TR 800 XXL 4

Publication No.
GR-800XXL-1/S2(U)-1E
Service Manual
01
GR-800XXL-1/S2(U)-1E
Rough Terrain Crane

Model
TR-800XXL-4
Applicable Serial No. 545870, 545961--
ｃ2006
◯
PRINTED IN JAPAN
0608 K
Downloaded from www.Manualslib.com manuals search engine

Safety
Safety [NOTICE]
[NOTICE] indicates an important operational or
Most accidents that occur during machine operation maintenance procedure or condition, which, if not
and maintenance are caused by failure to observe strictly observed, can result in damage to machine
basic safety rules and precautions. Before operating components or deteriorated machine performance.
your machine or performing maintenance, read and
become familiar with all the safety precautions and It is virtually impossible to anticipate every situation
recommendations given in this section. that might present a hazard. The safety precautions
Remember that failure to observe even a single given in this manual and on the machine labels are
not exhaustive.
precaution could involve you and the people around
the machine in a serious accident. It is important, therefore, to strictly follow the
instructions in this manual and be sensitive to
Foreseeing potential dangers is vital for preventing potential dangers in order to prevent bodily injury and
accidents. All personnel working with the machine, damage to the machine.
including the supervisor, machine operator and oiler,
should be sensitive to potentially dangerous situations Remember that your most important duty is to ensure
the safety of you, your co-workers and any other
and take the necessary measures to prevent
accidents. people in the area.
Safety precautions and recommendations are outlined

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
identified as "DANGER", "WARNING", "CAUTION" or
"NOTICE". 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 7.When the working is done on a team of more than
equipment 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 TR-800XXL-4 rough terrain crane, its repair, check
and adjustment methods and other relevant matters. Note that this service manual does not provide the
information in the separate service manuals given below.
This service manual applies to the cranes with the specification numbers given below. Check the specification
number on the nameplate of your crane.
Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.
1. Applicable spec. NO.
SPEC. NO. SERIAL. NO.
MFG.DATE.
KAGAWA, JAPAN
ISA04-001601
Spec. No. Applicable serial No.
GR-800-1-00211 545870--
2. Separate service manual

Separate Service Manual Information No.
General Cautions SA01-01-2E
Load Moment Indicator (AML) W301-0136E
Multiplex Data Transmitter W303-0257E
Torque Converter
W561-0101E
Transmission
Driving Axle W563-0052E
Please note that, for product improvement, some changes may have been
incorporated in the machine that are not covered in this manual.
1 WA04-2070E

Foreword
3. Outline of specifications
Spec. No.
Item GR-800-1-00211
2M2D
(North America)
No. of boom sections 5
No. of jib stages 2
Single top Option
Main winch Fitted
Auxiliary winch Fitted

Winch
Winch brake Automatic brake (Neutral brake)
Drum rotation indicator Touch-type (Option)
Weight Counterweight Removable type
Load moment indicator (AML) AML-L2C
Auto. stop solenoid valve energizing type Normally energized
AML external indicator lamp Fitted
Oil cooler Fitted
Air conditioner Option
Emergency steering Option
Engine model MITSUBISHI 6M60-TLA3B
Tires 29.5 × 25 - 22PR, 29.5 × 25 - 28PR
2 WA04-2070E

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 1X10 1X10 1.01972X10 14.5X10
3 -3 -2 -2
1X10 1 1X10 1.01972X10 14.5X10
6 3
1X10 1X10 1 1.01972X10 14.5X10
4 -2
9.80665X10 9.80665X10 9.80665X10 1 14.22
6895 6.895 0.006895 0.07031 1
3 WA04-2070E

Foreword
Work, energy
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
in-lbf
-2 -1 -3
1 1X10 1.01972X10 1.01972X10 0.00737 0.0885
2 -1
1X10 1 1.01972X10 1.01972X10 0.7376 8.851
-2 -2
9.80665 9.80665X10 1 1X10 0.0723 0.868
2 2
9.80665X10 9.80665 1X10 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 ℃ ゜F ℃ ゜F ℃ ゜F ℃ ゜F ℃ ゜F ℃
-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 o o 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 WA04-2070E

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 WA04-2070E

Foreword
5. Contents
Spec. No.
Chapter Section GR-800-1-00211
2M2D
(North America)
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) (Option)
Hydraulic Valve (Emergency Steering)
B-5
(Option)
Flow Control Valve B-6
Pressure Reducing Valve (Pilot Pressure) B-7
Solenoid Control Valve (Outrigger) B-8

B
Rotary Joint B-9
Hydraulic Pilot Control Valve

B-10
(Elevating, Telescoping, Winch)
Sequence Valve (Pilot Pressure) B-11
Solenoid Valve(Pilot Pressure) B-12
Solenoid Control Valve (Jib Set) B-13
Pilot Check Valve (Jib Set) B-14
Solenoid Valve (Oil Cooler) B-15
Hydraulic Motor (Oil Cooler) B-16
6 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Jib Lock pin B-17
Jib Offset Cylinder B-18

B
Check valve (Gauge Isolator) B-19
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)
Swing System
Swing System D-1
Swing Assembly D-2
D Hydraulic Pilot Control Valve (Swing) D-3
Hydraulic Motor (Swing) D-4
Swing Speed Reducer D-5
7 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Boom Elevating System
Elevating System E-1
Elevating Cylinder E-2

E
Counterbalance Valve (Elevating) E-3
Winch system
Winch System F-1
Winch F-2
F Hydraulic Motor (Winch) F-3
Counterbalance Valve (Winch) F-4
Hydraulic Valve (Winch Brake Release) F-5
Boom Telescoping system
Telescoping System G-1
Boom (Five-Section Boom) G-2
Jib G-3
Telescoping Cylinder G-4

G
Counterbalance Valve (Telescoping) G-5
Hose Reel G-6
Hydraulic Valve G-7
8 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Safety System
Safety System H-1
Load Moment Indicator (AML) Refer to separate manual W301-0136E
H Boom Length and Angle Detector H-2
Outrigger Extension Length Detector H-3
Solenoid Valve (Auto Stop) H-4
Cab
Crane Cab Glass K-1
Air Conditioner (Option) K-2
K
Hydraulic Motor(Air conditioner, Option) K-3
Solenoid Valve(Air conditioner, Option) K-4
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)
Solenoid Valve (Air) L-7
9 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Electrical System
N Multiplex Data Transmitter (MDT) Refer to separate manual W303-0257E
Driving Power Transmission System
Torque Converter and Transmission Refer to separate manual W561-0101E

R
Driving Axle Refer to separate manual W563-0052E
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
(Rear Steering Cylinder Lock)
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
10 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Suspension System
Suspension System U-1
Suspension Lock Cylinder U-2
Pilot Check Valve

U U-3
(Suspension Lock Cylinder)
Solenoid Valve
U-4
(Suspension 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
Adjustment and Checks Y-5
Check (Crane Operation) Y-6
Y Check (Driving Devices) Y-7
Oils and Grease Table Y-8
Mass Table Y-9
Specifications Y-10
Boom Connecting Pin and Thread Size

Y-11
Table
11 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
System Diagrams
Hydraulic Circuit Z-1
Torque Converter Circuit Z-2
Brake Circuit (Pneumatic Circuit) Z-3
Electric Circuit (AML, Crane) Z-4
Electric Circuit (MDT, Carrier/Upper) Z-5
Electric Circuit (MDT, Carrier/Lower) Z-6
Location of Installation
Location of Hydraulic Parts (Upper) Z-7
Location of Hydraulic Parts (Lower) Z-8
Location of Air Parts Z-9

Z
Location of Electric Parts (Inside Cab) Z-10
Location of Electric Parts

Z-11
(Swing Table, Boom)
Z-12
(Relay Assembly/Upper)
Location of Electric Parts (AML) Z-13
Location of Electric Parts (Lower) Z-14

Z-15
(Box Assembly/Lower)
Harness Diagrams
Harness (Connector No. Table) Z-16
Harness (Inside Cab) Z-17
Harness (Swing Table, Left) Z-18
12 WA04-2070E

Foreword
Spec. No.
2M2D
(North America)
Harness (Swing Table, Right) Z-19
Harness (Boom) Z-20
Harness (AML, Upper) Z-21
Z Harness (Overwind) Z-22
Harness (Lower, Main) Z-23
Harness (Lower, Sub) Z-24
Harness (Lower, Electronic Governor) Z-25
13 WA04-2070E

B B
Contents
B-1 Hydraulic Power Generating System B-6 Flow Control Valve.........................19

.................................................. 1
1. Structure ................................................. 19
1. General..................................................... 1
B-7 Pressure Reducing Valve

B-2 Hydraulic Pump (Double Variable (Pilot Pressure) ......................20
Displacement Pump) ............... 4
1. Structure ................................................. 20
1. Structure ................................................... 4
2. Theory of operating of regulator section.. 10 B-8 Solenoid Control Valve

(Outrigger) ..............................21
3. Air bleeding procedure............................ 12
1. Structure ................................................. 21
B-3 Hydraulic Pump

(Double Gear Pump).............. 13 B-9 Rotary Joint ....................................26
1. Structure ................................................. 13 1. Structure ................................................. 26
2. Air bleeding procedure............................ 15 2. Potentiometer.......................................... 33

2.1 Adjustment ................................................33
2.2 Soldering ...................................................33
B-4 Hydraulic Pump (Gear Pump,
Emergency Steering)............. 16
B-10 Hydraulic Pilot Control Valve
1. Structure ................................................. 16 (Elevating, Telescoping, Winch)
.................................................34
B-5 Hydraulic Valve (Emergency 1. Structure ................................................. 34

Steering) (Option) .................. 17
1. Structure ................................................. 17
i
B-11 Sequence Valve (Pilot Pressure) .. 46
1. Structure ................................................. 46
B-12 Solenoid Valve (Pilot Pressure) .... 49
1. Structure ................................................. 49
B-13 Solenoid Control Valve (Jib Set)... 51
1. Structure ................................................. 51
B-14 Pilot Check Valve (Jib Set)............ 57
1. Structure ................................................. 57
B-15 Solenoid Valve (Oil Cooler)........... 58
1. Structure ................................................. 58
B-16 Hydraulic Motor (Oil Cooler) ......... 60
1. Structure ................................................. 60
2. Air bleeding procedure............................ 60
B-17 Jib Lock Pin.................................... 61
1. Structure ................................................. 61
B-18 Jib Offset Cylinder ......................... 62
1. Structure ................................................. 62
B-19 Check Valve (Gauge lsolator) ....... 63
1. Structure ................................................. 63
ii
B-1 B-1
B-1 Hydraulic Power Generating System

1. General
Hydraulic Circuit for Carrier
winch, and auxiliary winch. This double variable

NOTICE]
displacement pump is driven only when the PTO
If the machine is not equipped with the optional
switch is turned on.
emergency steering, two points “A” are directly
joined and four portions “*1” are plugged.
3. The double gear pump supplies oil to the circuits
of outrigger,steering, swing, pilot pressure, jibset,
1. The hydraulic power for this crane is generated by
optional air conditioner, and oil cooler.
the double variable displacement pump, double
gear pump, and optional gear pump for the 4. The gear pump and the hydraulic valve in the
emergency steering circuit. emergency steering circuit are optional. They are
provided for the case when the double gear pump
2. The double variable displacement pump supplies
malfunctions.
oil to the circuits of elevating, telescoping, main
1 WB02-0261E

B-1 B-1
Hydraulic Circuit for Crane Applicable serial No. △

1 ：545520 ~
auxiliary winch). When the PTO switch is turned

[NOTICE]
on, the solenoid valve for automatic stop is shifted,
If the machine is not equipped with the optional air
making the condition of this circuit onloaded.
conditioner, two points "B" are directly joined.
Circuits for elevating, telescoping, main and auxiliary 2. The pressurized oil delivered through the P1 port
winches of the rotary joint is supplied to the circuits for the
main winch and the auxiliary winch.
1. The hydraulic oil provided from the pumps is The pressurized oil delivered through the P2 port
controlled (onloaded/unloaded) by the solenoid is provided to the circuits for elevating and
valve for automatic stop. This solenoid valve for telescoping. This oil, however, is supplied to the
automatic stop is switched by the AML output to circuits for the main winch and the auxiliary winch
control the vent ports of the relief valve (elevating, while neither elevating nor telescoping operation
telescoping) and the relief valve (main winch, is done.
2 WB02-0261E

B-1 . B-1 .
Circuit for pilot pressure, jibset, air conditioner(option),

and oil cooler
1. The pressurized oil delivered through the P6 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 circuits for the
jibset, air conditioner(option), and oil cooler.
3 WB02-0261E

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
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
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
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
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
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
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
2. Theory of operating of regulator section
10 W101-0272E

B-2 B-2
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 .
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]
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
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 .
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

366-533-00000 △
0
366-519-00000 △
0
366-531-70000 △
0
15 W101-0131E

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

[NOTICE]
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.Hexagon 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
Tightening torque
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) (Option)
B-5 Hydraulic Valve (Emergency Steering) (Option)

[NOTICE]
1. Structure
T
B
P2 P3
P1
A
IW123-016001
P1
P3 T
P2
X X
Y
IW123-0260E01
Tightening torque
N-m ft-lbf
P1, P3 G1 196 145
P2, T G3/4 167 123
17 W123-0261E

B-5 . B-5 .
Hydraulic Valve (Emergency Steering) (Option)
Cross section along the line X-X, Y-Y
14 13 5 9 6 2 A 1
12
3 11
8 C
X-X
7 10 B 11
Y-Y
IW123-0260E02
1.Body 5.Cover 9.O-ring 13.Spring washer

2.Check valve 6.Spring 10.Plug 14.Hexagon socket head bolt
3.Spool 7.Spring 11.Plug
4.Check valve 8.Spring 12.Plug
366-406-60000 △
0
18 W123-0261E

B-6 . B-6 .
Flow Control Valve
B-6 Flow Control Valve
[NOTICE]
1. Structure
PB
4
T
1
PA IW114-0130E02
2
PA
T 5
PB
6
IW114-0130E01 IW114-0130E03
1.Valve body 3.Spring 5.Plug 7.Relief valve assy

2.Spool 4.Plug 6.O-ring
Tightening torque
N-m ft-lbf
PA G3/4 167 123
T, PB G1/2 98 72
366-104-20000 △
0
19 W114-0132E

B-7 . B-7 .
Pressure Reducing Valve (Pilot Pressure)
B-7 Pressure Reducing Valve (Pilot Pressure)

[NOTICE]
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
Tightening torque
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
20 W120-0121E

B-8 B-8
Solenoid Control Valve (Outrigger)
B-8 Solenoid Control Valve (Outrigger)

[NOTICE]
1. Structure
A B
T
Sol. a1
Connector
R1
+-
(+): Red
P L
(-): Blue
G
IW121-0542E01
Sol. b1
IW112-015001
Sol. a1
R1
P T L
21 L
B
22
23
Sol. b1
10 1 15 IW112-015002
1.Body assy 15.T cover assy 22.Nut

10.P cover assy 21.Stud bolt 23.Spring washer
Tightening torque
N-m ft-lbf
P, T, L G1 196 145
A, B G3/4 167 123
G G1/4 29.4 22
21 W112-0152E

B-8 B-8
P cover assy
(illustrated as 10 on page 21)
1.Cover 7
2.O-ring
3.O-ring
R1
4.Shim
5.Plug
6.Plug assy
7.Relief valve assy
2
P
5 3
2
1
G
6
IW112-015003
22 W112-0152E

B-8 B-8
P cover assy (2/2)

Relief valve (illustrated as 7 on page 23)
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
23 W112-0152E

B-8 B-8
Body assy (1/2)

(illustrated as 1 on page 21)
1.Body 10
2.Spool
3.Plug
4.Plunger Sol. a1
5.Spring
6.O-ring
7.O-ring
8.O-ring
7
9.Shim
9
10.Pilot cover assy
6 A
8 1
3
5 2
7 B
Sol. b1
IW112-015004
24 W112-0152E

B-8 . B-8 .
Body assy (2/2)

Pilot cover assy (illustrated as 10 on page 21)
8 14 6 10 15 11 13 12
1.Cover
2.Plug
3.Spool
4.Spring
5.O-ring
6.Spring seat
7.Hexagon socket head bolt
8.Plug 1
9.Solenoid (DC24V)
10.Orifice
11.O-ring
12.O-ring
8
15.Spring
7 9 5 3 4 2
IW112-015005
366-460-20000 △
0
25 W112-0152E

B-9 B-9
Rotary Joint
B-9 Rotary Joint

[NOTICE]
1. Structure
[NOTICE]
The parts marked with (*1) - (*10) require special attention for disassembling and assembling. The required
attention is described in the "Attention" on page 37.
26 W181-0440E

B-9 B-9
Rotary Joint
Upper (view A)
Lower (view B)
27 W181-0440E

B-9 B-9
Rotary Joint
1.Slip ring assy 10.Support 19.Plug 28.Fitting

2.Plain bearing 11.Grease nipple 20.Support 29.Flare nut
3.Packing 12.Plain bearing 21.Flange bolt 30.Elbow fitting
4.Ring seal 13.Ring seal 22.Clamp 31.Support
5.Body 14.Packing 23.Nut 32.Grease nipple
6.Core 15.Ring seal 24.Plate 33.O-ring
7.Shaft 16.Bolt 25.Hexagon socket head bolt
8.Core 17.Flange bolt 26.Ring seal
9.Plain bearing 18.Plate 27.Pipe
Thread Tightening torque

Sign / port
size N-m ft-lbf
16 *1 M12 74 - 82 55 - 61
17 *1 (to secure the plate [18]) M8 11.8 – 13.7 9 - 10
21 *1 (to secure the slip ring ass’y [1]) M6 4.4 – 5.4 3.5 - 4
25 *1 M8 23.5 – 27.5 17 - 20
29 - 16 - 24 12 - 17
*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.
Hydraulic section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper
Winch G1 196 145
Lower
P1
Upper - - -
Outriggers pilot
Lower G1/4 29.4 22
Upper G1/4 29.4 22
P1’ Gauge
Lower - - -
Upper
P2 Boom elevating, Boom telescoping G1 196 145
Lower
Upper G1/4 29.4 22
P2’ Gauge
Lower - - -
Upper G3/4 167 123
P3 Swing, Steering
Lower G1 196 145
Upper
P4 Steering (left) G1/2 98 72
Lower
Upper
P5 Steering (right) G1/2 98 72
Lower
Upper
P6 Option G1/2 98 72
Lower
Upper
T1 Tank - - -
Lower
Upper G3/4 167 123
T2 Tank
Lower - - -
Upper
DR Drain G1/2 98 72
Lower
28 W181-0440E

B-9 B-9
Rotary Joint
Pneumatic section
Tightening torque
N-m ft-lbf
Upper Rc3/8 49 - 69 36 - 51
A1 Air supply
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
A2 Service brake (primary)
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
A3 Service brake (secondary)
Lower G1/4 29.4 22
L.L.C. section
Tightening torque
N-m ft-lbf
Upper
W1 Heater (IN) Rc3/8 49 - 69 36 - 51
Lower
Upper
W2 Heater (OUT) Rc3/8 49 - 69 36 - 51
Lower
Attention (*9): The "･" marks must be directed as shown in the

figure.
(*1): Face the "･" mark toward FRONT.
(*10): Do not use an organic solvent. The grease
(*2): Apply water-proof sealant equivalent to THREE grooves must be directed as shown below.
BOND 4101. Do not apply grease.
(*3): Apply thread locking agent equivalent to

THREE BOND 1401 to lock the threads.
(*4): Apply grease (EP2) when attaching.
(*5): Do not use an organic solvent.
(*6): Do not remove the shaft (8) from the core (7). It
is press-fit within the core.
(*7): To prevent rust, apply grease (EP2) when

assembling.
(*8): Tapped hole (2 places) for slinging. The

applicable thread size is M10.
29 W181-0440E

B-9 B-9
Rotary Joint
Slip ring Assy

21 22 20 31 28
31
C C
15
23
B
D D
24 19
A A 7 30
3 25
E E
2 T1
B
IW181-0260E03
27 26 13
11
12
F F
10
B-B
IW181-0260E04
4
12
8
29 6
16,17
3
9 18
7 1
P
A-A IW181-0290E03
P IW181-0260E05
30 W181-0440E

B-9 B-9
Rotary Joint
36 14
E-E
IW181-0260E09
C-C
IW181-0260E07
25
24
23
F-F
32,33 IW181-0260E10
D-D
IW181-0260E08
1.Shaft 10.BH+CB 19.O-ring 28.Hose band

2.Ring set plate 11.Spacer 20.Potentiometer 29.Hexagon socket set screw
3.Bearing 12.Spacer 21.Cover 30.Machine screw
4.Ring 13.BH+CB 22.Packing 31.Bolt
5.Ring 14.Support 23.Lever 32.Bolt
6.Ring set plate 15.Base 24.Pin 33.Spring washer
7.U nut 16.Dry lock nut 25.Guide 36.Hexagon socket head bolt
8.Support 17.Coned disc spring 26.Air breather
9.Stud bolt 18.Guide 27.Hose joint
Tightening torque
N-m ft-lbf
*1 *1
16 , T1 M6 4.9 3.6
31, 32, 36 M4 1.5 1.1
30 M3 0.63 0.5
*1：Apply LOCTITE 496 (strong quick-drying glue) to threaded sections.
31 W181-0440E

B-9 B-9
Rotary Joint
Wiring diagram
LOWER (Slip ring) UPPER (Brush holder)

G
3
W 2 3 2 1
R
1
3
2 B 6 6 5 4
Pot2 1 5
B
3 4
Pot1 2
1
Y Y
626 1 26 26 1 626
Y
2 1
3 2 23 Y 23 2 3 1 2
Y Y
627 12 27 27 12 627
Y 30 Y
628 11 28 28 11 628
Y 29 Y
629 10 29 29 10 629
Y 28 Y
630 9 30 30 9 630
Y 27 Y
20 8 20 20 8 20
1 2 3 4
Y 26 Y
4 3 2 1
5 6 7 8 21 7 21 21 7 21 8 7 6 5
Y 25 Y 12 11 10 9
9 10 11 12
22 6 22 22 6 22
Y 24 Y
4 5 24 24 5 4
Y 23 Y
615 4 15 15 4 615
Y 22 Y
16 3 16 16 3 16
Y 21 Y
618 2 18 18 2 618
Y 20 Y
19 1 19 19 1 19
19
Y 18 Y
12 6 12 12 6 12
Y 17 Y
13 5 13 13 5 13
1 2 3 Y 16 Y 3 2 1
614 4 14 14 4 614
4 5 6 Y 15 Y 6 5 4
8 3 8 8 3 8
Y 14 Y
9 2 9 9 2 9
Y 13 Y
10 1 10 10 1 10
12
Y Y
Y 11 Y
907 3 7 7 3 907
Y 10 Y
1 2 3 911
1 2 11 11 2 911 3 2 1
Y 9 Y
5 1 25 25 1 5
8
Y 7 Y
2 1 17 3 17 17 1 17 3
W W
6 1 6 6 2 6
3 W 6 W 1 2
2 2 5 5 3 2
5
W 4 W
1CC 4 3 3 4 1CC
W 3 W 1 2
2 1 1DD 3 4 4 3 1DD
W 2 W
1AA 2 1 1 2 1AA 3 4
4 3 W 1 W
1BB 1 2 2 1 1BB
Ring No.
Connector
Connector terminal No. ： Silver-plating ring
Mark No. IW181-0290E04
32 W181-0440E

B-9 . B-9 .
Rotary Joint
2. Potentiometer 3. Turn the potentiometer shaft using a slotted

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

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

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

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

another, coat the terminal section with epoxy
Stamp mark Guide adhesive (equivalent to 3M DP-420).
IW181-0260E13
346-305-71000 △
7
33 W181-0440E

B-1 0 B-1 0
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)
B-10 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch)

[NOTICE]
1. Structure
34 W134-0271E

B-1 0 B-1 0
C1 C2
Vent
Vent
(down) (down) (extending) (lowering)

b3,b4
b1 b2
b3 b4
B1 B2 T2 B3 B4
T1 P2 C3
A1 A2 A3 A4
a3 a4
a1 a2
a3,a4
Aux. winch Main winch Telescoping Elevating
(up) (up) (retracting) (raising)
P1
IW134-0270E02
35 W134-0271E

B-1 0 B-1 0
Tightening torque
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
36 W134-0271E

B-1 0 B-1 0
Cross section of whole body
B A
Aux. winch
Main winch
Telescoping
Elevating
B A
14 13
IW134-011012
37 W134-0271E

B-1 0 B-1 0
1
12
・
8
C C
Aux. winch
D D
Main winch
12
・
9
E E
2
F F
Telescoping
3
G G
Elevating
4 7 16
A-A IW134-0270E03
38 W134-0271E

B-1 0 B-1 0
Aux. winch
Main winch
Telescoping
Elevating
5 15 6
B-B
IW134-011004
1.Winch selector valve 5.O-ring 9.Main relief valve 15.Plug

2.Telescoping selector valve 6.O-ring 12.Hex. socket head bolt 16.Eye bol
3.Elevating selector valve 7.Hex. socket head bolt 13.Plug
4.End cover 8.Main relief valve 14.O-ring
Tightening torque
N-m ft-lbf
7 M12 57 - 59 42 - 43
12 M10 44 - 49 32.5 - 36
13 G1/4 24.5 - 29.4 18 - 22
15 - 10 - 12 7-9
39 W134-0271E

B-1 0 B-1 0
Winch selector valve
6 2 4 20 19 21 22 1
Overload relief valve
25,24,23,13 9 8 12,23,24,25
7
11 10
30
29
18 17 15 28 27 26 28 14 16,17
C-C (Aux. winch) , D-D (Main winch) IW134-0270E04
1 Main relief valve
18 17 15 28 27 26 5 28 16,17
E-E IW134-0110E07
40 W134-0271E

B-1 0 B-1 0
1.Winch selector valve body 8.Return spring 16.Plug 23.Hex. socket head bolt
2.Spool (main,aux. winch) 9.Return spring 17.O-ring 24.Plain washer
3.-------------------------------- 10.Spring seat 18.Spring retainer 25.Spring washer
4.Flow control valve 11.Spool end (flow control valve) 26.Plug
(main winch), (aux. winch) 12.Pilot cover 19.Check valve 27.O-ring
5.Flow control valve (junction) 13.Pilot cover 20.Spring (check valve) 28.Plug
6.O-ring 14.Orifice 21.Plug (check valve) 29.Steel ball
7.Spring seat 15.Spring (flow control valve) 22.O-ring 30.Hex. socket set screw

Tightening torque
N-m ft-lbf
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
1
30* M8 12 - 14 8.5 - 10
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 - 10 - 12 7-9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
41 W134-0271E

B-1 0 B-1 0
Telescoping selector valve
5 4 29 30 2 3 22 21 23 24 1
11 10
27,26,25,13 7 8 9 12,25,26,27
6 19,20 18 17 28 14 16 15 19,20
F-F (Telescoping) IW134-0270E03
1.Telescoping selector valve 7.Spring seat 15.Plug (shuttle valve) 23.Plug (check valve)
body 8.Return spring 16.O-ring 24.O-ring
2.Spool (telescoping) 9.Return spring 17.Orifice 25.Hex. socket head bolt
3.Flow control valve 10.Spring seat 18.Spring (flow control valve) 26.Plain washer
(telescoping) 11.Spool end 19.Plug 27.Spring washer
4.Steel ball 12.Pilot cover 20.O-ring 28.Plug
5.Hex. socket set screw 13.Pilot cover 21.Check valve 29.Plug
6.O-ring 14.Steel ball 22.Spring (check valve) 30.O-ring

Tightening torque
N-m ft-lbf
Overload relief valve (Telescoping) M27×1.5 77 - 88 58 - 65
1
5* M8 12 - 14 8.5 - 10
1
11* - 18 - 20 13 - 14
1
15* - 18 - 20 13 - 14
2
17* M6 5-6 3.5 - 4.5
19 M33 98 - 118 72 - 87
23 - 78.5 - 88.3 58 - 65
25 M8 27.5 - 29.4 20 - 22
28 - 10 - 12 7-9
29 G3/4 78.5 – 88.3 58 - 65
42 W134-0271E

B-1 0 B-1 0
Elevating selector valve

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

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

Tightening torque
N-m ft-lbf
M27×1.5 78 - 88 58 - 65
（Elevating）
1
5* M8 12 - 14 8.5 - 10
1
11* - 18 - 20 13 - 14
2
14* M6 5-6 3.5 - 4.5
16 M33 98 - 118 72 - 87
18 G3/4 78.5 - 88.3 58 - 65
20 M8 27.5 - 29.4 20 - 22
23 - 10 - 12 7-9
43 W134-0271E

B-1 0 B-1 0
Main relief valve

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

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

Tightening torque
N-m 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
44 W134-0271E

B-1 0 . B-1 0 .

