Tadano - Manual de Sevicio 2-S1 (U) - 1E

Publication No.
GR-750XL-2/S1(U)-1E
01
Rough Terrain Crane

Model GR-750XL-2
Applicable Serial No. 547121 --
Safety
Safety
Most accidents that occur during machine operation [NOTICE]
and maintenance are caused by failure to observe NOTICE indicates an important measure or
basic safety rules and precautions. Before operating condition for handling, and indicates that, if not
observed, there is a risk of damaging the equipment
your machine or performing maintenance, read and
or device, or degrading performance and function of
become familiar with all the safety precautions and the machine.
recommendations given in this section.
Remember that failure to observe even a single It is virtually impossible to anticipate every situation
precaution could involve you and the people around that might present a hazard. The safety precautions
the machine in a serious accident. given in this manual and on the machine labels are
not exhaustive.
Foreseeing potential dangers is vital for preventing
It is important, therefore, to strictly follow the
accidents. All personnel working with the machine,
instructions in this manual and be sensitive to
including the supervisor, machine operator and oiler,
potential dangers in order to prevent bodily injury and
should be sensitive to potentially dangerous situations
damage to the machine.
and take the necessary measures to prevent
accidents. Remember that your most important duty is to ensure
the safety of you, your co-workers and any other
Safety precautions and recommendations are outlined
people in the area.
in this section and are also included in the operation
and maintenance instructions given in subsequent
sections. Warning labels are also provided on the
machine.
The cautionary instructions in this manual are
identified as "DANGER", "WARNING", "CAUTION" or
"NOTICE". These terms are defined as follows:
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
1 WA01-0042E
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 a marker if necessary.
vehicle with only a jack or a hoist. Sustain the
vehicle positively with blocks and so on to prevent
2 WA01-0042E
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 WA01-0042E
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 WA01-0042E
Foreword
Foreword
This service manual describes the composition of the Model GR-750XL-2 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. and serial number
Spec. no. / model Applicable serial number
GR-750-2-00101 547121--
2. Separate service manual

Separate Service Manual Publication No.
1 General Cautions SA01-01-2E
2 Load Moment Indicator (AML-C) W301-0411E
3 Multiplex Data Transmitter (MDT-9) W303-0581E*
4 Torque Converter (EXEDY)
W561-0161E
5 Transmission (EXEDY)
6 Driving Axle (ASANO) W563-0181E
7 Service manual (Circuit diagrams and Data) GR-750XL-2/C1(U)-2E
*: to be published
Please note that, for product improvement, some changes may have been
incorporated in the machine that are not covered in this manual.
1 WA04-3550E
Foreword
3. External view
The following is the traveling posture of the H-type outrigger specification machine.
Front, rear, right, and left are the directions viewed from a position when operator sits on operator's seat with the
boom directed to the front of the frame. Those directions remain invariant regardless of swing direction of the
superstructure.
2 WA04-3550E
Foreword
4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km
-1 -3 -2 -3
1 1×10 1×10 3.93701×10 3.28084×10 1 1.60934
-2 -1 -2 -1
1×10 1 1×10 3.93701×10 3.28084×10 6.21373×10 1
1×103 1×102 1 3.93701×10 3.28084
-2
2.54×10 2.54 2.54×10 1 8.33333×10-2
3.048×102 3.048×10 3.048×10-1 1.2×10 1
Speed
km/h mile/h
1 6.21373×10-1
1.60934 1
Area
square millimeter, mm2 square centimeter, cm2 square meter, m2 square inch, in2 square foot, ft2
1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5
1×102 1 1×10-4 1.55×10-1 1.07639×10-3
1×106 1×104 1 1.55×103 1.07639×10
2 -4
6.4516×10 6.4516 6.4516×10 1 6.94444×10-3
9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1
Volume
cubic centimeter,
cubic meter, m3 cubic inch, in3 cubic foot, ft3 gallon, gal cubic inch, in3 liter, lit, L
cm3, cc
1 1×10-6 6.10237×10-2 3.53147×10-5 1 2.31×102 3.78541
6 4 -3
1×10 1 6.10237×10 3.53147×10 4.329×10 1 1.63871×10-2
1.63871×10 1.63871×10-5 1 5.78704×10-4 2.64172×10-1 6.10237×10 1
4 -2 3
2.83168×10 2.83168×10 1.728×10 1
Force
N kgf lbf
-1
1 1.01972×10 2.24809×10-1
9.80665 1 2.20462
-1
4.44822 4.53592×10 1
Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
-3 -2 -3 -6
1 1×10 3.5274×10 2.20462×10 1×10 1.10231×10-6
1×103 1 3.5274×10 2.20462 1×10-3 1.10231×10-3
2.83495×10 2.8349×10-2 1 6.25×10-2 2.83495×10-5 3.12494×10-5
4.53592×102 4.53592×10-1 1.6×10 1 4.53592×10-4 5×10-4
1×106 1×103 3.5274×104 2.20462×103 1 1.10231
5 2 4 3 -1
9.07185×10 9.07185×10 3.2×10 2×10 9.07185×10 1
3 WA04-3550E
Foreword
Pressure
Pa kPa MPa kgf/cm2 lbf/in2, psi
1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4
1×103 1 1×10-3 1.01972×10-2 1.45038×10-1
1×106 1×103 1 1.01972×10 1.45038×102
9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10
3 -3 -2
6.89476×10 6.89476 6.89476×10 7.03072×10 1
bar MPa kgf/cm2

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

-1
1 1.01972×10 7.37562×10-1
9.80665 1 7.23301
-1
1.35582 1.38255×10 1
Centigrade-Fahrenheit
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78
-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33
Conversion equation: t°C=5(ToF-32)/9, T°F=(9×t°C+160)/5
4 WA04-3550E
Foreword
5. Outline of specifications
Spec. No.
No. Item GR-750-2-00101
2M2D
(North America)
1 No. of boom sections 5
2 No. of jib stages 2
3 Single top Fitted
Main winch Fitted
Auxiliary winch Fitted
4 Winch Winch brake Automatic brake (Neutral brake)
Drum Main Fitted
Visual and
rotation
touch-type Auxiliary Fitted
indicator
5 Counterweight Removable type
6 Load moment indicator (AML) AML-C
7 Auto. stop solenoid valve energizing type Normally energized
8 Overwind cutout (anti-twoblock) device Fitted
9 External warning lamp Fitted
10 Oil cooler Fitted
11 Air conditioner Fitted
12 ICF (information controller) Fitted
13 SCT (satellite communications terminal) Fitted
14 Emergency steering Option
15 Engine model MITSUBISHI 6M60-TLA3B (Tier 3)
29.5 × 25 - 22PR
16 Tires
or 29.5 × 25 - 28PR
5 WA04-3550E
memo
6 WA04-3550E
6. Group index
A General
B Hydraulic Power Generating System B

C Outrigger System C
D Swing System D
E Boom Elevating System E
F Winch System F
G Boom Telescoping System G
H Safety System H
K Cab K
L Control System L
N Electric System N
R Driving Power Transmission System R

S Steering System S
T Brake System T
U Suspension System U
Y Data, Adjustment and Checks
Z System Diagrams
7 WA04-3550E
Foreword
7. Contents
Spec. No.
Chapter Section GR-750-2-00101

2M2D
(North America)
General
A General Cautions Refer to separate service manual
Hydraulic Power Generating System
Hydraulic Power Generating System B-1

Hydraulic Pump
B-2
(Double Variable Displacement Pump)
Hydraulic Pump
B-3
(Double Gear Pump)
Hydraulic Pump
B-4
(Gear Pump, Emergency Steering)
Hydraulic Valve (Emergency Steering) B-5
Flow Control Valve B-6

B
Center Joint B-7
Hydraulic Pilot Control Valve
B-8
(Elevating, Telescoping, Winch)
Sequence Valve (Pilot Pressure) B-9
Solenoid Valve(Pilot Pressure) B-10
Solenoid Valve(Positive Control) B-11
Check valve (Gauge Isolator) B-12
Outrigger System
Outrigger System C-1
Solenoid Control Valve (Outrigger) C-2
(UCHIDA) C-3
Solenoid Valve (Slide/Jack) (TOKIMEC) C-4
C (NACHI) C-5
Jack Cylinder C-6

Pilot Check Valve
C-7
(Jack Cylinder Retraction Prevention)
Extension Cylinder C-8
Check Valve
C-9
(Slide/Jack Extension Prevention)
8 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
Swing System
Swing System D-1
Hydraulic Pilot Control Valve (Swing) D-2
D Hydraulic Motor (Swing) D-3
Swing Speed Reducer D-4
Swing Assembly D-5
Boom Elevating System
Elevating System E-1
Elevating Cylinder E-2

