7
Brake Chamber

Pressure plate Clamp ring Spring Nut

Adapter Push rod

Special jig

IW576-0020E03

4. Cleaning and checking

1. The diaphragm and clamp ring are pressed
against the pressure plate by a spring.
4.1 Cleaning
2. In order to neutralize this force, use the special jig
1. Wash all parts in kerosine thoroughly, and dry
to first pull out the push rod by approximately 5
them by blowing with compressed air.
mm (0.2in) and fix it in place.
2. Don’t wash the diaphragm, but wipe it with dry
3. Remove bolts by unscrewing two clamp ring nuts,
cloth, and then, blow with air.
and remove clamp ring by expanding.
4.2 Checking

1. Pressure plate
Check for deformation (dents, etc.) and damage,
Nut
and replace if excessive defects are found.

2. Diaphragm
Bolt
Replace it after using for one year.
Clamp ring When it has not been used one year, check it for
IW576-0020E04
cracks, breaks and excessive wear, and replace it
if these defects are found.

4. Gradually loosen the nut of the special jig to 3. Spring

unload the spring, and remove push rod and Replace, if broken or rusted substantially.
spring from non-pressure plate.
4. Other parts
Check all the parts for breaks and other defects,
and replace all defective parts.

47 W576-0022E
T-7. T-7.
Brake Chamber

5. Reassembly
5. Align diaphragm and pressure plate to
1. Set push rod vertically on a flat bench, with its end non-pressure plate, hook clamp ring on the edge
up. of the pressure plate by expanding the ring, and
align the marks.
2. Put spring and non-pressure plate over the push
rod. 6. Clamp clamp ring with clamp bolts and nuts just
sufficient to stop air leaking.
3. Tighten the nut of the special jig to compress Tightening torque：9.8 - 14.7 N-m
spring, and keep it compressed. (7.2 - 10.8 ft-lbf)

4. Hook clamp ring on the edge of non-pressure 7. Loosen the nut of the special jig, and remove the
plate by expanding the ring, and align the marks. rod, nut, and the adapter.

Pressure plate Clamp ring Spring Nut

Adapter Push rod

Special jig

IW576-0020E03

6. Test 7. Maintenance standards

6.1 Air leak test 7.1 2000-hour or 1-year check

1. Apply soapy water to the entire surface of the 1. Disassemble the spring chamber, and replace
pressure plate, and to the gaps between the damaged or cracked parts.
clamps, non-pressure plate, and push rod.
2. Replace the diaphragm. Conduct the air leak test,
2. Apply compressed air at 0.5 - 0.8 MPa (72.5 - as described above.
116psi) to the inlet port, and check for air leakage.

367-001-40000 △
1

367-001-80000 △
0

367-001-50000 △
1

367-000-10000 △
1

48 W576-0022E
T-8 T-8
Solenoid Valve (Air)

T-8 Solenoid Valve (Air)

[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

OUT
Connector

＋ +-
ー
Diode
GP 15M IN
EXH
IW210-0120E01 IW210-0151E01

4 3 2 1 18,19
5
6
8
9
10
11
12
IN OUT
11
13 T1
14 15 16 17

IN
EXT

OUT
IW210-012002

49 W210-0123E
T-8. T-8.
Solenoid Valve (Air)

1.Core 6.Coil assy (DC24V) 12.Valve seat 17.Filter

2.O-ring 8.Rod 13.Valve 18.Packing
3.Case 9.Coil cover 14.Body 19.Packing holder
4.Spring 10.O-ring 15.Spring
5.Plunger 11.O-ring 16.Cover

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22

T1 M8x1.25 8 - 12 6-9

366-459-60000 △
5

50 W210-0123E
 U
Suspension System

Contents

U-1 Suspension System......................... 1

1. General..................................................... 1

U-2 Spring Lock Cylinder....................... 2

1. Structure ................................................... 2

U-3 Pilot Check Valve

(Spring Lock Cylinder) ............ 3

1. Structure ................................................... 3

U-4 Solenoid Valve (Spring Lock

Check Release)........................ 4

1. Structure ................................................... 4

i
U-1 . U-1 .
Suspension System

U-1 Suspension System

1. General
Hydraulic Circuit for Suspension Lock

1. Leaf springs are employed for both the front and

3. There are two kinds of pressure controlling valves
rear axle suspensions.
in the spring lock hydraulic circuit, namely a relief
2. The suspension lock function is either activated or valve and a pressure reducing valve. The relief
released by the four spring lock cylinders installed valve limits the highest pressure in the circuit, and
between the carrier frame and front/rear axles. the pressure reducing valve supplies the pilot
These four spring lock cylinders are hydraulically pressure to the solenoid valve (spring lock) and
controlled by the solenoid valve (spring lock) and the solenoid valve (spring lock check release).
the solenoid valve (spring lock check release).
These solenoid valves are switched according to
the outputs from the multiplex data transmitter
(lower).

1 WU02-0220E
U-2 . U-2 .
Spring Lock Cylinder

U-2 Spring Lock Cylinder

[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.Cylinder 6.Backup ring 11.Damper ring 16.Dust seal

2.Split pin 7.O-ring 12.Packing 17.Retaining ring
3.Piston 8.Backup ring 13.Backup ring 18.Rod
4.Plain bearing 9.O-ring 14.Plate
5.Packing 10.Backup ring 15.Rod cover

*1: Face the notch or the lip toward the pressurized side.

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A G1/2 98 72

360-609-40000 △
3
360-609-50000 △
3

2 W159-0030E
U-3 . U-3 .
Pilot Check Valve (Spring Lock Cylinder)

U-3 Pilot Check Valve (Spring Lock Cylinder)

[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
B
A

C
IW115-024001

1 2 3 4 5 6 7 8 9 10 11

C
12 13 2 14
IW115-024002

1.Plug 5.O-ring 9.Poppet 13.O-ring

2.O-ring 6.Backup ring 10.Poppet 14.Plug
3.Piston 7.O-ring 11.Spring
4.Backup ring 8.Sleeve 12.Body

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A G1/4 29 22

B G3/8 49 36
366-233-80001 △
1
366-233-70001 △
1

3 W115-0242E
U-4 U-4
Solenoid Valve (Spring Lock Check Release)

U-4 Solenoid Valve (Spring Lock Check Release)

[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

T
G A

P
IW121-0700E01

T P 5
2
A

3,4

1.Solenoid valve (DC24V)

2.Body
3.Plug
4.O-ring
5.Hexagon socket head bolt
G

T IW121-0700E02

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, P, T, G G1/4 34 - 38 25 - 28
5 M5 4.9 – 6.9 3.6 – 5.1
346-410-52500 △
0

4 W121-0702E
U-4 . U-4 .
Solenoid Valve (Spring Lock Check Release)

Solenoid valve assy

Connector

+-
(+): White
(-): Black

IW121-0542E01

11 17 13 12

IW121-044002

8 14 9 10 6 16 4 3 14 2 1 7

1.Body 6.Spring 10.Solenoid guide 14.O-ring

2.Spool 7.Detent spring 11.Solenoid coil 15.O-ring
3.Retainer 8.Nut 12.Name plate 16.O-ring
4.Retainer 9.Rod 13.Screw 17.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
8 - 5–7 3.6 – 5.1

366-498-90000 △
0

5 W121-0702E