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

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

Tightening torque
N-m 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
366-405-40000 △
0
45 W134-0271E

B-1 1 B-1 1
Sequence Valve (Pilot Pressure)
B-11 Sequence Valve (Pilot Pressure)

[NOTICE]
1. Structure

Tightening torque
N-m ft-lbf
P, V G1/2 98 72
Dr G3/8 49 36
Pi, G G1/4 29.4 22
46 W122-0113E

B-1 1 B-1 1
Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)
6
1.Body
2.Filter
3.Filter retainer 5
4.Back pressure regulating valve
5.Pressure reducing valve
7.Plug
8.O-ring
9.Plug 4
A-A 1 2 3
IW122-0112E01
Tightening torque
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
Tightening torque
N-m ft-lbf
1 M24×1.5 58.8 – 68.6 43.4 – 50.6
47 W122-0113E

B-1 1 . B-1 1 .
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
48 W122-0113E

B-1 2 B-1 2
Solenoid Valve (Pilot Pressure)
B-12 Solenoid Valve (Pilot Pressure)
[NOTICE]
1. Structure
A2 A1
T
P
IW121-067001
701
Connector
IW121-0671E01
171
T
A2 A1
P
101.Casing
701.Solenoid valve (DC24V)
101 T1 IW121-067002

Tightening torque
N-m 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
49 W121-0672E

B-1 2 . B-1 2 .
Solenoid Valve (Pilot Pressure)
Solenoid valve assy
31 1 326 324
P A T
312 361 362 363 861 801 802
IW121-067003
311.Spool 326.Retaining ring 363.O-ring 861. O-ring

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

Tightening torque
N-m ft-lbf
802 M6 6.9 - 7.9 5.1 - 5.8
367-401-00000 △
0
50 W121-0672E

B-1 3 B-1 3
Solenoid Control Valve (Jib Set)
B-13 Solenoid Control Valve (Jib Set)

[NOTICE]
1. Structure
CO
A2
B2
P P A1
B1
G P T
IW112-0220E01
Connector
+- (+) : Red
(-) : Black
IW121-0542E01
51 W112-0222E

B-1 3 B-1 3
A B
33
C
18 32
D
33
B2 B1
31
OUT
T
21
C･O
P
IN
OUT
A2 A1
C 33
D
33
A P.P B
27,38
29
P.P 33
IW112-0220E02
18.Name plate 27.Plug 31.Nut 33.Ball

21.Tigh rod 29.Hexagon socket head bolt 32.Ribbet screw 38.O-ring
Tightening torque
N-m ft-lbf
P, T G1/2 98 72
A1, B1, A2, B2 G3/8 49 36
C•O G1/2 98 72
P•P G1/4 29.4 22
52 W112-0222E

B-1 3 B-1 3
6.Collar 16 28 34 19 38 23 27 33
7.Spring folder
8.Plug
9.Spring 8
16.Solenoid 7
19.Body
20.Spring 22
22.Spring 25
6
23.Filter 44
25.Spool end 35
35
27.Plug
33
33.Ball
34.O-ring
35.O-ring
37.O-ring
38.O-ring
44.O-ring
35 33
35
28
37
8
9
33
16 34 19 38 27 23 20
A-A
IW112-0220E03
53 W112-0222E

B-1 3 B-1 3
14.Spol
15.Housing
17.Housing plunger 14
24.Housing 14
35
35.O-ring
43.O-ring
24
17
43
15
35
B-B IW112-0220E04
54 W112-0222E

B-1 3 B-1 3
C-C
IW112-0220E05
CO
D-D IW112-0220E06
55 W112-0222E

B-1 3 . B-1 3 .
Relief valve
39 11 13 5 36 42 12 2 41 1 40 10 4 30 3
IW112-0220E07
1.Spring 5.Spring 13.Poppet 40.O-ring

2.Needle valve 10.Housing 30.Screw 41.O-ring
3.Nut 11.Sleeve 36.O-ring 42.O-ring
4.Gasket 12.Sleeve 39.O-ring
366-489-20000 △
0
56 W112-0222E

B-1 4 . B-1 4 .
Pilot Check Valve (Jib Set)
B-14 Pilot Check Valve (Jib Set)

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

2.Sleeve 5.Piston 8.O-ring 11.Plug
3.Poppet 6.O-ring 9.O-ring 12.Plug
Tightening torque
Sign /port Thread size
N-m ft-lbf
A,B,C,D G1/4 29.4 22
366-241-40000 △
1
57 W115-0271E

B-1 5 B-1 5
Solenoid Valve (Oil Cooler)
B-15 Solenoid Valve (Oil Cooler)

[NOTICE]
1. Structure
4
b f
3
2
a
b f
1
P A
a T B
e T1
P
B
A
T
IW121-025001 IW121-025002
1.Solenoid valve assy 2.Body 3.Valve 4.Plug
Tightening torque
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7-8 5-6
58 W121-0253E

B-1 5 . B-1 5 .
Solenoid valve assy
Connector
+- (+): Red
(-): Blue
IW121-0542E01
T1 3
A P B
T T
T2 12 9 1 15 8 7 11 2
IW121-025003
1.Body 7.Spring seat 11.Spring

2.Plug 8.Square ring 12.Solenoid (DC24V)
3.Spool 9.O-ring 15.Hexagon socket head bolt
Tightening torque
N-m ft-lbf
2 - 44 - 49 32 - 36
15 M5 7 5
T1 - 39 - 49 29 - 36
T2 - 4.4 – 5.4 3-4
366-457-50000 △
1
59 W121-0253E

B-1 6 . B-1 6 .
B-16 Hydraulic Motor (Oil Cooler)

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

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

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

0
366-631-20000 △
0
60 W102-0122E

B-1 7 . B-1 7 .
Jib Lock Pin
B-17 Jib Lock Pin

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

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

*2 : Apply sealant equivalent to three bond 1104.
Tightening torque
N-m ft-lbf
A, B G1/4 29.4 22
360-531-60000 △
0
61 W180-0021E

B-1 8 . B-1 8 .
Jib Offset Cylinder
B-18 Jib Offset Cylinder

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

2.Split pin 6.O-ring 10.Damper ring 14.Dust seal
3.Nut 7.Rod 11.packing 15.---
4.Piston 8.Rod cover 12.Backup ring 16.Plain bearing
*1 : Face the notch or the lip toward the pressurized side.
Tightening torque
N-m ft-lbf
A, B G1/4 29.4 22
360-520-90000 △
0
62 W180-0031E

B-1 9 . B-1 9 .
Check Valve (Gauge Isolator)
B-19 Check Valve (Gauge lsolator)
[NOTICE]
1. Structure
Hydraulic symbols
P' S
P1 P2 P3 IW116-012001
7 8 1 2 5 4 3 6
IW116-012002
P1 P2 P3
Tightening torque
Sign / port Thread size Remark
N-m ft-lbf
P1, P2, P3, P’ G 1/4 29.4 22
G 3/8 49.0 36
S
M18×1.5 127 - 147 93 - 108 TT-300XL-1 only
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
366-244-50000 △
1
366-251-20000 △
0
63 W116-0123E

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
1. Structure ................................................... 4
C-4 Extension Cylinder .......................... 5
1. Structure ................................................... 5
C-5 Solenoid Valve (Slide/Jack)

(UCHIDA) .................................. 6
1. Structure ................................................... 6
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 WC02-0202E

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 WC02-0202E

C-2 . C-2 .
Jack Cylinder
C-2 Jack Cylinder
[NOTICE]
1. Structure
1.Cylinder 6.Stopper 11.O-ring 17.Backup ring

2.Rod 7.Spring pin 12.Backup ring 18.Dust seal
3.Bolt 8.Piston 13.O-ring 19.Damper ring
4.Spring washer 9.Packing 15.Rod cover assy 21.Backup ring
5.Bolt 10.Backup ring 16.Packing 22.Plain bearing
Tightening torque
N-m ft-lbf
3,5 M10 22 - 25 16 - 18
T1 M24 588 - 666 434 - 492
360-302-90000 △
8
3 W151-0112E

C-3 . C-3 .
Pilot Check Valve (Jack Cylinder Retracting Prevention)
C-3 Pilot check Valve (Jack Cylinder Retracting Prevention)
[NOTICE]
1. Structure
9
A B
C D
C D
IW115-023001
5 4 6 7,8
A B
IW115-0490E01
1.Valve body 4.Valve 7.O-ring

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

Tightening torque
N-m ft-lbf
A G1/4 29.4 22
B G1/4 29.4 22
Mounting
M10 43 - 49 32 - 36
bolt
366-200-00000 △
1
4 W115-0491E

C-4 . C-4 .
Extension Cylinder
C-4 Extension Cylinder
[NOTICE]
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

Tightening torque
N-m ft-lbf
A, B, C G3/8 49 36
D, E G1/4 29.4 22
2 M20 176 - 196 130 - 145

360-424-20000 △
1
5 W153-0012E

C-5 . C-5 .
Solenoid Valve (Slide/Jack) (UCHIDA)
C-5 Solenoid Valve (Slide/Jack) (UCHIDA)
[NOTICE]
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 (DC24V)

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

Tightening torque
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]
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 (DC24V) 7.Body 10.Centering washer

2.O-ring 5.Packing 8.O-ring 11.Spring
3.Solenoid core (DC24V) 6.O-ring 9.Spool 12.Spring pin
Tightening torque
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]
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 (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
Tightening torque
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]
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.Hexagon socket head bolt
3.Valve 6.Stop ring 9.Stopper 12.Spring washer
Tightening torque
N-m ft-lbf
P1 G1/2 98 72
P2 G1/2 98 72
366-245-40000 △
0
9 W116-0112E

D
Swing System D
Contents
D-1 Swing System................................... 1
1. General..................................................... 1
D-2 Swing Assmbly ................................ 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
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 WD02-0211E

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 WD02-0211E

D-2 D-2
Swing Assembly
D-2 Swing Assembly

[NOTICE]
1. Structure
1.Bolt
2.Plain washer
[NOTICE]
Apply torque control agent to the threaded sections of the bolts.
Tightening torque
Sign/port Thread size
N-m ft-lbf
1 M18 294 - 343 217 - 253
3 W514-0161E

D-2 D-2
Swing Assembly
2. Swing bearing mounting bolt
2.1 Bearing Inner ring bolts
6 7 8 9 7,10 1,3 1,3
1,2
View A A
"S" mark
4,5
Front
1.Pain washer 1,3

2.Bolt (L=185mm) 1,3 11
3.Bolt (L=155mm)
4.Plain washer 4,5
5.Bolt
6.Support
7.Nut 1,3 1,2
8.Bolt
9.End
10.Spring washer
11.Pin
IW514-0140E01
[NOTICE]
Install the bearing inner ring with the "S" mark
facing the rear of the carrier.
Apply torque control agent to the threaded sections Thread Tightening torque
Sign/port
of the bolts. size N-m ft-lbf
Install the plain washer, orienting its chamfer on the 2
internal periphery as shown below. (44 points)
M30 1620 - 1810 1195 - 1335
3
(4 points)
5 M12 69 - 82 51 - 60
4 W514-0161E

D-2 . D-2 .
Swing Assembly
2.2 Bearing outer ring bolts Applicable serial No. △

2 ：545543 --
△2 168
1.Bolt (L=160mm)
2.Bolt (L=190mm)
3.Plain washer (50points)
4.Nut (5points) D
5.Reamer bolt (L=185mm)
6.Plain washer (2points)
D 1
C
3
A
C
B 5
B 6
D
3
D B 4
A
4
3
FRONT
Swing table
3
C 2
3
D
IW514-0140E02
[NOTICE]
Apply torque control agent to the threaded sections
of the bolts.
Install the plain washer, orienting its chamfer on the Thread Tightening torque
Sign / port
internal periphery as shown below. size N-m ft-lbf
1
(42 points)
2
M27 1177 - 1275 868 - 940
(3 points)
5
(2 points)
343-007-20000 △
1
347-621-32000 △
0
342-310-40000 △
2
5 W514-0161E

D-3 D-3
Hydraulic Pilot Control Valve (Swing)
D-3 Hydraulic Pilot Control Valve (Swing)

[NOTICE]
1. Structure
(+):Red
(-):Blue
BM AM Sol.2
Sol.3
Sol.1 Dr
RV
Sol.4
P
G Pi1
Pb
Pa Pi2
Pa Pi2 Pi1 Pb
Pa' Pb'
IW134-0122E01
6 W134-0123E

D-3 D-3
Tightening torque
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
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
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
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 .
101.Casing 242.O-ring 401.Plug 552.Plug

151.Plug 243.O-ring 411.Plunger 561.O-ring
152.Plug 251.Orifice 412.Spring 562.O-ring
201.Spool 252.Plug 413.O-ring 641.Spring seat
211.Spacer bolt 253.Plug 414.Steel ball 642.Spring
212.Stopper 261.Solenoid 415.Stopper 643.Steel ball
221.Cover inverse-proportional 450.Air bleeder screw 644.Seat
222.Cover reducing valve 511.Poppet 661.O-ring
231.Spring seat 263.O-ring 512.Poppet 701.Relief valve
234.Spring 351.Hex. socket head bolt 521.Spring 702.Solenoid relief valve
235.Spring 352.Hex. socket head bolt 522.Spring 703.Relief valve
241.O-ring 353.Hex. socket head bolt 551.Cap 706.Solenoid valve (DC24V)
Tightening torque
Sing / port Thread size
N-m 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
366-461-30000 △
1
366-489-70000 △
0
11 W134-0123E

D-4 D-4
Hydraulic Motor (Swing)
D-4 Hydraulic Motor (Swing)
[NOTICE]
1. Structure
DR PB
A B
IW102-050001
464 485
A- A
443 106 432 117 121 118 114 706 702 707 712 472 106 438 303 401
471 A(B) A
A
304
433
444 DR
101 DR
491
437
PB PB
301 113 124 122 123 116 111 742 743 131 451 IW102-050002
12 W102-0501E

D-4 . D-4 .
Hydraulic Motor (Swing)
101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring

106.Spacer 123.Guide plate 437.Iocking ring 491.Oil seal
111.Cylinder 124.Shoe plate 438.Iocking ring 702.Brake piston
113.Spherical bush 131.Valve plate 443.Roller bearing 706.O-ring
114.Cylinder spring 301.Casing 444.Roller bearing 707.O-ring
116.Push rod 303.Valve cover 451.Spring pin 712.Brake plate
117.Spacer 304.Font cover 464.Plug 742.Friction plate
118.Spacer 401.Hex. socket head bolt 471.O-ring 743.Separator plate
121.Piston 432.Stop ring 472.O-ring
Tightening torque
N-m ft-lbf
PB G1/4 36 26.6
A, B G3/4 167 123
DR G1/2 108 80
464 G1/4 36 26.6
401 M20 430 317
366-635-90000 △
0
13 W102-0501E

D-5 D-5
Swing Speed Reducer
D-5 Swing Speed Reducer
[NOTICE]
1. Structure
7
30,31
20,21
19 22
18 23
16,17
15
24
14
13 25
12
26
11
27
10
9 28
8
7 26
6 29
IW511-024001
14 W511-0241E

D-5 . D-5 .
Swing Speed Reducer
[NOTICE]
Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer
bracket (19).
Inject lithium based grease to the mating faces of the retainer (2) and the roller bearing (3).
After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into
casing(4).
Apply lithium based grease to the inner circumference of oil seal(5).
The amount of the gear oil is approx. 1 gal (US). (3.8 L).
Do not disassemble the king pins (8), (27) nor spacer (13).
1.Spur gear 9.Carrier 17.Spring washer 25.Needle bearing

2.Retainer 10.Bearing washer 18.Sun gear 26.Bearing washer
3.Roller bearing 11.Needle bearing 19.Bracket 27.King pin
4 Casing 12.Planetary gear 20.Bolt 28.Sun gear
5.Oil seal 13.Spacer 21.Spring washer 29.Snap ring
6.Ball bearing 14.Carrier 22.Snap ring 30.Bolt
7.Plug 15.Bearing washer 23.Coupling 31.Seal washer
8.King pin 16.Bolt 24.Planetary gear
Tightening torque
N-m ft-lbf
20 M16 206 152
Mounting bolt (*1) M18 294 - 343 217 - 253
*1: Apply torque control agent to threaded sections.
360-816-51000 △
0
15 W511-0241E

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 WE02-0200E

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 WE02-0200E

E -2 E -2
Elevating Cylinder
E-2 Elevating Cylinder

[NOTICE]
1. Structure
3 W155-0231E

E -2 . E -2 .
Elevating Cylinder
36 35 4,5 4,6 7,40 38 12 13,14 15
16,17,18
1 2 3 8 9 10 11 39 11 IW155-0230E02
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.Retainer 26.T-fitting 36.Grease nipple
7.O-ring 17.Spring washer 27.Pipe 37.Pipe
8.Piston 18.Bolt 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
Tightening torque
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 24 - 27 17 - 20
360-267-50000 △
0
4 W155-0231E

E -3 E -3
Counterbalance Valve (Elevating)
E-3 Counterbalance Valve (Elevating)

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

2-1.Valve seat 2-9.Spool 3-1.Valve seat 4.Orifice
2-2.O-ring 2-10.Orifice 3-2.O-ring 5.Filter element
2-3.O-ring 2-11.Steel ball 3-3.O-ring 6.Snap ring
2-4.Backup ring 2-12.Spring 3-4.Backup ring 7.Stopper
2-5.O-ring 2-13.Holder 3-5.Poppet
2-6.Backup ring 2-14.Spring 3-6.Spring
2-7.O-ring 2-15.Cap 3-7.Cap
5 W119-0212E

E -3 E -3
Tightening torque
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 .
2. Function
a
P.P B
b
A
IW119-021003
This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the 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
FF
Contents
F-1 Winch System .................................. 1 F-5 Hydraulic Valve

(Winch Brake Release) ..........12
1. General..................................................... 1
1. Structure ................................................. 12
F-2 Winch ................................................ 4
1. Structure ................................................... 4
F-3 Hydraulic Motor (Winch) ................. 6
1. Structure ................................................... 6
2. Air bleeding procedure.............................. 8
F-4 Counterbalance Valve (Winch) ....... 9
1. Structure ................................................... 9
2. Function.................................................. 10
2.1 Balancing and holding functions .............. 10
2.2 Overload relief function ............................ 10
3. Principle of operation ...............................11

3.1 When control valve is in neutral ................11
3.2 Hoisting up.................................................11
3.3 Hoisting down ............................................11
i
F-1 F-1
Winch System
F-1 Winch System

1. General
Hydraulic Circuit for Winch
1 WF02-0251E

F-1 F-1
Winch System
Boom Telescoping/Auxiliary Hoist (~#545522)
Boom Telescoping / Auxiliary Hoist (#545523~)
2 WF02-0251E

F-1. F-1.
Winch System
[NOTICE]
4. Circuit for boom telescoping/auxiliary hoist
The remote control valve and the solenoid valve are
connected to the hydraulic pilot control valve at the In this hydraulic circuit, the two solenoid valves
points having the same symbols such as "a2", "a3", (boom telescoping/auxiliary hoist) switch the pilot
"b2", and "b3". circuit from the remote control valve (boom
telescoping/auxiliary hoist control lever) to the
1. The main winch is controlled by the hydraulic pilot
hydraulic pilot control valve to either the boom
method. The pilot pressure from the remote
telescoping pilot circuit or the auxiliary winch pilot
control valve (main hoist control lever) controls the
circuit.
hydraulic pilot control valve. The auxiliary winch
employs a similar hydraulic pilot method. 5. Circuit for remote control pressure vent
In this hydraulic circuit, the solenoid valve (remote
2. The maximum pressure in the main and auxiliary
control pressure vent) controls the pilot pressure
winch hydraulic circuits is regulated by the relief
to the remote control valve (main winch), the
valve (main winch, auxiliary winch).
remote control valve (boom telescoping/auxiliary
3. The overload relief valve (down) regulates the hoist control lever), the hydraulic valve (main
maximum pressure in the hoist-down circuit for winch brake release), and the hydraulic valve
the main winch. This valve suppresses the surge (auxiliary winch brake release).
pressure that may occur in a sudden hoist-down
operation so as to assure a smooth hoist-down
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
auxiliary winch employs a similar hoist-down
circuit.
3 WF02-0251E

F-2 F-2
Winch
F-2 Winch
[NOTICE]
1. Structure
1 17 18 19 20
12,13
3,4
21
29
22 24,25,26
5 9,10
31
7
32
8
9,10
11
12,13
14
15
28 27 30
16
12,13 23 41
A- A
IW526-012002
4 W526-0122E

F-2. F-2.
Winch
Note: Apply THREE-BOND 1104 to the following 5 places: mating face of the gear case (18) and the gear case
cover (37); mating face of the gear case (18) and the bracket (1); mating face of the gear case (18) and the
bearing retainer (7); mating face of the gear case (18) and the bearing retainer (21); mating face of the gear case
(18) and the bearing retainer (22). When installing the oil seals (5) and (23), apply THREE-BOND 1215 to their
external periphery and inject lithium based grease to their internal periphery. Apply NEVER-SEEZ to the
following 2 places: toothed mating face of the drum shaft (30) and the drum boss (27); cylindrical mating face of
the drum shaft (30) and the drum (29). The amount of the gear oil is approx. 1.1 gal. (4 L). Do not disassemble
the sleeve (41).
1.Bracket 13.Spring washer 23.Oil seal 33.Bolt

3.Bolt 14.Drum gear 24.Bolt 34.Spring washer
4.Spring washer 15.Collar 25.Spring washer 35.Plug
5.Oil seal 16.Ball bearing 26.Lock plate 36.Elbow joint
7.Bearing retainer 17.Ball bearing 27.Drum boss 37.Gear case cover
8.Ball bearing 18.Gear case 28.Pin 38.Plug
9.Nut 19.Spur gear 29.Drum 41.Sleeve
10.Washer 20.Ball bearing 30.Drum shaft
11.Collar 21.Bearing retainer 31.Ball bearing
12.Bolt 22.Bearing retainer 32.Bearing stand
Tightening torque
N-m ft-lbf
3 *1 M14 177 - 190 130 - 140
12 M12 69 - 82 51 - 61
24 M20 353 - 392 260 - 289
33 M8 32 - 34 24 - 25
35 *2 R3/4 106 - 132 78 - 98
38 *3 R3/8 44 - 62 33 - 46
Mounting bolt M20 431 - 471 318 - 347

*1: Apply THREE-BOND 1305 to threaded sections.
*2: Oil filler port.
*3: Oil level port on the top and drain port on the bottom.
360-730-30000 △
0
360-731-80000 △
0
5 W526-0122E

F-3 F-3
Hydraulic Motor (Winch)
F-3 Hydraulic Motor (Winch)
[NOTICE]
1. Structure
Tightening torque
N-m ft-lbf
DR G3/4 167 123
PR G1/4 36 27
DA1 M10x1.25 16 12
DA2 M10x1.25 16 12
T1 M12 69 51
Mounting bolt M20 431 - 470 318 - 347
6 W102-0132E

F-3 F-3
Cross section of the hydraulic motor
491 471 123 114 464 131 451 401 762

304 122 121 485 111 697 303 761
476
473
701
705
432
463
A
702
403 106 113 301 402 703 741 720 707

101 443 431 124 444 472 710 742 706 404
IW102-013003
(720) 773 771 772
A
IW102-013004
7 W102-0132E

F-3. F-3.
121.Piston 301.Casing 471.O-ring 707.O-ring

122.Shoe 304.Front cover 472.O-ring 710.Brake shim
111.Cylinder 401.Hex. socket head bolt 473.O-ring 720.Brake casing
131.Valve plate 402.Hex. socket head bolt 476.O-ring 741.Separater plate
303.Valve cover 403.Bolt 485.O-ring 742.Friction plate
451.Pin 404.Hex. socket head bolt 491.Oil seal 761.Plug
101.Drive shaft 431.Stop ring 697.O-ring 762.O-ring
106.Spacer 432.Stop ring 701.Brake cover 771.Air breeder screw seat
113.Spherical bush 443.Self-aligning roller bearing 702.Brake piston 772.Air breeder screw
114.Cylinder spring 444.Needle bearing 703.Coupling 773.O-ring
123.Set plate 463.Plug 705.Brake spring
124.Shoe plate 464.Plug 706.O-ring
Tightening torque
N-m ft-lbf
401 M18 333 246
402 M18 333 246
403 M10 57 42
404 M12 98 72
463 R3/8 44 33
464 G3/4 167 123
761 G1/4 36 27
771 G1/4 36 27
772 M10 16 12
2. Air bleeding procedure

366-628-20000 △
0
366-635-50000 △
0
8 W102-0132E

F-4 F-4
Counterbalance Valve (W inch)
F-4 Counterbalance Valve (W inch)
[NOTICE]
1. Structure
B1 A1
b
a1
φ0.7
a
Dr
B A
IW119-0500E01
165 152
162 302 361 362 301 101 312 355 322 354 351 204 203 321 272 271
b a
202 Dr
262
253
B A
273
274 161 161 201 261 252 256
B1
A1
600
562 563 551 521 51 1 514
164 151
171 B A
172
a1
Dr
B1 A1
163
IW119-0500E02
9 W119-0501E

F-4 F-4
101.Casing 201.Cover 272.Square spring washer 355.Orifice

151.Plug 202.Cover 273.Hex. socket head bolt 361.O-ring
152.Plug 203.Spacer 274.Square spring washer 362.O-ring
161.O-ring 204.Spacer 301.Spool 511.Plunger
162.O-ring 252.Air bleeder screw seat 302.Pilot piston 514.Seat
163.O-ring 253.Plug 312.Steel ball 521.Spring
164.O-ring 256.Air bleeder screw 321.Spring 551.Plug
165.O-ring 261.O-ring 322.Spring 562.O-ring
171.Hex. socket head bolt 262.O-ring 351.Orifice 563.Backup ring
172.Square spring washer 271.Hex. socket head bolt 354.Orifice 600.Relief valve

Tightening torque
N-m ft-lbf
151, 152 G3/8 69 - 79 51 - 58
171 M12 64 - 74 47 - 54
252 G1/4 34 - 38 25 - 28
253 G1/4 34 - 38 25 - 28
256 M10 14 - 18 10 - 13
271, 273 M12 88 - 108 65 - 80
551 M33 181 - 211 134 - 156
600 M33 166 - 186 123 - 137
2. Function 2.2 Overload relief function
When the circuit pressure rises above the preset

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

this valve closes the return passage to hold the
load at a desired position.
10 W119-0501E

F-4. F-4.
3. Principle of operation
c b d
B A
B1 a
A1

IW119-0500E03
3.1 When control valve is in neutral 3. This pressure flows through choke b in the spool,
enters into chamber c, where it pushes the
The holding pressure of the hydraulic motor is plunger to the right by overcoming the spring force,
locked by the seat area a of the check valve, the and opens land d.
land area d of the spool and the overload relief
valve. 4. As a result, the return oil from the motor is
discharged to the control valve via land d to drive
3.2 Hoisting up the motor.
1. When the control valve sends oil to port A, the oil 5. When the load tends to pull the motor faster than
pushes open the check valve and flows to port A1 the speed corresponding to the flow rate to port B,
connected to the motor. the pressure in chamber c drops.
2. On the other hand, the return oil from the motor 6. Maintaining balance with the spring force to
port enters through port B1, and then, is automatically adjust the oil passage area in land d
discharged through port B to the control valve. to prevent the load from falling at speeds faster
than the motor drive speed.
3.3 Hoisting down
1. As oil is sent to port B by the control valve, it flows

to the motor via port B1.
2. The return oil from the motor is blocked at port A1,

to raise the pressure at port B.
366-058-20000 △
0
11 W119-0501E

F-5. F-5.
Hydraulic Valve (Winch Brake Release)
F-5 Hydraulic Valve (Winch Brake Release)
[NOTICE]
1. Structure
T3
B1
P1
Dr
B1 P2
AC
P1
B2 T B2
P2
T 9 4 10 2 6 7 1 5 2 3 8
Dr AC T2 T1
IW123-020001 IW123-020002
1.Valve body 4.Side cover 7.Plug 10.Spring seat

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

Tightening torque
N-m ft-lbf
AC, B1, B2, Dr
G1/4 29.4 22
T, P1, P2
T1, T2 M8 23 - 27 17 - 20
T3 M10 23 - 27 17 - 20
366-452-90000 △
0
12 W123-0281E

G
Boom Telescoping System
Contents G
G-1 Telescoping System ........................ 1 4.4 Installing slide plates onto sides of
rear end...............................................18
1. General..................................................... 1
5. Adjustment .............................................. 18
2. Description of telescoping system (Refer to 5.1 Adjusting clearance for the boom.................18
the circuit diagram in Chapter Z.)... 5 5.2 Adjusting boom telescoping wire rope .........18
2.1 Extension circuit ......................................... 5
2.2 Retraction circuit......................................... 6 6. Test .................................................... 19
6.1 Operation test ...........................................19
3. Boom telescoping mechanism .................. 7 6.2 Boom lateral warp test ..............................19
3.1 Extension.................................................... 7 6.3 Other functional test..................................19
3.2 Retraction ................................................... 8
G-3 Jib .................................................20

G-2 Boom (Five-Section Boom) ........... 10
1. Structure ................................................. 20
1. Structure ................................................. 10 1.1 Location of Jib...........................................20
1.2 Jib main body............................................22
2. Disassembly ........................................... 13
2.1 Removing the 2nd boom section.............. 13 2. Adjustment .............................................. 24
2.2 Removing the 3rd boom section............... 14 2.1 Adjusting jib 1-2 connecting spring pin .....24
2.3 Removing the 4th boom section............... 15 2.2 Adjusting jib inclination..............................24
2.4 Removing the top boom section............... 15 2.3 Adjusting inclination of jib 2.......................25
3. Check .................................................... 17
3.1 Boom ........................................................ 17 G-4 Telescoping Cylinder .....................26
3.2 Slide plate................................................. 17
3.3 Sheave ..................................................... 17 1. Structure ................................................. 26
3.4 Boom telescoping wire rope ..................... 17
4. Reassembly............................................ 17
4.1 Greasing ................................................... 17
4.2 Install anti-buckling bolts for
telescoping cylinder............................ 17
4.3 Installing lower slide plates....................... 18
i
G-5 Counterbalance Valve
(Telescoping) ......................... 28
1. Structure ................................................. 28
2. Function.................................................. 29
2.1 When control valve is at the
neutral position ................................... 29
2.2 While actuator is being pushed up ........... 29
2.3 While actuator descends .......................... 29
G-6 Hose Reel ....................................... 30
1. Structure ................................................. 30
2. Dismounting............................................ 31
3. Mounting................................................. 31
4. Disassembly ........................................... 31
5. Reassembly............................................ 31
G-7 Hydraulic Valve .............................. 33
1. Structure .................................................... 33
ii
G-1 G-1
Telescoping System
G-1 Telescoping System

1. General
Hydraulic Circuit for Boom Telescoping (2M2D)
Boom Telescoping/Auxiliary Hoist (~#545522)
1 WG02-0321E

G -1 G -1
Telescoping System
Boom Telescoping/Auxiliary Hoist (#545523~)
2 WG02-0321E

G -1 G -1
Telescoping System
Telescoping cylinder at select
3 WG02-0321E

G -1 G -1
Telescoping System
[NOTICE]
The solenoid valve and the hydraulic pilot control
valve are connected at the two points having the
same symbols such as "a4" and "b4".
1. The telescoping operation is controlled by the

hydraulic pilot method. The pilot pressure from
the remote control valve (boom
telescoping/auxiliary hoist control lever) or the
remote control valve (boom telescoping control
pedal) controls the hydraulic pilot control valve.
2. The maximum pressure in the boom telescoping

hydraulic circuits is regulated by the relief valve
(elevating, telescoping).
3. Circuit for boom telescoping/auxiliary hoist

In this hydraulic circuit, the two solenoid valves
(boom telescoping/auxiliary hoist) switch the pilot
circuit from the remote control valve (boom
telescoping/auxiliary hoist control lever) to the
hydraulic pilot control valve to either the boom
telescoping pilot circuit or the auxiliary winch pilot
circuit.
4. Circuit for remote control pressure vent

In this hydraulic circuit, the solenoid valve (remote
control pressure vent) controls the pilot pressure
to the remote control valve (boom
telescoping/auxiliary hoist control lever) and the
remote control valve (boom telescoping control
pedal).
5. Circuit for top cylinder select

In this hydraulic circuit, the solenoid valve (top
cylinder select) controls the hydraulic valve which
delivers the pressurized oil from the hydraulic pilot
control valve to the No.1 cylinder circuit or the
No.2 cylinder circuit.
In this hydraulic circuit, the another solenoid valve

protects the No.2 cylinder retraction while mode II
select.
4 WG02-0321E

G -1 G -1
Telescoping System
2. Description of telescoping system

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

4th boom section retraction wire Fix at the rear end of the 2nd boom section.
4th boom section extension wire Fix at the rear end of the 4th boom section.
Fix at the head of the 4th boom section. Fix at the rear end of the top boom section.
IWG02-0260E01
2.1 Extension circuit 4. In this case, you need not keep pressing the next
section extension switch when the No. 2
Telescoping mode I telescoping cylinder extends slightly because the
(The 2nd boom section extends first.) boom full retraction switch is shifted and the
solenoid self-holding circuit for the hydraulic valve
1. When the boom telescoping lever (linked to the
is established.
remote control valve) is operated to the extension
side, pilot pressure is led to the hydraulic pilot 5. The 4th and top boom sections are extended by
control valve, shifting the telescoping control valve the wire-rope mechanism linked to the No. 2
to extension side and delivering the pressurized telescoping cylinder.
oil from the hydraulic pump to the selector valve.
Telescoping mode II
2. The pressurized oil is sent to the No. 1 (The 3rd through top boom sections extend first.)
telescoping cylinder, making the 2nd boom
section extend. 1. When the boom telescoping lever (linked to the
remote control valve) is operated to the extension
3. After the 2nd boom section is fully extended, side, pilot pressure is led to the hydraulic pilot
press the next section extension switch while control valve, shifting the telescoping control valve
keeping the boom telescoping lever operated. The to extension side and delivering the pressurized
hydraulic valve will be energized, the pressurized oil from the hydraulic pump to the selector valve.
oil will be sent to the No. 2 telescoping cylinder
and the 3rd boom section will extend. 2. The pressurized oil is sent to the No. 2
telescoping cylinder, making the 3rd boom section
extend.
5 WG02-0321E

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

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

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

retracted, the boom full retraction detector switch
is activated and disestablishes the solenoid
self-holding circuit for the hydraulic valve.
Consequently the selector valve automatically
shifts, the No. 1 telescoping cylinder retracts and
the 2nd boom section retracts.
6 WG02-0321E

G -1 G -1
Telescoping System
3. Boom telescoping mechanism

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

Extended by the wire rope mechanism that
WT
synchronizes with the extension of No.2 cylinder. 4th boom
F3
2nd boom
3rd boom
3rd boom
W4 W4
2nd boom
E4
4th 4th . IWG02-0420E02
boom boom
E5 : top boom section travel
W4 E3=L2
3rd E4 : 4th boom section travel
boom F4 : 4th boom section fotce
No.2 cylinder WT : Top boom section weight
2nd boom
2nd boom
IWG02-0420E01
WT
Balance of force : F4 = 3 ×
2
E4 : 4th boom section travel
Equation of workload : W T × E5 = F4 ×E4
E3 : 3rd boom section travel
(=L2: No.2 cylinder stroke) E4
∴E 5 = F4 ×
F3 : 3rd boom section force WT
(=No.2 cylinder force) WT E 4
= 3× ×
W 4 : 4th boom section weight 2 WT
3
= E
Balance of force : F3 = 2W 4 2 4
From equation (a)
Equation of workload : W 4 × E4 = F3 × E3
3
E3 E5 = × 2L 2 = 3L 2
∴E 4 = F3 × 2
W4
E3 Top boom section travel (E5) = 3L2
= 2W 4 ×
W4
= 2E3 = 2L2 - - - (a)
4th boom section travel (E4) = 2L2
7 WG02-0321E

G -1 G -1
Telescoping System
3.2 Retraction WT
Balance of force : F3 = 6 × = 3 WT
1. Top boom section 2
Retracted by the wire rope mechanism that Equation of workload : W T × R5 = F3 × R3
synchronizes with the retraction of 3rd boom R3
section. ∴R 5 = F3 ×
WT
R3
2nd boom F3 = 3 WT ×
R3=L2 WT
3rd boom 3rd boom
= 3R3 = 3L2 - - - (b)
WT WT WT
2 WT 2 2 Top boom section travel (R5) = 3L2
2 WT WT
2 2
2. 4th boom section

Retracted by the wire rope machanism that
synchronizes with the retraction of top boom
2nd section.
boom
2nd boom
4th
boom
3rd boom
2nd boom
R5
4th boom
WT WT
2 2 F5
Top boom R5
Top boom
Top
Top
boom
boom
IWG02-0420E03
F5 R4
2 F5
F5
R5 : Top boom section travel 2 2
R3 : 3rd boom section travel
4th boom
(=L2: No.2 cylinder stroke)
W4
F3 : 3rd boom section force
IWG02-0420E04
(=No.2 cylinder force)
W T : Top boom section weight
R4 : 4th boom section travel
R5 : Top boom section travel
F5 : Top boom section force
W4 : 4th boom section weight
8 WG02-0321E

G -1 . G -1 .
Telescoping System
F5
Balance of force : 3× = W4
2
2W4
∴F5 =
3
Equation of workload : W 4 × R4 = F5 × R5
R5
∴R 4 = F5 ×
W4
2 W4 R5
= ×
3 W4
2
= R
3 5
From equation (b)

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

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

Retraction by No.1 cylinder
2nd boom section travel (R2) = L1
9 WG02-0321E

G -2 G -2 G -2
Boom (Five-Section Boom)
G-2 Boom (Five-Section Boom)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures,
make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
10 W536-0761E 10