E
Counterbalance Valve (Elevating) E-3
Pressure Sensor E-4
Winch system
Winch System F-1
Winch F-2
Hydraulic Motor and (Winch) F-3
F Counterbalance Valve (Winch) F-4
Hydraulic Valve (Winch Brake Release) F-5
Accumulator (Winch Brake) F-6
Pressure Sensor F-7
9 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
Boom Telescoping system
Telescoping System G-1
Boom (Five-Section Boom) G-2
Jib G-3
Telescoping Cylinder G-4
Counterbalance Valve (Telescoping) G-5
G Hose Reel G-6
Hydraulic Valve (Winch Brake Release) G-7
Jib Lock Pin Cylinder G-8
Jib Offset Cylinder G-9
Solenoid Control Valve (Jib Set) G-10
Pilot Check Valve (Jib Set) G-11
Safety System
Safety System H-1
Load Moment Indicator (AML) Refer to separate service manual
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 K-2

Hydraulic Motor
K K-3
(Air Conditioner)
Solenoid Valve
K-4
(Air Conditioner)
Relief Valve
K-5
(Air Conditioner)
10 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
Control System
Inside Cab Control Device L-1
Shift Switch L-2
Solenoid Valve (Air) L-3
Remote Control Valve (Lever) L-4

L
Remote Control Valve (Pedal) L-5
Shuttle Valve (Lever/Pedal) L-6
Solenoid Valve
L-7
(Boom Telescoping/Aux. Winch)
Proportional Control Valve
L-8
(Elevation Slow Stop)
Electric System
Multiplex Data Transmitter (MDT) Refer to separate service manual
Display Control Unit (DCU) N-1
Combination Meter N-2

N
Signal Transmitter (STM-E) N-3
Engine Control Unit (ECU) N-4
Satellite Communications N-5
Driving Power Transmission System
Driving Power Transmission System R-1
R Torque Converter and Transmission Refer to separate service manual
Driving Axle Refer to separate service manual
11 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
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 hydraulic Lock)
Brake System
Brake System T-1
Brake Valve T-2
Booster T-3
T
Air Dryer T-4
Brake Chamber T-5
Solenoid Valve
T-6
(Parking Brake) (Air)
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) (Free/Lock)
Pressure Reducing Valve (Pilot Pressure) U-5
12 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
Data, Adjustment and Checks

(Refer to separate service manual)
Service Date Y-1
Adjusting pressure (Hydraulic Pressure) Y-2
Adjusting pressure (Pneumatic Pressure) Y-3
Air Bleeding Procedure Y-4
Adjusting procedure (Electric) Y-5
Y Assembly Adjustment (Crane Operation) Y-6
Assembly Adjustment (Traveling Device) Y-7
Operation Check (Crane Operation) Y-8
Operation Check (Traveling Device) Y-9
Inspection and Maintenance Y-10
Boom Connecting Pin and Thread Size

Y-11
Table
System Diagrams
(Refer to separate service manual)
Hydraulic Circuit Z-1
Torque Converter Circuit Z-2
Pneumatic Circuit Z-3

Z
Electric Circuit (Upper) (Crane) Z-4
Electric Circuit (Upper) (Carrier) Z-5
Electric Circuit (Lower) Z-6
13 WA04-3550E
Foreword
Spec. No.

2M2D
(North America)
Location of Installation
Hydraulic Parts Location Diagram (Upper) Z-7
Hydraulic Parts Location Diagram (Lower) Z-8
Hydraulic Parts Location Diagram

Z-9
(Torque Converter)
Pneumatic Parts Location Diagram Z-10
Electric Parts Location Diagram (Upper) Z-11
Z Electric Parts Location Diagram

Z-12
(AML, Overwinding)
Electric Parts Location Diagram (ICF, SCT) Z-13
Electric Parts Location Diagram (Lower) Z-14
Harness Diagrams
Harness (Upper) (Crane) Z-15
Harness (Upper) (Carrier) Z-16
Harness (Lower) Z-17
14 WA04-3550E
B B
Contents
B-1 Hydraulic Power Generating B-3 Hydraulic Pump

System...................................... 1 (Double Gear Pump) ..............13
1. Function ..................................................... 1 1. Structure .................................................. 13

1.1 Hydraulic pump........................................... 1
1.2 Solenoid control valve (outrigger)............... 1
1.3 Center joint ................................................. 1 B-4 Hydraulic Pump (Gear Pump,
1.4 Hydraulic pilot control valve Emergency Steering).............16
(elevating, telescoping,
main winch and auxiliary winch)........... 1 1. Structure .................................................. 16
1.5 Sequence valve (pilot pressure) and
solenoid valve (pilot pressure) ............. 1
B-5 Hydraulic Valve
2. Hydraulic system description ..................... 2 (Emergency Steering)............17
2.1 Pump (P1) circuit........................................ 2
2.2 Pump (P2) circuit........................................ 2 1. Structure .................................................. 17
2.3 Pump (P3) circuit........................................ 2
2.4 Pump (P4) circuit........................................ 2
B-6 Flow Control Valve.........................19
B-2 Hydraulic Pump (Double Variable 1. Structure .................................................. 19

Displacement Pump) ............... 3
1. Structure .................................................... 3
1.1 General view............................................... 3
1.2 Pump main body ........................................ 4
1.3 Regulator .................................................... 5
2. Operation ................................................... 7
2.1 Regulation of flow rate by discharging
pressure ............................................... 7
2.2 Regulation of flow rate by external pilot
(positive control) ................................. 10
i
B-7 Center Joint .................................... 20
1. Structure .................................................. 20
1.1 General view............................................. 20
1.2 Port size table........................................... 22
1.3 Swivel joint
(hydraulics and pneumatics) ............ 23
1.4 Swivel joint (heated water) ....................... 25
2. Slip ring.................................................... 26
2.1 General view............................................. 26
2.2 Harness and connector ............................ 27
2.3 Maintenance of ring and brush................. 27
B-8 Hydraulic Pilot Control Valve

(Elevating, Telescoping,
Winch) .................................... 28
1. Structure .................................................. 28
B-9 Sequence Valve

(Pilot Pressure) ...................... 39
1. Structure .................................................. 39
B-10 Solenoid Valve

(Pilot Pressure) ...................... 42
1. Structure .................................................. 42
B-11 Solenoid Valve

(Positive Control)................... 44
1. Structure .................................................. 44
B-12 Check Valve (Gauge lsolator) ....... 46
1. Structure .................................................. 46
ii
B-1 B-1
B-1 Hydraulic Power Generating 1.4 Hydraulic pilot control valve

System (elevation, telescoping,
main winch and auxiliary winch)
1. Function 1. This valve block comprises hydraulic pilot
direction control valves used in elevation,
1.1 Hydraulic pump
telescoping, main winch and auxiliary winch
1. This unit utilizes a double variable displacement circuits.
pump (P1, P2), a double fixed displacement pump
2. This valve is operated by the controlled pilot
(P3, P4), and a single bidirectional-rotation pump
pressure from the remote control valve for crane
(emergency steering).
operation.
2. Pump (P1) is used for the main winch and aux.
3. One unloading relief valve incorporated in this
winch circuits.
block serves for controlling main circuit pressure
3. Pump (P2) is used for the elevation, telescoping, in main and auxiliary winch circuits and for AML
main winch and aux. winch circuits. vent. The other unloading relief valve serves for
controlling main circuit pressure in elevation and
4. Pump (P3) is used for the steering and swing
telescoping circuits and for AML vent.
circuits.
5. Pump (P4) is used for outrigger circuit, the release 1.5 Sequence valve (pilot pressure) and
solenoid valve (pilot pressure)
circuits for the suspension lock, winch brake and
swing brake, the pilot pressure circuits for the This valve supplies the pressurized oil from pump
crane operation and winch high speed selection, (P4) at the specified pressure to the release
and for the jib set, C/W removal and air circuits for winch brake and swing brake, and the
conditioner circuits. pilot pressure circuits for crane operation and
winch high speed selection.
6. Pump (emergency steering) is used in case of
pump (P3) malfunctions.
1.2 Solenoid control valve

(outrigger)
(For the structure, refer to the chapter C.)
This valve supplies the pressurized oil from pump

(P4) to the outrigger circuit.
The circuit pressure is controlled by relief valve
built into the circuit.
1.3 Center joint
This connects the hydraulic circuits, electrical

circuits, hot water circuit for the air conditioner,
and pneumatic circuits between the
superstructure and the vehicle chassis. It allows
each of the independent circuits to be formed in
any swing position.
1 WB02-0510E
B-1. B-1.
2. Hydraulic system description 2.3 Pump (P3) circuit

(Refer to hydraulic circuit in chapter Z.) 1. The pressurized oil discharged by pump (P3)
passes through the center joint and enters the
2.1 Pump (P1) circuit priority valve.
1. The pressurized oil discharged by pump (P1) 2. The priority valve delivers pressurized oil to the
passes through the center joint, and enters steering circuit preferentially, thus the oil enters
hydraulic pilot control valve. It is employed in the the hydraulic control valve (swing) and is
main winch and aux. winch circuits. employed in the swing circuit. It passes through
2. When the auxiliary winch and main winch are not the center joint and returns to the tank.
operated, the pressurized oil passes through the

2.4 Pump (P4) circuit
flow control valve for the auxiliary winch, the flow
control valve for the main winch, the tank path in 1. The pressurized oil discharged by pump (P4)
the selection valve for the main winch, the tank enters the solenoid control valves (outrigger).
path in the selection valve for the auxiliary winch, While the spool of the solenoid control valve
and center joint, and then returns to the tank. (outrigger) is in the neutral position, the
pressurized oil passing through the carry-over port
2.2 Pump (P2) circuit passes through the center joint, and enters the
1. The pressurized oil discharged by pump (P2) sequence valve and the solenoid valve (pilot
pressure). The sequence and solenoid valves
passes through the center joint and enters the
supply pressurized oil from pump (P4) at the
hydraulic pilot control valve. It is employed in the
specified pressure to the release circuits for the
elevation, telescoping, main winch and auxiliary
suspension lock, winch brake and swing brake,
winch circuits.
and the pilot pressure circuits for the crane
2. When neither elevation nor telescoping operation operation and winch high-speed selection.
is made or surplus oil exists during elevation or The pressurized oil branching off at the sequence
telescoping operation, the pressurized oil (or valve passes through the solenoid valve (jib set
surplus oil) passes through the junction flow and C/W self-mounting) and the solenoid valve
control valve and joins the pressurized oil from (air conditioner), and center joint, then returns to
pump (P1). It passes through the tank path in the the tank.
selection valve for the main winch, the tank path
in the selection valve for the auxiliary winch, and
center joint, then returns to the tank.
2 WB02-0510E
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, the hydraulic symbols and so on differ from the parts for this machine.
Although there is not so much difference in functions and disassembly procedures, make sure of the serial
number of this machine and the part sales unit described in the parts catalog before starting disassembling
operations.
1. Structure
1.1 General view

This pump is a variable displacement piston
pump. The angle of the swash plate is controlled
by the regulator.
In addition, regulation of flow rate by the
external pilot (P11, P12) (positive control) can
change the pump displacement according to
lever control input.
3 W101-0490E
B-2 B-2
1.2 Pump main body
Apply adhesive (No. 1305N of Threebond make)
808 535 789 732 532 548 214 702 792 534 724 901 954 719 124 151 152 113 406 710
531
953
886
717
Apply (Sealub L101) 406

to the oil seal surface
circumference
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
IW101-0274E01
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.Hexagon socket head bolt 719.O-ring 953.Hexagon socket set screw
156.Spherical bush 406.Hexagon socket head bolt 724.O-ring 954.Set screw
157.Cylinder spring 466.Plug 725.O-ring
211.Shoe plate 467.Plug 728.O-ring
Thread size and tightening torque
Sign / Thread Tightening torque Sign / Thread Tightening torque

Port size N-m kgf-m ft-lbf Port size N-m kgf-m ft-lbf
401 M16 240 24.5 177 531,
406 M6 12 1.2 8.8 M20x1.5 240 24.5 177
532
466 G1/4 36 3.7 26.5 808 M16 130 13.3 96
467 G1/2 110 11.2 81
NPTF
490 8.8 0.9 6.5
1/16
4 W101-0490E
B-2 B-2
1.3 Regulator
5 W101-0490E
B-2 B-2
412.Hexagon socket head bolt 627.Adjust stem 722.O-ring 858.Snap ring

413.Hexagon socket head bolt 628.Adjust screw 724.O-ring 874.Pin
436.Hexagon socket head bolt 629.Cover 725.O-ring 875.Pin
438.Hexagon socket head bolt 630.Locknut 728.O-ring 876.Pin
496.Plug 631.Pf sleeve 730.O-ring 887.Pin
601.Casing 641.Pilot cover 732.O-ring 897.Pin
611.Feedback lever 643.Pilot piston 733.O-ring 898.Pin
612.Lever 644.Sprig seat 734.O-ring 924.Hexagon socket set screw
613.Lever 645.Adjust stem 735.O-ring
614.Center plug 646.Pilot spring 753.O-ring
615.Adjust plug 651.Sleeve 755.O-ring
621.Compensator piston 652.Spool 756.O-ring
622.piston case 653.Sprig seat 763.O-ring
623.Compensator rod 654.Return sprig 801.Nut
624.spring seat 655.Set sprig 802.Nut
625.Outer spring 656.Cover 814.Snap ring
626.inner spring 708.O-ring 836.Snap ring
Sign / Tightening torque

Thread size
Port N-m Kgf-m ft-lbf
436, 438 M6 12 1.2 8.8
412, 413 M8 29 3.0 21.4
496 NPTF1/16 8.8 0.9 6.5
630 M30×1.5 160 16.3 118
801 M8 16 1.6 11.8
802 M10 19 1.9 14.0
6 W101-0490E
B-2 B-2
2. Operation
3. While the pressure of the pressurized oil (P) is
below a certain level, the lever 1 does not move
2.1 Regulation of flow rate by discharging
pressure because the rightward force of the compensator
piston on the compensator rod is smaller than the
1. The pressurized oil (P) from the pump flows to reaction force of the outer spring. (When the
areas A and B shown in the figure via the path in compensator rod moves rightward, it moves the
the regulator casing. The pressurized oil (P) also lever 1 via the pin C.)
flows to small-diameter end H on the servo piston.
4. Thus the feedback lever is pushed leftward, the
2. The pressurized oil (P) flowing in the area A goes spool moves leftward, and the seating area E
through the clearance between the compensator opens. Then the pressurized oil at the
piston and piston case then into the chamber F, large-diameter end G on the servo piston flows via
applying rightward pressure to the compensator the port D to the drain line, and the displacement
piston. is kept to maximum by the pressurized oil at
small-diameter end H and the outer spring.
7 W101-0490E
B-2 B-2
5. When the discharge pressure exceeds the 1st 6. The rightward movement of the compensator rod
turning point (P1), the rightward force of the is transferred to the lever 1 via the pin C. Thus the
compensator piston on the compensator rod lever 1 swings around the pin A fixed on the
overcomes the reaction force of the outer spring. casing.
8 W101-0490E
B-2 B-2
7. The pins B are engaged with the large bore in 15. The movement of the servo piston is transferred
each lever 1. Thus the feedback lever revolves to the spool by the feedback mechanism. The
around the [Point J] and the spool moves seating areas C and E on the spool open to the
rightward as the lever 1 swings. amount which the hydraulic pressure in the
large-diameter end G and small-diameter end H
8. When the spool moves, the seating area E closes
on the servo piston are balanced.
and the seating area C opens. Then the
pressurized oil (P) flowing in the port B goes via 16. As explained above, the displacement of the
the port D to the large-diameter end G on the variable displacement pump is controlled by the
servo piston. The servo piston moves rightward balance between the force acting on the
and decreases the displacement. compensator rod and the force of the inner and
outer springs for horsepower setting, and by the
9. The rightward movement of the servo piston is
consequential balance between the hydraulic
transferred to the feedback lever via the [Point J],
pressure in the large-diameter end G and the one
and the feedback lever revolves around the pin B.
in the small-diameter end H on the serve piston.
Then the spool moves leftward.
17. The position for maximum displacement is set by
10. The seating areas C and E on the spool open to
the set screw 954, and the position for minimum
the amount which the hydraulic pressure at the
displacement is set by the set screw 953.
large-diameter end G and small-diameter end H
on the servo piston are balanced. 18. The 1st turning point (P1) bon the set
horsepower curve is determined by the tightening
11. While the spring force only by the outer spring
amount of the adjuster screw A. The 2nd turning
acts on the compensator rod, the discharge
point (P2) is determined by the tightening amount
pressure is between P1 and P2. When the spring
of the adjuster screw B. The incline of the
force by both of the outer spring and inner spring
horsepower curve is determined by the spring
acts on the compensator rod, the discharge
constant.
pressure is between P2 and P3. (P2 represents
the 2nd turning point.)
12. When the discharge pressure decreases on the

contrary, the compensator rod is pushed back by
the reaction force of the outer spring and the lever
1 swings on the pin A.
13. As the lever 1 swings, the feedback lever

revolves around the [Point J] and the spool moves
leftward.
14. When the spool moves, the seating area C

closes and the seating area E opens. Then the
pressurized oil (P) at the large-diameter end G on
the servo piston goes to the drain line. The servo
piston moves leftward and increases the
displacement.
9 W101-0490E
B-2 B-2
2.2 Regulation of flow rate by external pilot

(positive control) 2. The pins D fixed on the lever 2 are engaged with
the each groove [Point A] of the pilot piston. As
the pilot piston moves, the lever 2 revolves around
the [Point B] (fixed by the center plug and pin E).
3. The pins B are engaged with the large bore [Point