G -2 G -2 G -2
11 W536-0761E 11

G -2 G -2
1.Base boom section 47.Hexagon socket head bolt 93.Pin 139.Sheave assy
2.Second boom section 48.Slide plate 94.Sheave assy 140.Bolt
3.Third boom section 49.Bolt 95.Bolt 141.Split pin
4.Fourth boom section 50.Adjuster assy 96.Plate 142.Hexagon socket head bolt
5.Top boom section 51.Bolt 97.Spacer 143.Retaining ring
6.Slide plate 52.Plain washer 98.Spacer 144.Hexagon socket head bolt
7.Pin 53.Spring washer 99.Pin 145.Spring washer
8.Plate 54.Set screw 100.Split pin 146.Support
9.Bolt 55.Plain bearing 101.Pin △
6 --- 147.Pin
10.Spring washer 56.Retaining ring 102.Bolt 148.Plate
11.Plate 57.Spacer 103.Bolt 149.Spacer
12.Nut 58. Pin 104.Set screw 150.Spacer
13.Tooth washer 59.Pin 105.Plate 151.Pin
14.Pin 60.Pin 106.Slide plate 152.Sheave assy
15.Snap pin 61.Spacer 107.Retainer 153.Pin
16.Spacer 62.Retaining ring 108.Retainer 154.Retaining ring
17.Spacer 63.Slide plate 109.Slide plate 155.Retainer
18.Sheave assy 64.Slide plate 110.Plate 156.Slide plate
19.Spacer 65.Plate 111.Plate 157.Plate
20.Pin 66.Plate 112.Retainer 158.Plate
21.Sheave assy 67.Plate 113.Bolt 159.Slide plate
22.Spacer 68.Plate 114.Retainer 160.Plate
23.Pin 69.Hexagon socket head bolt 115.Slide plate 161.Plate
24.Bolt 70.Bolt 116.Plate 162.Retainer (L)
25.Nut 71.Plate 117.Plate
△
6
163.Retainer (R)
26.Pin 72.Plate 118.Retainer assy (L) 164.Retainer
27.Snap pin 73.Support 119.Retainer assy (R) 165. ----------
28.Wire rope 74.Support 120.Slide plate 166. Slide plate
29.Nut 75.Slide pIate 121.Plate 167.Bolt
△
6
30.Nut 76.Hexagon socket head bolt 122.Plate
△
6
168.Retainer assy (L)
31.Wire rope 77.Shim 123.Retainer assy (L) 169.Retainer assy (R) △
6 ---
32.Nut 78.Shim 124.Retainer assy (R) 170.Bolt

33.Nut 79.Slide plate 125.Slide plate 171.Bolt
34.Wire rope 80.Nut 126.Plate 172.Bolt
35.Plug 81.Tooth washer 127.Plate
△
6
173.Nut
36.Grease nipple 82.Sheave assy 128.Retainer assy (R) 174.Plate
37.Hexagon socket head bolt 83.Guide 129.Retainer assy (L) 175.Plate
38. ---------- 84.Guide 130.Pin 176.Bolt
39.Bolt 85.Bolt 131.Retaining ring 177.Retainer (L)
40.Nut 86.Spring washer 132.Support 178.Retainer (R)
41.Support 87.Plain washer 133.Bolt 179.Plate △
7 ---
42.Slide plate 88.Support 134.Spring washer 180.Pin

43.Grease nipple 89.Guide 135.Spacer 181.Split pin
44.Nut 90.Pin 136.Pin △
6 182.Retainer(R)
45.Bolt 91.Bolt 137.Guide △183.Retainer(L)

6
46. ---------- 92.Pin 138.Bolt 342-016-60000 △

9
12 W536-0761E

G -2 G -2
Telescoping cylinder
2. Disassembly
The procedure to remove the 2nd boom section and
further sections as an assembly is described below.
2.1 Removing the 2nd boom section
1. Retract the boom fully and set the crane level.
2. Remove the hook block and the rope socket. High-pressure hose
Wind up the wire rope on the drum.
3. Swing the boom to place where there is enough

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

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

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

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

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

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

crane, and place it on a level platform.
13 W536-0761E

G -2 G -2
2.2 Removing the 3rd boom section Top boom section

3rd boom section Bolt 1
1 Remove the wire rope for top boom section Pin 1 Support
extension/4th boom section retraction located on Nut Sheave assy
the top of the 2nd boom head by loosening the

nut.
[NOTICE]
Before loosening the nut, measure the length of the
wire rope protrusion (L1) as a guide for reassembly.
Pin 2 Bolt 2 Wire rope (for top boom section retraction)
IW536-0620E08
Wire rope Nut L1
6. Remove the support assy of the No. 1 telescoping

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

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

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

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

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

end of the 3rd boom section) by loosening the bolt
1, and remove the pin and sheave assy by
loosening the nut.
5. Remove the pin from the rear end of the top boom 8. Remove the nut for the wire rope (for 4th boom
section by loosening the bolt 2 and remove the section extension) located on the rear end of the
wire ropes for top boom section retraction (2 2nd boom section, then loosen the bolt and
pieces). remove the support.
14 W536-0761E

G -2 G -2
2. Lift up the rear end of the telescoping cylinder

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

L3
2nd boom section

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

boom section head and removing the slide plate, Connecting pin
pull out the 3rd boom section by approx. 1 m. Wire rope (for 4th boom section extension)
IW536-0620E13
10. While lifting the 3rd boom section slightly, remove
the retainer from the bottom of the 2nd boom
section head. 4. After removing the retainer on the top of the 3rd
11. Lift and pull out the 3rd boom section using a pull out the 4th boom section by approx. 1 m.
crane, and place it on a level platform.
5. While lifting the 4th boom section slightly, remove
2.3 Removing the 4th boom section the retainer from the bottom of the 3rd boom
section head.
1. Remove the nut for the wire rope (for 4th boom
section extension) located on the rear end of the 6. Lift and pull out the 4th boom section using a
4th boom section, loosen the hexagon head bolt, crane, and place it on a level platform.
and remove the plate and support.
2.4 Removing the top boom section
[NOTICE]
Before loosening the nut, measure the length of the 1. Remove the four bolts and detach the guide.
2. Remove support by loosening the bolts 2 (4
4th boom section
pieces) on both sides of the 4th boom section
head, draw out the wire rope forward by approx.
Nut 0.5 m, remove the retaining ring, detach the pin
Plate and separate the wire rope from the support.
Hexagon
socket head bolt
Support L4 Support
Wire rope (for 4th boom section extension) Nut
IW536-0620E12
15 W536-0761E

G -2 G -2
Guide Bolt 1
Support
Bolt 2
Pin
Wire rope
(for top boom section extension / 4th boom section retraction)
IW536-0620E14
3. To prevent damage to the wire rope, secure it to

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

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

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

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

extension/4th boom section retraction from the
rear end of the top boom section.
16 W536-0761E

G -2 G -2
3. Check 4. Reassembly
3.1 Boom 4.1 Greasing
Check the boom for twist, deformation, wrap, and • When installing unplated pins, apply grease
cracks. beforehand.
3.2 Slide plate • Apply TNR-2 Grease sufficienty to the sliding

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

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

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

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

the pins A and B.
2. Adjust the bolt C locked with nuts D and E so that
it can be turned by hand and the clearance (S) is
0.5mm (0.02in) or less.(Apply thread locking
agent.)
[NITICE]
Refer to normal insert directions of bolt•C shown on
[2.Disassembly]
17 W536-0761E

G -2 G -2
4.3 Installing lower slide plates 5. Adjustment

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

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

section head
After retracting each boom section fully, lock the

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

section in the Y chapter.
18 W536-0761E

G -2 . G -2 .
6. Test
[NOTICE]
◆Bleed the telescoping cylinders completely and
apply grease to the boom sliding surfaces before
starting the tests.
6.1 Operation test
Telescope the boom several times, and make sure

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

[Conditions]
･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 200mm (7.9 in) in all boom
directions by shim adjustment.
2. After shim adjustment, the hook displacement (A

in sketch) under the above test conditions under
the total rated load must be within the specified of
500mm (19.7 in).
When the displacement is more than the specified
limit, readjust the shim.
19 W536-0761E

G -3 G -3 G -3
Jib Applicable serial No. △
1 ：545419,545430~,475327~ △
4 ：545419,545457~,475330~
△
2 ：545410~,475326~ △
5 ：545511~,475349~,437366~
G-3 Jib △
3 ：545419,545430~,475330~
1. Structure
1.1 Location of Jib
20 W537-0102E 20

G -3 G -3
Jib
1.Support assy 13.Support 25.End 37.Stopper

2.Plate 14.Plate 26.Pin 38.Stopper
3.Pin assy 15.Bolt 27.Split pin 39.Bolt
4.Bolt 16.Nut 28.Plain washer 40.Spring washer
5.Spring washer 17.Plain washer 29.Clamp 41.----------------------
6.Plain washer 18.Support 30.Flange nut 42.----------------------
7.Bolt 19.Pin assy 31.Control cable 5 43.Plate
8.Plain washer 20.Support 32.Support 5 44.Plate
9.Slide plate 21.Support assy 33.Spring 5 45.Plate
10.Shim 22.Support assy 34.Plate 5 46.Bolt
11.Slide plate 5 23.Support assy 5 35.Pin assy 5 47.Nut
12.Support assy 24.Plate 36.Stopper 5 48.Support
5 49.Nut
342-215-40500 △
5
21 W537-0102E

G -3 G -3 G -3
Jib Applicable serial No. △
1 ：545410~,475326~ △
4 ：545419,545457~,475330~
△
2 ：545410~,475326~ △
5 ：545511~,475349~,437353~
1.2 Jib main body △

3 ：545410~,475326~
22 W537-0102E 22

G -3 G -3
Jib
1.Jib 2 15.Pin assy 29.Roller assy 43.Spacer

2.Jib1 16.Spacer 30.Spacer 44.Pin
3.Support 17.Sheave assy 31.Pin 45.Bolt
4.Snap pin 18.Plate 32.Bar 46.Spring washer
5.Pin 19.Pin 33.Pin 47.Roller assy
6.Pin 20.---------------------- 34.Split pin 48.Pin
7.Retaining ring 21.Link 35.Plate 49.Spacer
8.Sheave assy 22.Plate 36.Pin assy 50.Snap pin
9.Grease nipple 23.Plate 37.Nut 51.Spacer
10.Pin 24.Plate 38.Bolt 5 52.Pin
11.Snap pin 25.Pin 39.Plate 5 53.Pin
12.Guide assy 26.Plain washer 40.Pin assy 5 54.Spacer
13.Bolt 27.Split pin 41.Pin
14.Spring washer 28.Stopper 42.Support
342-215-42000 △
5
23 W537-0102E

G -3 G -3
Jib
2. Adjustment
2.1 Adjusting jib 1-2 connecting spring pin

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

IW537-0100E07
24 W537-0102E

G -3 . G -3 .
Jib
2.3 Adjusting inclination of jib 2

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

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

support on the boom rear end and shims (t3 mm
(t0.12 in)) on the center support of the jib 2 to
facilitate the jib 1-2 connecting pin.
[NOTICE]
Boom rear end support: The rear end of the jib 2 is
raised when shims are added; lowered when shims
are removed.
Center support on jib 2: The rear end of the jib 2 is
lowered when shims are added; raised when shims
are removed.
25 W537-0102E

G -4 G -4
Telescoping Cylinder
G-4 Telescoping Cylinder

[NOTICE]
1. Structure
1. No.1 cylinder
2. No.2 cylinder
3. Hose
4. Hexagon socket head bolt
5. Bolt
Tightening torque
N-m ft-lbf
A1, B G3/4 108 - 123 80 - 90
A2 G1/2 54 - 64 40 - 47
4 M12 68.6 - 82.4 50.6 - 60.7
5 M10 43 - 49 32 - 36
26 W157-0402E

G -4 . G -4 .
Telescoping Cylinder
*1
1 2 3 4 5,6 7 8 9 10 11 12 31 13 14 15 16 17 18
IW157-0390E03
1.Plug 6.Packing 11.O-ring 16.Backup ring

2.Spring pin 7.Plain bearing 12.Rod cover assy 17.Plain bearing
3.Nut 8.O-ring 13.Support 18.Dust seal
4.Piston 9.Cylinder 14.Damper ring 31.O-ring
5.Backup ring 10.Rod 15.Packing
*1: Face the notch or the lip toward the pressurized side.
360-171-10000 △
1
360-171-20000 △
2
360-169-10000 △
1
360-169-20000 △
2
27 W157-0402E

G -5 G -5
Counterbalance Valve (Telescoping)
G-5 Counterbalance Valve (Telescoping)

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

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

Tightening torque
N-m 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 - -
28 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
29 W119-0222E

G -6 G -6
Hose Reel
G-6 Hose Reel
[NOTICE]
1. Structure
1.Drum plate 8.Spring washer 15.Pin 22. --------

2.Drum plate 9.Nut 16.Support 23.Retaining ring
3.Seat packing 10.Bearing 17.Set screw 24.Oil seal
4.Spring case 11.Bush 18.Nut 25.Spacer
5.Spring 12.Bearing 19.Spring washer 26.O-ring
6.Aux. spring 13.Seal ring 20.Plate 27.Bolt
7.Special bolt 14.Backup ring 21. Bolt 28.Spring washer
29.Stop Plate
30 W183-0131E

G -6 G -6
Hose Reel
2. Dismounting 1) Remove the protection plate from the case 4

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

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

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

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

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

follows:
31 W183-0131E

G -6 . G -6 .
Hose Reel
2) With the lower side coated with grease,

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

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

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

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

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

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

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

surfaces of drum plates.
366-716-50000 △
0
32 W183-0131E

G -7 G -7
Hydraulic Valve
G-7 Hydraulic Valve
[NOTICE]
1. Structure
PP
P C T Dr
IW123-017001
PP
Dr
C P T
IW123-017002
Tightening torque
N-m ft-lbf
P, C, T G3/4 167 123
PP, Dr G1/4 29.4 22
33 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
Tightening torque
N-m ft-lbf
Mounting bolt
M5 7 5
(for solenoid valve.6)
34 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
Tightening torque
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
35 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]
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 W305-0451E

H-2 H-2
1.Plate 16.Spring 31.Pin terminal 46.Cable

2.Case 17.Cover 32.Nut 47.Holder
3.Drum assy 18.Clip 33.Washer 48.Terminal
4.Slip ring assy 19.Support 34.Screw 49.Terminal
5.Contact assy 20.Clamp 35.Bolt 50.Angle detector
6.Contact assy 21.Cord guide 36.Bolt 51.Plug
7.Bearing case 22.Collar 37.Screw 52.Collar
8.Bearing 23.Packing 38.Screw 53.Bolt
9.Retaining ring 24.Packing 39.Screw 54.Spring washer
10.Retaining ring 25.Packing 40.Screw 55.Plain washer
11.Speed reducer 26.Connector 41.Screw 56.Bolt
12. -------- 27.Connector 42.Screw 57.Plain washer
13.Gear 28.Cord lock 43.Set screw 58.Spring washer
14.Bracket 29.Screw 44.Nut 59.Clip
15.Potentiometer 30.Pin terminal 45.Rubber bush 60.Collar
Potentiometer Resistance : 5000 ± 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
3 W305-0451E

H-2 H-2
Drum assy
2. Disassembly and reassembly
2.1 Removing the cord
1. Remove the connector and the cord lock from the

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

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

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

2. Pass the new cord through the hole of the drum
the plate.
assy. Solder it on the slip ring assy.
[NOTICE]
Attach the cord core wire to the inner slip ring.
Attach the shield wire to the outer slip ring.
Completely insulate the soldered section.
4 W305-0451E

H-2 H-2
Core wire original position after it is rotated a quarter turn by

Cord
finger and released. If it is not returned, loosen the
bolt and adjust the position of the bracket.
Shield wire
[NOTICE]
Drum assy
Vinyl tube If the potentiometer is faulty, replace it referring to
IW305-0230E07 the "Replacing the potentiometer (boom length
detector)" described later.
3. Install the slip ring assy so that the cord is not 10. Fix the gear in the notched section of the speed
slackened. reducer shaft using a set screw. Apply thread
locking agent to the set screw.
4. Wind the new cord around the drum assy while
taking up slack in the cord. When the 0-marker on Tightening torque : 1.18 N-m {0.87ft-lbf}
the 8.83 m (29.0ft) point of the cord shows on the
drum, wind the cord 13 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 W305-0451E

H-2 H-2
13. Draw out the cord slightly from the drum and 2.4 Disassembling the potentiometer
make sure that the resistance between the red (for boom length detector)
and white terminals increases smoothly. [NOTICE]
14. Connect the cable to the terminals for the If both the cord and spiral spring are faulty, remove
the detector assy from the boom.
potentiometer and angle detector.
If only the potentiometer is faulty, it is not necessary
15. Attach the cover. to remove the detector.
16. Pull the cable to eliminate slack, and tighten the 1. Loosen the 2 clamps and remove the bolt and
clamp. (2 places) cover.
17. Install the cord lock on the cord end and install 2. Disconnect the lead wire terminals (3 pieces) and
the lead wires and the connector close to the cord cable terminal from the potentiometer, and
end. Completely insulate the soldered remove the potentiometer together with the
connections. bracket.
8.5 m (27.9ft) [NOTICE]

0.08 m
f t) (0.26ft) Before replacement, disconnect the wiring to the
(0.8
m boom angle detector from the pin terminal section to
0.25
disconnect the lead wires (red and black) from the
Cord lock boom angle detector.
0-marker
Wind HI-BOND tape for
Connector waterproofing and then Gear
wind insulating tape.
70 Spring
7 Yellow 10
Cord Bracket
7 50 10
White Lead wire
IW305-0230E11
Lead wire
18. Check for conduction and shortcircuit between Potentiometer Black

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

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

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

2.3 Replacing spiral spring end of the cord. Wind up the cord on the drum
slowly until no tension of the spring is applied on
[NOTICE]
the cord.
If the spiral spring is broken, replace the whole
drum assy. For removing and installing the spring,
refer to the "Removing the cord" and "Installing the
cord" above mentioned.
6 W305-0451E

H-2 . H-2 .
2.5 Reassembling potentiometer 2.6 Replacing the boom angle detector
1. Install a new potentiometer. Disconnect the lead wires to the boom angle
detector from the pin terminal section, and replace
[NOTICE]
the boom angle detector assy.
To avoid exposing the potentiometer to high
temperature for a long time, solder the
potentiometer terminal and the lead wires quickly.
3. Adjustment
Fix the potentiometer terminal including the lead
wires to the bracket using insulating sealant.
1. Adjust the cord lock so that the 0-marker on the
cord is on the edge of the cord guide when the
Recommended sealant: Shin-Etsu Silicone
boom is fully retracted.
KE45RTV (Shin-Etsu Chemicals Industry)
Bracket
0-marker Cord lock

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

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

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

step 12. and below of the "Installing the cord"
section. 361-322-80000 △
0
7 W305-0451E

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
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
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 .
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]
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
Tightening torque
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
Tightening torque
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 Structure ..................................................... 5 10. How to charge air conditioner gas ........... 24
3.2 Conditions for air conditioning equipment .. 6 10.1 Charging gas in automatic operation .........24
3.3 Refrigerant.................................................. 7 10.2 How to charge air conditioner gas .............26
3.4 Refrigeration cycle of a car air conditioner. 8 10.3 How to check air conditioner ......................28
3.5 Comparison with a household air conditioner
............................................................. 8 11 Diagnosis table.......................................... 29
3.6 Receiver functions ...................................... 9 11.1 Car air conditioner system diagnosis 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..................... 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]
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 W701-0220E

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 W701-0220E

K-2 K-2
Air Conditioner
3. Basic refrigeration cycle

2. Compressor
This component absorbs the gaseous refrigerant
3.1 Structure
that was vaporized in the evaporator, and
An ordinary air conditioner circulates a volatile compresses it to higher pressure so that it can be
liquid (called a refrigerant) that is contained in more easily liquefied in the condenser.
piping. In this piping, the refrigerant is repeatedly
3. Condenser
vaporized and condensed.
In this component, the high-temperature
This device is made up of the following
high-pressure refrigerant gas that was
components.
compressed by the compressor is cooled and
1. Evaporator liquefied.
In this component, the refrigerant vaporizes and
4. Expansion valve
absorbs heat from around the pipes, thus cooling
This is a kind of throttle valve which functions as a
the room.
barrier to keep the inside of the evaporator at low
pressure. It sprays the high-pressure liquid
refrigerant from the condenser into the evaporator
through a tiny opening, forming a low-pressure
low-temperature mist that is can easily and rapidly
vaporize.
5 W701-0220E

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 W701-0220E

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 W701-0220E

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 W701-0220E

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 W701-0220E

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 W701-0220E

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 W701-0220E

K-2 K-2
Air Conditioner
WARNING Air outlet changeover switch

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

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

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

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

These switches are used to adjust the
temperature of the air from the air conditioner
among eight steps.
The current temperature is shown by the bargraph
on the display.
12 W701-0220E

K-2 K-2 K-2
Air Conditioner
4. Layout
4.1 Overall layout
345-107-61000 △
4
13 W701-0220E 13

K-2 K-2 K-2
Air Conditioner
4.2 Overall layout
345-110-73000 △
0
14 W701-0220E 14

K-2 K-2 K-2
Air Conditioner
4.3 Evaporator section
345-107-02000 △
5
15 W701-0220E 15

K-2 K-2
Air Conditioner
5. Compressor Assy
16 W701-0220E

K-2 K-2 K-2
Air Conditioner
6. Evaporator Assy
17 W701-0220E 17

K-2 K-2 K-2
Air Conditioner
7. Condenser Assy
18 W701-0220E 18

K-2 K-2 K-2
Air Conditioner
8. Electric
8.1 Electric circuit
363-205-60030 △
0
19 W701-0220E 19

K-2 K-2 K-2
Air Conditioner
8.2 Main harness A
20 W701-0220E 20

K-2 K-2 K-2
Air Conditioner
8.3 Main harness B
21 W701-0220E 21

K-2 K-2
Air Conditioner
9. Important points for assembly

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

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

Inject gas from the low-pressure side while
operating the cycle.
22 W701-0220E

K-2 K-2
Air Conditioner
9.3 Check for gas leakage and amount of 9.5 Run-in operation
refrigerant charge
Operate the A/C for 5 minutes or more under the
[NOTICE] conditions below to perform the initial run-in
Never check using a halide-torch type leak detector. operation.
Engine speed :Idle
1. Insert refrigerant in gas form until the gauge
(High-speed starting is especially prohibited.)
pressure reads 98.1 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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Air Conditioner
Jigs
Flow
Procedure Safety point and
No.
tools
1 Plug the power supply cord of the main unit.
2 Connect the coupler of the high-pressure side (red hose) and the Be careful to the
low-pressure side with the compressor main body sequentially. scaffold
Purge residual pressure before connecting because the
connection of coupler becomes firm if there is residual pressure in
the unit.
(Usually it has been performed at work end. Refer to Flow No.14.)
54453 Attach all freon cans. (6 cans) Be careful that gas

Tighten as it is though the gas leaks a little when attaching. liquor does not splash
4 Turn ON the automatic gas sweep switch. (to increase degree of
vacuum)
(If the gas is insufficient, turning OFF is allowed.)
5 Set the time switch to "20 minutes".
(Set to longer period if there is a time.)
6 Turn the power switch to the automatic side. (starts vacuum)
7 Vacuum operation is finished when the buzzer sounds 15-20
minutes later. Starts gas charging.
8 Engine start is allowed when buzzer sound stops. (Turn ON the air Make sure to check
conditioner switch.) surroundings
(Keep idling for at least 10 minutes --- specified by DENSO.)
9 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
10 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 rpm
The blowing temperature must be in the graphic chart value.
(Refer to the graphic chart.)
(Near the outside air temperature scale in the gauge is a standard
pressure.)
11 Stop the engine Pull out the key
12 Wait for two minutes until pressure falls, and detach the Be careful to the
high-pressure side and low-pressure side quick couplers. scaffold
13 Test gas leakage. (for all hose connections) Be careful to the Gas
(Check the gas leakage from the lower side because the freon is scaffold leak
heavier than air.) tester
Compressor: 2 places
Compressor charge coupler: 2 places
Receiver: 2 places
Condenser Assy: 2 places
Main body of air conditioner: 2 places
Pressure switch hose connections : 1 place
11 places in total
14 Detach the empty gas can, and purge pressure in the hose.
1) Set the timer knob to the vacuum side.
2) Set the power switch to the automatic or manual.
3) Turn OFF the power switch when the high/low-pressure gauge
indicates approx. "0" pressure-value after a few seconds.
15 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.
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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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Remove blocked
foreign object, or
------------------------------ TXV failure (blocking)
replace TXV and
R/D.
Will not get cold when driving
Replace R/D.
continuously, and repeats getting Freezing of TXV by
Both high Bubble appears in sight glass, then cold after a while. Blow air volume contamination of water.
Insufficient and fill refrigerant.
pressure and low it changes transparently. does not change.
cooling.
pressure low. Evaporator dirt and
Wash or replace.
blocking.
Seal the joint with
Air leakage between cooling
No air blow or air volume is few. repair tape or
unit and heater unit.
packing agent.
Blower electric circuit or Check and repair
blower motor failure. circuit, or replace.
High pressure is High-pressure side and
Compressor discharge Repair or replace
No cooling. low, and low low-pressure side will be balanced ------------------------------
failure. compressor.
pressure is high. after stopping compressor.
Improve contact of
therms sensor
TXV therms sensor tube part. Correct heat
Low-pressure piping is abnormally ------------------------------ contacts to piping, or heat insulation.
Insufficient Low pressure is
cold and frosting. (refrigerant insulation failure. Replace therms
cooling. high.
returning) sensor tube
fixation clip.
TXV adjustment failure Readjust or
-------------------------------
(raise too much) replace TXV.
Insufficient
cooling. (Normal Blowing air volume changes Evaporator is frosting. Thermistor Check thermistor,
cooling at gradually. When A/C is OFF, and is not cold. If louver blowing Turning OFF temperature of thermo amp., and
--------------------
beginning, and blower is ON, much water is temperature gets cold enough, thermostat has lowered. mechanical
gradually reduce drained from drain hose. compressor will be OFF tentatively. thermo.
cooling later.)
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Check that thermo
Evaporator is frosting. Thermistor Installation position failure of therms sensor is in
is not cold. If louver blowing thermo therms sensor proper position.
----------------
Blowing air volume changes temperature gets cold enough, (thermistor and mechanical Move it to proper
gradually. When A/C is OFF, and compressor will be OFF tentatively. thermo capillary). position in case of
blower is ON, much water is NG.
Insufficient drained from drain hose. Evaporator is frosting. Thermistor
Check thermo
cooling. (Normal is cold. If louver blowing Thermistor or thermo amp.
---------------- system wiring, or
cooling at temperature gets cold enough, failure (will not turn OFF).
replace parts.
beginning, and compressor will not be OFF.
gradually reduce Seal with repair
cooling later.) Gas leakage from
---------------- tape or packing
evaporator case.
Air volume is small from the agent.
Evaporator frost formation.
beginning. Gas leakage from joint of
Affix packing
---------------- heater unit and evaporator
again.
unit.
---------------- Air volume does not decrease. Freezing of TXV Water intrusion in circuit.
and fill refrigerant.
Outside air intrusions to Adjust inside and
------------------------------------ inside, though inside outside air switch
circulation. dumper.
Warmed with heater. (Water
Check and adjust
valve adjustment failure or
Blowing temperature is high and it ------------------------------------- water valve and air
leakage, and air mix dumper
does not get cold (refrigeration mix dumper.
does not close completely.)
circuit is normal).
Check thermostat.
Insufficient (Check mechanical
Normal Thermostat operating
cooling. ------------------------------------- thermo, thermistor,
temperature failure.
thermo amp., and
thermo VR.)
Air volume is few and does not get Wash or replace
------------------------------------- Blocking of evaporator fin.
cold, though blowing temperature is evaporator.
cold. Blower motor revolution is Check and replace
slow. blower motor.
-------------------------------------
Blocking of blower
Check and repair.
inhalation vent.
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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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Air Conditioner
11.4 Car air conditioner system diagnosis table IV (Electronic thermo system)
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Compressor Check thermistor. Measure resistance of Resistance is small. Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. (Abnormal if resistance is
ON. about 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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K-2 K-2
Air Conditioner
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp. internal Replace thermo amp.
cooling. (Clutch thermistor with not change. failure.
works ON and new one.
OFF.) Check installation Positioned correctly. -------------------------------- Thermistor failure. Replace thermistor.
condition of Incorrect position or comes off. -------------------------------- -------------------------------- Install thermistor in correct
thermistor. position.
Insufficient Refer to other -------------------------------- -------------------------------- -------------------------------- --------------------------------
cooling. (Clutch diagnosis tables.
stayed ON) (Excluding the
cause of
electronic thermo
system.)
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12. Compressor
12.1 Compressor abnormal sound diagnosis chart
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Air Conditioner
12.2 Compressor diagnosis chart (1/2)
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K-2 K-2 K-2
Air Conditioner
Compressor diagnosis chart (2/2)
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K-2 K-2
Air Conditioner
13.Troubleshooting
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Air Conditioner
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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 - - - -
ＨＩＬＯ
Hi OFF - - - - - - - - - - - - - - - - - - - - OFF ← ← ON - - - -
Thermo operation OFF - - - - - - - - - - ＯＮＯＦＦ Note1 - - - - - - - - - - - - - ON - Note1 -
Compressor clutch
Frost formation detection OFF - - - - - - - - - - ＯＮＯＦＦ 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 - - - - - - - - - - ＯＮＯＦＦ - - - - - - - - - - - - - - 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 W701-0220E 47

K-3 K-3
Hydraulic Motor (Air Conditioner) (Option)
K-3 Hydraulic Motor (Air Conditioner) (Option)

[NOTICE]
1. Structure
2 16 12 1 8 11 A 10 4 B 3
24 19
A B
9 13 15 IW102-037001
48 W102-0370E

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
360-634-40002 △
0
360-634-40001 △
0
49 W102-0370E

K-4 K-4
Solenoid Valve (Air Conditioner) (Option)
K-4 Solenoid Valve (Air Conditioner) (Option)

[NOTICE]
1. Structure
b f
b f 1
P A
T1
a T B
e
P
B
A
T
IW121-076001 IW121-076002
1.Solenoid valve assy 2.Body
Tightening torque
N-m 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
Tightening torque
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 Solenoid Valve (Air) .......................14
1. General of hydraulic pilot system .............. 1 1. Structure ................................................. 14
2. General of pneumatic control devices ....... 2
L-2 Remote Control Valve (Lever)......... 3 L

1. Structure ................................................... 3
L-3 Remote Control Valve (Pedal)......... 6
1. Structure ................................................... 6
L-4 Shuttle Valve (Lever / Pedal)........... 9
1. Structure ................................................... 9
L-5 Solenoid Valve (Boom Telescoping

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

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

1. General of hydraulic pilot system
Hydraulic Pilot Circuit
1 WL02-0090E

L-1. L-1.
Control System
2. General of pneumatic control devices
Pneumatic Circuit
2 WL02-0090E

L-2 L-2
Remote Control Valve (Lever)
L-2 Remote Control Valve (Lever)

[NOTICE]
1. Structure
TP
1 2 3 4
IW135-013001
A A
455
247
T
P
171
172
101
PORTS 1＆ 2 PORTS 3＆ 4
A 123 A
103
IW135-0130E02
3 W135-0132E

L-2 L-2
Cross section along the line A-A
501
402
445
454
453
452
481 411
212
401
211
213
214
T 215
216
217 161
241
131 P
221
201
PORTS 1•3 PORTS 2•4 122

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

103.Casing 172.Nut 217.Washer 452.Disc
111.Port plate 201.Spool 221.Spring 453.Cam shaft
122.O-ring 211.Plug 241.Spring 454.Set screw
123.O-ring 212.Push rod 247.Spring pin 455.Bush
125.Hexagon socket head bolt 213.Seal 401.Upper cover 481.Hexagon socket head bolt
131.Bush 214.O-ring 402.Lever 501.Boot
161.Plug 215.Washer 411.Set screw
4 W135-0132E

L-2. L-2.
Tightening torque
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
366-349-20000 △
0
5 W135-0132E

L-3 L-3
Remote Control Valve (Pedal)
L-3 Remote Control Valve (Pedal)

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

101 103 A IW135-015002
6 W135-0152E

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

102.Casing 217.Shim 301.Spool 414.Bush
103.Casing 251.RO plug 311.Spring seat 420.Cam
115.Plate 261.O-ring 313.Washer 431.Block
201.Cover 262.O-ring 315.Iock nut 471.Ball
202.Plug 263.O-ring 323.Iever 472.Set screw
210.Seal 271.Hexagon Socket head bolt 324.Spring 473.Hexagon socket head
bole
212.O-ring 272.Hexagon Socket head bolt 335.Spring
501.Boot
7 W135-0152E

L-3. L-3.
Tightening torque
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
8 W135-0152E

L-4. L-4.
Shuttle Valve (Lever/Pedal)
L-4 Shuttle Valve (Lever / Pedal)

[NOTICE]
1. Structure
c d
e f
a b
IW128-011001
c d d(c)
2
f(e)
1
a b b(a)
IW128-011002
1.Body 2.Joint 3.O-ring 4.Steel ball
Tightening torque
N-m 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
9 W128-0112E

L-5 L-5
Solenoid Valve (Boom Telescoping/Aux. W inch)
L-5 Solenoid Valve (Boom Telescoping / Aux. W inch)

[NOTICE]
1. Structure
H F G D B C
E T A
IW121-031001
Connector
+-
(+): Red
(-): Black
IW121-0542E01
10 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.Hexagon socket head bolt 15.O-ring
Tightening torque
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
11 W121-0313E

L-6 L-6
Solenoid Control Relief Valve (Elevating Slow Stop)
L-6 Solenoid Control Relief Valve (Elevating Slow Stop)

[NOTICE]
1. Structure
601
171
151
A2 A1
101.Casing P2 P1
151.Plug
601.Proportional reducing valve
101 T1 IW136-0250E01
Tightening torque
N-m 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
12 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
Tightening torque
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
13 W136-0251E

L-7 L-7
Solenoid Valve (Air)
L-7 Solenoid Valve (Air)

[NOTICE]
1. Structure
Connector
+-
IW210-0151E01
14 W210-0170E

L-7. L-7.
1 2 3 4 5 6 7
8
9
10 21
11 22
12 27
13
18
IN
14
17
15
19 EXH
OUT 16
OUT
IN EXH IN
A-A B-B
IW210-0170E03 IW210-0170E04
1.Packing holder 8.Plunger 15.Valve 22.Valve seat

2.Packing 9.Rod 16.Spring 23.Bolt
3.Coil assy (DC24V) 10.O-ring 17.O-ring 24.Bolt
4.Core 11.Coil cover 18.Body 25.Spring washer
5.Spring 12.O-ring 19.Body 26.Filter
6.O-ring 13.Valve seat 20.Housing 27.Spring
7.Case 14.O-ring 21.Spring 28.Plug
Tightening torque
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22
23 - 2-3 1.5 - 2.0
T1 M8x1.25 8 - 12 6-9
366-474-50000 △
3
15 W210-0170E

S
Steering System
Contents
S-1 Steering System............................... 1 S-6 Pilot Check Valve (Rear Steering

Cylinder Lock)........................12
1. General..................................................... 1
1. Structure ................................................. 12
S-2 Priority Valve .................................... 2
1. Structure ................................................... 2
2. Function.................................................... 2
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
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 WS02-0070E

S -2 S -2
Priority Valve
S-2 Priority Valve

[NOTICE]
1. Structure
LS CF EF
P IW126-003001
6 12 9 13 10 14 11 7 8 3 2 1
LS
16 15
17 16 EF CF IW126-003002
1.Housing 7.Ring 11.Boll 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.Boll Holder
Thread size and tightening torque 2. Function
Sign/ Tightening torque This valve serves to allow the hydraulic oil to flow
Thread size to the 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 W126-0051E

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.
366-103-80000 △
1
3 W126-0051E

S -3 S -3
Orbitrol
S-3 Orbitrol
[NOTICE]
1. Structure

Tightening torque
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
Tightening torque
N-m ft-lbf
1, 2 - 24 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]
1. Structure
A1,A2
B
C D
16 17 18
15 1 2 3 19 5 6 7 8 20 9 10,11 13 15
IW160-0020E01
1.Cylinder 7.Rod cover 13.Dust seal 19.Plain bearing

2.Spring pin 8.O-ring 15.Plain bearing 20.Plain bearing
3.Piston 9.Damper ring 16.Clip
5.O-ring 10.Packing 17.Boot
6.Rod 11.Backup ring 18.Clip
Tightening torque
N-m ft-lbf
A1, A2, B G3/8 49 36
C, D Rc1/8 9 - 12 6.5 - 9
360-603-50000 △
6
8 W160-0021E

S -5 S -5
Solenoid Valve (Steering Mode)
S-5 Solenoid Valve (Steering Mode)

[NOTICE]
1. Structure
A1 B1
SOL2 SOL1
Pp
B2
Dr
Connector
SOL4 SOL3
A2
+- (+): Red
(-): Blue
IW121-0542E01
P T IW121-039001
301 403 104 502

3-d
B
SOL2 Pp
SOL1
B1 A1
Dr
A
A2 B2
A
SOL4
SOL3
P T B
501 502 IW121-039002
104.Spool 501.Plug
301.Hexagn socket head bolt 502.Plug
403.O-ring
9 W121-0392E

S -5 S -5
Section A-A
T1
T2
601
102 402 403 101 103 105 401 201
T3
A2 B2 Dr
Pp T
302 501 102
IW121-039003
Section B-B
Pp
101.Casing
102.Cover
103.Spool
105.Spring seat
201.Spring
302.Hexagon socket head
bolt
401.O-ring
402.O-ring
403.O-ring
601.Solenoid valve assy
P T
IW121-039004
10 W121-0392E

S -5 . S -5 .
Tightening torque
N-m ft-lbf
d(mounting bolt) M8 29.5 ± 3 22 ± 2.2
T1 - 2 or less 1.5 or less
T2 - 5.4 ± 0.5 4 ± 0.4
T3 - 44 ± 5 32.5 ± 3.7
302 - 11.8 ± 1.5 9 ± 1.1
501 - 6.9 ± 1 5 ± 0.7
502 - 9.8 ± 1.5 7 ± 1.1
P, A1, A2, B1, B2, T G 1/2 98 72
Pp, Dr G 1/4 29.4 22
366-438-60002 △
0
11 W121-0392E

S -6 . S -6 .
Pilot Check Valve (Rear Steering Cylinder Lock)
S-6 Pilot Check Valve (Rear Steering Cylinder Lock)

[NOTICE]
1. Structure
A B
C D
IW115-003001
6 9 3 8 5 11 4 7,10 1 2
A B
C D IW115-041001
1.Body 4.Poppet 7.O-ring 10.Backup ring

2.Piston 5.Spring 8.O-ring 11.Valve
3.Sleeve 6.Plug 9.O-ring
Tightening torque
N-m ft-lbf
A, B, C, D G 1/2 98 72
Mounting bolt M8 14 ± 1 10 ± 0.7
366-254-50000 △
0
12 W115-0411E

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 .................................................. 21
2.3 Release of air pressure ............................ 10
i
3. Principles of operation ............................ 22 T-7 Brake Chamber...............................44
3.1 Relay valve ............................................... 22
3.2 Cylinder .................................................... 24 1. Structure ................................................. 44
2. Function .................................................. 45
T-5 Air Dryer ......................................... 25
3. Disassembly............................................ 45
1. Structure ................................................. 25
4. Cleaning and checking ............................ 46
2. Function.................................................. 29 4.1 Cleaning ....................................................46
2.1 Dehumidification ....................................... 29 4.2 Checking ...................................................46
2.2 Regeneration ............................................ 30
2.3 Intake position .......................................... 31 5. Reassembly ............................................ 47
2.4 Release position ....................................... 31
6. Test .................................................... 47
3. Precautions for handling ......................... 32 6.1 Air leak test ...............................................47
4. Maintenance and inspections.................. 32 7. Maintenance standards ........................... 47

4.1 Daily inspection ........................................ 33 7.1 2000-hr or 1-year check............................47
4.2 Inspection and part replacement every 1 year
or 100,000 km (62140mi) of driving ... 33
T-8 Solenoid Valve (Air) .......................48
5. Disassembly ........................................... 33
5.1 Removing DU-3 ........................................ 33 1. Structure ................................................. 48
5.2 Disassembly of cartridge .......................... 33
6. Reassembly............................................ 35
6.1 Cartridge (lower)....................................... 35
6.2 Tapping ..................................................... 36
6.3 Cartridge (upper) ...................................... 36
7. Troubleshooting ...................................... 37
T-6 Brake (Parking Brake) ................... 40
1. Structure and function ............................. 40
2. Replacing pad......................................... 41
3. Remounting ............................................ 42
3.1 Connecting parking brake to spring chamber
........................................................... 42
3.2 Adjusting parking brake clearance ........... 42
4. Check .................................................... 43
ii
T-1. T-1.
Brake System
T-1 Brake System

1. General
Brake Circuit (air over hydraulic brake)
1 WT02-0120E

T-2 T-2
Brake (Service Brake)
T-2 Brake (Service Brake)
[NOTICE]
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 W577-0152E

T-2 T-2
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.
5.5
deforming the piston seals. (Fig. 2) 2
0.
R
C
0.
60±0.2
5
90 IW577-017201
(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
distance becomes zero.
slip relative to the seals, but when the hydraulic Piston
Back plate
pressure is removed, the pistons are pulled back 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 W577-0152E

T-2 T-2
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 W577-0152E

T-2 T-2
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 W577-0152E

T-2. T-2.
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 W577-0152E

T-3 T-3
Brake Valve
T-3 Brake Valve
[NOTICE]
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
tightening torque
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
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
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

and lower body. Clamp the lower body in a vise, Retaining ring
with the exhaust check facing up.
Special washer
5. Unscrew the 4 screws, and remove the exhaust
O-ring
cover and lower valve assy.
Screw Retainer
Exhaust check
Valve spring
Exhaust cover
Valve retainer
Lower valve assy Upper valve

Lower body
Upper valve assy
IW202-0010E15
Retaining ring
Special washer
O-ring
IW202-0010E13
O-ring
Retainer
6. Remove retaining ring from the groove inside
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
Stem assy
IW202-0010E17
IW202-0010E14
5. Cleaning and checking

7. Disassemble the upper valve assy lower valve
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
agents.
13 W202-0013E

T-3 T-3
Brake Valve
3. The mount plate incorporates an oilless alloy bush. 2. Build the lower valve assy into lower body.
Wash it with kerosene and dry it with compressed
3. Install exhaust cover, and secure with screw and
air.
washers. Pack grease in the groove in the surface
5.2 Checking of lower body which mates with upper body; install
O-ring coated with grease.
1. Check the parts for cracks, deformation, etc., and
check the sliding surfaces for dents; replace any Screw
faulty parts.
Exhaust cover
2. Examine the springs for corrosion, and replace if
faulty.
Lower valve assy
Lower body
6. Reassembly
[NOTICE]
Apply lithium base grease (Idemitsu Daphne
Coronex Grease EP2, or equivalent) to the valve
sliding surface, body sliding surface, and the relay
piston sliding surface. O-ring
IW202-0010E18
When inserting O-rings, be sure to apply lithium
base grease to them, (Idemitsu Daphne Coronex
Grease EP2) and fill the O-ring groove with grease
in advance. 6.2 Reassembly of the primary side
Apply lithium base grease containing MoS2 (bearing
1. Place the upper valve on the work bench with the
grease No.3 by Nippon Molybdenum, or equivalent)
to the sliding surfaces of the plunger, and to the valve seat side down.
roller and fulcrums.
2. Install the valve retainer, valve spring, retainer
with 2 O-rings, and special washer in sequence.
6.1 Reassembly of the secondary side
Secure these parts with the retaining ring.
1. Place lower valve on the work bench with the
valve seal side down; install valve retainer, valve [NOTICE]
spring, retainer with O-rings, and special washer, Apply grease to the O-ring.
and secure with retaining ring.
Retaining ring Retaining ring
Special washer Special washer
O-ring O-ring
Retainer Retainer
Valve spring Valve spring
Valve retainer Valve retainer
Lower valve Upper valve
Lower valve assy

IW202-0010E16
Upper valve assy
IW202-0010E15
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]
1. Structure
28 7 10 9 11 8 1 2 37 13 27 3 4 5 6
33-16
Signal (from brake valve)
33-17
29
23
33-13
From oil reservoir
33-12 22
21 34
33-15
33-14 20
Supply Delivery
18
33-2
36
33-3
33-6 33-11
33-10 33-4
Exhaust
33-5 17 16 14-2 14-3 15 14-1 19 Output
33-9 33-19 hydraulic
33-1 33-7 pressure
33-8 26 25
Relay valve (air pressure) Air cylinder Oil cylinder
IW404-0010E01
33-11 7
Delivery
27 12
Joint section of relay valve and air cylinder

IW404-0010E02
35
28
30
28
31
Relay valve side of exhaust pipe (28) Air cylinder side of exhaust pipe (28)
IW404-0010E04 IW404-0010E03
18 W404-0012E

T-4 T-4
Booster (Brake)
Enlarged view of relay valve
28 7 10 9 11 8
33-16
Signal (from brake valve)
33-17
29
33-13
33-12
33-15
33-14
Supply Delivery
33-2
33-3
33-6 33-11
33-10 33-4
Exhaust
33-9 33-19 33-5
33-1 33-7
33-8 IW404-0010E05
Enlarged view of oil cylinder
1 2 37 13 27 3 4 5 6
23
From oil reservoir
22
21 34
20
18
36
Output
hydraulic
pressure
26 25 17 16 14-2 14-3 15 14-1 19 IW404-0010E06
19 W404-0012E

T-4 T-4
Booster (Brake)
[NOTICE]
When assembling the relay valve, apply appropriate amount of the silicon grease to the following places:
sliding surfaces of the air piston (33-14) and valve (33-19); O-rings; O-ring grooves. When assembling the air
cylinder, apply appropriate amount of silicon grease to the inner surface of the air cylinder (7), the outer
surface of the air piston assy (8), air piston ring (9), and the air piston ring (10). When assembling the oil
cylinder, apply appropriate amount of NIPPON GREASE NIGLUBE RX-2 to the outer surface of the air piston
assy (8) rod, the inner surface of the casing (1) bush, the seal cups (2) and (4). Apply appropriate amount of
CCI CCI #20 to the outer surface of the oil piston (14-1), backup ring (14-2), piston cup (14-3), inner surface of
the oil cylinder (19) and oil cylinder O-ring (20).
1.Casing 14-3.Piston cup 30.Seal rubber 33-14.Air piston

2.Seal cup 15.Valve 31.O-ring 33-15.O-ring
3.Backup ring 16.Piston pin 33-1.Body 33-16.Cover
4.Seal cup 17.Pin holder 33-2.Valve retainer 33-17.Bolt
5.Support ring 18.End cap 33-3.Valve spring 33-19.Valve
6.C-ring 19.Oil cylinder 33-4.Valve holder 34.Lock nut
7.Air cylinder 20.Oil cylinder o-ring 33-5.Valve spacer 35.Bolt
8.Air piston assy 21.Pipe connector 33-6.Valve holder plate 36.Nipple
9.Air piston ring 22.Air bleeder screw 33-7.Dust seal rubber 37.Bolt
10.Air piston seal 23.Cap 33-8.C-ring
11.Return spring 25.Plug 33-9.O-ring
12.Spring washer 26.Lock washer 33-10.Valve holder o-ring
13.Cylinder seal 27.Nut 33-11.O-ring
14-1.Oil piston 28.Exhaust pipe 33-12.O-ring
14-2.Backup ring 29.Pipe holder 33-13.Return spring
Tightening torque
N-m ft-lbf
18 - 118 - 147 87 - 108
21 - 20 - 39 14 - 29
22 - 12 - 20 9 - 14
25 - 20 - 29 14 - 22
27, 37 M10 25 - 29 18 - 22
33-17 M8 10 - 20 7 - 14
34 M50 118- 147 87- 108
35 M4 1.5 – 2.5 1–2
36 - 20 - 39 14 - 29
20 W404-0012E

T-4 T-4
Booster (Brake)
2. Function
This booster receives pressurized air from the
relay valve into the air cylinder, and outputs
hydraulic pressure in proportion to the pneumatic
pressure to the wheel cylinders and other
members of the brake system. It comprises the
following three major components.
1. Air cylinder
The air cylinder incorporates air piston assy 8,
return spring 11. The return spring side is always
open to the atmosphere, and the opposite side is
subject to the output pressure of the relay valve.
2. Oil cylinder
Oil piston 14-1 is connected to air piston assy 8 by
piston pin 16, via valve 15, and pin holder 17
prevents the pin from coming off. The pressurized
oil in the oil cylinder is sealed by a tight fit
between the valve in valve 15 and oil piston 14-1.
3. Relay valve
This valve serves to make the brake applied and
released quickly.
21 W404-0012E

T-4 T-4
Booster (Brake)
3. Principles of operation
3.1 Relay valve
1. Booster not in operation 2. Booster in operation for assisting braking
The above figure shows the state of the relay When the brake pedal is depressed, the signal
valve when the booster is not in operation. Since pressure is applied to the service port. This
chamber A is open to the atmosphere via the pressure acts on piston 33n and the piston
brake valve, piston 33n is held in its raised compresses return spring 33m, bringing the piston
position by return spring 33m. In this state, seat in contact with valve assy 33s. This causes
chamber B is also open to the atmosphere chamber B to shut off path C, and simultaneously
through path C. the valve assy is pressed down. As a result, the
body seat opens, allowing compressed air to flow
from chamber D to chamber B, to delivery port,
and then to the air cylinder.
Booster in operation
22 W404-0012E

T-4 T-4
Booster (Brake)
When the inside pressure in chamber B reaches 3. Booster in operation when releasing brakes
the signal pressure level (same level as pressure
When the brake pedal is released slightly, the
in chamber A), the body seat comes in contact
pressure in chamber A becomes lower than that in
with valve assy 33s, shutting off the passage
chamber B, causing piston 33n to be moved up.
between chamber D and chamber B. Therefore,
As a result, the piston clears from valve assy 33s,
the pressure in chamber B does not increase.
and the compressed air in chamber B is
discharged to the atmosphere through path C,
Pressure in balance thereby decreasing pressure in the air cylinder.
When the compressed air is discharged until the
pressure in chamber A becomes equal to that in
chamber B, piston 33n comes in contact with
valve assy 33s again.
In this manner, the pressure in chamber A is
constantly balanced with that in chamber B also
when the air is discharged.
When brakes are released
When the signal pressure becomes higher, the

above sequence is repeated, increasing the outlet
pressure proportionately with the increase in
signal pressure. In this manner, the pressure in
chamber A is constantly balanced with that in
chamber B during operation.
4. Brakes completely released
When the brake pedal is released completely, the

signal pressure becomes zero. The compressed
air having been supplied to the air cylinder is
discharged from chamber B to atmosphere
through path C.
The relay valve is now in the booster
non-operation state.
23 W404-0012E

T-4. T-4.
Booster (Brake)
3.2 Cylinder
3. Brakes are released
When the compressed air in the air cylinder

becomes open to the atmosphere through the
1. Booster not in operation relay valve, air piston assy 8, valve 15 and oil
piston 14a are brought back to the positions
When the booster is not in operation, the air corresponding to the booster non-operation state
cylinder are open to the atmosphere and air piston by return spring 11.
assy 8, therefore, is pushed toward the left of air The brakes are now released.
cylinder 7 by return spring 11.
Under this condition, the valve 15 is clear of oil
piston 14a, allowing brake fluid from the oil
reservoir tank to flow to oil cylinder chamber J
through path G, chamber H, clearance between oil
piston 14a and valve 15, and path I.
2. Booster in operation
When the compressed air flows from the relay

valve to the air cylinder, the air pressure causes
air piston assy 8 to shift rightward. Valve 15
connected to the end of the push rod of air piston
assy is moved rightward together with the air
piston assy, and it comes into contact with oil
piston 14a. This closes the center hole of the oil
piston, closing the passage between the oil
reservoir and chamber J.
As a result, according to the air pressure from the
relay valve, a fluid pressure proportionate to the
ratio of air cylinder diameter to oil cylinder
diameter is generated.
360-614-20000 △
0
360-614-30000 △
0
24 W404-0012E

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
described in the parts catalog before starting
IN
disassembling operations. OUT
Drain valve
1. Structure
Governor
IW232-0030E01
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
25 W232-0032E

T-5 T-5
Air Dryer
View A
58
39
B B
59 Heater
2
C
A
IW232-0030E03
26 W232-0032E

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 IW232-0030E04
IN
View C
61
60 Thermostat
63
62
39 OUT
C IW232-0030E05
27 W232-0032E

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
Tightening torque
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
28 W232-0032E

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
29 W232-0032E

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
30 W232-0032E

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.
31 W232-0032E

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.)
32 W232-0032E

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.
Load → Unload: 861 - 910 kPa {129.4 - 132.2psi} 2. Open the drain cock on the air tank. Discharge the
Unload → Load: 740 - 780 kPa {106.7 -113.8psi} 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.
33 W232-0032E

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.
34 W232-0032E

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)
35 W232-0032E

T-5 T-5
Air Dryer
6.2 Tapping 6.3 Cartridge (upper)
[NOTICE]
DANGER Applying grease to the raised part of the check
valve will allow it to be inserted more easily.
When tapping is not performed, the desiccant
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.
2. Install the O-ring onto the case, then insert the set
[NOTICE]
spring. Tighten the screws and washers while
When tapping, place 2, 3 sheets of shopcloth or
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
(1.5 - 2.9 ft-lbf)
Check valve Case cover
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.
36 W232-0032E

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.
37 W232-0032E

T-5 T-5
Air Dryer
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.
38 W232-0032E

T-5. T-5.
Air Dryer
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.
368-703-70000 △
3
368-703-60000 △
3
39 W232-0032E

T-6 T-6
Brake (Parking Brake)
T-6 Brake (Parking Brake)
[NOTICE]
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
40 W577-0141E

T-6 T-6
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.
41 W577-0141E

T-6 T-6
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 ”
42 W577-0141E

T-6. T-6.
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.
43 W577-0141E

T-7 T-7
Brake Chamber
T-7 Brake Chamber
[NOTICE]
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
Tightening torque
N-m ft - lbf
7, 8 － 9.8 - 14.7 7.2 - 10.8
44 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
45 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.
46 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
47 W576-0022E

T-8 T-8
T-8 Solenoid Valve (Air)
[NOTICE]
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
EXH
OUT
IW210-0123E01
48 W210-0123E

T-8. T-8.
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
Tightening torque
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22
T1 M8x1.25 8 - 12 6-9
366-459-60000 △
5
49 W210-0123E

U
Suspension System
Contents
U-1 Suspension System......................... 1
1. General..................................................... 1
U-2 Suspension Lock Cylinder .............. 2
1. Structure ................................................... 2
U-3 Pilot Check Valve (Suspension Lock

Cylinder)................................... 3
1. Structure ................................................... 3
U-4 Solenoid Valve (Suspension 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. The suspension lock function is either activated or 2. There are two kinds of pressure controlling valves
released by the two suspension lock cylinders in the suspension lock hydraulic circuit, namely a
installed between the carrier frame and rear axles. flow control valve and a pressure reducing valve.
These two suspension lock cylinders are The relief valve in the flow control valve limits the
hydraulically controlled by the solenoid valve highest pressure in the circuit, and the pressure
(suspension lock check release). This solenoid reducing valve supplies the pilot pressure to the
valve is switched according to the outputs from solenoid valve (suspension lock check release).
the multiplex data transmitter (lower).
1 WU02-0190E

U-2 . U-2 .
Suspension Lock Cylinder
U-2 Suspension Lock Cylinder

[NOTICE]
1. Structure
1 2 3 4 5 6 7 8 10 9 11 12
A
For air bleeding
B IW159-0020E01
1.Cylinder 4.Plain bearing 7.Rod 10.O-ring

2.Spring pin 5.Packing 8.Rod cover 11.Packing
3.Piston 6.O-ring 9.Damper ring 12.Dust seal
Tightening torque
N-m ft-lbf
A, B G3/8 49 36
- - - -
360-501-10002 △
6
2 W159-0021E

U-3 . U-3 .
Pilot Check Valve (Suspension Lock Cylinder)
U-3 Pilot Check Valve (Suspension Lock Cylinder)

[NOTICE]
1. Structure
1.Plug 5.O-ring 8.Valve 11.Plug

2.O-ring 6.Body 9.Spring
3.Plunter 7.Valve 10.Plug
Tightening torque
N-m ft-lbf
T, P•P, A, B G1/4 29.4 22
1, 10 M34×1.5 93 - 103 68.7 – 75.9
366-205-30001 △
1
3 W115-0501E

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

[NOTICE]
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
G
T IW121-0700E02
Tightening torque
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
Tightening torque
N-m ft-lbf
8 - 5–7 3.6 – 5.1
366-498-90000 △
0
5 W121-0702E

Y
Data, Adjusting and Checks
Contents
Y-1 Hydraulic Pressure Setting Table... 1 5. Jib lock pin and jib offset cylinder ....................14
1. Winch ............................................................. 1 6. Suspension lock cylinder .................................15
2. Telescoping and Elevating ................................ 2 7. Hydraulic pilot circuit........................................16
3. Steering ............................................................. 3 7.1 Swing ........................................................16
4. Swing ............................................................. 4 7.2 Elevating ...................................................16
5. Outrigger ........................................................... 5 7.3 Telescoping ...............................................16
6. Lower pilot pressure.......................................... 6 7.4 Winch (main and aux.) ..............................16
7. Pilot pressure .................................................... 7 8. Oil cooler motor ...............................................16
8. Flow control valve ............................................. 8 9. Air condition motor (option) .............................16
9. Torque converter oil pressure ........................... 8
10. Pressure reducing valve
[for Europe and Canada (option)] ........ 9 Y-4 Electric Switch Adjustment ...........17
1. 3rd / top boom full retraction detection switch
(CN859) ..............................................17
Y-2 Air Pressure Setting Table ............ 10 2. 2nd boom full retraction detection switch
1. Air pressure setting table ................................ 10 (CN553).............................................17
3. Jib stowed detection proximity switch
(CN572) ..............................................17
Y-3 Air Bleeding Procedure ................. 11 4. Jib lock pin retraction detection switch
1. Starting pump ...................................................11 (CN573) ..............................................18
1.1 Before starting the engine .........................11 5. Main winch drum rotation detection proximity
1.2 Shakedown of the pump............................11 switch (CN591) (option) ......................18
1) Steering, winch brake pilot pressure pump 6. Aux. winch drum rotation detection proximity
(double gear pumps) ...........................11 switch (CN592) (option) ......................18
2) Main pump......................................................11 7. Over-front detection proximity switch
3) Others ............................................................11 (CN521).............................................18
2. Service brake circuit........................................ 12 8. Control lever stand position detection switch
3. Swing circuit .................................................... 12 (Swing control and boom
3.1 Swing motor.............................................. 12 telescoping/aux. hoist) (CN529) .........19
3.2 Swing hydraulic pilot control valve ........... 12 9. Straight ahead detection proximity switch
4. Winch circuit (main and aux.).......................... 13 (CN408) ..............................................19
4.1 Winch motor ............................................. 13 10. Counterweight equipped detection proximity
4.2 Winch counterbalance valve .................... 13 switch (CN994) ...................................19 Y
4.3 Winch brake release circuit ...................... 13
i
Y-5 Adjustment and Checks ................ 20 Y-8 Oil and Grease Table .....................36
1. Service brake adjustment ............................... 20
1.1 Adjusting the brake pedal......................... 20
1.2 Tightening the cap of reserve tank of service Y-9 Mass Table......................................37
brake fluid........................................... 20
2. Accelerator adjustment ................................... 20
2.1 Accelerator pedal ..................................... 20 Y-10 Specifications.................................38
3. Parking brake adjustment ............................... 21 1. Engine speed...................................................38
3.1 Adjusting the parking brake clearance 1.1 Idling speed...............................................38
(between pad and disc plate) ............. 21 1.2 MAX. speed (unload) ................................38
3.2 Connecting the parking brake and spring 1.3 Stall speed.................................................38
chamber ............................................. 21 2. Hydraulic pump (for crane) (Double Variable
4. Tire steering angle adjustment........................ 21 Displacement Pump) ..........................38
4.1 Tire air pressure ....................................... 21 2.1 Pump speed ..............................................38
4.2 Adjusting the tire Steering angle .............. 21 2.2 Pump displacement ..................................38
5. Engine speed (and governer setting).............. 22 3. Hydraulic pump (for steering)
6. Torque converter and transmission................. 22 (Double Gear Pump)...........................38
6.1 Maximum allowable speed ....................... 22 3.1 Pump speed ..............................................38
6.2 Adding oil to the torque converter and 3.2 Pump displacement ..................................38
transmission ....................................... 22 4. Charging pump (for torque converter) .............38
7. Braking force ................................................... 23 4.1 Pump speed ..............................................38
7.1 Parking brake force .................................. 23 4.2 Pump displacement ..................................38
7.2 Service brake force .................................. 23 5. Emergency steering pump (option) .................38
8. Adjusting the headlight light axes ................... 23 5.1 Pump speed ..............................................38
9. Adjusting boom telescoping wire ropes .......... 24 5.2 Pump displacement ..................................38
6. Winch motor.....................................................38
7. Swing driving unit ............................................38
Y-6 Check (Crane Operation)............... 28 7.1 Swing motor ..............................................38
1. Outrigger status indicator ................................ 28 7.2 Swing speed reducer ................................38
2. Hoisting ........................................................... 29
3. Backward stability control ............................... 29
4. Outrigger emergency setting........................... 29 Y-11 Boom Connecting Pin and Thread
5. Jib ........................................................... 29 Size Table ...............................39
6. Boom Telescoping Control .............................. 30
6.1 Telescoping mode I .................................. 30
6.2 Telescoping mode II ................................. 31
7. Alarms ........................................................... 32
8. Outrigger slide plate adjustment ..................... 32
Y-7 Check (Driving Devices)................ 33

1 Exhaust brake (EXB) ...................................... 33
2. Automatic transmission................................... 33
3. Steering mode change .................................... 34
4. Emergency switches ....................................... 34
5. Overshift prevention ........................................ 35
6. Warnings ......................................................... 35
ii
Y-1 Y-1
Hydraulic Pressure Setting Table
Y-1 Hydraulic Pressure Setting Table

1. Winch
[NOTICE]
Oil temperature: 45 - 55°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Confirm set pressure on AML (load moment indicator) moment display
Shift the elevation slow stop cancel switch to OFF side
Set pressure Engine
Item speed Check procedure
MPa psi -1
(min )
Main winch 1. Place the main winch brake in the hold state. *1
hoisting up 2. Turn the PTO switch ON.
(RV1) 3. Move the main winch control lever fully to the hoist
2150
27 - 28 3910 - 4050 up position while the boom elevating control lever
(MAX.)
Aux. winch is fully moved to the boom lowering position. In this
-1
hoisting up state, set the engine speed to 2150 min and
(RV1) check the pressure.
1. Place the auxiliary winch brake in the hold state. *1

Aux. winch 2. Turn the PTO switch ON.
hoisting (IDL.) 3. Move the boom telescoping /auxiliary winch control
8.3 - 9.3 1210 - 1350
down 670 lever fully to the hoist down position while the boom
(PR1) elevating control lever is fully moved to the boom
lowering position. In this state, check the pressure.
1. Place the main winch brake in the hold state. *1

Main winch 2. Turn the PTO switch ON.
hoisting (IDL.) 3. Move the main winch control lever fully to the hoist
8.3 - 9.3 1210 - 1350
down 670 down position while the boom elevating control
(PR2) lever is fully moved to the boom lowering position.
In this state, check the pressure.
(*1): When the winch brake is in the hold state, the winch brake will not be released and winch drum will
not rotate by hoist up or hoist down operation. To have the winch brake placed in the hold state,
remove the pipes for the winch brake release to the hydraulic motor for winch. The pilot pressure for
the winch brake release will be produced during the hoist up or hoist down operation, therefore, fit on
the cap to avoid the oil leak. (After checking the pressure, return the pipes to the original position and
bleed the winch brake release circuit.)
1 WY02-0640E

Y-1 Y-1
2. Telescoping and Elevating

[NOTICE]
Confirm set pressure on AML (load moment indicator) moment display
Set pressure Engine
MPa psi -1
(min )
1. Turn the PTO switch ON.
2. Fully extend the boom.
Boom
2150 3. Move the boom telescoping control lever fully to the
extending 19.1 – 20.1 2770-2910
(MAX.) boom extension position. In this state, set the
(PR4) -1
engine speed to 2150 min and check the
pressure.
Boom 2. Fully retract the boom.
2150
retracting 23 - 24 3340-3480 3. Move the boom telescoping control lever fully to the
(MAX.)
(RV2) boom retraction position. In this state, set the engine
-1
speed to 2150 min and check the pressure.
1. Turn the PTO switch ON
2. Shift the elevation slow stop cancel switch to OFF
side.
Boom
2150 3. Fully extend the boom elevating cylinder.
raising 23 - 24 3340-3480
(MAX.) 4. Move the boom elevating control lever fully to the
(RV2)
boom raising position.
-1
In this state, set the engine speed to 2150 min
and check the pressure.
2. Shift the elevation slow stop cancel switch to OFF
Boom side.
(IDL.)
lowering 2.9 – 3.4 420 - 490 3. Fully retract the boom elevating cylinder.
670
(PR3) 4. Move the boom elevating control lever fully to the
boom lowering position. In this state, check the
pressure.
2 WY02-0640E

Y-1 Y-1
3. Steering
[NOTICE]
Set pressure Engine
MPa psi -1
(min )
1. Connect a pressure gauge to the pressure check
port.
2. Turn the PTO switch OFF.
3. With the outriggers stowed, turn the steering wheel
Steering 2600
12.7 - 14.7 1850 - 2130 to the right to bring the steering cylinders to the
(RV5) (MAX.)
travel ends. (Do steering as to get lightly to travel
end.) In this state, set the engine speed to 2600
-1
min and check the pressure by the pressure
gauge. (Adjusting the relief pressure is impossible)
Pressure
check port (G1/4)
Steering cylinder
Front axle
Pressure check port IWY03-0210E01
Steering
(RV5)
Priority valve (Steering)

IWY03-0210E02
3 WY02-0640E

Y-1 Y-1
4. Swing
[NOTICE]
Confirm set pressure on AML (load moment indicator ) moment display
Set pressure Engine
MPa psi -1
(min )
*1
(21.1) (3060) -
(RV4)
Unable to be checked. (The pressure is preset by the

Swing
valve manufacturer.)
*2
(RA, (26) (3770) -
RB)
*1 : Relief valve
*2 : Overload relief valve (high pressure)
4 WY02-0640E

Y-1 Y-1
5. Outrigger
[NOTICE]
Set pressure Engine
MPa psi -1
(min )
1. Connect a pressure gauge to the pressure

check port.
Outrigger 2600
20.1 – 21.1 2920 - 3060 3. Extend all the jack cylinders fully. And again
(RV3) (MAX.)
press the outrigger collective control switch. In
-1
this state, set the engine speed to 2600 min
and check the pressure by the pressure gauge.
Pressure check port

(for relief valve, G1/4) Relief valve (RV3)
Solenoid control valve (Outrigger)

IWY03-0210E03
5 WY02-0640E

Y-1 Y-1
6. Lower pilot pressure

[NOTICE]
Set pressure Engine
MPa psi -1
(min )
check port.
Lower Pilot 3. Select the jib set status on the AML.
(IDL.)
pressure 3.1 - 4.1 452 - 592 4. Retract the jib lock pin fully to stroke end.
670
(RDV2) 5. Since this valve is unable to adjust the pressure,
abnormal pressure valve indicates the valve is
defective. Renew the reducing valve if the
abnormal pressure is defected.
Pressure check port