C] in each lever 2. Thus the pin B moves
rightward as the lever 2 swings.
4. The parallel walls [Point D] of the notch in the

feedback lever are engaged with the feedback pin
As shown in the above figure, the pump which is fixed on the tilting pin swinging the
displacement can be changed as desired by the swashplate. Thus the feedback lever revolves
external pilot pressure. around the [Point D] as the pin B moves.
decreasing the displacement
1. When the external pilot pressure (PP) decreases,

the pilot piston moves leftward by the pilot spring
force, and stops where the pilot spring force and
hydraulic pressure are balanced.
10 W101-0490E
B-2 B-2
5. The spool is connected to the feedback lever via 8. When the servo piston moves rightward, the
the pin F. Thus the spool moves rightward. [Point D] also moves rightward.
6. Because the seating area C opens as the spool 9. The return spring attached on the spool always
moves rightward, the pressurized oil (P) flowing in pulls the spool leftward. So the pin B is engaged
the port B goes through the spool, and flows via with the larger bore [Point C] of the lever 2.
the port D to the large-diameter end G on the
10. Thus the feedback lever revolves around the
servo piston.
[Point C] and the spool moves leftward as the
7. Some pressurized oil (P) always flows to the [Point D] moves.
small-diameter end H on the servo piston.
11. The servo piston keeps moving until the opening
However, the different cross sectional area of the
between the sleeve and the spool closes. When
chambers makes the servo piston go rightward.
the opening closes, the piston stops.
Thus the displacement (swashplate inclination)
decreases.
11 W101-0490E
B-2. B-2.
Increasing the displacement
1. When the external pilot pressure (PP) increases,

the pilot piston moves rightward, and the lever 2
revolves around the [Point B].
2. The pins B are engaged with the large bore [Point

C] in each lever 2. Thus the pins B move leftward
as the lever 2 turns.
3. As the pin B moves, the feedback lever revolves

around the [point D].
4. The spool is connected to the feedback lever via

the pin F. Thus the spool moves leftward.
5. When the spool moves leftward, the seating area

E opens. Then the pressurized oil (P) at the
large-diameter end G on the servo piston goes via
the port D to the drain.
6. The pressurized oil (P) at the small-diameter end

on the servo piston H moves the servo piston
leftward. Thus the displacement (swashplate
inclination) increases.
7. When the servo piston moves leftward, the [Point

D] also moves leftward.
8. The feedback lever revolves around the [Point C],

and the spool moves rightward.
9. The servo piston keeps moving until the opening

between the sleeve and the spool closes. When
the opening closes, the piston stops.
366-545-30001 △
0
12 W101-0490E
B-3 B-3
Hydraulic Pump (Double Gear Pump)
B-3 Hydraulic Pump (Double Gear Pump)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1 2 3
IW101-013001
1.Gear pump assy 2.Connecting section 3.Gear pump assy
13 W101-0132E
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.Hexagon 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.Hexagon socket head bolt
14 W101-0132E
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.Hexagon socket head bolt 15.Rear cover
366-533-00000 △
0
366-519-00000 △
0
366-531-70000 △
0
15 W101-0132E
B-4. B-4.
Hydraulic Pump (Gear Pump, Emergency Steering)
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
Sign / Port Thread size
N-m kgf-m ft-lbf
A, B G3/4 62 - 75 6.3 - 7.6 46 - 56
D G1/4 24 - 29 2.4 - 3.0 17 - 22
31 M10 48 - 51 4.9 - 5.2 35 - 38
366-535-20000 △
2
16 W101-0143E
B-5 B-5
Hydraulic Valve (Emergency Steering)
B-5 Hydraulic Valve (Emergency Steering)

[NOTICE]
1. Structure
Tightening torque
N-m kgf-m ft-lbf
P1’ G1/4 29.4 3 22
P3’ G3/8 49 5 36
P1, P2, P3, T G3/4 167 17 123
17 W123-0420E
B-5. B-5.
Hydraulic Valve (Emergency Steering)
Cross section along the line X-X, Y-Y, Z-Z
1.Body 5.Spring 9.Plug

2.Poppet 6.Spring 10.O-ring
3.Spool 7.Spring 11.Plug
4.Spring 8.Plug
366-408-30010 △
1
18 W123-0420E
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 kgf-m ft-lbf
4, 5 - 80 - 110 8.2 - 11.2 59 - 81
7 - 120 - 160 12.2 - 16.3 88.5 - 118
PA G3/4 167 17 123
T, PB G1/2 98 10 72
366-104-20000 △
0
19 W114-0133E
B-7 B-7
Center Joint
B-7 Center Joint

[NOTICE]
1. Structure
1.1 General view
20 W181-0561E
B-7 B-7
Center Joint
3 14
9,10
11,12 15
14
View A View B IW181-0380E02
1.… 6.Slip ring assy 11.Bolt 16. Swivel joint assy

2.Swivel joint assy 7.Bolt 12.Spring washer
3.Plate 8.Bolt 13.…
4.… 9.Hexagon socket head bolt 14.Plug
5.… 10.Spring washer 15.Plug
Tightening torque
Sign / port Thread size
N-m kgf-m ft-lbf
7*1 M10 43 - 49 4.4 - 5 32 - 36
8*1 M12 54 - 66 5.5 - 6.7 40 - 49
9*1 M6 6.6 - 8 0.7 - 0.82 5-6
11*1 M10 18 - 22 1.8 - 2.2 13 - 16
*1：Apply LOCTITE242 to threaded sections.
21 W181-0561E
B-7 B-7
Center Joint
1.2 Port size table
port circuit remarks port size
P1 Winch G1
Elevating
P2 Telescoping G1
Steering
P3 Swing G1/2
P4 Steering left G1/2
P5 Steering right G1/2
P6 Option G3/8
P7 Air conditioner G1/2
T Tank Ф50
DR Drain G1/2
A1 Air suppy G3/8
A2 Service brake Primary G3/8
A3 Service brake Secondary G3/8
W1 Heater IN 13
W2 Heater OUT 13
22 W181-0561E
B-7 B-7
Center Joint
1.3 Swivel joint (hydraulics and pneumatics)
23 W181-0561E
B-7 B-7
Center Joint
[NOTICE]
Before seal parts are installed in seal grooves of the body 2, remove oils and fats from seal grooves
completely. (To prevent the seal parts from turning with the core 1)
Before apply the silicon grease (NOK UNISILKON L 205) on faces X2, X3 and X4 of the body 2 and on side
X1 of the core 1 shown in view X, remove oils and fats from seal grooves completely.
1.Core 5.O-ring 9.Seal ring 13.Plug

2.Body 6.O-ring 10.Hexagon socket head bolt 14.Seal ring
3.Cover 7.O-ring 11.Plug 15.Plug
4.Plate 8.Seal ring 12.Plug 16.O-ring
Tightening torque
N-m kgf-m ft-lbf
10*1 M8 30 - 34 3.1 - 3.5 22 - 25
*1：Apply LOCTITE242 to threaded sections.
24 W181-0561E
B-7 B-7
Center Joint
1.4 Swivel joint (heated water)
1
A
5
2 B
4
6
3
IW181-028004
[NOTICE]
Before seal parts are installed in seal grooves of the core 3, remove oils and fats from seal grooves
completely. (To prevent the seal parts from turning with the body 4)
Before install plain bearings 5 and 6 into the core 3, apply Molybdenum Grease No.2 to inner and outer
surfaces of the bearing 5 and upper and lower surfaces of the bearing 6.
1.Packing 3.Core 5.Plain bearing 7.Retaining ring

2.O-ring 4.Body 6.Plain bearing
Tightening torque
N-m kgf-m ft-lbf
A
R1/4 22 - 25 2.2 - 2.5 16 - 18.5
(INLET)
B
R1/4 22 - 25 2.2 - 2.5 16 - 18.5
(OUTLET)
346-309-31000 △
0
25 W181-0561E
B-7 B-7
Center Joint
2. Slip ring
2.1 General view
26 W181-0561E
B-7. B-7.
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
2.2 Harness and connector
2.3 Maintenance of ring and brush
[NOTICE]
Maintenance-free from grease job of the contacts.
Never apply grease to contacts between rings and
brushes, rings for the upper power circuits (6
circuits) and disk type rings for the lower weak
signal circuits (24 circuits).
These slip-rings adopt carbon brushes on the

power and weak signal circuits.
These slip-rings have enough operating durability

with self-lubricating carbon materials. Therefore
grease job is not necessary like metal contacts.
346-309-32000 △
0
27 W134-0561E
B-8 B-8
B-8 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

[NOTICE]
There is a case that the appearance and so on differs from the parts for this machine. Although there is not so
1. Structure
28 W134-0460E
B-8 B-8
Tightening torque
N-m kgf-m ft-lbf
C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 3 22
A3,B3,A4,B4 G3/4 167 17 123
P1,P2,A1,B1,A2,B2 G1 196 20 145
29 W134-0460E
B-8 B-8
30 W134-0460E
B-8 B-8
31 W134-0460E
B-8 B-8
1.Winch selector valve 5.Hexagon socket head bolt 10.Eye bolt 15.O-ring
2.Boom selector valve 6.Main relief valve 11.Plug
(telescoping, elevating) 7.Main relief valve 12.O-ring
3.O-ring 8.Hexagon socket head bolt 13.Overload valve plug
4.O-ring 9.Overload relief valve 14.Plug
Tightening torque
N-m kgf-m ft-lbf
5 M12 63.7 - 65.7 6.5 - 6.7 47 - 48.5
8 M10 44.1 - 49 4.5 - 5 32.5 - 36
11 G1/4 24.5 - 29.4 2.5 - 3 18 - 22
14 G3/8 49 5 36
32 W134-0460E
B-8 B-8
Winch selector valve
33 W134-0460E
B-8 B-8
1.Winch selector valve body 7.Return spring 15.Plug 23.Plain washer