Front Solenoid valve (for pressure reducing valve, G1/4)
(Suspension lock)
R View
Reducing valve Solenoid valve (Suspension lock)
(RDV2) IWY03-0210E04 IWY03-0210E05
6 WY02-0640E

Y-1 Y-1
7. Pilot pressure
[NOTICE]
Set pressure Engine
MPa psi -1
(min )
check port.
3. Remove the solenoid connector for the oil cooler
to prevent the oil cooler from operating.
4. Turn the power switch of the air conditioner
*1
2.5 or (IDL.) (option) OFF.
(RG 360 or over
over 670 5. Make sure that constant pressure is being
V1)
produced while engine is running. And check
the pressure by the pressure gauge. Since this
valve is unable to adjust the pressure,
Pilot abnormal pressure value indicates the valve is
pressure defective. Renew the valve if the abnormal
pressure is detected.

check port.
*2
2150 2. Turn the PTO switch ON.
(RD 3.4 or less 500 or less
(MAX.) 3. Turn the oil cooler switch ON. Then, set the
V1) -1
engine speed to 2150 min and check the
pressure by the pressure gauge.
*1: Low pressure

*2: High pressure
7 WY02-0640E

Y-1 Y-1
8. Flow control valve

[NOTICE]
Oil temperature: 45 – 55°C (113 – 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
MPa psi -1
(min )
Flow control
2150 check port (U).
valve 17.6 – 18.6 2560 – 2700
(MAX) 2. Turn the PTO switch ON.
(RV6)
3. Retract the jib lock pin fully to stroke end.
Front
Pressure check port

(U)
RV6
T View
Flow control valve

Flow control valve
IWY03-0220E02 IWY03-0210E07
9. Torque converter oil pressure
Set pressure Engine

MPa psi -1
(min )
(IDL.)
1.7 or over 250 or over
Torque 670 1. Turn the PTO switch OFF.
converter oil 2. Check the pressure at the torque converter oil
pressure 2600 pressure gauge on the combination meter.
2 – 2.3 290 - 340
(MAX.)
8 WY02-0640E

Y-1 . Y-1 .
10. Pressure reducing valve [for Europe and Canada (option)]

[NOTICE]
Set pressure Engine
MPa psi -1
(min )
check port.
Pressure
2600 3. Retract the jack fully to stroke end.
reducing valve 4.9 or less 711 or less
(MAX.) 4. Since this valve is unable to adjust the pressure,
(RDV3)
abnormal pressure valve indicates the valve is
defective. Renew the reducing valve if the
abnormal pressure is defected.
345-803-31500 △
0
347-320-30000 △
1
9 WY02-0640E

Y-2 . Y-2 .
Air Pressure Setting Table
Y-2 Air Pressure Setting Table

1. Air pressure setting table
Pressure
Item
KPa psi
Turning on pressure 725 - 765 105 - 111

Pressure regulator
Turning off pressure 813 - 853 118 - 124
Cracking pressure 853 124

Safety valve
Full opening pressure 931 - 971 135 - 141
Light-on pressure 490 - 549 71 - 80

Air low-pressure switch
(low air pressure warning)
Light-off pressure 490 - 598 71 - 87
Air pressure switch (stop lamp) Operating pressure 19 - 49 2.8 - 7.1
Air low-pressure switch (parking brake) Operating pressure 352 - 392 51 - 57
345-800-02000 △
0
10 WY03-0141E

Y-3 Y-3
Air Bleeding Procedure
Y-3 Air Bleeding Procedure 3) Others

• After the shakedown of the pump, do not let the
1. Starting pump engine speed exceed the middle range (1000
-1
min ) if you bleed the cylinders.
1.1 Before starting the engine When you try to raise the oil temperatuer in
order to adjust the hydraulic pressure, make
Make sure that sure that there is no bubbles caused by the
• PTO switch is turned OFF. bleeding in the tank.
• The oil cooler is not functioning (due to the
hydraulic oil temperature below 50°C (122°F)).
1.2 Shakedown of the pump
1) Steering, winch brake pilot pressure pump

(double gear pumps)
1. Fill the oil tank with hydraulic oil.
2. With the engine stopped, loosen the air-bleed plug

on the suction flange of the main pump. After
bleeding air from the suction side, tighten the plug
again.
3. Start the engine (with PTO OFF) and run it at idle

-1
(approx. 700 min ) while bleeding the air from the
circuit for 1 minute.
4. Start the engine, and run-in the engine for 10

minutes at idle.
2) Main pump
1. Fill the oil tank with hydraulic oil. (If the suction
section was disassembled for repair or other
reasons, bleed air from the air-bleed plug on the
suction side, as described above.)
[NOTICE]
If the tank is to be pressurized, pressurize it at a
pressure of 15 kPa {2.2 psi} or less.
2. Bleed the air from the pump case. Remove the

drain plug or drain hose from the pump. Inject oil
into this location until it overflows, then reinsert
the plug.
3. Start the engine, with PTO ON, and run-in the

engine at idle for 5 minutes.
11 WY05-0581E

Y-3 Y-3
2. Service brake circuit 3. Swing circuit

[NOTICE] 3.1 Swing motor
The vehicle has two boosters; one for the front
wheel brakes and the other for the rear wheel Bleed the swing motor by following either (1), (2) or (3).
brakes.
(1) Pour the hydraulic oil through the drain port into
Four air bleeder screws are on the calipers for the
front wheel brakes, and two are on those for the the casing until the oil flows out.
rear wheel brakes.
(2) Perform the right or left swing operation slowly for
Take care of the spill of the brake fluid and the fluid
level in the fluid reservoir while bleeding. approx. one minute.
(3) Set the swing brake switch to ON. Perform the

1. With the sufficient air in the air reservoir, depress
right or left swing operation and keep the swing
the brake pedal and loosen the air bleeder screw
circuit hydraulic pressure at approx. 4.9MPa (710
on the booster. Then tighten the air bleeder screw
psi) for approx. 30 seconds.
before releasing the brake pedal. Repeat the
above steps until the flowing brake fluid contains
no air bubbles. After the air bubbles go out,
tighten the air bleeder screw while letting the oil
flow out.
Drain port
2. Bleed the calipers of the axles as the step 1 (TR-600,TT-600) (TR-800,TT-800,GR-700E)

above. IWY05-0580E06
Air bleeder screw 3.2 Swing hydraulic pilot control valve

Tightening torque: 22.5 - 28.5N-m (17 - 21ft-lbf)
Set the PTO switch and the swing brake switch to
ON, and set the engine speed to the maximum
-1
(2150 min ). Repeat the rapid swing operation to the
right or the left until no more air bubbles come out of
the air bleeder screw.
Front wheel (right) IWY05-0580E05
12 WY05-0581E

Y-3 Y-3
4. Winch circuit (main and aux.)

[NOTICE]
Bleed the main and auxiliary winch circuits by following the procedures below. The procedures are common to
the both circuits.
4.1 Winch motor 4.3 Winch brake release circuit
Bleed the winch motor by following either (1) or (2). Repeat the slow hoist-up and slow hoist-down
operations with the engine idling until no more air
(1) Pour the hydraulic oil through the drain port into
bubbles come out of the air bleeder screw.
the casing until the oil flows out.
(2) Perform the slow hoist-up or hoist-down

operation for approx. 1 minute.
4.2 Winch counterbalance valve
Repeat the slow hoist-up and slow hoist-down

operations, while increasing the engine speed
-1
gradually to the maximum (2150 min ) until no more
air bubbles come out of the air bleeder screw.
13 WY05-0581E

Y-3 Y-3
5. Jib lock pin and jib offset cylinder

[NOTICE]
Bleed the jib lock pin, jib offset cylinder by following
either (1), (2), or (3).
(1) Start the engine, turn the PTO switch ON, and
raise the engine speed to approx. 2,150 rpm.
(2) Attach a hose to the bleeder screw (A).and

loosen the bleeder screw. In this condition, repeat
the rapid jibset operation to the retract or the
extend until no more air bubbles come out of the
air bleeder screw.
Air bleeder plug
(A) (B)
Jib lock pin
Air bleeder plug
(C) (D)
Jib offset cylinder

IWY05-0580E02
[NOTICE]
Bleed in the order of bleeder plugs, (A), (B), (C) and
(D).
(3) After air-bleeding is over, fasten the bleeder plug

and remove the hose.
14 WY05-0581E

Y-3 Y-3
6. Suspension lock cylinder

(6) Turn off the starter switch and connect the on/off
[NOTICE] connector in the inside-cab relay box.
Bleed the suspension lock cylinder by following
either (1), (2), (3), (4), (5), (6) or (7).
(1) Set the crane in the traveling configuration on

level ground.
(2) Keep the starter switch to OFF, open the door of ON/OFF connector
the inside-cab relay box, and disconnect the on/off
connector.
IWY05-0580E03
(7) Turn on the starter switch. Turn the PTO switch

on. Make sure then the suspension lock indicator
lamp lights.
ON/OFF connector
IWY05-0580E03
(3) Start the engine, turn the PTO switch on, and
raise the engine speed to approx. 2,150 rpm.
(4) Attach a hose to the bleeder screw (A).and

loosen the bleeder screw. In this condition, bleed
the axle for approx. one minute.
[NOTICE]
Bleed in the order of bleeder screws, (A), (B), (C)
and (D).
IWY05-0580E04
(5) After air-bleeding is over, fasten the bleeder

screw and remove the hose.
15 WY05-0581E

Y-3 . Y-3 .
7. Hydraulic pilot circuit 8. Oil cooler motor
7.1 Swing Pour the hydraulic oil through the drain port into the
casing until the oil flows out.
o o
Set the hydraulic oil temperature to 50 C (122 F) or
higher, set the PTO switch and the swing brake
switch to ON, let the engine idle, and move the 9. Air condition motor (option)
swing control lever fully to the right-swing side. Keep
Pour the hydraulic oil through the drain port into the
the above conditions for 20 seconds or more for
casing until the oil flows out.
bleeding. Proceed the same steps by moving the
swing control lever to the left-swing side.
7.2 Elevating
Pull out the connector of the AML vent solenoid. Set

o o
the hydraulic oil temperature to 50 C (122 F) or
higher, set the PTO switch to ON, let the engine idle,
and move the boom elevating control lever fully to
the boom lowering side. Keep the above conditions
for 20 seconds or more for bleeding. Proceed the
same steps by moving the boom elevating control
lever to the boom raising side.
7.3 Telescoping

o o
and move the boom telescoping control lever fully to
the retraction side. Keep the above conditions for 20
seconds or more for bleeding. Proceed the same
steps by moving the boom telescoping control lever
to the boom extension side.
7.4 Winch (main and aux.)
[NOTICE]
Bleed the main and auxiliary winch circuits by
following the procedures below. The procedures are
common to the both circuits.

o o
and move the hoist control lever fully to the hoist-up
side. Keep the above conditions for 20 seconds or
more for bleeding. Proceed the same steps by
moving the hoist control lever to the hoist-down side.
345-800-92500 △
0
345-800-00500 △
0
16 WY05-0581E

Y-4 Y-4
Electric Switch Adjustment
Y-4 Electric Switch Adjustment Tightening torque :

3.7N-m (33in-lbf)
1. 3rd / top boom full retraction detection (*1)
switch (CN859)
Adjust the switch position so that its contact is
shifted (opened/closed) when the top boom section
is extended/retracted beyond the position where it is
5-8 mm (0.2-0.31 in) longer than its fully retracted
length.
Tightening torque :
4.9-5.9N-m (43-52in-lbf)
Base boom 2nd boom
IWY04-0430E02
Top boom 3. Jib stowed detection

proximity switch (CN572)
Adjust the switch position so that the dimension A
becomes 4-5 mm (0.16-0.19 in) with the jib stowed.
(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).
IWY04-0430E01
2. 2nd boom full retraction

detection switch (CN553)
Adjust the switch position so that its contact is
shifted (opened/closed) when the 2nd boom section
is extended/retracted beyond theposition where it is -
2-3 mm (0.08-0.12 in) linger than its fully retracted
length.

17 WY04-0900E

Y-4 Y-4
4. Jib lock pin retraction

detection switch (CN573)
becomes 30.5 –31.5mm (1.2 –1.24 in) with the
switch in free position.

Tightening torque :
4-6N-m (35-53in-lbf)
(*1)
A
6. Aux. winch drum rotation detection

Free position proximity switch (CN592) (option)
Detail D Fullow the same procedure as that in MAIN WINCH
DRUM ROTATION DETECTION PROXIMITY
SWITCH (CS13).
7. Over-front detection proximity switch

D (CN521)
Fully retract the boom and swing it to the over-front.
Insert the swing lock pin and set the boom angle to
0°. Then, adjust the switch position so that the
dimension A becomes 2.5-3 mm (0.1-0.12 in).
IWY04-0430E04
5. Main winch drum rotation detection

proximity switch (CN591) (option)
becomes 2-3 mm (0.08-0.12 in).

18 WY04-0900E

Y-4 . Y-4 .
8. Control lever stand position detection 9. Straight ahead detection proximity

switch (Swing control and boom switch (CN408)
telescoping/aux. hoist) (CN529)
Set the rear wheels in a straight-forward position,
Before the adjustments below, tilt the lever stand by and adjust the switch position so that the dimension
the angle of 16°. Squeeze the switch upward and A becomes 2.5-3 mm (0.1-0.12 in).
secure it temporarily where its contact is shifted
(opened/closed). Then, lower the switch by 1 mm
(0.039 in) from the temporary secured position and
secure it. (A rotation of the switch mounting nut
makes the switch move upward or downward by
approx. 1 mm (0.039 in) ).

10. Counterweight equipped detection

proximity switch (CN994)
becomes 4-6mm (0.16-0. 2in)

19 WY04-0900E

Y-5 Y-5
Adjustment and Checks
Y-5 Adjustment and Checks 2. Accelerator adjustment

1. Service brake adjustment 2.1 Accelerator pedal
1.1 Adjusting the brake pedal
With the pedal weight causing the roller to contact

the plunger, adjust the bolt until it contacts the Switch
(Idle volume)
stopper, then use the nut to lock it in place.
A
Bolt
Idling
Nut
Roller
MAX
Plunger
IWY05-0141E07
1. Adjust bolt F so that lever I is vertical, then lock

IWY05-0141E10 the bolt with the nut.
Viewed from A
1.2 Tightening the cap of reserve tank of service
brake fluid
Lever I Nut H
After bleeding air, pour the brake fluid up to a
Bolt F
required level, and tighten the cap until it stops at
Bolt E
the stopper. At this time, the position of tank body
and cap should be as shown in Fig.1. In addition,
tighten the cap until the mark is aligned with the IWY05-0141E08
mark on tank as shown in Fig.2. [NOTICE]

The stopper might be broken when tightening the Be sure to check that the idle SW operates reliably.
cap too much.
2. Move the accelerator sensor lever so that it
contacts stopper C. Then adjust nut H until there
is no pedal play.
Apply grease
Stopper D
Lever
Stopper C
(Idle SW)
IWY05-0141E09
3. When at Max. position (accelerator sensor lever in

contact with stopper D), place bolt E in contact
with the lever on the underside of the pedal, and
lock in place with the nut.
20 WY05-1390E

Y-5 Y-5
3. Parking brake adjustment 4. Tire steering angle adjustment
3.1 Adjusting the parking brake clearance 4.1 Tire air pressure
(between pad and disc plate)
unit: kPa {psi}
Adjust so that the clearance between pad and Tire size Traveling On-tire operation
disc plate becomes approx. 0.15 mm (0.006 in) 29.5 - 25 - 22PR 350 - 450 (50.75 - 65.25) 400 - 440 (58 - 63.8)
per side. 29.5 - 25 - 28PR 330 - 430 (47.85 - 62.35) 430 - 470 (62.35 - 68.15)
3.2 Connecting the parking brake and spring 4.2 Adjusting the tire Steering angle
chamber
(1) Move the spring chamber to the end of its stroke.

(Use air pressure to move it to the end of its
extension stroke.) Then adjust the position of Link,
connect the chamber and brake lever.
(2) After connecting, check so that the clearance

between the pad and disc plate becomes apporox.
0.15 mm (0.006 in) per side. Then lock in place
1. Jack up the vehicle. Operate the steering cylinder
with the nut.
2 to 3 times with 4-wheel steering (to bleed air out
from the cylinder).
2. Before adjusting the tire turning angle, use a

side-slip tester to check that the amount of tire
side-slip is no more than ± 5 mm (0.197 in) for
both the front and rear tires.
3. If it is more than ± 5 mm (0.197 in), loosen the

bolts that fasten the left and right tie-rod ends.
Then rotate the tie-rod and adjust the toe-in..
4. Jack up the vehicle on a level road surface (so

that the height of the left and right tires is the
same). Use a tire turning angle measurement jig
to adjust the turning angle in direction A to 24° -
25° at stopper bolt X, and in direction B to 24° -
25° at stopper bolt Y.
5. Adjust the rear wheels as the procedures of the

front wheels.
21 WY05-1390E

Y-5 Y-5
5. Engine speed (and governer setting) 6. Torque converter and transmission

[NOTICE] 6.1 Maximum allowable speed
Before checking the engine speed, run the engine Units: MPH (km/h)
to warm it up. (Light weight grease should reach
Shift position Hi position Lo position
approximately 50°C (122°F).)
1 5.5 (8.9) 1.6 (2.5)
1. No-load Max. speed 2 11.6 (18.5) 3.2 (5.1)
• PTO - OFF : 2860 ± 40 min
-1 D 22.5 (36.2) 6.2 (10.0)
-1
• PTO - ON : 2150 - 2200 min R 3.9 (6.2) 1.6 (2.5)
-1
2. Idling speed : 645 - 695 min (PTO - OFF) [NOTICE]
-1
Engine speed: 2600 min
3. Stall speed
Gauge display
(1) Set the switches and levers as described below. Pay attention to the tachometer and do not overrun
the engine.
• PTO switch : OFF -1
(Max. 2900 min )
• Shift lever : 2nd gear
Drive-speed selection must be done with the
• Drive speed selector switch : 4WD Hi vehicle at a complete stop and with the brakes not
• Service brake : ON applied.
The mechanism does not allow 2WD selection in Lo
(2) Depress the accelerator pedal all the way. Check position.
the speed when the engine speed has stabilized.
Max. speed standard when stalled: 6.2 Adding oil to the torque converter and
-1
Approx. 2160 min transmission
[NOTICE]
When checking the oil level, turn PTO OFF. Check
at an oil temperature of 50°C, once the oil level has
stabilized after the engine is started.
Do not add too much or too little oil.
Do not allow dust or water to enter when adding oil.
1. With the engine stopped, add oil to the oil injection

port in the top of the T/C, to the prescribed level
on the T/M oil level gauge.
2. Put the T/M in neutral and start the engine. While

-1
idling (670 min ), continue to add oil. Check that
the oil level has stabilized within the range
indicated by the * mark on the T/M oil level gauge.
Total oil volume:

approx.46L (12.2gal)
22 WY05-1390E

Y-5 Y-5
7. Braking force 8. Adjusting the headlight light axes
7.1 Parking brake force (1) Turn the switch to the high beam side.
1. Must be 20% or more of the vehicle weight. Check (2) Use a tester and adjust as following.
that both the front and rear braking forces. Left-right direction: 0°
Braking force Up-down direction: 0°
TR-800XXL-4 94.7 kN or more

{9663 kgf}
(21307 lbf)
GR-700EXL-1 95.0 kN or more
{9697 kgf}
(21382 lbf)
{8596 kgf}
(18954 lbf)
GR-550EX-1 84.6 kN or more
{8630 kgf}
(19029 lbf)
7.2 Service brake force
1. Check that the difference in braking force between

the left and right wheels is 8% or less of axle load.
Braking force
TR-800XXL-4 19.4 kN or less
GR-700EXL-1 {1976 kgf}
(4357 lbf)
GR-550EX-1 {1840 kgf}
(4057 lbf)
Check that the difference in braking force between
the left and right wheels is 6.86kN {700 kgf}.
2. Check the braking force

• FRONT .... 75 kN{7700 kgf}(16980 lbf) or more
• REAR....... 45 kN{4600 kgf}(10140 lbf) or more
23 WY05-1390E

Y-5 Y-5
9. Adjusting boom telescoping wire ropes

1. With the boom fully retracted, tighten the nut-A until a tension is placed on the top boom section retraction
wire rope (to keep the boom fully retracted).
[NOTICE]
Loosen the sway stopper bolt
on the bottom of each boom
section until it is out of contact
with the support.
2. Tighten the four nut-B’s equally until the 4th boom section extends by 1-5 mm (0.04-0.2 in) from the 3rd
boom section.
3. Tighten the two nut-C’s equally until the top boom section extends by 1-5 mm (0.04-0.2 in) from the 4th
boom section.
24 WY05-1390E

Y-5 Y-5
4. Tighten the nut-A until the top and 4th boom sections are fully retracted.
5. Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control lever and then retract
it fully. Check the boom is fully retracted.
NG OK
END
6. Check the tension of the two 4th boom section extension wire ropes.
7. When the wire rope is slack: 8. When the wire rope is tense:
7.1 Tighten the two nut-B’s by approx. a third turn equally.
7.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control
NG
lever and then retract it fully. Check the boom is fully retracted.
OK
END
25 WY05-1390E

Y-5 Y-5
8. When the wire rope is tense:

8.1 Tighten nut-A by approx. a third turn.
8.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
NG OK
9. When only the 4th boom section is not fully retracted: END
9.1 Tighten two nut-C’s by approx. a third turn equally.
9.2 Extend the boom by 200-300mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
OK
END
26 WY05-1390E

Y-5 . Y-5 .
10. Adjust the sway stopper bolt for the each boom section.
[NOTICE]
Refer to “Adjusting the bolt on the bottom of each boom section head” in chapter G.
345-803-33000 △
0
345-800-62500 △
1
27 WY05-1390E

Y-6 Y-6
Check (Crane Operation)
Y-6 Check (Crane Operation)
1. Outrigger status indicator
Main switch : ON
Shift lever : Not in N position
Operate the outrigger extension/retraction switch.
N Lamp lights.
O/R SW
IWY05-014019
Press all operation push-buttons.
Outriggers do not operate.
Main switch : ON
Shift lever : N position
Operate the outrigger extension/retraction switch.
N Lamp lights.
O/R SW
IWY05-014019
Press all operation push-buttons.
Outriggers operate.
28 WY05-1400E

Y-6 Y-6
2. Hoisting 5. Jib
1. Make sure that the two-blocking function does not
[Condition]
work while the jib set status is registered.
• Load :None
-1
• Engine speed :Approx.670 min to medium speed 2. Check the jib lock indicator lamp.
• Make sure that the lamp is lit when the jib slides
[Procedure]
out of the center support on the boom.
1. Shift the boom telescoping lever to full stroke first.
2. Make sure that the main winch moves slowly

Lamp is lit
while the auxilialy winch lever is slightly operated. JIB LOCK
IWY04-0510E01
3. Make sure that the main winch does not move
while the auxilialy winch lever is operated to full 3. Check the operation of the jib mounting/stowing
stroke. cylinder.
(1) Make sure that the jib mounting/stowing
cylinder can be moved while the boom is
3. Backward stability control retracted fully.
Select the on-tires for outrigger set status on the
cylinder does not move when the 2nd boom
AML.
section extends by 100 mm (3.94 in).
The boom raising operation must be stopped at
69° automatically.
cylinder does not move when the 3rd to top
The boom lowering must be operated.
boom sections extend by 100 mm (3.94 in).
4. Outrigger emergency setting
1. Turn the switch of the upper right panel in the cab

ON.
2. Make sure that the indicator lights up.
3. Check that the extension width can be changed

on AML manually regardless of current extension
width (360-degree same).
29 WY05-1400E

Y-6 Y-6
6. Boom Telescoping Control Retraction
[Boom length: 11.5 - 44.0 m (37.7 - 144.4 ft)] Appox. 27.75m (91.0ft) boom (3rd)
S1: Emergency telescoping switch for 3rd to top
boom sections
S2: Emergency telescoping switch for 2nd boom 3rd to top boom sections retract.
section
S7: Extension switch for 3rd to top boom sections
L7: Full-retraction detection limit switch for 3rd to Switch L7: ON
top boom sections
L8: Full-retraction detection limit switch for 2nd
boom section 2nd boom section retract.
(Even if stroke remains for the 3rd to top
6.1 Telescoping mode I boom sections at this time, the hydraulic
valve orifice causes them to fully retract.)
Extension
11.5m (37.7ft) boom (base)

Emergency telescoping
Telescoping possible only for

2nd boom section. 11.5m (37.7ft) boom (base)
Turn the AML override key to the

Boom length: 19.47m (63.9ft) emergency side, and turn PTO swtch to
“OVER RIDE” side.
With switch S1 pressed, extend the 3rd, 4th, and top

Switch S7 : OFF
boom sections by approximately 1m(3.3ft) each.
2nd boom section can be moved With switch S2 pressed, fully extend the 2nd boom
to the stroke ends. section.
(AML function: 2nd boom section) At this time, check that the error contents are as
follows until the boom length reaches 19.22m (63.0ft).
Switch S7: ON With switch S2 pressed, retract the 2nd boom section
and reduce the boom length to 18.6m (61.0ft) or less.
At this time, because the No. 2 cylinder is connected
to the tank through the hydraulic valve orifice, the 3rd
Extension is possible of 3rd to top boom to top boom sections may also retract.
sections.
(AML function changes to 3rd boom section
when switch L7 turns OFF.) With switch S1 pressed, retract the 3rd to top
boom sections.
30 WY05-1400E

Y-6 Y-6
6.2 Telescoping mode II Retraction
Extension
Appox. 39.93m (131.0ft) boom (4th and 5th)
2nd boom section retract.

3rd to top boom sections
extend.
Boom length: 35.72m (117.2ft) Switch L8: ON
Switch S7 : OFF
3rd to top boom sections retract.
3rd to top section can be moved

to the stroke ends.
(AML function: 4th boom section)
Emergency telescoping
Switch S7: ON
Extension is possible of 2nd boom section.

(AML function changes to 4th and 5th boom
Turn the AML override key to the
sections when switch L8 turns OFF.)
emergency side, and turn PTO switch to
“OVER RIDE” side.
With switch S2 pressed, fully extend the 2nd boom

section. At this time, check that when the boom
length reaches 19.22m (63.0ft).
With switch S1 pressed, extend the 3rd, 4th and

top boom sections by approx. 1m (3.3ft) each.
With switch S1 pressed, retract the 3rd to top

boom section and reduce the boom length to
18.6m (61.0ft) or less.
With switch S2 pressed, retract the 2nd boom

section.
31 WY05-1400E

Y-6 . Y-6 .
7. Alarms
Type of
Item Sound Checking procedure
alarm
• 280Hz Occurs at 100% when main switch is ON and PTO switch
Electronic
AML limit • continous is ( | ) ON. (Intermittent low tone sound occurs at 90% and
buzzer
low tone above.)
• 2300Hz
Electronic • continous Occurs when the overwind switch of either the main or
Overwind warning
buzzer high-low auxiliary winch is turned ON by winch hoist-up operation.
tones
• 2300Hz Sounds when either the outrigger extension/retraction or

Outrigger operation Electronic jack slide selector switch has been left in any position
• Intermittent
switch detection buzzer other than neutral 10 seconds after operation is
beeping
completed.
• AML buzzer: When main switch is ON and PTO switch is (I) ON, make
E/G cover interference Electronic
sounds 3 sure that the operation stops while boom angle is 8° or less
automatic stop buzzer
seconds and swing angle is between 135° and 220°.
8. Outrigger slide plate adjustment
1. With the outriggers fully retracted, install the slide

plate and the plate into the outrigger box.
2. Adjust the slide plate with the bolt X so that the

slide plate is 2mm away from the upper surface of
outrigger box bottom plate.
3. Tighten the nut Y to secure the bolt X in position.
345-803-34500 △
0
32 WY05-1400E

Y-7 Y-7
Check (Driving Devices)
Y-7 Check (Driving Devices) Manual shift
1 Exhaust brake (EXB)

1. Turn the EXB switch ON.
Engine speed is idling.
(The pilot lamp illuminates.)
2. Check pattern
[Low position]
[NOTICE]
Check whether or not EXB is operating from the [NOTICE]
engine noise and from the movement of the air No automatic shift in Low position.
cylinder.
Seq. EXB
1 With the shift lever in the N position. OFF
Move the shift lever from the N
2 ON
position to the D position.
3 Depress the accelerator pedal. OFF
Release your foot from the accelerator
4 ON
pedal.
Use the service brake to reduce speed
5 OFF
to 1 km/h or less.
Release your foot from the service
6 brake pedal. ON
7 Move the shift lever to the N position. OFF
2. Automatic transmission
[NOTICE]
Numbers indicate speedometer readings
(units: km/h)
( ) Indicates lock-up ON and OFF values.
[High position]
33 WY05-1410E

Y-7 Y-7
3. Steering mode change
2-wheel 4-wheel Crab Rear
Change the steering mode switch to 4-wheel, crab, or rear steering.
IWY05-0141E16
Turn the steering wheel, and check the steering.
Check that the lamp is ON, except when it is straight advancement

of the state of the rear tire.
R/CENTER
IWY05-014016
Match the rear tire in the state of straight advancement.
Check that the lamp is OFF.
R/CENTER
IWY05-014016
Change the steering mode switch to 2-wheel steering.
4. Emergency switches
1. Emergency gear shifting procedure
After turning the emergency transmission switch
to ON, make sure that gear shift lever position “D”,
“2” and ”1” are assigned to the 3rd gear, 2nd gear
and 1st gear respectively for traveling.
2. Emergency accelerator
Turn the emergency accelerator switch to ON, and
make sure the engine revolution rises to
maximum when the accelerator pedal is dipressed
even slightly.
3. Emergency engine stop

Make sure that the engine stops when the
emergency engine stop switch is pulled.
34 WY05-1410E

Y-7 . Y-7 .
5. Overshift prevention
4. Maintain a speed of 10 km/h. Move the shift lever
[NOTICE] to “1.” Check that transmission does not downshift
Jack up the vehicle and shift to 4WD Hi position. (display: 2).
Perform the operations below and check the shift
position with the combination meter. 5. Gradually decrease speed. Check that
transmission downshifts to 1st gear at 8 km/h
1. Move the shift lever to “D” and increase speed to
(display: 1).
18 km/h or more. Check that transmission shifts to
3rd gear (display: D). Combination meter
Meter speed
display
2. Gradually reduce speed. Maintain a speed of 20 a 18 D
km/h. Move the shift lever to “2.” Check that b 18 2
transmission does not downshift (display: D). c 10 2
d 8 1
3. Gradually reduce speed. Check that transmission
downshifts to 2nd gear when the speed is 18 km/h
(display: 2).
6. Warnings
Warning
Item Identification Check conditions
type
Buzzer does not sound when the following conditions are met.
It sounds at all other times.
2
Low air pressure Electronic • 2300 Hz 1.Air pressure is 540 kPa {5.5 kgf/cm } or less. From parking
and parking buzzer • Continuous beep OFF, main switch is turned ON.
2.Parking and brake lock are ON, shift lever is in D position,
and speed is 1 km/h or less.
-1
The mechanism sounds at engine speed of 2950 min . There
Electronic • 2300 Hz is not need to check it.
Engine overrun
buzzer • Intermittent beeping -1
Turns OFF at 2700 min .
Attach a step-up gear to the vehicle speed detection gear box.
Accelerating:
• 2300 Hz Speedometer reading 39 km/h: Intermittent sound
Electronic
Speed warning • Continuous and 42 km/h: Continuous sound
buzzer
intermittent sounds Decelerating:
Speedometer reading 40 km/h: Intermittent sound
37 km/h: OFF
Torque converter Electronic • 2300 Hz Buzzer sounds if the parking brake is OFF, and the torque
2
low pressure buzzer • Continuous beep converter pressure is 1.0 MPa (10.0 kgf/cm ) or less.
Sounds if vehicle speed exceeds 0.6MPH when 2-/4-wheel
Electronic • 2300 Hz
2WD/4WD select switch condition is differ from 2-/4-wheel indication in the meter
buzzer • Continuous beep panel.
Sounds if vehicle speed exceeds 0.6MPH when Hi/Lo selector
Electronic • 2300 Hz
Hi/Lo select switch condition is differ from Hi/Lo indication in the meter
buzzer • Continuous beep panel.
Check is unnecessary because structurally sounds when oil
Torque converter Electronic • 2300 Hz temperature exceeds 110℃ if vehicle speed exceeds 0.6MPH.
oil temperature buzzer • Continuous beep No sound when oil temperature is below 100℃ or vehicle is
stop.
345-803-34000 △
0
35 WY05-1410E

Y-8 . Y-8 .
Oil and Grease Table
Y-8 Oil and Grease Table
Item Quantity :L (gaL) Remarks

Hydraulic oil 995 (263) TADANO Hydraulic oil LL (*2): #22
Swing assy 3.8 (1.0) Mobil Gear 632
Winch assy Main 4.0 (1.06) ISO VG 320
API Service Class GL-3
Gear oil Aux. 4.0 (1.06)
Carrier axle 24 (6.3) It has enclosed it APOROIL gear oil HE90S
Axle SAE 90
Planetary gear 5 (1.3) × 2 in the maker API Service Class GL-5
Brake fluid 1.7 (0.45) TADANO Genuine Brake Fluid DOT 5.1
Torque converter oil 46 (12.15) Mobil ATF: GM Dexlon II
Engine oil 13 - 15 (3.44 - 3.96) Mobil Delvac 1330
SAE 30
Full level 11 (2.9) API Service Class CD
Low level 9 (2.4) (*2)
Mobil Delvac Super 1300
Oil Filter 4 (1.06)
SAE 10W-30
API Service Class CD
Grease 1 (0.26) Daphne Coronex Grease EP No.2
Fuel tank 300 (79.3) Light Oil (JIS K 2204 2)
Cooling Engine 13 (3.44)
water (*1) Radiator 8.8 (2.3) Amount approx. 30 (7.9)
Connecting hose 8.5 (2.2)
(*1): Applicable to a machine equipped with an air conditioner