2.Spool (main, aux. winch) 8.Return spring 16.O-ring 24.Spring washer
3.Flow control valve 9.Spring seat 17.Spring retainer 25.Plug
(main winch), (aux. winch) 10.Spool end 18.Check valve 26.O-ring
4.Flow control valve (junction) 11.Pilot cover 19.Spring 27.Plug
5.O-ring 12.Pilot cover 20.Plug 28.Plug
6.Spring seat 13.Orifice 21.O-ring 29.O-ring
14.Spring 22.Hexagon socket head bolt

Tightening torque
N-m kgf-m ft-lbf
Plug
M27×1.5 78.5 - 88.3 8-9 58 - 65
(Main winch), (Aux. winch)
10*1 - 17.7 - 19.6 1.8 - 2 13 - 14.5
2
13* M6 4.9 - 5.88 0.5 - 0.6 3.5 - 4.5
15 M33 98.1 - 118 10 - 12 72.5 - 87
17 - 98.1 - 118 10 - 12 72.5 - 87
20 - 78.5 - 88.3 8-9 58 - 65
22 M8 27.5 - 29.4 2.8 - 3 20 - 22
25 G3/8 39.2 - 49 4-5 29 - 36
27 NPT 1/16 9.81 - 11.8 1 - 1.2 7-9
28 G1/4 24.5 - 29.5 2.5 - 3 18 - 22
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.

34 W134-0460E
B-8 B-8
Boom selector valve (telescoping)
1.Telescoping selector valve 8.Spool end 16.Plug 24.Check valve

body 9.Hexagon socket set screw 17.O-ring 25.Plain washer
2.Spool (telescoping) 10.Steel ball 18.Orifice 26.Spring washer
3.--- 11.--- 19.Spring (flow control valve) 27.Steel ball
4.Spring seat 12.O-ring 20.Plug 28.O-ring
5.Return spring 13.Pilot cover 21.Plug 29.Plug
6.Return spring 14.Hexagon socket head bolt 22.O-ring 30.Flow control valve
7.Spring seat 15.--- 23.Spring 31.Pilot cover

Tightening torque
N-m kgf-m ft-lbf
Plug
M27×1.5 78.5 - 88.3 8-9 58 -65
(telescoping)
8*1 - 17.7 - 19.6 1.8 - 2 13 - 14.5
9*1 M8 11.8 - 13.7 1.2 - 1.4 8.5 - 10
14 M8 27.5 - 29.4 2.8 - 3 20 - 22
16 M33 98.1 - 118 10 - 12 72.5 - 87
2
18* M6 4.9 - 5.88 0.5 - 0.6 3.5 - 4.5
21 - 78.5 - 88.3 8-9 58 - 65
1
29* - 17.7 - 19.6 1.8 - 2 13 - 14
35 W134-0460E
B-8 B-8
Boom selector valve (elevating)
1.Elevating selector valve body 8.Spool end 15.Flow control valve 22.O-ring
2.--- 9.Hexagon socket set screw 16.Plug 23.---
3.Spool (elevating) 10.Steel ball 17.O-ring 24.---
4.Spring seat 11.Pilot cover 18.Orifice 25.Plain washer
5.Return spring 12.O-ring 19.Spring (flow control valve) 26.Spring washer
6.Return spring 13.Pilot cover 20.Plug
7.Spring seat 14.Hexagon socket head bolt 21.Plug

Tightening torque
N-m kgf-m ft-lbf
Overload relief valve
(elevating) M27×1.5 78.5 - 88.3 8-9 58 - 65
Plug
8*1 - 17.7 - 19.6 1.8 - 2 13 - 14.5
1
9* M8 11.8 - 13.7 1.2 - 1.4 8.5 - 10
14 M8 27.5 - 29.4 2.8 - 3 20 - 22
16 M33 98.1 - 118 10 - 12 72.5 - 87
18*2 M6 4.9 - 5.88 0.5 - 0.6 3.5 - 4.5
21 - 78.5 - 88.3 8-9 58 - 65

36 W134-0460E
B-8 B-8
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
5.Backup ring 10.Cap nut 15.Spring 20.Tie up wire

Tightening torque
N-m kgf-m ft-lbf
1 - 28.4 - 30.4 2.9 - 3.1 21 - 22.4
10 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
13 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
14 - 38.2 - 40.2 3.9 - 4.1 28.2 - 29.6
37 W134-0460E
B-8. B-8.
Overload relief valve

(Elevating)
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

Tightening torque
N-m kgf-m ft-lbf
1 - 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
8 M27×1.5 78.5 - 88.3 8-9 58 - 65
13 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
14 M14×1 18.6 - 20.6 1.9 - 2.1 13.7 - 15.2
367-418-60000 △
1
38 W134-0460E
B-9 B-9
Sequence Valve (Pilot Pressure)
B-9 Sequence Valve (Pilot Pressure)

[NOTICE]
1. Structure

Tightening torque
N-m kgf-m ft-lbf
P, V G1/2 58.5 - 68.6 6-7 43 - 51
Dr G3/8 39.2 - 49 4-5 29 - 36
Pi, G G1/4 24.5 - 29.4 2.5 - 3 18 - 22
39 W122-0116E
B-9 B-9
Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)
6
1.Body
2.Filter
3.Filter retainer 5
4.Back pressure regulating valve
5.Pressure reducing valve
6.Hexagon socket head bolt
7.Plug
8.O-ring
9.Plug 4
A-A 1 2 3
IW122-0112E01
Tightening torque
N-m kgf-m ft-lbf
3 G1/2 9.8 - 11.8 1 - 1.2 7.2 - 8.7
6 M6 9.8 - 10.8 1 - 1.1 7.2 - 8
Back pressure regulating valve

(illustrated as 4 in the cross section along the line A-A)
1 2 6 7 3 4 8 5
1.Spring cover
2.Stopper
3.Piston
4.Valve
5.Socket
6.Spring
7.O-ring
8.O-ring
IW122-011004
Tightening torque
N-m kgf-m ft-lbf
1 M24×1.5 58.8 - 68.6 6-7 43.4 - 50.6
40 W122-0116E
B-9. B-9.
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
41 W122-0116E
B-10 B-10
Solenoid Valve (Pilot Pressure)
B-10 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 (24V DC)
101 T1 IW121-067002

Tightening torque
N-m kgf-m ft-lbf
P,T,A1,A2 G1/4 34 - 38 3.5 - 3.9 25 - 28
171 M5 6-8 0.6 - 0.8 4.5 - 6
T1 M8 26 - 32 2.7 - 3.3 20 - 24
42 W121-0674E
B-10. B-10.
Solenoid valve assy
31 1 326 324
P A T
312 361 362 363 861 801 802
IW121-067003
311.Spool 326.Retaining ring 363.O-ring 861. O-ring

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

Tightening torque
N-m kgf-m ft-lbf
802 M6 6.9 - 7.9 0.7 - 0.8 5.1 - 5.8
367-401-00000 △
0
43 W121-0674E
B-11. B-11.
Counterweight Cylinder
B-11 Counterweight Cylinder
[NOTICE]
1. Structure
1.Cylinder 7.Rod 13.Backup ring 19.O-ring

2.--- 8.Rod cover 14.Dust seal 20.Nut
3.--- 9.--- 15.Retaining ring 21.Set screw
4.Piston 10.O-ring 16.Plug
5.plain bearing 11.--- 17.O-ring
6.O-ring 12.Packing 18.Plug
*1 : This dimension indicates the clearance with plug (18) loosened for 3 turns from the fully tightened condition.

Tightening torque
N-m kgf-m ft-lbf
20 M10 20.6 – 23.5 2.1 – 2.4 15.2 – 17.3
21 M8 13.2 – 16.2 1.35 – 1.65 9.7 – 11.9
360-539-70001 △
1
44 W180-0150E
B-12. B-12.
Pilot Check Valve (Counterweight Cylinder)
Applicable serial No. △
1 ：547121 --
B-12 Pilot Check Valve (Counterweight Cylinder)
[NOTICE]
1. Structure
A B
C D
IW115-023001
1.Body 4.Sleeve 7.Check valve 10.Plug

1 2.O-ring Cap seal 5.O-ring 8.O-ring 11.O-ring
3.Piston 6.Backup ring 9.Spring 1 12.Buckup ring ---
Tightening torque
N-m kgf-m ft-lbf
A G1/4 29.4 3 22
B G1/4 29.4 3 22
366-242-30000 △
1
45 W115-0046E
B-13. B-13.
Relief Valve
B-13 Relief Valve
[NOTICE]
1. Structure
1.Body 5.Spring 9.Adjuter 13.O-ring

2.Sleeve 6.Poppet 10.Cap 14.O-ring
3.Valve 7.Spring 11.Locknut 15.O-ring
4.Sheet 8.Plug 12.O-ring 16.Seal
Tightening torque
N-m kgf-m ft-lbf
P, T G1/2 98 10 72
366-068-80000 △
0
366-061-10000 △
0
46 W111-0360E
B-14 B-14
Solenoid Valve (Positive Control)
B-14 Solenoid Valve (Positive Control)

[NOTICE]
1. Structure
Connector
IW121-0671E01
101.Casing
Tightening torque
Sign/Port Thread size
N-m Kgf-m ft-lbf
P, T, A1 G1/4 34 - 38 3.5 – 3.9 25 - 28
171 M5 6-8 0.6 – 0.8 4.5 – 6.0
T1 M6 6.9 - 7.9 0.7 – 0.8 5.1 - 5.8
T2 M8 26 - 32 2.7 – 3.3 20 - 24
47 W121-0941E
B-14. B-14.
Solenoid valve assy
31 1 326 324
P A T
312 361 362 363 861 801 802
IW121-067003
311.Spool 326.Retaining ring 363.O-ring 861. O-ring

312.Sleeve 361.O-ring 801.Solenoid valve
324.Spring 362.O-ring 802.Seal nut
Tightening torque
N-m kgf-m ft-lbf
802 M6 6.9 - 7.9 0.7 - 0.8 5.1 - 5.8
367-401-10000 △
0
48 W121-0941E
B-15. B-15.
Check Valve (Gauge Isolator)
B-15 Check Valve (Gauge lsolator)
[NOTICE]
1. Structure
Hydraulic symbols
P' S
P1 P2 P3 IW116-012001
7 8 1 2 5 4 3 6
P' S
IW116-012002
P1 P2 P3
1. Body 3. Poppet 5. O-ring 7. Plug

2. Plug 4. Spring 6. Screw 8. O-ring
Tightening torque
Sign / port Thread size Remark
N-m kgf-m ft-lbf
P1, P2, P3, P’ G 1/4 29.4 3 22
G 3/8 49.0 5 36
S
TT-300XL-1
M18×1.5 127 - 147 13 - 15 93 - 108
only
Mounting bolt M8 13 - 15 1.3 - 1.5 9.6 - 11.0
366-244-50000 △
2
366-251-20000 △
1
49 W116-0125E
C C
Outrigger System
Contents
C-1 Outrigger System............................. 1 C-4 Solenoid Valve (Slide/Jack)

(TOKIMEC)..............................10
1. Function ..................................................... 1
1.1 Solenoid control valve (outrigger)............... 1 1. Structure .................................................. 10
1.2 Solenoid valve (slide/jack).......................... 1
1.3 Jack cylinder............................................... 1
1.4 Pilot check valve C-5 Solenoid Valve (Slide/Jack)
(jack cylinder retraction prevention) ..... 1 (NACHI)...................................11
1.5 Extension cylinder ...................................... 1
1.6 Check valve 1. Structure ...................................................11
(slide/jack extension prevention).......... 1
2. Hydraulic system description ..................... 1 C-6 Jack Cylinder..................................12

2.1 Outrigger extension operation .................... 1
2.2 Outrigger retraction operation .................... 1 1. Structure .................................................. 12
3. Electric system........................................... 2
3.1 Outrigger operation inside operation cab ... 2 C-7 Pilot Check Valve
(Jack Cylinder Retracting
Prevention) .............................13
C-2 Solenoid Control Valve
(Outrigger)................................ 3 1. Structure .................................................. 13
1. Structure .................................................... 3
1.1 General view............................................... 3 C-8 Extension Cylinder.........................14
1.2 Body assy ................................................... 5
1.3 P cover assy ............................................... 7 1. Structure .................................................. 14
C-3 Solenoid Valve (Slide/Jack) C-9 Check Valve

(UCHIDA) .................................. 9 (Slide/Jack Extending
Prevention) .............................15
1. Structure .................................................... 9
1. Structure .................................................. 15
i
C-1 C-1
Outrigger System
C-1 Outrigger System 2. Hydraulic system description

(Refer to hydraulic circuit in chapter Z.)
1. Function
Extension/retraction of outriggers is controlled by
1.1 Solenoid control valve the solenoid control valve (extension/retraction)
(outrigger)
and four solenoid valves (slide/jack)
This valve selects the outrigger extension and
retraction for outrigger circuit. A relief valve is built 2.1 Outrigger extension operation
into this valve to control the circuit pressure. 1. The pressurized oil from the pump (P4) passes
through the solenoid control valve and solenoid
1.2 Solenoid valve (slide/jack)
valve (slide/jack). And only the cylinder selected
This valve selects the hydraulic circuit of outrigger by the solenoid valve (slide/jack) extends.
system between the extension cylinder and jack
2. Back pressure is generated in the return oil by the
cylinder when the outriggers are operated.
check valve (slide/jack extension prevention). The
1.3 Jack cylinder return oil then passes through the solenoid control
valve (extension/retraction) and returns to the
This cylinder acts to set the crane in crane tank.
operation configuration.
2.2 Outrigger retraction operation
1.4 Pilot check valve
(jack cylinder retraction prevention) 1. The pressurized oil from pump (P4) passes
through the solenoid control valve
This safety device is attached to each jack
(extension/retraction) and check valve (slide/jack
cylinder, and fully locks the holding pressure in the
extension prevention), and operates on the
jack cylinder for crane operation configuration. It
retraction side of the slide and jack cylinders. Only
maintains the crane in operating configuration
the cylinder selected by the solenoid valve
even if the piping between the solenoid valve
retracts.
(slider/jack) and jack cylinder is damaged.
2. The return oil passes through the solenoid control
1.5 Extension cylinder valve (extension/retraction) and returns to the
tank.
This cylinder acts to extend and retract the
outrigger inner case.
1.6 Check valve

(slide/jack extension prevention)
This valve prevents extension of the jack and

extension cylinders during traveling by generating
back pressure in the return circuit.
1 WC02-0350E
C-1. C-1.
Outrigger System
3. Electric system
The control device of the outrigger system is

provided inside the cab.
3.1 Outrigger operation inside operation cab
1. Turn the PTO switch to "ON". Engage the PTO

clutch to take in the pressurized oil from the P4
pump.
2. When the outrigger operation is made inside the

cab, the contacts of the relay output RY1–7 in the
MDT (multiple data transmitter) are turned
ON/OFF and the corresponding outrigger
extends/retracts.
3. If the shift lever is out of N position (*1), however,

no outrigger can be extended and retracted
because all the contacts of the relay output RY1–7
are OFF.
(*1) : Detected by upper input Di6 (N) of MDT.
2 WC02-0350E
C-2 C-2
Solenoid Control Valve (Outrigger)
C-2 Solenoid Control Valve (Outrigger)

[NOTICE]
1. Structure
1.1 General view
Connector
+- (+): Red
(-): Yellow
IW121-0542E01
3 W112-0300E
C-2 C-2
1.Body assy 15.T cover assy 22.Nut 100.plug

10.P cover assy 21.Stud bolt 23.Spring washer
Tightening torque
N-m kgf-m ft-lbf
P, T, L G1 196 20 145
A, B G3/4 167 17 123
G G1/4 29.4 3 22
22 - 74 - 83 7.5 - 8.4 54.6 - 61.2
4 W112-0300E
C-2 C-2
1.2 Body assy
5 W112-0300E
C-2 C-2
1.Body 7.O-ring 13. O-ring 19.Spring

2.Spool 8.O-ring 14. O-ring 20.Spool
3.Plug 9.plug 15.Hexagon socket head bolt 21.Barrel
4.Plunger 10.Solenoid 16.Hexagon socket head bolt
5.Spring 11.Cover 17.plug
6.O-ring 12.Orifice 18.Spring seat
Tightening torque
N-m kgf-m ft-lbf
3 - 78 - 98 8 - 10 57.5 - 72.3
Tube section - 17 - 20 1.7 - 2 12.5 - 14.8
10
Nut section - 2.9 - 3.9 0.3 - 0.4 2.1 - 2.9
12 *1 M4 0.78 - 1.0 0.08 - 0.1 0.6 - 0.74
15 M8 28 - 35 2.9 - 3.6 20.7 - 25.8
1
16 M8 28 - 35 2.9 - 3.6 20.7 - 25.8
6 W112-0300E
C-2 C-2
1.3 P cover assy
7 W112-0300E
C-2. C-2.
1.Cover 5.Plug 9.O-ring 13.Distance pieace