1. Turn the starter switch to ON and shift the temperature adjustment switch fully toward the Hot side.
2. Press the air conditioner shutdown switch and then start the switch.
3. Bleed the circuit from the engine via the radiator to the rotary joint completely.
4. Bleed the circuit with the 1st step of the wind volume and the air conditioner switch turned ON.
(Engine speed: idling)
5. Check the cooling water level after bleeding.
(*2): Canada Specification
345-803-31000 △
0
36 WY01-1160E

Y-9 . Y-9 .
Mass Table
Y-9 Mass Table

Spec. No.
Part Name GR-800-1-00211
2M2D
(North America)
Boom assy (including telescoping
11470kg (25290lbf)
cylinder, jib-1 and jib-2)
Telescoping cylinder (No.1) 790kg (1740lbf)
Boom Telescoping cylinder (No.2) 880kg (1940lbf)
Jib-1 560kg (1230lbf)
Jib-2 280kg (620lbf)
Elevating cylinder 950kg (2090lbf)

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

Main winch assy
640kg (1410lbf)
(including winch motor)
Winch Auxiliary winch assy
640kg (1410lbf)
(including winch motor)
Winch motor (main/auxiliary) 150kg (330lbf)
Weight Counterweight 1 7900kg (17420lbf)

Outrigger inner case assy
(including jack cylinder and 800kg (1760lbf)
extension cylinder)
Outrigger
Jack cylinder 170kg (370lbf)
Extension cylinder 60kg (130lbf)
Front axle 1570kg (3460lbf)
Rear axle 1460kg (3220lbf)
Engine 630kg (1390lbf)
Torque converter 230kg (510lbf)
Transmission 450kg (990lbf)
Wheel assy (tires: 29.5×25-22PR) 790kg (1740lbf)
37 WY01-1170E

Y-1 0 . Y-1 0 .
Specifications
Y-10 Specifications Idling speed: 605 - 652min

-1
1. Engine speed Max. speed: 1645 - 2720min

-1
3.2 Pump displacement

• Engine model : MITSUBISHI 6M60-TLA3B
3 3
• T/C model : RF80C-76F4 52.2 + 31.1cm /rev (3.18 + 1.9in /rev)
1.1 Idling speed 4. Charging pump

-1
645-695min (PTO: OFF) (for torque converter)
1.2 MAX. speed (unload) 4.1 Pump speed

-1 Engine speed
2820-2900min (PTO: OFF) (Pump speed= )
1.066
-1
2150-2200min (PTO: ON)
-1
Idling speed: 605 - 652min
1.3 Stall speed -1
Max. speed: 2645 - 2720min
-1
Approx. 2160min (measured value for reference)
Measuring conditions:
3 3
PTO switch: OFF 33.2cm /rev (2.03in /rev)
Gearshift position: 2nd
Drive mode select switch: H/4WD 5. Emergency steering pump
Service brake: Fully applied (option)
Accelerator pedal: Fully operation
5.1 Pump speed
2. Hydraulic pump (for crane) -1
Pump speed (min )
(Double Variable Displacement
Transmissi on output shaft revolution
Pump) =
1.439
2.1 Pump speed
Engine speed
(Pump speed= ) 3 3
0.918 14.56cm /rev (0.89in /rev)
-1
Idling speed: 703 - 757min 6. Winch motor
-1
Max. speed: 2342 - 2397min 3
Displacement: 533cm /rev (32.5in /rev)
3

7. Swing driving unit
3 3
82 + 82cm /rev (5 + 5in /rev)
7.1 Swing motor
3. Hydraulic pump (for steering) 3
Displacement: 169.4cm /rev (10.33in /rev)
3
(Double Gear Pump)

7.2 Swing speed reducer
3.1 Pump speed
Reduction ratio: 33.68
Engine speed
(Pump speed= )
1.066
38 WY01-1200E

Y-1 1 . Y-1 1 .
Boom Connecting Pin and Thread Size Table
Y-11 Boom Connecting Pin and Thread Size Table

(mm)
Applicable model TR-450XL-4, TR-500XL-4 GT-350C-1
Part Name Diameter Thread size Diameter Thread size
Rod end pin Φ100 M30×3.5 Φ100 M30×3.5

Elevating cylinder
Base pin Φ90 M30×3.5 Φ90 M30×3.5
M16×2.0 M18×2.5
Boom base pin Φ90 Φ100
(Qty:4) (Qty:4)
(mm)
GT-550E-1, TR-600XL-4,
TR-600XXL-4, TR-800XXL-4,
Applicable model
TT-600XL-1, TT-800XXL-1,
GR-700EXL-1,GT-700E-1
Part Name Diameter Thread size
Rod end pin Φ120 M33×3.5

Elevating cylinder
Base pin Φ110 M30×3.5
M18×2.5
Boom base pin Φ100
(Qty:4)
(mm)
Applicable model TR-300XL-4, GR-300EX-1 TT-300XL-1
Part Name Diameter Thread size Diameter Thread size
Rod end pin Φ100 M30×3.5 Φ90 M30×3.5

Elevating cylinder
Base pin Φ110 M30×3.5 Φ90 M30×3.5
Boom base pin Φ100 M30×3.5 Φ90 M30×3.5
(mm)
Applicable model TR-150XL-4
Part Name Diameter Thread size
Rod end pin Φ60 -

Elevating cylinder
Base pin Φ70 M24×3.0
Boom base pin Φ60 M10×1.5
39 WY01-0624E

Z
System Diagrams
Contents
Z-1 Hydraulic Circuit .............................. 1 Z-11 Location of Electric Parts

(Swing Table, Boom) .............23
Z-2 Torque Converter Circuit ................ 3
Z-12 Location of Electric Parts
(Relay Assembly / Upper) .....24
Z-3 Brake Circuit (Pneumatic Circuit)... 4
Z-13 Location of Air Parts (AML)...........25

Z-4 Electric Circuit (AML, Crane) .......... 5
Z-5 Electric Circuit (Lower)....................................26
(MDT, Carrier/Upper) ............... 7
Z-6 Electric Circuit (Box Assembly / Lower) ........27
(MDT, Carrier/Lower) ............... 9
Z-16 Harness (Connector No. Table).....28
Z-7 Location of Hydraulic Parts
(Upper).................................. 11 Z-17 Harness (Inside Cab) .....................31
1. Cab and swing table.........................................11
2. Boom ........................................................... 14 Z-18 Harness (Swing Table, Left) ..........32
Z-19 Harness (Swing Table Right).........33

(Lower) ................................... 15
Z-20 Harness (Boom) .............................34
1. Carrier ........................................................... 15
1.1 Front ......................................................... 16
1.2 Center....................................................... 17
Z-21 Harness (AML, Upper) ...................35
1.3 Rear.......................................................... 18
Z-22 Harness (Overwind) .......................36
Z-9 Location of Air Parts...................... 19

Z-23 Harness (Lower, Main)...................37
1. Cab and swing table........................................ 19
2. Carrier ........................................................... 20
Z-24 Harness (Lower, Sub) ....................38
Z-10 Location of Electric Parts Z-25 Harness (Lower,

(Inside cab) ............................ 22 Electronic Governor) .............39
Z
i
Z-1 Z-1
Hydraulic Circuit
Z-1 Hydraulic Circuit Applicable serial No. △

1 ：545520 ~
1.Engine 43….
2.Torque converter 44….
3.Double variable displacement pump 45….
4.Double gear pump 46.Solenoid control valve (jib set)
5.Gear pump (emergency steering, option) 47.Sequence valve (pilot pressure)
6.Drain filter 48.Priority valve
7.Hydraulic oil tank 49.Check valve
8.Return filter (in hydraulic oil tank) 50.Joint (orifice)
9.Line filter 51….
10.Flow control valve 52.Orbitrol
11.Hydraulic valve (emergency steering, option) 53.Hydraulic pilot control valve (swing)
12.Solenoid control valve (outrigger) 54.Hydraulic motor (swing)
13.Check valve (outrigger extending prevention) 55.Swing speed reducer
14.Solenoid valve (slide/jack) 56.Solenoid valve (pilot pressure)
15.Extension cylinder 57.Solenoid valve (auto stop)
16.Jack cylinder 58.Check valve
17.Pilot check valve (jack cylinder retracting prevention) 59.Check valve
18-1.Pressure reducing valve (pilot pressure) 60.Accumulator
18-2.Pressure reducing valve (emergency steering) 61.Remote control valve (lever)
19.Solenoid valve (suspension lock check release) 62.Shuttle valve (lever/pedal)
20.Pilot check valve (suspension lock cylinder) 63.Pressure switch
21.Suspension lock cylinder 64.Joint (orifice)
22.Filter 65.Solenoid control relief valve (elevating slow stop)
23.Solenoid valve (steering mode) 66.Remote control valve (pedal)
24.Pilot check valve (rear steering cylinder lock) 67.Solenoid valve (boom telescoping/aux. hoist)
25.Steering cylinder 68.Hydraulic pilot control valve (elevating, telescoping, winch)
26.Steering cylinder 69.Filter
27.Rotary joint 70.Hydraulic valve (winch brake release)
28.Thermo switch [50°C (122°F) ] 71.Pressure sensor
29.Thermo switch [85°C (185°F) ] 72.Elevating cylinder
30.Check valve (gauge isolator) 73.Orifice
31.Pressure sensor 74.Counterbalance valve (elevating)
32.Check valve 75.Telescoping cylinder (no.1)
33.Oil cooler 76.Telescoping cylinder (no.2)
34.Hydraulic motor (oil cooler) 77.Counterbalance valve (telescoping)
35.Check valve 1 78Hose reel
36.Solenoid valve (air conditioner, option), (oil cooler) 79-1.Hydraulic valve (Top cyl. select)
37.Check valve 79-2.Hydraulic valve
38.Hydraulic motor (air conditioner, option) (protection of No.2 cylinder retraction while mode II select)
39.Jib offset cylinder 80.Hydraulic motor (winch)
40.Pilot check valve (jibset) 81.Winch
41.Joint (orifice) 82.Pressure switch (emergency steering)
42.Jib lock pin 1 89.Solenoid valve (air conditioner, option)
1 WZ01-1131E

Z-1. Z-1. Z-1.
Hydraulic Circuit
[NOTICE]
When the optional emergency steering is not installed, two points "A" are directly joined and four
portions "*1" are plugged.
When the optional air conditioner is not installed, two points "B" are directly joined.
344-018-90000 △
1
2 WZ01-1131E 2

Z-2. Z-2. Z-2.
Torque Converter Circuit
Z-2 Torque Converter Circuit
347-411-60000 △
0
3 WZ05-0330E 3

Z-3. Z-3. Z-3.
Brake Circuit (Pneumatic Circuit)
Z-3 Brake Circuit (Pneumatic Circuit)
347-411-50000 △
0
4 WZ06-0410E 4

Z-4 Z-4 Z-4
Electric Circuit (AML, Crane)
Z-4 Electric Circuit (AML, Crane)
CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page
60 Air solenoid valve （air horn） F-2 576 Boom length and angle detector B-18 931 Touch-type winch drum indicator controller (option) N-19
100 AML (Load moment indicator) vent solenoid valve H-5 580 Swing angle detector C-18 932 Touch-type main winch drum indicator solenoid (ISO array)(option) D-8
102 Remote control pressure vent solenoid valve I-2 581 Pressure sender (main pressure) C-17 933 Touch-type main winch drum indicator solenoid (ISO array)(option) D-8
120 Swing right proportional control valve H-5 583 Pressure sender (air pressure) G-6 934 Touch-type aux. winch drum indicator solenoid (ISO array)(option) C-7
121 Swing left proportional control valve H-4 584 Pressure sender (elevating cylinder, boom raising) F-18 935 Touch-type aux. winch drum indicator solenoid (ISO array)(option) C-7
124 Boom raising proportional control valve I-3 585 Pressure sender (elevating cylinder, boom lowering) F-18 936 Touch-type aux. winch drum indicator solenoid (TDN array) (option) D-7
125 Boom lowering proportional control valve I-3 591 Main winch drum rotation detection proximity switch (option) H-2 937 Touch-type aux. winch drum indicator solenoid (TDN array) (option) D-7
143 Boom telescoping/aux. hoist control selector solenoid valve I-2 592 Aux. winch drum rotation detection proximity switch (option) H-2 938 For air bleeding of suspension lock cylinder G-10
144 Boom telescoping/aux. hoist control selector solenoid valve I-2 595 Main rope run-out detection switch (option) G-2 939 Rope run-out release switch (option) M-19
160 Swing brake release solenoid valve H-5 596 Aux. rope run-out detection switch (option) G-2 949 Buzzer 5 (external alarm) G-2
161 Swing free/lock solenoid valve H-4 665 AML connector 1 C-20 964 Harness (AML) M-18
162 Swing relief proportional control valve H-4 666 AML connector 2 I-20 965 Winch selector switch F-16
192 Jib lock pin extending solenoid valve C-5 667 AML connector 3 K-20 966 Winch selector indicator lamp F-16
193 Jib lock pin retracting solenoid valve C-5 817 Buzzer 4 (overwind (two-blocking) alarm) H-16 967 Winch selector indicator lamp F-16
222 Jib mounting solenoid valve C-4 818 Buzzer 3 (AML alarm) H-16 968 Fuse (for drum indicator) (main) C-8
223 Jib stowing solenoid valve C-4 820 For reducing the main pressure G-10 969 Fuse (for drum indicator) (aux.) C-8
230 Top cylinder selector solenoid valve H-6 821 AML vent solenoid valve G-10 976 Telescoping mode Ⅰ/Ⅱswitch N-7
238 Protection of NO.2 cylinder retraction while mode Ⅱselect solenoid valve C-5 828 AML external indicator lamp (yellow) E-1 977 Telescoping mode Ⅰindicator lamp 0-7
281 Oil cooler solenoid valve C-3 829 AML external indicator lamp (red) E-1 978 Telescoping mode Ⅱindicator lamp N-7
380 Visible type winch drum indicator (option) O-19 837 Condenser (C2) (washer motor) P-4 991 For separated transport of boom and swing table F-19 Next
484 Swing brake switch G-16 849 Washer motor (roof) P-4 Next 992 For separated transport of boom and swing table F-19 page
485 Boom telescoping/aux. hoist control selector switch M-7 Next 850 Washer motor (front) P-4 page 993 For separated transport of boom and swing table B-18
486 Swing stop cancel switch G-16 page 852 Working lamp G-4 994 Counterweight equipped detection proximity switch F-2
487 Swing free/lock selector switch L-7 853 Working lamp (boom) A-4 995 Jib lock pin switch D-2
488 Jib mounting / stowing switch D-2 858 Cord reel (boom length detector) B-4 999 Jib mounting / stowing operationality indicator lamp C-1
491 Elevating slow stop cancel switch H-16 859 3rd/top boom full retraction detection switch B-3 KR27 Telescoping mode Ⅰ/Ⅱselector relay O-8
503 3rd/top boom emergency telescoping switch K-7 886 Harness (AML) E-18 R1 AML power supply relay 1 O-12
504 2nd boom emergency telescoping switch L-7 887 Harness (boom, base)(for separated transport of boom and swing table) A-6 R11 2nd boom emergency telescoping relay O-9
505 Overwind cutout (anti-twoblock) disable switch F-16 888 Harness (boom, top) A-4 R13 3rd/top boom emergency telescoping relay O-10,O-4
506 3rd/top boom extending switch (ISO array) B-9 889 Harness (Swing table, right) E-6 R2 Boom full ret. detection relay C-10
507 3rd/top boom extending switch (TDN array) D-9 890 Harness (Swing table, right) F-6 R22 AML lamp assy relay G-8
518 Over-rear detection proximity switch F-2 891 Harness (Swing table, right) D-6 R23 AML lamp assy relay G-8
521 Over-front detection proximity switch E-2 892 Harness (AML) D-18 R26 AML power supply relay 2 O-11
529 Control lever stand position detection switch C-9 893 Harness (Swing table, left) N-2,H-6 R29 Oil cooler relay G-8
530 Connector C-9 894 Harness (Swing table, left) I-6 R33 Elevating slow stop cancel relay H-17
531 Swing horn switch B-9 896 Harness (AML) I-18 R36 Overwind (two-blocking) relay C-10
532 Main winch hoisting up detection switch K-2 897 Harness (AML) K-18 R4 Swing free selector relay O-10
533 Aux. winch hoisting up detection switch L-2 898 Harness (AML) L-18 R46 Telescoping mode Ⅰ/Ⅱselector (diode) relay O-9
534 Boom extending detection switch K-2 899 Harness (AML) K-18 R47 Remote control pressure vent relay O-4
536 Boom raising detection switch L-2 904 Jib state switch M-18 R53 Telescoping mode Ⅰ/Ⅱselector relay O-9
537 Boom lowering detection switch L-2 905 Jib removed indicator lamp N-17 R8 AML emergency switch relay H-10
540 Swing right detection switch L-2 906 Jib removed indicator lamp N-18 R9 Swing brake relay H-17
541 Swing left detection switch M-2 907 Emergency outrigger state register switch N-19
546 Main winch hoisting down detection switch (option) K-2 908 Emergency outrigger state control indicator lamp N-17
547 Aux. winch hoisting down detection switch (option) K-2 909 Emergency outrigger state control indicator lamp N-18
553 2nd boom full retraction detection switch B-4 916 Controller (outdoor air temperature sensor) N-4
555 Thermo switch (50°C/122°F) G-4 917 Emergency crane operation switch N-4
556 Thermo switch (85°C/185°F) F-4 918 For emergency jib operation F-10
558 AML override switch J-2 919 For emergency jib operation F-10
572 Jib stowed detection proximity switch A-2 922 Boom telescoping/aux. hoist control indicator lamp M-7
573 Jib lock pin retracting detection switch A-3 923 Boom telescoping operation indicator lamp M-7
574 Oil cooler switch K-7 924 Aux. winch operation indicator lamp N-7
5 WZ03-3290E 5

Z-4. Z-4. Z-4.
Electric Circuit (AML, Crane)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Jib lock pin retracting
detection switch
Working lamp
(boom)
Notice (1) This program includes options ; is based on the following conditions : (2) Wire specification codes are based on JIS D607. (4) The wiring numbers 900999 show 12-voltage system, the other show 24-voltage system. (6) Applicable model list Mark (-) is not applied. Mark () is applied. Mark () is option
70W 2 2
(contact closes at
pin retracting) 1.Crane : traveling condition (3) Wire gauges of inside cab are CAVS 0.5mm (0.0008in ) or (5) Following sign indicates the connection of the same number mutually. TR-600-4 TR-800-4 GR-700E-1 GR-700E-1
2 2 North North 00211 00212
2.PTO switch : OFF AVS 0.85mm - (0.0014in -). Receiving side of power supply : Supply side :
America America Europe General
CN853
Jib stowed detection Outside cab Inside cab

3.Boom : fully retracted, over-the-front Wire gauges of swing table and boom are AVS. Receiving side of signal and load : Supply side :
A proximity switch
(contact closes at stowing)
4.Hook blocks : overwound
2 2
(Size not shown are 0.5mm (0.0008in ) ). (It becomes it for the negative-type logic circuit contrary to the electric current direction of the load.) - -
Export
-
A
Rope run-out release
Rope run-out
1741.25YR
5.Starter switch : OFF - -

Output
Boom, top Main and Aux. rope run-out detection -

W
01.25B
R
B
+
Boom, base
-
CN888
CN573
3 1 2 CN887 6.Control levers : neutral positions Main and Aux. hoisting down detection - - -
Br
2
B
L
CN572
350.85Br 0.85Br 35 35Br

1 2 3 GL785
1
7850.85GL 0.85GL785
5
785GL External alarmBuzzer 5 - - -
8 7
GR781
1.25YR174
4
7810.85GR 0.85GR781
6
781GR
1741.25YR
Touch-type controller - -
1741.25YR 1.25YR174
3 4
1.25Lg250
5
2501.25Lg 1.25Lg250
12
2501.25Lg Touch-type SOLMain/Aux. - -
GW367 3670.85GW 0.85GW367 367GW Drum indicator
1.25B 0
7
01.25B 1.25B 0
11
01.25B Visible type indicator - -
6 9
0.85G304 304G
3rd/top boom full ret. detection switch
(contact closes at full ret.) 0.85LgY301
2
301LgY
Main/Aux. winch drum rotation detection proximity switch
1
Overwind/two-blocking detection
switch (boom)
0.75B CN859 CN858 0.85R305
3
305R Reverse steering - - -
B (for right installation)
(contact opens at overwinding/
two-blocking)
0.85R
0.85B
2
1.25LgB
1.25YB 1.25B
0.75W
1.25LgB
2
1
W
Y
W 3040.85G
Y
2
3010.85LgY
1
8
10
Left lever
CN531
Indicator assy (outdoor air temperature indicator) - - - B
1
Cord reel
For separated transport of
324LW Telescoping mode select - - -
Connecting when boom and swing table 1 Boom length detector Boom angle detector
(Boom length detector) Swing horn switch 470LgY
For left installation
1.25Y 1.25YB
the boom operating 2
CN576 CN993
Counterweight removable type - - -
01.25B
2 CN553
1
1.25Y 2nd boom full retraction R
2 3rd/top boom
CN506 B
1
G G
1
G Counterweight fitted type -
detection switch B 01.25B 0B W W W W
1 extending switch 1 3 3
0.85R 0.85LgB 0.85LgB (contact opens at full ret.) W 3050.85R 277LG R R R R
3 Touch-type aux. winch drum (ISO array) 2 4 4
0.85B 1.25B 1.25B indicator solenoid (ISO array) G B B B
Connecting when the jib oerating 6 6
(option) 344RB CN969 Shield Shield Shield Shield
Connecting when
Telescoping system select CN934 0.3A 470LgY 5 5
the 2nd jib poerating R Swing angle detector 2 Swing angle detector 1
Connecting when the single top operating Protection of NO.2 cylinder 2 2
B 450BY (Pot1) (Pot2)
(option) retraction while mode For separated transport of
0.85B 1.25Y Oil cooler Jib lock pin retracing Jib lock pin extending CN935
select solenoid valve boom and swing table
0.85R 1.25Y solenoid valve Jib stowing Jib mounting solenoid valve solenoid valve (Energized:top cylinder select) R 311GR
(Energized: solenoid valve solenoid valve (Energized:pin (Energized:pin Control lever stand position 2
SL.238 B 2501.25Lg CN580
Connecting when the single top operating cooler operating) (Energized:stowing)(Energized:mounting) retracting (free)) extending (lock)) detection switch 1
2501.25Lg
2501.25Lg
W B R
(contact opens at stowing) 3 4
C SL.281 SL.223 SL.222 SL.193 SL.192
C
252LgW
Overwind detection switch (jib and single top)

253LgB
301LgY
G W
(contact opens at overwinding) CN529 3
304G
W G
0B
0B
1
R B
6
Jib mounting/stowing operation box 1 2 Right lever
3 1 4 2 3 1 4 2 Shield Shield
5
CN665 AML connector 1
Relay
2 AML-L B/C
R36
R2
CN281
CN223
CN222
CN193
CN192
CN238
Jib mounting/stowing B
operationality indicator lamp785GL 1 2 1 2 1 2 1 2 1 2 1 2
Connector
B
CN530
343GY R R W
CN581
R
1 DET1GND Make R1,2,4,8,13,22,23,26,
2
311GR Pressure sender
Output
B
1
B W
2 DET1SRC contact R29,33,36,47
CN999
0B Touch-type main winch drum
1
Overwind relay Boom full ret. detection relay (main pressure)
-
R
2
R G
3 ANAINA Boom length input 1pole
3 + 3 4 ANAINB Boom angle input
CN968 Break
786LgR
787LgY
321LW
292RG
W
792BG
791BR
indicator solenoid (ISO array) (contact opens (contact closes at full ret.)
CN932 0.3A 5 ANAINC Swing angle 1 input
contact R9,11,53
0B
0B
0B
0B
0B
0B
(option) R 342R 470LgY at overwinding) AML Shield

6 DET1SLD
CN488 B 440BR CN892 B
7 DET2GND
B 785GL G 22 22G R
3 CN933 6 8 DET2SRC C
contact R46
R 787LgY G 22 22G G
1 CN936 5 9 ANAIND Swing angle 2 input
786LgR R 344RB 1.25Lg250 250Lg W
2 4 10 ANAINE Main pressure input
W B 450BY 1.25Lg250 250Lg
Jib mounting/stowing 3 11 ANAINF Input spare
CN937 GR371 371GR Shield
2poles KR27
D switch
B
CN995
3
781GR
Touch-type aux. winch drum 3rd/top boom
indicator solenoid (TDN array) extending switch
1
CN507
1
0B
2
1
LgB253
R 305
12
13
14
DET2SLD
Di1 Overwind (two-blocking) detection
Di2 2nd boom full retraction detection
D
R 791BR Swing table,right (option) (TDN array) 277LG LgW252
1 2 2 15 Di3 3rd/top boom full retraction detection
792BG
2
BL378
16 Di4 Swing free input 4poles
W CN891 G22
Jib lock pin switch 17 MB
RG157 157RG G22
1 18 MB
BrW279 279BrW Lg250
2 19 RB
YR259
BrY295
3
259YR
295BrY
LgB253
R305
6
253LgB
305R
Lg250
20 RB Diode
AML (Load moment indicator) 4 5 21 TC
external indicator lamp 5
352LW LgW252
4
252LgW GR371
22 ACC Swing stop cancel input
For 1A
LgR165 165LgR BL378 378BL
(red)20W
6 WY384
3
384WY WY384
23 NC For 3A
CN829 WR385
2 24 Di5 Overwind cutout (anti-twoblock) disable
0B 0B CN889 385WR WR385
YG349
1 25 Di6 AML override
412GW GW412 412GW 349YG YG349
0B CN828 411GL GL411
3
4
411GL GW367
14
13
367GW GW367
26
27
Di7 Elevating slow stop cancel input
Di8 Jib stowed detection
Resistance
BW333 333BW BW333 333BW BW333
(yellow)20W 8 LgW275
12 28 Di9 Over-front detection
E 6
9
275LgY
2501.25Lg B011
11
10
275LgW
0B
LgY275
B0
29
30
Di10 input spare
GND E
LgY470
RY451
17
470LgY
451RY
B011
9
0B B0
B
31 GND Condenser
0111.25B
10 8 32 MOGND/DET3GND
CN521 LY130
12
130LY
7
R
33 MOSRC/DET3SRC C2
Over-front detection B 333BW O441 441O W
proximity switch Output 1 13 CN886 34 MOINP/ANAING (Elevating cylinder raising pressure input)
L 0B 10W GL785 785GL AML W
(contact closes at - 2 1 35 MOINN/ANAINH (Elevating cylinder lowering pressure input)
Br 1561.25RY GR781 781GR Shield
over-front) + 3 2 36 MOSLDSLD
1.25YR174 1741.25YR
Reverse steering 5 37 NC
CN518 1.25RY156 1561.25RY
7 38 NC
Over-rear detection B 165LgR LW321 321LW CN584 CN991
Output 1 1 11 39 SIF1GND 2A
proximity switch L 0B BrR294 294BrR W W W W
- 2 2 14 Front controll panel Output 1 2 40 SIF1SRC
(contact closes at Br 157RG Y296 296Y B B B B
over-rear) + 3 3 15 Winch selector indicator lamp - 2 3 41 SIF1TXD+
YG298 298YG CN967 R R R R
16 CN966 + 3 1 42 SIF1TXD-
1.25B 0 01.25B 2501.25Lg 319YL Shield Shield
C/W removable type 18 4 43 SIF1RXD+
CN994 Pressure sender
For separated transport of 44 SIF1RXD-
Counterweight equipped B G 294BrR CN890 (elevating cyllinder boom raising)
Output 1 1 boom and swing table 45 SIF1SLD
F detection proximity switch
(contact closes when
C/W equipped)
-
+
L
Br
2
3
2
0B
1561.25RY
3
RG292 292RG
4
3
CN965 F
6 318LY CN585 CN992
2 Winch selector switch 3
C/W fitted type (MSM select) 5 0 B W W W W
1 For emergency jib operation 4 Output 1 2
(connect when jib setting in AML failure) B B B B
Thermo switch (85/185°F) - 2 3
CN60 (contact closes at 85/185°F) CN918 CN919 R R R R
Overwind cutout (anti-twoblock) + 3 1
1561.25RY
1561.25RY
0B 2501.25Lg CN505 Shield

SL.60 1 1 1 disable switch Shield
SOL CN556
296Y 4
470LgY
470LgY
470LgY
470LgY
130LY
412GW
781GR 384WY Pressure sender

321LW
298YG
6
402YR
411GL
Air horn 2 (contact closes at 3

401O
0 B For separated transport of

overwinding) 5
4 (elevating cyllinder boom lowering)
0B boom and swing table
For air bleeding of suspension lock cylinder
CN949 3 1 4 2 3 1 4 2 3 1 4 2 (not connect with PTO-ON at air bleeding)
CN555
R29
R23
R22
B 0B 298YG CN938 CN484

Buzzer 5(external alarm) 1 1
P 259YR 22 G 2 35Br
2 2 1 2
0B R R R 22AG 5 0 B
5
Swing brake switch 4 0 B
Rope run-out (option) Thermo switch (50/122°F) 4
Oil cooler relay (contact closes 352LW
(contact closes at 50/122°F) AML lamp assy relay 3
3
For reducing the main pressure at braking)
1 2501. 25Lg
G Main rope run-out
detection switch (option)
R
B
2
1
CN595
G
2
295BrY
0B
1
Pressure sender
CN583
- 1
(connect with PTO-OFF)
1
CN820
1
1561.25RY
1
G
(contact opens when CN852 (air pressure)
W Working lamp 1741.25YR 228W 2501.25Lg CN486
rope run-out) 3 3 (RH,Swing table) 2 2 2
0B 227R 2 35Br
70W + 3 4 4
Swing stop 5 0 B
1 1
CN596 CN821 cancel switch 1 0 B
(contact closes
3 3
Aux. rope run-out R G 279BrW 336P 3 371GR
2 2 Connect CN821 to valve when AML is failure AML vent 2 at release) 5 5
detection switch (option) B 0B 0B 4 2501. 25Lg
(contact opens when 1 1 solenoid valve 1 2 2
W
rope run-out) 3 3 Swing brake
release Top cylinder selector
Drum indicator (option) Swing free/lock Swing relief Swing proportional solenoid valve solenoid valve CN491
CN591 solenoid valve proportional control valve (energized : AML vent (energized : Elevating slow stop 2 35Br
control valve (left) cancel switch 4 4
Main winch drum rotation B 441O (energized : free) (right) brake release) solenoid valve top cylinder select) 0 B
385WR
314YW
5
detection proximity
Output 1 1 SL.161 SL.162 SL.121 SL.120 SL.160 SL.100 SL.230 (contact closes 1 1
L 0B 0 B
0B
0B
1
switch (option) - 2 2 at release) 3 3
+
Br
3
470LgY
3 A 3 1 4 2
3
5 5
347YL
2501. 25Lg
CN121
CN120
4
2 2
R8
H Aux. winch drum rotation

detection proximity
Output
B
L
1
CN592
1
451RY
0B
1 2 1 2
R
H
CN161
CN162
CN160
CN100
CN230
- 2 2
271RW
281YW
270RB
280YB
switch (option) 1 2 1 2 1 2 1 2 1 2
2501.25Lg
Br 470LgY CN818
+ 3 3 Swing talbe, left
AML emergency switch relay W
352LW
349YG
CN893
347YL
H 1
353O
Boom lowering Boom raising (contact closes at AML override) Buzzer 3 B 0 B
01.25B
0B
0B
0B
8 2
348BW
proportional proportional
256YG
290LgR
291LgY
303RL
(AML alarm) R 259YR

353O
02B
R33
control valve control valve 10 L 3
0B
0B
0B
R9
SL.125 SL.124 3 1 4 2 3 1 4 2
11 Stabilizing power 3A
13 CN817
Buzzer 4 (Overwind R 257YO supply circuit
14 (two-blockomg)
CN124
CN125
746RY B 0 B R R
6 alarm)
1 2 1 2 O353 353O
5 AML
YG256 256YG Swing brake relay Elevating slow stop CN896
1 (contact opens cancel relay
WR262 262WR
7 7
272RG
282YG
at braking) (contact closes

273RL
283YL
WY268 268WY
9 at relese) 9
BW348 348BW
SL.102 2 10
Remote control pressure vent solenoid valve 01B RL303 303RL GR781 781GR
1 12 6
I (energized : remote control pressure on-load) 2
CN102
343GY GY343
LgW337
4
3
343GY
337LgW
GW793
RY746
1
3
793GW
746RY CN666 AML connector 2
Auto. stop 1 (AML vent) 3A
I
YG256 256YG YG256 RLY1
8 1
YR259 259YR Output spare RLY2
5 2 3A
Boom telescoping/aux. hoist control select YW260 260YW GR781 Jib setting RLY3
Swing talbe, left 4 3
CN143 CN894 YO257 257YO YR259 Buzzer output (AML alarm) RLY4
SL.143 2 4 3A
Boom telescoping/aux. hoist control 03B RB270 270RB RB270 270RB YW260 Telesclping control output RLY5
1 10 18 5
selector solenoid valve 337LgW YB280 280YB YB280 280YB GW793 Telescoping system select RLY6
2 11 17 6
Buzzer output (Over wind alarm) 3A
(energized : telescoping operation) RW271 271RW RW271 271RW YO257 RLY7
12 16 7
CN144 YW281 281YW YW281 281YW RY746 Output spare RLY8
SL.144 13 15 8
04B RG272 272RG RG272 272RG W261
Boom telescoping/aux. hoist control 1 14 14 9 Di11 Main winch hoisting up detection 3A
selector solenoid valve 337LgW YG282 282YG YG282 282YG WR262
2 15 13 10 Di12 Main winch hoisting down detection
(energized : telescoping operation) RL273 273RL RL273 273RL V267
16 12 11 Di13 Aux. winch hoisting up detection
YL283 283YL YL283 283YL WY268
17 11 12 Di14 Aux. winch hoisting down detection 2A
WG263 263WG RB270
3 13 (CNTL1P)Right swing proportional control valve output Current
1.25B 0 01.25B AML CN897 YB280 Supply
20 14 (CNTL1N)Right swing proportional control valve COM
W261 261W W261 261W RW271
J V267
WB265
1
2
4
267V
265WB
V267
WB265
5
3
11
267V
265WB
YW281
WG263
15 (CNTL2P)Left swing proportional control valve output
16 (CNTL2N)Left swing proportional control valve COM
17 Di15 Boom extention
amplifier
J
WL266 266WL WL266 266WL LY318
5 10 18 Di16 Aux. winch employed
GL286 286GL GL286 286GL WB265
6 9 19 Di17 Boom raising
AML override switch GR287 287GR GR287 287GR WL266
7 8 20 Di18 Boom lowering
(contact closes at overriding) LgR290 290LgR WR262 262WR GL286
18 4 21 Di19 Swing right
CN558 LgY291 291LgY WY268 268WY GR287
19 2 22 Di20 Swing left 2A
22G G 22 22G WG263 263WG RG272
2 8 1 23 (CNTL3P)Boom raising proportional control valve output Current
KEY
336P P336 336P LY318 318LY YG282

1 9 6 24 (CNTL3N)Boom raising proportional control valve COM Supply
RL273
Right side control panel 7 25 (CNTL4P)Boom lowering proportional control valve output amplifier
YL283
12 26 (CNTL4N)Boom lowering proportional control valve COM
Rope run-out (option) CN574 27 (CNTLSLD)
CN546 2 35Br
Main winch hoisting down 2 AML 28 SIF2GND 2A
G 0B 5 0B CN899
detection switch (option) 1 1 Oil cooler switch 5 29 SIF2SRC
262WR 4 0B W196 196W W196
(contact opens at hoisting down) 2 2 (contact closes 4 1 30 SIF2TXD+
3 321LW G197 197G G197
at ON position) 3 2 31 SIF2TXD-
K Aux. winch hoisting down

detection switch (option)
1
CN547
G
1
0B
268WY
1
1
1561.25RY R198
B199
5
198R
199B
6
R198
B199
Shield
32 SIF2RXD+
33 SIF2RXD-
K
(contact opens at hoisting down) 2 2 3 34 SIF2SLD
CN503 4
CN534 1 35Br CN667 AML connector 3
Boom extending 2 AML CN898
0B 3rd/top boom emergency 5 0B
detection switch 1 telescoping switch 6 5 1 TR1 External indicator(90%)
263WG 2 2501.25Lg O401 401O O401
(contact opens at extending) 2 (contact closes at 3 4 2 TR2 External indicator(90100%)
3 332V YR402 402YR YR402
emergency telescoping) 4 3 3 TR3 External indicator(100%)
CN532 4 0B 178Sb Sb178
Main winch hoisting up 5 2 4 TR4 Output spare
0B 794YB YB794
detection switch 1 1 5 TR5 Output spare
261W CN504 YL319 319YL YL319
(contact opens at hoisting up) 2 12 6 TR6 Aux. winch employed
1 35Br
2nd boom emergency 2 11 7 TR7 Output spare
CN533 5 0B
Aux. winch hoisting up telescoping switch 6 10 8 TR8 Output spare
0B (contact closes at 2 2501.25Lg
detection switch 1 3 9 9 NC
267V emergency telescoping) 3 379Y BW748
(contact opens at hoisting up) 2 4 8 10 Di25 Emergency outrigger state control
4 0B LB289
5 7 11 Di26 Rope run-out release
CN536 LW276
6 12 Di27 Telescoping system select
L Boom raising
detection switch
(contact opens at raising)
1
0B
265WB
2
Front control panel AML CN964
LG277
13
14
Di28 Top boom extension
NC
L
CN487 BW748 748BW
7 15 NC 2A
CN537 Swing free/lock 2 35Br LB289 289LB LgR290
Boom lowering selector switch
2 6 16 (CNTL5P)Swing relief proportional control valve output Current
0B 5 0B LW276 276LW LgY291
detection switch 1 (contact closes at 5 5 17 (CNTL5N)Swing relief proportional control valve COM supply
266WL 4 0B LG277 277LG amplifier
(contact opens at lowering) 2 Boom telescoping/aux. swing free) 4 4 18 (CNTL6P)
3 348BW LgR290 290LgR
hoist control select 3 3 19 (CNTL6N)
CN540 1 2501.25Lg LgY291 291LgY
Swing right
1 18 20 CNTLSLD
0B WL288 288WL WL288
detection switch 1 SWF 15 21 Di21 Jib state switch
286GL CN485 BrR294 294BrR BrR294
(contact opens at swing right) 2 14 22 Di22 Counterweight equipped detection
2501.25Lg BrY295 295BrY BrY295
Boom telescoping/aux. hoist 5 13 23 Di23 Main rope run-out detection
CN541 337LgW BrW279 279BrW BrW279
control selector switch 7 12 24 Di24 Aux. rope run-out detection
Swing left 0B 729LgR
detection switch 1 1 20
287GR (Up:telescoping)
(contact opens at swing left) 2 6 19
8 17
2 16
01.25B
M 3
4
11
10
9
289LB
CN939
3
6
Rope run-out
release switch
M
Indicator lamp 0 B
35Br 5
9 8 4 (contact closes
0B at release)
10 SWF 2 Rope run-out
CN922 Jib removed indicator lamp 1 (option)
Indicator assy {outdoor air temperature indicator} (option) 337LgW
(when outdoor air temperature becomes minus 25°C (minus 13°F)
or less, crane operation is stopped) Boom telescoping operation CN923 CN904
indicator lamp 0B 288WL 288WL
2 Jib state switch
Remote control pressure vent signal taking out 748BW 0 B KEY
1 (contact closes without jib)
Swing talbl,left 729LgR CN906
CN893 Aux. winch operation CN905
2501.25Lg 288WL
indicator lamp CN924
Gy 0B
8 8
Gy CN909 CN907
10 10 CN908
Gy 2501.25Lg 748BW 748BW Emergency outrigger state
11 11 Telescoping system select 2 KEY
Gy 0 B register switch
13 13 1
Gy Telescoping mode CN976 Emergency outrigger state (contact closes at emergency)
14 14
N Outdoor air
O353
5
6
Gy
Gy
5
6
746RY
353O
switch
(up : mode
down: mode )
2
5
4
1
35Br
0B
0B
control indicator lamp
N
YG256 Gy 256YG 1
3
temperature 1 1 Emergency crane operation 274LB
WR262 Gy 262WR switch in minus 25°C CN917 3
5
sensor 7 7 2501.25Lg Touch-type winch drum indicator controller (option)
WY268 Gy 268WY (minus 13°F) or less in 2501.25Lg 4
2 CN931
(TS5051) 9 9 2
To remote control
BW348
RL303
2
12
Gy
Gy
2
12
348BW
303RL
outdoor air temperature KEY
(contact closes at
emergency operation)
480BW
1 B Telescoping mode
indicator lamp CN978
285LR
0B 0 B
LgY470
B 0
3
2
9
10
1A N.C.
+24V
pressure vent GY343 343GY
4 4 PTO power supply and 1 11 GND
(SL.102) LgW337 Gy 337LgW 440BR BR440
3 3 Controller(TR7430)
1 N.C. Power supply 1
Br Br
CN916
1
2501.25Lg
earth signal taking out
B 441O O441
5
11
7
1
Solenoid output M
Lead switch input M1
1561.25RY
284L
2501.25Lg
B B 480BW Telescoping mode 10 2 Lead switch input M2

2 Sencor Output1 4 4 CN977
B
indeicator lamp
470LgY
W W 0B
159YB
3 N.C. Output2 2 2 9 3 Lead switch input M3

22G
22G
L L 0B 450BY BY450
4 8 Solenoid output S
2501.25Lg
4 Sencor GND 3 3
0
0
2501.25Lg
RY451
2501.25Lg
451RY
B
R26
8 4 Lead switch input S1

R1
B
B
260YW
3 1 4 2 3 1 4 2
260YW
260YW
348BW
276LW
292RG
784GB
481G
782LG
285LR
782LG
783LY
285LR
303RL
303RL
332V
783LY
274LB
378BL

379Y
332V
284L
343GY
0

0
0
R13
R53
KR27
R46
R11
3 1 4 2
O 5 11 6 1 4 3 2 10 9 8 7 2 1 4 6 3 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 R R
O
B
GW
RG
R4
480BW
R13
YL
343GY
Br
W
G
R
Y
B
L
481G
AML power AML power Visible type winch drum indicator (option)
0
R R R R R supply relay 2 supply relay 1 CN380
Outside cab Inside cab A 3 1 4 2

R R (contact closes (contact closes LgY470
1
B
2501.25Lg
KR27
2nd boom 3rd/top boom Swing free selector relay at P.T.O) at P.T.O) O441
2 LED1(Main)
B
1c emergency emergency (contact closes at swing free) RY451

R47 2c RESET SET 3
R telescoping telescoping W
Gy
Gy
Remote control pressure vent

0
R13
(contact opens at minus 25°C relay relay

(minus 13°F) or less) 3 1 4 2 Telescoping system select relay LED2(Aux.)
1741.25YR
1561.25RY
R
2B
1581.25L
165LgR
294BrR
793GW
188YW
314YW
333BW
157RG
324LW
195YO
298YG
784GB
159YB
130LY
Washer tank
22AG
35Br
336P
296Y
22G
Washer motor
roof front
Power supply (PTO synchronization)
Residence (telescoping system select)

Power supply (AML relay board)
Diode (telescoping system select)
P P
MDT Oil temperature 85 (185°F)
M M Upper MDT Electric Circuit

Power supply (AML main bord)
Power supply (clearance lamp)
GMDT Oil temperature 50 (122°F)
MDT Over-front area detection

MDT Over-rear area detection
CN849
CN850
MDT C/W equipped detection
MDT AML serial input/output

Power sypply wiper washer
1 2 1 2
MDT Air pressure input
Power supply (sensor)
Washer relay (front)
60B
Washer relay (roof)
Working lamp relay

1581.25L
1581.25L
IWZ03-3290E01
Diode, horn relay
Diode, horn relay
188YW
195YO
PTO switch
PTO switch
0.5F
MDT PTO
C2
CN837 1581.25L
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
6 WZ03-3290E 344-121-81000 0 6

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

CN No. Usage Coordinates Page CN No. Usage Coordinates Page
461 Power window switch (outside cab) P-4 813 Door junction P-4
467 Power window switch O-3 814 Flasher unit C-5
468 Roof wiper switch C-1 815 Buzzer 1 (air low pressure alarm) J-6
470 Working lamp switch B-3 816 Buzzer 1 (air low pressure alarm) J-6
473 Reverse steering switch I-5 819 Engine speed output D-13
476 High/low and 2/4wheel drive select switch I-4 824 Cigarette lighter G-5
480 Outrigger switch (for jack/slide select) O-3 833 Condenser (C1) (roof wiper motor) E-3
494 Hazard switch B-2 834 Condenser (C3) (power window motor) P-5
495 Roof washer switch C-2 835 Condenser (C5) (front wiper motor) C-3
497 Outrigger switch (for ext./ret. select) N-3 836 Condenser (C7) (power window motor) P-4
498 Outrigger Individual operation switch (ALL) M-3 863 Terminal assy A-6
499 Outrigger Individual operation switch (FL) M-3 864 DC-DC converter O-11
500 Outrigger Individual operation switch (FR) N-3 865 DC-DC converter N-11
501 Outrigger Individual operation switch (RL) N-3 870 Fuse box (right) O-8
502 Outrigger Individual operation switch (RR) N-3 871 Fuse box (right) O-8
509 P.T.O switch F-6 872 Fuse box (right) P-8
510 Parking brake switch G-6 873 Fuse box (right) P-8
511 Combination switch A-4 875 Fuse box (left) O-9
513 Mission select switch (shift lever) M-3 876 Fuse box (left) O-9
514 Steering mode select switch K-5 877 Fuse box (left) P-9
517 Engine emergency stop switch L-2 878 Fuse box (left) P-9
548 Accelerator switch F-13 880 Rotary joint N-16
557 Starter switch F-6 881 Rotary joint N-16
562 Combination switch A-5 882 Rotary joint P-16 Next
563 Mission select switch (shift lever) L-3 883 Rotary joint P-16 page
564 Emergency switch (system check, mission, accelerator) K-2 884 Rotary joint O-16
586 Accelerator sensor F-13 Next 885 Rotary joint O-16
587 Idling adjustment switch F-13 page 895 Swing table harness (air) E-13
588 Idling adjustment switch G-13 915 Crane operation emergency stop switch F-6
620 MDT (upper) CN1 M-16 925 Vehicle speed limit H-5
621 MDT (upper) CN2 C-16 926 Fan (switch, motor) (option) O-6
622 MDT (upper) CN3 J-16 998 Pulse transducer (engine speed) N-14
623 MDT (upper) CN4 L-16 RA1 Working lamp relay 1 C-6
624 MDT (upper) CN5 I-16 RA2 Working lamp relay 1 C-7
625 MDT (upper) CN6 L-16 RA10 Emergency stop relay E-6
626 MDT (upper) CN7 D-16 RA14 Horn relay C-6
627 MDT (upper) CN8 F-16 RA26 Washer relay (front) C-5
629 MDT (upper) CN9 C-16 RA3 Washer relay (roof) E-4
630 MDT (upper) CN10-1 H-16 RA4 Neutral starter relay P-10
631 MDT (upper) CN10-2 G-16 RA5 Turn signal relay (R) C-5
639 MDT (upper) (for maintenance) L-15 RA6 Turn signal relay (L) C-4
780 Rotary joint N-16 RB5 Air conditioner power supply cut relay O-7
781 Rotary joint P-16 RC1 Roof wiper ON relay E-3
782 Rotary joint P-16 RC2 Front wiper ON relay C-3
783 Rotary joint N-16 RC3 Front wiper Hi relay C-3
784 Rotary joint O-16 RC7 Power window relay P-4
785 Rotary joint O-16 RF1-1 Emergency transmission selector relay N-12
802 Air conditioner (option) N-6 RF1-2 Emergency transmission selector relay O-12
804 Room lamp E-3
805 Bubble level (illumination) A-3
806 Harness with cab (room lamp, roof wiper motor, working lamp) D-2
810 Combination meter B-15
811 Combination meter B-13
812 Front wiper motor B-3
347-508-80000 △
1
7 WZ03-3300E 7

Z-5. Z-5. Z-5.
Electric Circuit (MDT, Carrier/Upper)
IWZ03-3300E01
8 WZ03-3300E 8

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

Suspension lock selector solenoid valve 608 MDT (lower) CN7 L-3 773 Fuse box (R) J-22
02 Suspension lock J-6 609 MDT (lower) CN8 K-3 774 Fuse box (R) I-21
03 Suspension free J-7 610 MDT (lower) CN9 H-3 775 Fuse box (R) J-21
Outrigger ext./ret. selector solenoid valve 611 MDT (lower) CN10 I-3 778 Fuse (upper power supply) (75A) L-21
20 Retracting H-15 612 MDT (lower) CN11 J-3 779 Fuse (main) (75A) L-21
21 Extending H-15 619 MDT (for maintenance) G-4 780 Rotary joint N-3
22 Slide (for FL) J-18 685 ECU (A connector) D-14 781 Rotary joint P-3
23 Jack (for FL) J-18 686 ECU (B connector) B-14 782 Rotary joint P-3
24 Slide (for FR) J-17 687 ECU (C connector) B-14 783 Rotary joint N-3
25 Jack (for FR) J-17 688 ECU (D connector) A-14 784 Rotary joint O-3
26 Slide (for RL) J-17 689 ECU (E connector) A-14 785 Rotary joint O-3
27 Jack (for RL) J-18 690 Q-ADJ B-12 788 Sub. harness F-13
28 Slide (for RR) J-16 691 MUT-Ⅲ D-12 789 Sub. harness G-13
29 Jack (for RR) J-17 700 Head lamp (LH) N-15 790 Harness (electronic governor) B-12
Steering mode selector solenoid valve 701 Head lamp (LH) N-15 791 Harness (electronic governor) A-12
30 Crab, K-7 702 Head lamp (RH) N-16 792 Harness (engine) A-19
31 4 wheel, K-6 703 Head lamp (RH) N-16 793 Harness (engine) C-19
32 Reverse, K-6 704 Head lamp relay H-21 794 Harness (engine) D-19
33 Rear select K-6 705 Head lamp relay H-21 795 Harness (engine) D-19
Transmission selector solenoid valve 706 Head lamp relay H-22 797 MEMORY CLEAR F-11
42 R L-12 707 Head lamp relay H-22 880 Rotary joint N-2
43 F1 L-11 708 Head lamp relay H-22 881 Rotary joint N-2
44 F2 L-11 709 Combination lamp (RH) N-16 882 Rotary joint P-2
45 F3 L-11 710 Combination lamp (RH) N-16 883 Rotary joint P-2
41 PTO solenoid valve N-13 711 Combination lamp (LH) N-15 884 Rotary joint O-2
49 Lockup solenoid valve M-13 712 Combination lamp (LH) N-14 885 Rotary joint O-2
50 Air solenoid valve (parking brake) G-15 717 Rear combination lamp (L) P-14 940 Thermo switch (T/C oil 110°C/230°F) I-10
51 Air solenoid valve (2/4 wheel drive shift) F-15 718 Rear combination lamp (L) P-15 941 Hour meter (option) J-11
52 Air solenoid valve (High/Low select) F-15 719 Rear combination lamp (R) P-16 942 Lower outrigger operation box (L) (option) H-16 Next
Next Next page
54 Air solenoid valve (exhaust brake) F-15 720 Rear combination lamp (R) P-16 943 Bubble level (illumination) (L) (option) H-13
page page
408 Straight ahead detection proximity switch D-6 721 Backup lamp P-15 944 Low-pressure switch (steering pump low-pressure alarm) (option) D-6
409 Low pressure switch (Engine oil) E-19 723 License lamp (option) P-16 945 Side turn signal (LH) N-14
410 Air Low-pressure switch F-15 726 Bubble level (illumination) (R) (option) I-13 946 Side turn signal (RH) N-17
411 Air low-pressure switch (parking brake) F-15 730 DIAG switch F-11 957 Spare circuit M-21
413 Lead switch (4WD detection) C-4 731 ECU DIAG lamp-1 (red) F-11 959 Diode assy (lower outrigger operation) (option) J-13
414 Lead switch (reservoir assy) F-16 732 ECU DIAG lamp-1 (red) F-11 RA11 Backup lamp relay P-14
415 Lead switch (reservoir assy) F-16 733 ECU DIAG lamp-2 (umber) F-10 RA17 Steering power supply relay P-4
416 Water in fuel sensor E-6 734 ECU DIAG lamp-2 (umber) F-10 RA8 Clearance lamp relay P-13
419 Pressure sender (torque converter oil pressure) C-4 745 Air drier heater G-16 RA9 Battery power supply keeping relay K-21
420 Main speed sensor A-4 747 Starter relay (SW) L-19 RA21 ECU main power supply relay F-9
421 Pickup sensor (sub. speed) A-4 748 Alternator (R terminal, L terminal) L-20 RA22 Electronic governor power supply relay K-21
422 Outrigger length detector (FL) B-4 749 Alternator (B terminal) L-20 RA28 Glow relay F-10
423 Outrigger length detector (FR) B-4 750 Alternator (P terminal) L-20 RB1 Transmission power supply cut relay O-10
424 Outrigger length detector (RL) B-4 751 Back buzzer P-16 RB3 PTO limiter relay O-11
425 Outrigger length detector (RR) C-4 755 Fuse (Grid heater) (70A) M-21 RB4 Engine emergency stop relay F-10
426 Engine water temperature thermo sender M-11 758 Battery relay M-22 RB6 Lower outrigger power supply select relay M-15
427 Torque converter oil temp. thermo sender M-12 759 Battery relay M-22 RB7 Lower outrigger operation box relay M-14
428 Fuel sender G-16 760 Battery relay M-22 RB8 Lower outrigger operation box relay I-15
434 Lower outrigger operation box (R) L-16 761 Battery relay M-22 RB11 Starter continuous energizing prevention relay F-9
440 Lead switch (High/Low detection) C-4 762 Battery relay M-22 RB12 Starter interception relay F-9
568 Pressure switch (stop lamp) G-15 763 Battery relay M-22 RC5 Emergency accelerator relay 1 C-6
569 Pressure switch (stop lamp) G-15 765 Diode assy B-6 RC6 Emergency accelerator relay 2 C-7
600 MDT (lower) CN1-1 F-3 766 Diode (fuse box) J-21 RD4 Lower outrigger operation box relay M-14
601 MDT (lower) CN1-2 D-3 767 Fuse box (L) I-22 RD5 Lower outrigger operation box relay I-15
602 MDT (lower) CN2 G-3 768 Fuse box (L) I-22 RF2-1 Emergency transmission selector relay M-10
603 MDT (lower) CN3 M-3 769 Fuse box (L) H-21 RF2-2 Emergency transmission selector relay M-10
604 MDT (lower) CN4 A-3 770 Fuse box (L) I-21 RF3-1 Outrigger jack/slide select relay J-15
605 MDT (lower) CN5 G-3 771 Fuse box (R) I-22 RF3-2H Outrigger jack/slide select relay J-16
606 MDT (lower) CN6 B-3 772 Fuse box (R) J-22
9 WZ03-3310E 9

Z-6 Z-6 Z-6
Electric Circuit (MDT, Carrier/Lower)
IWZ03-3310E01
10 WZ03-3310E 10

Z-7 Z-7
Location of Hydraulic Parts (Upper)
Z-7 Location of Hydraulic Parts (Upper)

1. Cab and swing table
(*1) : For the A section in the figure below, see the enlarged view on the following page.
11 WZ07-0691E

Z-7 Z-7
List of components illustrated in the “Cab and swing table” figure (in alphabetical order)
Compressor (air conditioner, option)
Condenser (air conditioner, option)
78.Hose real
38.Hydraulic motor (air conditioner, option)
34.Hydraulic motor (oil cooler)
79-2.Hydraulic valve (Protection of No.2 cylinder retraction while mode II select) (SL238)
33.Oil cooler
52.Orbitrol
48.Priority valve
61.Remote control valve (lever)
27.Rotary joint
47.Sequence valve (pilot pressure)
46.Solenoid control valve (jib set) (SL192, SL193, SL222, SL223)
89.Solenoid valve (air conditioner, option) (SL280)
36.Solenoid valve (oil cooler) (SL281)
12 WZ07-0691E

Z-7 Z-7
A section (behind cab)
List of components illustrated in the “A section” figure (in alphabetical order)

60.Accumulator
30.Check valve (gauge isolator)
68.Hydraulic pilot control valve (elevating, telescoping, winch)
53.Hydraulic pilot control valve (swing) (SL120, SL121, SL161, SL162)
70.Hydraulic valve (winch brake release)
79-1.Hydraulic valve (top cyl. select)
31.Pressure sensor
66.Remote control valve (pedal)
62.Shuttle valve (lever/pedal)
65.Solenoid control relief valve (elevating slow stop) (SL124,SL125)
57.Solenoid valve (auto stop) (SL100)
67.Solenoid valve (boom telescoping/aux. hoist) (SL143,SL144)
56.Solenoid valve (pilot pressure) (SL102,SL160)
Water pump (air conditioner, option)
13 WZ07-0691E

Z-7. Z-7.
2. Boom
List of components illustrated in the “Boom” figure (in alpha betical ovder)
42.Jib lock pin
39.Jib offset cylinder
40.Pilot check valve (jib set)
14 WZ07-0691E

Z-8 Z-8
Location of Hydraulic Parts (Lower)
Z-8 Location of Hydraulic Parts (Lower)

1. Carrier
[NOTICE]
The parts on the carrier are divided in to Front, Center and Rear and magnified of each is shown on the
following pages.
15 WZ07-0592E

Z-8 Z-8
1.1 Front
List of components illustrated in the “Front” figure (in alphabetical order)

17.Pilot check valve (jack cylinder retracting prevention)
14.Solenoid valve (slide/jack) (for FL) (SL22,SL23)
14.Solenoid valve (slide/jack) (for FR) (SL24,SL25)
16 WZ07-0592E

Z-8 Z-8
1.2 Center
(*1): Application
Canada Option
North America ―
List of components illustrated in the “Center” figure (in alphabetical order)

13.Check valve (outrigger extending prevention) 20.Pilot check valve (suspension lock cylinder)
6.Drain filter 18-1.Pressure reducing valve (pilot pressure)
10.Flow control valve 18-2.Pressure reducing valve (emergency steering)(*1)
5.Gear pump (emergency steering, option) 8.Return filter (in hydraulic oil tank)
7.Hydraulic oil tank 12.Solenoid control valve (outrigger) (SL20, SL21)
11.Hydraulic valve (emergency steering, option) 23.Solenoid valve (steering mode)
9.Line filter (SL30, SL31, SL32, SL33)
19.Solenoid valve (suspension lock check release)
Line filter (torque converter circuit)
(SL02, SL03)
17 WZ07-0592E

Z-8. Z-8.
1.3 Rear
List of components illustrated in the “Rear” figure (in alphabetical order)

4.Double gear pump 14.Solenoid valve (slide/jack) (for RL) (SL26, SL27)
3.Double variable displacement pump 14.Solenoid valve (slide/jack) (for RR) (SL28, SL29)
17.Pilot check valve (jack cylinder retracting prevention)
24.Pilot check valve (Rear steering cylinder lock)
18 WZ07-0592E

Z-9 Z-9
Location of Air Parts
Z-9 Location of Air Parts

1. Cab and swing table
List of components illustrated in the “Cab and swing table” figure (in alphabetical order)
Air pressure sender
Air solenoid valve (air horn) (SL60)
Air tank (10L)
Brake valve
Check valve 347-112-70000 △
0
347-219-30000 △
0
343-453-10000 △
0
19 WZ08-0300E

Z-9 Z-9
Location of Air Parts
2. Carrier
Enlarge view of A (center of the carrier’s right hand)
20 WZ08-0300E

Z-9. Z-9.
Location of Air Parts (inside cab)
List of components illustrated in the “Carrier” figure (in alphabetical order)

Air brake chamber (parking)
Air cylinder (parking)
Air dryer
Air low-pressure switch (low air pressure warning)
Air Low-pressure switch (parking brake)
Air pressure switch (stop lamp)
Air solenoid valve (2/4 wheel drive shift) (SL51)
Air solenoid valve (exhaust brake) (SL54)
Air solenoid valve (Hi/Lo shift) (SL52)
Air solenoid valve (parking brake) (SL50)
Air tank (10L)
Air tank (20L)
Air tank (40L)
Booster (front brake)
Booster (rear brake)
Exhaust brake
Lead switch (reservoir assy)
Safety valve
349-221-60000 △
1
349-221-70000 △
1
21 WZ08-0300E

Z -1 0 . Z-10. Z -1 0 .
Location of Electric Parts (Inside cab)
Z-10 Location of Electric Parts (Inside cab)
343-536-21000 △
1
22 WZ02-2970E 22

Z -1 1 . Z-11. Z -1 1 .
Location of Electric Parts (Swing Table, Boom) [NOTICE]
The connection in frame ( ) in figure is applied only for Europe: CN546,547,595,596,CN518,CN949
Z-11 Location of Electric Parts (Swing Table, Boom) (*1): CN238 is applied only for GR-800XXL-1.
(*2): CN994 is not applied only for GR-600XXL-1.
343-536-22000 △
1
343-536-82000 △
0
23 WZ02-2980E 23

Z -1 2 . Z-12. Z -1 2 .
Location of Electric Parts (Relay Assembly / Upper)
Z-12 Location of Electric Parts (Relay Assembly / Upper)
343-536-21500 △
1
343-632-33000 △
0
24 WZ02-2990E 24

Z -1 3 . Z-13. Z -1 3 .
Location of Air Parts (AML)
Z-13 Location of Air Parts (AML)
343-632-81000 △
0
343-632-31000 △
0
25 WZ02-3000E 25

Z -1 4 . Z-14. Z -1 4 .
Location of Electric Parts (Lower)
[NOTICE]
The connection in frame ( ) in figure is applied only for Europe.
Z-14 Location of Electric Parts (Lower)
349-310-00000 △
2
26 WZ02-3010E 26

Z -1 5 . Z-15. Z -1 5 .
Location of Electrical Parts (Box Assembly / Lower)
Z-15 Location of Electrical Parts (Box Assembly / Lower)
349-310-02000 △
0 349-310-01000 △
0
349-310-02300 △
1 349-310-01300 △
0
27 WZ02-3020E 27

Z -1 6 Z-16 Z-16
Harness (Connector No. Table)
Z-16 Harness (Connector No. Table)

Suspension lock selector solenoid valve 408 Straight ahead detection proximity switch B-11 514 Steering mode select switch J-2
37 31
02 Suspension lock J-4 409 Low pressure switch (Engine oil) B-12 517 Engine emergency stop switch G-6
37
03 Suspension release J-5 410 Air Low-pressure switch 518 Over-rear detection proximity switch
38 33
Outrigger ext./ret. selector solenoid valve 411 Air low-pressure switch (parking brake) 521 Over-front detection proximity switch
20 Retracting J-5 413 Lead switch (4WD detection) K-5 37 529 Control lever stand position detection switch J-8
21 Extending J-5 414 Lead switch (reservoir assy) 530 Connector I-8 31
38
22 Slide (for FL) F-3 415 Lead switch (reservoir assy) 531 Swing horn switch K-6
23 Jack (for FL) F-2 416 Water in fuel sensor D-6 532 Main winch hoisting up detection switch
37
24 Slide (for FR) I-3 419 Pressure sender (torque converter oil pressure) K-9 533 Aux. winch hoisting up detection switch
37
25 Jack (for FR) I-2 420 Main speed sensor K-7 534 Boom extending detection switch
26 Slide (for RL) B-14 421 Pickup sensor (sub. speed) C-10 536 Boom raising detection switch
27 Jack (for RL) B-15 422 Outrigger length detector (FL) G-2 537 Boom lowering detection switch 32
28 Slide (for RR) I-11 423 Outrigger length detector (FR) J-2 540 Swing right detection switch
37
29 Jack (for RR) I-11 424 Outrigger length detector (RL) B-14 541 Swing left detection switch
Steering mode selector solenoid valve 425 Outrigger length detector (RR) I-12 546 Main winch hoisting down detection switch (option)
30 Crab, I-4 426 Engine water temperature thermo sender G-10 547 Aux. winch hoisting down detection switch (option)
31 4 wheel, I-4 427 Torque converter oil temp. thermo sender K-3 548 Accelerator switch I-1 31
37
32 Reverse, I-4 428 Fuel sender 38 553 2nd boom full retraction detection switch 34
33 Rear select J-4 434 Lower outrigger operation box (R) B-7 555 Thermo switch (50°C/122°F) 33
37
Transmission selector solenoid valve 440 Lead switch (High/Low detection) K-9 556 Thermo switch (85°C/185°F) 33
42 R E-8 461 Power window switch (outside cab) K-8 557 Starter switch C-2 31
43 F1 E-9 467 Power window switch J-4 558 AML override switch 32
37
44 F2 E-9 468 Roof wiper switch A-2 562 Combination switch E-2
45 F3 E-9 470 Working lamp switch A-3 563 Mission select switch (shift lever) H-3 31
41 PTO solenoid valve K-5 473 Reverse steering switch K-4 564 Emergency switch (system check, mission, accelerator) F-7
37
49 Lockup solenoid valve K-4 476 High/low and 2/4wheel drive select switch J-2 31 568 Pressure switch (stop lamp)
38
50 Air solenoid valve (parking brake) 480 Outrigger switch (for jack/slide select) D-6 569 Pressure switch (stop lamp)
51 Air solenoid valve (2/4 wheel drive shift) 484 Swing brake switch C-3 572 Jib stowed detection proximity switch
38 34
52 Air solenoid valve (High/Low select) 485 Boom telescoping/aux. hoist control selector switch C-4 573 Jib lock pin retracting detection switch
54 Air solenoid valve (exhaust brake) 486 Swing stop cancel switch C-4 574 Oil cooler switch A-4 31
60 Air solenoid valve （air horn） 33 487 Swing free/lock selector switch E-4 576 Boom length and angle detector 34
100 AML (Load moment indicator) vent solenoid valve 488 Jib mounting / stowing switch 33 580 Swing angle detector
35
102 Remote control pressure vent solenoid valve 491 Elevating slow stop cancel switch C-5 581 Pressure sender (main pressure)
120 Swing right proportional control valve 494 Hazard switch J-5 583 Pressure sender (air pressure) 33
121 Swing left proportional control valve 495 Roof washer switch A-1 584 Pressure sender (elevating cylinder, boom raising)
35
124 Boom raising proportional control valve 497 Outrigger switch (for ext./ret. select) D-6 585 Pressure sender (elevating cylinder, boom lowering)
125 Boom lowering proportional control valve 32 498 Outrigger Individual operation switch (all) E-6 586 Accelerator sensor I-1
143 Boom telescoping/aux. hoist control selector solenoid valve 499 Outrigger Individual operation switch (FL) F-5 587 Idling adjustment switch D-3 31
144 Boom telescoping/aux. hoist control selector solenoid valve 500 Outrigger Individual operation switch (FR) F-6 588 Idling adjustment switch D-2
160 Swing brake release solenoid valve 501 Outrigger Individual operation switch (RL) E-6 591 Main winch drum rotation detection proximity switch
161 Swing free/lock solenoid valve 502 Outrigger Individual operation switch (RR) F-5 592 Aux. winch drum rotation detection proximity switch
31 33
162 Swing relief proportional control valve 503 3rd/top boom emergency telescoping switch B-6 595 Main rope run-out detection switch (option)
192 Jib lock pin extending solenoid valve 504 2nd boom emergency telescoping switch B-6 596 Aux. rope run-out detection switch (option)
193 Jib lock pin retracting solenoid valve 505 Overwind cutout (anti-twoblock) disable switch C-2 600 MDT (lower) CN1-1 H-4
33
222 Jib mounting solenoid valve 506 3rd/top boom extending switch (ISO array) J-6 601 MDT (lower) CN1-2 H-4
223 Jib stowing solenoid valve 507 3rd/top boom extending switch (TDN array) I-6 602 MDT (lower) CN2 G-5
230 Top cylinder selector solenoid valve 32 509 P.T.O switch C-3 603 MDT (lower) CN3 G-5 37
238 Protection of NO.2 cylinder retraction while mode Ⅱselect solenoid valve 510 Parking brake switch K-4 604 MDT (lower) CN4 G-5
33
281 Oil cooler solenoid valve 511 Combination switch D-2 605 MDT (lower) CN5 F-5
380 Visible type winch drum indicator (option) D-1 31 513 Mission select switch (shift lever) H-3 606 MDT (lower) CN6 F-4
28 WZ04-2260E 28

Z -1 6 Z-16 Z-16
608 MDT (lower) CN7 H-6 734 ECU DIAG lamp-2 (umber) B-2 37 813 Door junction I-2
609 MDT (lower) CN8 G-6 745 Air drier heater 38 814 Flasher unit D-16
610 MDT (lower) CN9 G-7 747 Starter relay (SW) C-13 815 Buzzer 1 (air low pressure alarm) C-16
37
611 MDT (lower) CN10 F-6 748 Alternator (R terminal, L terminal) H-9 816 Buzzer 1 (air low pressure alarm) C-15
37
612 MDT (lower) CN11 F-6 749 Alternator (B terminal) H-9 817 Buzzer 4 (overwind (two-blocking) alarm) C-15
31
619 MDT (for maintenance) B-6 751 Back buzzer C-15 818 Buzzer 3 (AML alarm) C-14
620 MDT (upper) CN1 B-9 755 Fuse (Grid heater) (70A) E-14 819 Engine speed output E-8
621 MDT (upper) CN2 B-9 758 Battery relay F-15 820 For reducing the main pressure F-8
622 MDT (upper) CN3 B-10 759 Battery relay F-15 821 AML vent solenoid valve G-5
623 MDT (upper) CN4 C-9 760 Battery relay F-16 824 Cigarette lighter E-6
624 MDT (upper) CN5 C-9 761 Battery relay E-15 828 AML external indicator lamp (yellow)
33
625 MDT (upper) CN6 A-12 762 Battery relay E-15 829 AML external indicator lamp (red)
31
626 MDT (upper) CN7 A-12 763 Battery relay E-16 833 Condenser (C1) (roof wiper motor) A-9
627 MDT (upper) CN8 A-12 765 Diode assy D-3 834 Condenser (C3) (power window motor) G-2
629 MDT (upper) CN9 B-12 766 Diode (fuse box) F-14 835 Condenser (C5) (front wiper motor) H-1
630 MDT (upper) CN10-1 B-12 767 Fuse box (L) G-12 836 Condenser (C7) (power window motor) C-11 31
631 MDT (upper) CN10-2 C-12 768 Fuse box (L) G-12 837 Condenser (C2) (washer motor) H-1
639 MDT (upper) (for maintenance) E-7 769 Fuse box (L) H-12 849 Washer motor (roof) G-1
665 AML connector 1 770 Fuse box (L) H-12 850 Washer motor (front) G-2
37
666 AML connector 2 35 771 Fuse box (R) F-12 852 Working lamp 33
667 AML connector 3 772 Fuse box (R) F-12 853 Working lamp (boom)
34
685 ECU (A connector) 773 Fuse box (R) G-12 858 Cord reel (boom length detector)
686 ECU (B connector) 774 Fuse box (R) F-12 859 3rd/top boom full retraction detection switch 36
687 ECU (C connector) 39 775 Fuse box (R) G-12 863 Terminal assy F-10
688 ECU (D connector) 778 Fuse (upper power supply) (75A) F-14 864 DC-DC converter B-15
689 ECU (E connector) 779 Fuse (main) (75A) G-14 865 DC-DC converter B-16
690 Q-ADJ D-5 37 780 Rotary joint F-9 870 Fuse box (right) D-10
691 MUT-III 39 781 Rotary joint F-9 871 Fuse box (right) D-11
700 Head lamp (LH) K-1 782 Rotary joint G-9 872 Fuse box (right) D-9
701 Head lamp (LH) J-1 783 Rotary joint F-9 873 Fuse box (right) E-9
702 Head lamp (RH) F-1 784 Rotary joint F-9 875 Fuse box (left) E-9
703 Head lamp (RH) F-1 785 Rotary joint G-9 876 Fuse box (left) F-9
31
704 Head lamp relay H-14 Sub. harness B-8 37 877 Fuse box (left) F-9
788
705 Head lamp relay H-14 To main harness 38 878 Fuse box (left) F-8
706 Head lamp relay H-13 Sub. harness B-9 37 880 Rotary joint I-12
789
707 Head lamp relay H-13 To main harness 38 881 Rotary joint I-13
708 Head lamp relay H-13 Harness (electronic governor) E-4 37 882 Rotary joint I-13
790
709 Combination lamp (RH) E-1 To main harness 39 883 Rotary joint J-13
710 Combination lamp (RH) E-1 Harness (electronic governor) E-4 37 884 Rotary joint J-12
791
711 Combination lamp (LH) K-1 To main harness 885 Rotary joint J-12
37
712 Combination lamp (LH) K-2 792 Harness (engine) Harness (AML) I-9
39 886
717 Rear combination lamp (L) J-11 793 Harness (engine) To inside cab harness 35
718 Rear combination lamp (L) J-12 794 Harness (engine) Harness (boom, base)(for separated transport of boom and swing table) H-15 31
887
719 Rear combination lamp (R) B-15 795 Harness (engine) B-11 To inside cab harness
37 34
720 Rear combination lamp (R) B-15 797 MEMORY CLEAR B-6 888 Harness (boom, top)
721 Backup lamp A-16 802 Air conditioner (option) H-7 Harness (Swing table, right) J-15 31
889
723 License lamp (option) D-16 804 Room lamp H-7 To inside cab harness 33
726 Bubble level (illumination) (R) (option) E-7 805 Bubble level (illumination) H-6 Harness (Swing table, right) J-15 31
890
730 DIAG switch B-6 806 Harness with cab (room lamp, roof wiper motor, working lamp) A-8 31 To inside cab harness 33
731 ECU DIAG lamp-1 (red) B-1 810 Combination meter F-2 Harness (Swing table, right) J-15 31
891
732 ECU DIAG lamp-1 (red) B-1 811 Combination meter F-2 To inside cab harness 33
733 ECU DIAG lamp-2 (umber) B-2 812 Front wiper motor I-1
29 WZ04-2260E 29

Z -1 6 . Z-16. Z -1 6 .
Harness (AML) I-9 31 Harness (AML) K-9 31 RB1 Transmission power supply cut relay C-4
892 964
To inside cab harness 35 To inside cab harness 35 RB11 Starter continuous energizing prevention relay C-4
Harness (Swing table, left) I-15 31 965 Winch selector switch C-1 RB12 Starter interception relay C-3 37
893
To inside cab harness 32 966 Winch selector indicator lamp C-2 RB3 PTO limiter relay C-4
Harness (Swing table, left) I-15 31 967 Winch selector indicator lamp C-1 RB4 Engine emergency stop relay C-4
894
To inside cab harness 32 968 Fuse (for drum indicator) (main) D-8 RB5 Air conditioner power supply cut relay E-11 31
31
Swing table harness (air) A-14 31 969 Fuse (for drum indicator) (aux.) D-8 RB6 Lower outrigger power supply select relay A-4 37
895
To inside cab harness 33 976 Telescoping mode Ⅰ/Ⅱswitch K-2 RB7 Lower outrigger operation box relay A-4
37
Harness (AML) J-9 31 977 Telescoping mode Ⅰindicator lamp K-3 RB8 Lower outrigger operation box relay A-3
896
To inside cab harness 35 978 Telescoping mode Ⅱindicator lamp K-2 RC1 Roof wiper ON relay G-12
Harness (AML) J-9 31 991 For separated transport of boom and swing table RC2 Front wiper ON relay G-13 31
897 35
To inside cab harness 35 992 For separated transport of boom and swing table RC3 Front wiper Hi relay G-15
Harness (AML) K-9 31 For separated transport of To harness (AML) 34 RC5 Emergency accelerator relay 1 D-2
898 993 37
To inside cab harness 35 boom and swing table To harness (boom) 35 RC6 Emergency accelerator relay 2 D-1
Harness (AML) J-9 31 994 Counterweight equipped detection proximity switch RC7 Power window relay G-14 31
899 33
To inside cab harness 35 995 Jib lock pin switch RD4 Lower outrigger operation box relay C-2
37
904 Jib state switch A-7 998 Pulse transducer (engine speed) B-15 31 RD5 Lower outrigger operation box relay C-3
905 Jib removed indicator lamp A-6 999 Jib mounting / stowing operationality indicator lamp 33 RF1-1 Emergency transmission selector relay F-9 31
906 Jib removed indicator lamp A-6 R1 AML power supply relay 1 F-12 RF1-2 Emergency transmission selector relay G-9 31
907 Emergency outrigger state register switch A-5 31 R11 2nd boom emergency telescoping relay E-10 RF2-1 Emergency transmission selector relay D-2
908 Emergency outrigger state control indicator lamp A-5 R13 3rd/top boom emergency telescoping relay D-14 RF2-2 Emergency transmission selector relay D-1
37
909 Emergency outrigger state control indicator lamp A-5 R2 Boom full ret. detection relay E-15 RF3-1 Outrigger jack/slide select relay C-1
915 Crane operation emergency stop switch J-2 R22 AML lamp assy relay E-12 RF3-2H Outrigger jack/slide select relay C-1
916 Controller (outdoor air temperature sensor) R23 AML lamp assy relay E-12 KR27 Telescoping mode Ⅰ/Ⅱselector relay G-10 31
31
917 Emergency crane operation switch R26 AML power supply relay 2 F-12
918 For emergency jib operation C-7 R29 Oil cooler relay E-13
919 For emergency jib operation D-7 R33 Elevating slow stop cancel relay E-13
922 Boom telescoping/aux. hoist control indicator lamp D-4 R36 Overwind (two-blocking) relay E-14
923 Boom telescoping operation indicator lamp D-3 R4 Swing free selector relay E-15
924 Aux. winch operation indicator lamp D-4 R46 Telescoping mode Ⅰ/Ⅱselector (diode) relay G-13
925 Vehicle speed limit E-9 R47 Remote control pressure vent relay
926 Fan (switch, motor) (option) H-8 R53 Telescoping mode Ⅰ/Ⅱselector relay E-11
931 Touch-type winch drum indicator controller (option) D-13 R8 AML emergency switch relay D-14
31
932 Touch-type main winch drum indicator solenoid (ISO array)(option) J-6 R9 Swing brake relay E-10 31
933 Touch-type main winch drum indicator solenoid (ISO array)(option) J-6 RA1 Working lamp relay 1 D-12
934 Touch-type aux. winch drum indicator solenoid (ISO array)(option) J-7 RA10 Emergency stop relay F-14
935 Touch-type aux. winch drum indicator solenoid (ISO array)(option) J-7 RA11 Backup lamp relay A-4 37
936 Touch-type aux. winch drum indicator solenoid (TDN array) (option) I-7 RA14 Horn relay F-14 31
937 Touch-type aux. winch drum indicator solenoid (TDN array) (option) I-7 RA17 Steering power supply relay B-4 37
938 For air bleeding of suspension lock cylinder G-7 RA2 Working lamp relay 1 D-12 31
939 Rope run-out release switch (option) A-6 RA21 ECU main power supply relay B-4
37
940 Thermo switch (T/C oil 110°C/230°F) C-12 RA22 Electronic governor power supply relay G-16
941 Hour meter (option) D-14 RA26 Washer relay (front) F-15 31
942 Lower outrigger operation box (L) (option) I-7 RA28 Glow relay B-3 37
943 Bubble level (illumination) (L) (option) I-6 37 RA3 Washer relay (roof) D-13
944 Low-pressure switch (steering pump low-pressure alarm) (option) K-7 RA4 Neutral starter relay D-13
31
945 Side turn signal (LH) K-2 RA5 Turn signal relay (R) F-13
946 Side turn signal (RH) E-2 RA6 Turn signal relay (L) F-13
949 Buzzer 5 (external alarm) 33 RA8 Clearance lamp relay A-4
37
959 Diode assy (lower outrigger operation) (option) A-3 37 RA9 Battery power supply keeping relay H-15
30 WZ04-2260E 30

Z -1 7 . Z-17. Z -1 7 .
Harness (Inside Cab)
Z-17 Harness 1 2 3 4 5 6 7 8 9 10 11 12
625
800 801
F CN6
802 803
13 14 15 16
80
(Inside Cab)
LR LW LG LB
O/R O/R J3
35
Br F 187
V
173
LY
158
1.25L
35
Br
F 152
1.25LO
35
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F 156
1.25RY F F F 806
804
Br
804
Br
804
Br
804
Br
250 908 250
35
0 0 186 0 35 0 0 0 167 0 0 321 748 0 0 289 905 288 0 626
A B B LB B Br B B B YG B B LW
1.25Lg BW B
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1.250
233
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F 915 907 908
F
911
CN7
912 A
904 J34
80 WY P LgW WL LgY
495 468 470 574 748 907 939 288
0 184 158 183 4 0 0
80
80
80
80
80
80
80
B 1.25LW 1.25L 1.25LG 158 YW B B DC DC
80
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BW WL 1.25L ( )
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620 F CN1
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55
612
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622
633
634
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40
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100
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150
0
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13
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150
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J33
P.T.O 50
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998
F F 314 F 22 35 F 250 250 F 0 250 F 0 80 F
40
02 01 622 630 155 918
YW G Br 1.25Lg 1.25Lg B 1.25Lg B
B 1.25B F CN3 F CN10 RW PB 50
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907 07
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55
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80
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B B V 1.25Lg B B Y 1.25Lg 50 B YG RY RB RW RL R Sb 1.25B 1.25B Earth Y YG G WG F 0 257 212 155
918 J32
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C 557 YR B 817 C
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YL BrR BrY Br 1.25B 2 816
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470 157 35 0 M 200
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B Br
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150 0
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D 632
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Y GB Br RW 3 F 250 487 925 157
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200
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E J76
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0 0
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B B BW
F F 639 M
352 250 379 260 234 234 303 285
Earth
120
120
120
120
120
120
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F MDT 213 154 156 LW 1.25Lg Y YW YR YR RL LR
J63 42 157 72 157 WB Y 1.25RY
J73 804 800 802 J46 0 353 0 303 559 5 8 0 292 J16 J1 J14 J13 J12 J11 J10 J9
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O/R(RL) 501 O/R(ALL) 498 801 803
1.25LO R 35 35 35 35 35 35 30
80
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120
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120
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100
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F F
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F J94 J95 J96 J100 J29 R1 R26 RA5 RA6 RA14 RA10 RA26
191 24 143 08 211 35 820
W YB Y B WR Br 1 1 1 1 22 156 22 159 180 179 202 179 155 155 30 251 150 0
J77 J86 41 157 44 157 35 35 35 75
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1.25W 1.25W 1.25W 1.25W
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100
W RG WY RG 877 G 1.25RY G YB GB L GR L RW RW RL RY 1.25LR 1.25B
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LY
157
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M 563
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793
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182
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F
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B 1.25Lg B LgY B LR B LB Sb LY B LR YB YO F
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( ) Earth 45 157 214 20 157 ASSY
80
PB RG 878 876 35 35 35 35 35 35 35
Y YG RG
343-536-21020
218 100 130 08 0 10 RF1-1

M6 O/R(FL) 499
0
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10
F
M RC1 RC2 R46 RC7 RC3
300
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31 32 33 40
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100
849 850
4000
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G R 1.25L 1.25L L 0 629 F 10 250 285 F 284 0
G
( 5
120
120
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120
120
188 195 B GR GY 1.25Lg LR L B 130
(300)
YW YO 20 12 8 276 0 782 0 783 J26 J25 J24 J97 J23

F YG YO YR LW B LG B LY
100 RF1-2 35 35 35 70 60
0 16
150
2B
80
(100) J43 0
J84 J44
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J41 50 85 M6 2B
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M6
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( ) Earth 011
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B F 804 ON 887 F
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F 897
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RG BrW YR BrY LW LgR

75 53 76 F 35 0 277
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B 898
GL BrW G Br B 80 19
WG
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F
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LY F 50 50 200
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850
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291 288 294 295 279

978 LR 50 LgY WL BrR BrY BrW
977 SW F
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
31 WZ04-2270E 343-536-21020 △
1 31

Z -1 8 . Z-18. Z -1 8 .
Harness (Swing Table, Left)
Z-18 Harness (Swing Table, Left)
343-536-22020 △
1
32 WZ04-2280E 32

Z -1 9 . Z-19. Z -1 9 .
Harness (Swing Table Right)
Z-19 Harness (Swing Table Right)
343-536-22010 △
1
33 WZ04-2290E 33

Z -2 0 . Z-20. Z -2 0 .
Harness (Boom)
Z-20 Harness (Boom)
Boom, base
Boom, top
343-536-22030 △
0
343-536-22040 △
0
34 WZ04-2300E 34

Z -2 1 . Z-21. Z -2 1 .
Harness (AML, Upper)
Z-21 Harness (AML, Upper)
343-632-31300 △
1
343-632-31200 △
1
343-632-31100 △
1
35 WZ04-2310E 35

Z -2 2 . Z-22. Z -2 2 .
Harness (Overwind)
Z-22 Harness (Overwind)
343-724-40000 △
3
343-724-40010 △
1
343-721-83000 △
1
343-723-61000 △
2
36 WZ04-2320E 36

Z -2 3 . Z-23. Z -2 3 .
Harness (Lower, Main)
Z-23 Harness 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RB7 RB6
(Lower, Main) ASSY, 249A 249B
R LR
ASSY F 959
236A 236B
RY LY
236B 561
LY R
0 30 141A
560
RY
0 30
141
RB
561
249 142 563 564 236
A RL 0.85BrW G GL YB B BR B R
A
80
80
80
DIAG LAMP J55 J54

( ASSY,
35 35
RB8 RA11 RA8 M 721
638 98
Br WR 236A 561 40 124 124 124 M 168
DIAG LAMP RY R R RY RY RY YL
0 43 0 44
125
( 0 30 141B 0 30 168 35 142 719 B B

98 (734) (733) M MPK015-01022(MH058959)
WR (731) B RL B YL Br 0.85BrW
363-613-22210 ASSY)
50 9
80
80
80
J57 J49 J48 J47

B B
F 789 795 F (RR) (RR) 720 0.85LR
J46 26 27
50
F F
MDT F 434 4 F 788 50 101 124 82 8B
13
B 20 150 70 35 50 50 YL WY RY BW 108 0 40 109 0 41 101 B
0
619
0
F
10
41 46 45A 0 54 655 79 YO B YG B
637
(732) RA28 RA21 RA17 DIAG F 730 W WL LB B BW Gy
035 175
1.25B GW
19
WG
WY 142
BrR 54 679 600 600 94 94 804 800 802 249A 43 44 42A 51 83 0.85BrW
Br LR LG 556 117 244
100
50
50
636 0 45 R WB WY WL YB BL
LO L R 1.25R G G RW GW YO
75
LR B 801 803 141A 62 236A

0 30 79 609 602 247 248 LW LB ( ) 409
300
BR Y RY
B Gy BY 1.25RB GB GL F 408 350 85
R H
80 RL F 424 200
( 4 5) BR
80
80
80
J41 F 797 50 BOX(R)

123
RG
0 36
B
78
Y
RF3-1 J56 J40 J39 RL RL RL
J52
40 200
98 635 R B W R ( 4 5)
350
ASSY, 35 35 50 WR LY 80 751
30
50 0
0 30 44 F 45
RB12
600
B WY PB RB3 RB1
300
RD4 614 689 22 22 20 96 M 30 940 575 COT 7
50
46 41 42
L R G G YG YL 0 38 0 45 0 53 0 54 025 0 30 F 421 LR
F
75
WL W WR
C 0 30 42 B B B B B B 1.25B B 135 129 SW F 747
J33
C
750
B WR 0 30 21 245 246 0 30 89 0 31 035 350
RF3-2 Q ADJ W B
250
B 1.25B 696
800
B LG YR GY B GB 13
COT 7
800
46 45A 45 42A
M WL
1050
0
106 108 110 112 50 Earth M6 M6 Earth 0
13
647
80
80
80
YW YO RW RL WL LB PB WL 50 0 58 400
J37 J36 BW
50
M6 Earth
700
J35 B
130
107 109 111 113 310
250
Earth M6 M6 Earth
130
642
100
35 35 50 0 0
YB YG RB RG
80 LgR 13 ( 4
50
J20
RD5 J38 RB11 RB4 150 200 J22 150 200 110
RC6 5) 0 42 0 43 0 44 0 46
50
F 0 30 F 41 98 689 614 649 690 J42 COT 28 J9 COT 22 J43 J23
550
B B B B
0 30 615 623 624 604 B W WR R L 1.25BY J25 , ,
75
B GL YL YB Y J21
350 200 400 200 500 450 950 1550 380 300
46 44B 44 41B 694 696 0 30 601
RF2-1 0 40
35
WL RL WY RW YW WL B 1.25WY
B
130
130
350
50
F
80
80
0 30 629 10
350
B GR GY J18 J17 J10
D J19 416 0 58 0 39
D
400
M
0
B B 570 723
10
20 12 8 35 35 50 120 Earth 142
YG YO YR 0 38 684 50 RB
M6 M6 Earth M6 0.85BrW
50
J16 B BG
RF2-2 50 765 F 100 13 941 J34
0
1850
50
130
50
M (
0
147 118 117 681 660 606 647 607

RC5 0 36
12
WR Lg LY BW GY 1.25B M5
13
GR GL GW Earth B 0 39
0 46
617
0
F B
31 32 33 40 B B
500
1500
50
626 615 606 604 607

RY RB RW R ASSY
50
WB GL LY Y GY
R F2 F3 F1 COT 7
F 791 F 726 M
F 42 F 44 F 45 F 43
655 681 617 609 54 Earth M8 0 53 563 (755) 8B +
BW WR B BY LO B G 40
R
0 31
B
32
RB
0 32
B
33
RW
0 33
B
31
RY
0 34
B
(762)
R
80
683 638 637 635 98 679

L Br BrR LY WR L 0 21 0 24 70A 134
300
142
E 9 0.85BrW R
790
B B
ASSY,
M6 1.25RL
- E
0.85LR F
M4 (763)
250
9 680 52 21 694 626 601 636 22 1.25B
710 0.85LR RL Y LG YW WB 1.25WY LR G
100
F 957
0
25
642 602 203 910 644 624 616 625 647 3R
946 LgR 1.25RB W WB LgB YB YR YG BW 630 628 627 M8
709 80 02
GO GW GB 200
0.85B J26
(761)
Earth
CN6 606 CN11 612 F 766 100 M8
01
M5
200 F F
M 783 16 134 0 42 696 100 1F
+
B J1 FL FR RL RR 220 FL FR RL RR 222 91 90 87 45 44 42 41 8W
130
R R R R R B B B B B 100 100 GO GR P PB WY WR W
R 771
1.25YL 1.25RL B WL
(760)
250
FL FR RL RR 221 J11 43 62 46 560 029 F 780 918
PB
911
WL
5
LY ASSY 200 M8
W W W W W B B B B B 220 WB Y WL RY 1.25B
772 1B
145 626 3 M8
250
221 1B 5W
702 FL FR RL RR 222 WB WR 100 J28
BrW 784 J27
F 5W M8
F
60
M 3R 1C
CN5 F 605 CN10 F 611 F 781 100
1B 80 (758) 8W
100
8 9 10 3W
146 1D
80
800 801 802 803 95 79 6 2 YR 0.85LR GY 3R

1.25BrB FR FR LR LW LG LB 100 100 RL Gy J8 1.25O 1.25Y 12 13 614
3W
774
100
J7
1150
YO 0.85LB L
804 804 804 804 J12 50 51 570 52 36 028 778 M
0
23 22 400 17
Br Br Br Br YL YB RB Y BrR 1.25B
M
10
F F 1.25LW 123 124 141
COT 10
05
1.25B 703 113 03 112 04 RG RY RB 1F (759)
CN4 F 604 M
1000
RG B RL B 8W
F 782 125 98 556
60
135 129 203 918 913 911 615 16 19

W B W PB WG WL 1A 1A GL 1.25YL WG
1.25RL WR RW 1A
80
773
50
225
50
RH 914 0 24 910 616 623 625 617 CN9 F 610 2W 2W 20 21 22 4 775 8W

426
50
200 200 WR B WB YR YL YG B YG LG G YW
1A 1A
100
644
LgB
660
Lg 2W 2W 627 628 629 630
600 M2 1D M
100
GB GW GR GO 118 1.25R 1.25Y W

CN3 F 603 J13 0 27
B
0 27
B
0 27
B
0 27
B
027
1.25B
GL
17 6 105 1C
G 5 3 0 23 4
785 1.25LW 1.25O W 8W G
COT 13
50 LY WR B YW
75
60
86 245 35 247 0 23
( ) 1E
100
0 FL F 422 BG YR Br GB B
L RA22
200
CN8 F 609 767 8W

5)
FL FL FL 88 89
768 779 16 17
R B W CN2 F 602 100 100 GY GB
1D
J31 50 1.25YL 1.25LW
J50 105 105 105 022 0 22 0 22 J14 0 26 680 026 1D
1100
W W W 1.25B B B B RL 1.25B 2W J29 50 0 42 649

( 4
2W
1000
1D B 1.25BY
100
1D
75
CN1 F 600 2W
2W
SE-08BK
60
82 85 83 78 244 70
769
700
BW BR BL Y YO GB J32
Earth
175
GW
161
G
71
GL
575
LR
637
BrR
638
Br
0 21
B
0 21
B CN7 F 608 748 M 87
P
90
GR 150 50
93 248 58 31 32 33
(707)
50
100
100
130 GW GL LgY RY RB RW
01 04
601 F 10 96 79 88
50
H M6 B B
683
CN1
684
F J15 40
R
37
BrY
566
LY
567
LG
48
LR
47
LB
57
PB
53 025
BrW 1.25B 86 1B 150 YL Gy GY 50 H
05
L BG BG W
0 150 770 (708) (706)
25
550
21 236 249 0 21 0 21
1.25B LG TB RL B B COT 10 95
RL
M M4 M4
S2 M4 S1 50
RA9
749 M8 94 93 91
B
06 0 37 J3 J5 G GW GO 36 37 (704) (705) 86 17
2200 150 1E BrR 125 BrY BG 1.25LW
B 1.25B
8W 1.25RL M4 M4
350
Earth F 25 L2 M4 0 42 134
250
13
B 1.25RL
09 130 111 06 SL31 31 146 145
0
M6 RB B
F
FL
50
0.85B 1.25BrB 0 42 BrW

53 0 10
BrW B ASSY, B S L1
24 RR F 425
50
F 0 47 0 49
M6 F 942 (RL) 28 (RL) 29
SE-08BK
M F F
I 110 07 SL32 F 32 RR RR RR B B
I
700
RW B FL Earth 0 10 0 13 M 45 46 41B 0 56 R B W
900
PB WL RW B 106 0 47 107 0 48
200
47 0 11 B B YW B YB B
LB B 249B 43 42 44B Earth M6
150
LR WB WR RL
50
50
300
141B 62 236B
100 200 30
580
SL30
50
F
50
RL Y LY
943
130
F
50
57 0 12 J53
PB B 0 55 564
B GL
85
50
0 SL33 F 33 BOX(L) 200 50 560 650

3 20 21
50
F F F
COT 10
48 0 13
717
1300(COT 7)
LR B 567 0 50 62 0 14 43 0 15
J51
400
LG B Y B WB B 101
50 FR F
1200
WY
1000
LH 142
1300
FR FR FR
J 0.85BrW
J
50
50
50
R B W
145
701 F 2 Earth
BrW 423 J44
566 0 51 50 130 0 55 0 57
LY B M6 B B
13 718
100 500 100 150 350 550 L H 0.85LB
100
146
80
400
1.25BrB
Earth
200
0 49
037 , 130 0 14 0 17 B
180
( (P.T.O. 4WD M6
1.25B 700 49 41 413 F 944 B B
F F F (
50 123 0 57 161 0 50 0 51
58 0 20 246 0 19 70 0 18 RG B G
08 200 J4 LgY B GY B GB B B
, B
B M5
50 M
80
420 419
K K
50
09 F F
0
150
Earth Earth
13
0.85B 914 0 16 913 222 221 220

711 0 18 0 20 WR B WG B W R
945 M8 13 50
COT 7
COT 7
B B 0 J45
50
100
400
142 712 13
0.85LB L 200 0 F 440
0.85BrW 13
147 200 COT 7 J6 3050 ,
0.85LB 71 0 17
( ) GR ( 4 5) 1350 600 450
GL B Hi Lo
L
427 (COT 10)
IWZ04-2330E01
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
37 WZ04-2320E 349-310-00100 △
2 37

Z -2 4 . Z-24. Z -2 4 .
Harness (Lower, Sub)
Z-24 Harness (Lower, Sub)
349-310-00200 △
2
38 WZ04-2450E 38

Z
System Diagrams
Contents
Z-1 Hydraulic Circuit .............................. 1 Z-11 Location of Electric Parts

(Swing Table, Boom) .............23
Z-2 Torque Converter Circuit ................ 3
(Relay Assembly / Upper) .....24
Z-3 Brake Circuit (Pneumatic Circuit)... 4
Z-13 Location of Air Parts (AML)...........25

Z-4 Electric Circuit (AML, Crane) .......... 5
Z-5 Electric Circuit (Lower)....................................26
(MDT, Carrier/Upper) ............... 7
Z-6 Electric Circuit (Box Assembly / Lower) ........27
(MDT, Carrier/Lower) ............... 9
Z-16 Harness (Connector No. Table).....28
(Upper).................................. 11 Z-17 Harness (Inside Cab) .....................31
1. Cab and swing table.........................................11
2. Boom ........................................................... 14 Z-18 Harness (Swing Table, Left) ..........32
Z-19 Harness (Swing Table Right).........33

(Lower) ................................... 15
Z-20 Harness (Boom) .............................34
1. Carrier ........................................................... 15
1.1 Front ......................................................... 16
1.2 Center....................................................... 17
Z-21 Harness (AML, Upper) ...................35
1.3 Rear.......................................................... 18
Z-22 Harness (Overwind) .......................36
Z-9 Location of Air Parts...................... 19

Z-23 Harness (Lower, Main)...................37
1. Cab and swing table........................................ 19
2. Carrier ........................................................... 20
Z-24 Harness (Lower, Sub) ....................38
Z-10 Location of Electric Parts Z-25 Harness (Lower,

(Inside cab) ............................ 22 Electronic Governor) .............39
Z
i
Head Office Ko-34,Sinden-cho, Takamatsu, Japan
Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785
History of revision
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TR 800 XXL 4

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Publication No.

Rough Terrain Crane

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Safety precautions and recommendations are outlined

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

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2.The oil cooler fan may rotate the moment the

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1. Applicable spec. NO.

SPEC. NO. SERIAL. NO.

Spec. No. Applicable serial No.

2. Separate service manual

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No. of boom sections 5

No. of jib stages 2

Single top Option

Main winch Fitted

Auxiliary winch Fitted

Drum rotation indicator Touch-type (Option)

Weight Counterweight Removable type

Load moment indicator (AML) AML-L2C

Auto. stop solenoid valve energizing type Normally energized

AML external indicator lamp Fitted

Oil cooler Fitted

Air conditioner Option

Emergency steering Option

Engine model MITSUBISHI 6M60-TLA3B

Tires 29.5 × 25 - 22PR, 29.5 × 25 - 28PR

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B Hydraulic Power Generating System

E Boom Elevating System

G Boom Telescoping System

Y Data, Adjustment and Checks

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

Hydraulic Power Generating System

Hydraulic Power Generating System B-1

Flow Control Valve B-6

Pressure Reducing Valve (Pilot Pressure) B-7

Solenoid Control Valve (Outrigger) B-8

Hydraulic Pilot Control Valve

Sequence Valve (Pilot Pressure) B-11

Solenoid Valve(Pilot Pressure) B-12

Solenoid Control Valve (Jib Set) B-13

Pilot Check Valve (Jib Set) B-14

Solenoid Valve (Oil Cooler) B-15

Hydraulic Motor (Oil Cooler) B-16

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Hydraulic Power Generating System

Jib Lock pin B-17

Jib Offset Cylinder B-18

Outrigger System C-1

Jack Cylinder C-2

Pilot Check Valve

Extension Cylinder C-4