2.Spool 6.O-ring 10.O-ring 14.Relief valve
3.Spring seat 7.O-ring 11.Plug 15.Plug
4.Spring 8.O-ring 12.Plug 16.Orifice
Tightening torque
N-m kgf-m ft-lbf
5 - 30 - 37 3.1 - 3.8 22 - 27
12 - 62 - 82 6.3 - 8.4 46 - 60.5
14 - 78 - 88 8-9 58 - 65
1 *1
16 M6 2.4 - 2.9 0.24 - 0.3 1.8 - 2.1
Relief valve
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
366-460-20001 △
0
8 W112-0300E
C-3. C-3.
Solenoid Valve (Slide/Jack) (UCHIDA)
C-3 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 (24V DC)

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

Tightening torque
N-m kgf-m ft-lbf
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
T2 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
366-478-90000 △
1
9 W121-0265E
C-4. C-4.
Solenoid Valve (Slide/Jack) (TOKIMEC)
C-4 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 (24V DC) 7.Body 10.Centering washer

2.O-ring 5.Packing 8.O-ring 11.Spring
3.Solenoid core (24V DC) 6.O-ring 9.Spool 12.Spring pin
Tightening torque
N-m kgf-m ft-lbf
1 - 8.8 - 10.8 0.9 - 1.1 6.5 - 8
3 - 18 - 22 1.8 - 2.2 13.3 - 16.2
Mounting bolt M5 6.9 - 7.8 0.7 - 0.8 5.1 - 5.8
366-465-40000 △
1
10 W121-0275E
C-5. C-5.
Solenoid Valve (Slide/Jack) (NACHI)
C-5 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 (24V DC) 16.O-ring

2.Spool 7.Nut 13.O-ring
3.Retainer 8.Rod 14.O-ring
4.Retainer 9.Solenoid guide (24V DC) 15.O-ring
Tightening torque
N-m kgf-m ft-lbf
7 - 5-7 0.5 - 0.7 3.7 - 5.1
Mounting bolt M5 6-8 0.6 - 0.8 4.4 - 5.9
366-457-31000 △
1
11 W121-0285E
C-6. C-6.
Jack Cylinder
C-6 Jack Cylinder
[NOTICE]
1. Structure
1.Cylinder 6.Stopper 11.O-ring 16.Backup ring

2.Rod 7.Set screw 12.Backup ring 17.Dust seal
3.Bolt 8.Piston 13.O-ring 18.Damper ring
4.Spring washer 9.Packing 14.Rod cover assy 19.Plain bearing
5.Bolt 10.Backup ring 15.Packing
*1: Face the notch or the lip toward the pressurized side.
*2: Apply Three-bond 1104 or equivalent.
Tightening torque
N-m kgf-m ft-lbf
3,5 M10 22 - 25 2.2 - 2.5 16 - 18
7 M8 13.2 - 16.2 1.35 - 1.65 9.7 - 11.9
Mounting bolt M24 588 - 666 60 - 68 434 - 492
360-367-10000 △
0
12 W151-0520E
C-7. C-7.
Pilot Check Valve (Jack Cylinder Retracting Prevention)
C-7 Pilot check Valve (Jack Cylinder Retracting Prevention)
[NOTICE]
1. Structure
9
C D A B
C D
IW115-023001
5 4 10 6 7,8
A B 1
IW115-023002
1.Valve body 4.Valve 7.O-ring 10.Seat

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

Tightening torque
N-m kgf-m ft-lbf
A G1/4 29.4 3 22
B G1/4 29.4 3 22
Mounting
M10 43 - 49 4.5 - 5 32 - 36
bolt
366-250-30000 △
0
13 W115-0233E
C-8. C-8.
Extension Cylinder
C-8 Extension Cylinder
[NOTICE]
1. Structure
1.Cylinder 4.Piston 7.O-ring 10.Dust seal

2.Nut 5.Rod 8.Packing 11.O-ring
3.Seal ring 6.Rod cover 9.Backup ring
*1 : Apply adhesive (Loctite 638) to the 3rd - 5th threads of rod [5] beyond the tip of the piston [4].

Tightening torque
N-m kgf-m ft-lbf
A, B, C G3/8 49 5 36
D, E G1/4 29.4 3 22
2 M20 176 - 196 18 - 20 130 - 145
360-435-40000 △
2
14 W153-0260E
C-9. C-9.
Check Valve (Slide/Jack Extending Prevention)
C-9 Check Valve (Slide/Jack 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 kgf-m ft-lbf
P1 G1/2 98 10 72
P2 G1/2 98 10 72
366-245-40000 △
0
15 W116-0114E
D
Swing System D
Contents
D-1 Swing System................................... 1 D-5 Swing Assembly.............................12
1. Function ..................................................... 1 1. Structure .................................................. 12

1.1 Swing drive unit (hydraulic motor and
swing speed reducer)........................... 1 2. Swing bearing mounting bolt ................... 13
1.2 Hydraulic pilot control valve (swing) ........... 1 2.1 Bearing inner ring bolts .............................13
1.3 Solenoid valve (swing brake release) ........ 1 2.2 Bearing outer ring bolts.............................14
1.4 Swing free function..................................... 1
2. Hydraulic system description ..................... 1
D-2 Hydraulic Pilot Control Valve

(Swing) ..................................... 2
1. Structure .................................................... 2
D-3 Hydraulic Motor (Swing).................. 8
1. Structure .................................................... 8
D-4 Swing Speed Reducer ................... 10
1. Structure .................................................. 10
i
D-1. D-1.
Swing System
D-1 Swing System 2. Hydraulic system description

1. Function
1. The hydraulic pilot control valve controls the
1.1 Swing drive unit (hydraulic motor and swing direction of the pressurized oil flowing in. This
speed reducer) pressurized oil is sent to the hydraulic motor of the
This unit incorporates a hydraulic motor with wet swing drive unit for left or right swing.
brake and a three-stage planetary speed reducer.
2. The rotational force of the hydraulic motor is
It converts the pressurized oil sent by the pump
transmitted through the speed reducer to the
into low-speed, high-torque rotational force to
swing bearing gears, swinging the superstructure.
drive the superstructure.
3. The spring-type swing brake is installed inside the
1.2 Hydraulic pilot control valve (swing) swing drive unit hydraulic motor.
This valve is the hydraulic pilot control valve. It

switches the direction of the pressurized oil and
controls the revolution of the hydraulic motor.
1.3 Solenoid valve (swing brake release)
This valve is installed inside the solenoid valve

(pilot pressure). When energized, this valve sends
pressurized oil to the swing brake cylinder, and
the swing brake is released.
1.4 Swing free function
While the swing free/lock selection switch is

shifted to the “ON” side, the swing free function is
activated.
You can perform the operations that follow while

the swing free function is activated.
(1) When a load is hoisted up, the superstructure
turns in the direction of the load.
(2) When the boom is swung with a load lifted and
the control lever is returned to the neutral
position, the boom continues swinging by the
inertia force.
1 WD02-0410E
D-2 D-2
Hydraulic Pilot Control Valve (Swing)
D-2 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
2 W134-0126E
D-2 D-2
Tightening torque
N-m kgf-m ft-lbf
P, R G1 200 - 240 20 - 24 145 - 174
AM, BM G3/4 150 - 180 15 - 18 108 - 130
G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 3.5 - 3.9 25 - 28
Dr G1/4 34 - 38 3.5 - 3.9 25 - 28
3 W134-0126E
D-2 D-2
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
4 W134-0126E
D-2 D-2
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
5 W134-0126E
D-2 D-2
Cross section along the line C-C (in A-A section)
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
6 W134-0126E
D-2. D-2.
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.Hexagon socket head bolt 521.Spring 702.Solenoid relief valve
235.Spring 352.Hexagon socket head bolt 522.Spring 703.Relief valve
241.O-ring 353.Hexagon socket head bolt 551.Cap 706.Solenoid valve (24V DC)
Tightening torque
N-m kgf-m ft-lbf
151 R1/4 20 - 24 2 - 2.4 14 - 17
152, 252 NPTF1/16 6-8 0.6 - 0.8 4.5 - 6
211 *1 M8 16 - 18 1.6 - 1.8 12 - 13
251 *1 M5 3.5 - 4.5 0.35 - 0.45 2.5 - 3.5
253 G1/4 34 - 38 3.5 - 3.9 25 - 28
261 M22 39 - 49 4-5 29 - 36
351, 352, 353 M6 10.5 - 13.5 1.05 - 1.35 8 - 10
401 M24 58 - 70 5.9 - 7.1 43 - 51
450 M10 14.5 - 17.5 1.45 - 1.75 10.5 - 12.5
551 M33 190 - 210 19 - 21 140 - 155
552 M24 120 - 140 12 - 14 88 - 103
641 G1/8 8 - 10 0.8 - 1 6-7
701 M30 110 - 130 11 - 13 81 - 96
702 M22 39 - 49 4-5 29 - 36
703 M27 69 - 79 7-8 51 - 58
706 M22 39 - 49 4-5 29 - 36
367-416-60000 △
0
366-461-30000 △
1
366-489-60000 △
0
366-489-70000 △
0
366-409-60000 △
0
367-416-20000 △
0
7 W134-0126E
D-3 D-3
Hydraulic Motor (Swing)
D-3 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
8 W102-0503E
D-3. D-3.
Hydraulic Motor (Swing)
101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring

106.Spacer 123.Guide plate 437.Locking ring 491.Oil seal
111.Cylinder 124.Shoe plate 438.Locking 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.Front cover 464.Plug 742.Friction plate
118.Spacer 401.Hexagon socket head bolt 471.O-ring 743.Separator plate
121.Piston 432.Stop ring 472.O-ring
Tightening torque
N-m kgf-m ft-lbf
PB G1/4 36 3.7 26.6
A, B G3/4 167 17 123
DR G1/2 108 11 80
464 G1/4 36 3.7 26.6
401 M20 430 43.8 317
366-635-90000 △
0
9 W102-0503E
D-4 D-4
Swing Speed Reducer
△
2 ：475394 --, 546434 --
D-4 Swing Speed Reducer Applicable serial No. △

1 ：475377 --, 546080 --
[NOTICE]
1. Structure
10 W511-0244E
D-4. D-4.
Swing Speed Reducer
[NOTICE]
Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer
bracket (19). △ 2 (2)
Inject SHELL ALBANIA S3 grease to the mating faces of the retainer (34) and the spacer (35).
Enclose SHELL ALBANIA S3 grease with the roller bearing (36) (3). △ 2
After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into
casing(4).
Apply lithium based grease to the inner circumference of oil seal(5).
The amount of the gear oil is approx. 3.8 L (1 gal).
Do not disassemble the king pins (8), (27) nor spacer (13).
1.Spur gear 10.Bearing washer 19.Bracket 28.Sun gear

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

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

1 36.Roller bearing △
2
Tightening torque
N-m kgf-m ft-lbf
16 M10 49 5 36
20 M16 206 21 152
30 M10 24.5 2.5 18
Mounting bolt (*1) M18 294 - 343 30 - 35 217 - 253
*1: Apply torque control agent to threaded sections.
360-816-51000 △
3
11 W511-0244E
D-5 D-5
Swing Assembly
D-5 Swing Assembly

[NOTICE]
1. Structure
1.Bolt
2.Plain washer
[NOTICE] Thread size and tightening torque

Apply torque control agent to the threaded sections
of the bolts.
Tightening torque
Install the plain washer, orienting its chamfer on the Sign / port
Thread
internal periphery as shown below. size
N-m kgf-m ft-lbf
1 M18 294 - 343 30- 35 217 - 253
12 W514-0440E
D-5 D-5
Swing Assembly
2. Swing bearing mounting bolt
2.1 Bearing inner ring bolts
1. Support 4. Spring washer 7. Bolt (L = 140 mm)

2. Support 5. Plain washer 8. Bolt
3. Bolt 6. Bolt (L = 170 mm) 9. Plain washer
[NOTICE]
Install the bearing inner ring with the "S" mark
facing the rear of the carrier.
Apply torque control agent to the threaded sections Tightening torque
of the bolts. Thread
Sign / port
size
Install the plain washer, orienting its chamfer on the N-m kgf-m ft-lbf
internal periphery as shown below.
6
(44 points)
1620 - 165 - 1195 -
M30
1810 185 1335
7
(4 points)
7.4 -
3 M12 74 - 82 56 - 60
8.4
13 W514-0440E
D-5. D-5.
Swing Assembly
2.2 Bearing outer ring bolts
1.Bolt (L=152mm)
2.Bolt (L=175mm)
3.Plain washer (50points)
4.Nut (5points)
5.Reamer bolt (L=176mm)
6.Plain washer (2points)
[NOTICE]
Apply torque control agent to the threaded sections
of the bolts.
Install the plain washer, orienting its chamfer on the Tightening torque
internal periphery as shown below. Thread
Sign / port
size
N-m kgf-m ft-lbf
1
(42 points)
2 1177 - 120 - 868 -
M27
(3 points) 1275 130 940
5
(2 points)
343-009-20000 △
0
347-629-12000 △
0
342-313-80000 △
1
14 W514-0440E
E
Boom Elevating System
E
Contents
E-1 Elevating System ............................. 1 E-4 Pressure Sensor...............................7
1. Function ..................................................... 1 1. Structure .................................................... 7

1.1 Elevating cylinder ....................................... 1 1.1 Internal section............................................7
1.2 Counterbalance valve................................. 1 1.2 Connection diagram....................................7
1.3 Pressure sensor ......................................... 1 1.3 Specification................................................7
1.4 Elevation slow stop..................................... 1 1.4 Conversion used by AML from
sensor output voltage into
2. Hydraulic system description ..................... 1 hydraulic pressure ................................7
E-2 Elevating Cylinder............................ 2
1. Structure .................................................... 2
E-3 Counterbalance Valve

(Elevating) ................................ 4
1. Structure .................................................... 4
2. Function ..................................................... 6
2.1 When control valve is at the neutral
position ................................................. 6
2.2 While actuator is being pushed up ............. 6
2.3 While actuator descends ............................ 6
i
E-1. E-1.
Elevating System
E-1 Elevating System 3. When the boom is being raised, the circuit
pressure is controlled by relief valve in the
1. Function hydraulic pilot control valve. When the boom is
being lowered, the circuit pressur is controlled by
1.1 Elevating cylinder port relief valve. This port relief valve cuts the
initial surge pressure, and prevents boom hunting.
This cylinder elevates the boom.
Pressure sensors of the extension/retraction are
attached on this cylinder.
1.2 Counterbalance valve
When the elevating cylinder is being retracted,

this valve prevents acceleration due to the load
weight, and provides a boom lowering speed that
corresponds to the amount of oil supplied to the
cylinder.
It also prevents the cylinder from retracting if the
piping between this valve and the hydraulic pilot
control valve is damaged.
1.3 Pressure sensor
They convert the extension and retraction

pressure into the electric signal (voltage).
1.4 Elevation slow stop
The boom elevation slow stop function reduces

load sway by decelerating the boom elevating
speed when the boom elevating is being stopped.
2. Hydraulic system description

(Refer to hydraulic circuit in Chapter Z.)
1. When the boom is being elevated, the pressurized

oil sent from the hydraulic pilot control valve
(elevating block) passes through the
counterbalance valve and is supplied to the
extension side of cylinder.
2. When the boom is being lowered, the pressurized

oil is supplied directly to the retraction side of
cylinder. At the same time, it acts as the
counterbalance valve pilot pressure, and the
counterbalance valve opens in accordance with
the amount of oil supplied.
1 WE02-0370E
E-2 E- 2
Elevating Cylinder
E-2 Elevating Cylinder

[NOTICE]
1. Structure
2 W155-0420E
E-2. E-2.
Elevating Cylinder
1.Cylinder 12.Damper ring 23.O-ring 34.O-ring

2.--- 13.Packing 24.Pipe 35.Orifice
3.Plain bearing 14.Backup ring 25.Pipe 36.Grease nipple
4.Packing 15.Dust seal 26.T-fitting 37.Pipe
5.Backup ring 16.--- 27.Pipe 38.O-ring
6.Backup ring 17.--- 28.Clamp assy 39.Head cover
7.O-ring 18.--- 29.Sleeve 40.Backup ring
8.Piston 19.Support 30.Bolt 41.Set screw
9.Rod assy 20.Fitting 31.Spring washer 42.---
10.--- 21.Fitting 32.Counter balance valve assy 43.Rod cover assy
11.O-ring 22.Fitting 33.Fitting 44.Retaining ring
*1:Face the notch or the lip toward the pressurized side.

*2:Apply Three-bond 1401 or equivalent. Do not close the hole [ 0.6 mm (0.024 in) ].
*3:Apply Three-bond 1104 or equivalent.
*4:Apply KONISHI car body sealer or equivalent (waterproof), however it is not possible to paint on the rubber
side of dust seal.
*5:After tightening, punch (2 places).
*6:Apply NEVER SEEZ or equivalent to threaded section.
Tightening torque
N-m kgf-m ft-lbf
A G3/4 108 - 123 11 - 12.5 80 - 90
B G1/2 54 - 64 5.5 - 6.5 40 - 47
C, D G3/8 25 - 30 2.5 - 3 18.5 - 22.0
30 M8 23.5 - 27.4 2.4 - 2.8 17 - 20
41 M8 13.2 - 16.2 1.35 - 1.65 9.7 - 12
360-282-50000 △
4
360-282-10000 △
4
3 W155-0420E
E-3 E- 3
Counterbalance Valve (Elevating)
E-3 Counterbalance Valve (Elevating)

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

2-1.Valve seat 2-9.Spool 3-1.Valve seat 4.Orifice
2-2.O-ring 2-10.Orifice 3-2.O-ring 5.Filter element
2-3.O-ring 2-11.Steel ball 3-3.O-ring 6.Snap ring
2-4.Backup ring 2-12.Spring 3-4.Backup ring 7.Stopper
2-5.O-ring 2-13.Holder 3-5.Poppet
2-6.Backup ring 2-14.Spring 3-6.Spring
2-7.O-ring 2-15.Cap 3-7.Cap
4 W119-0213E
E-3 E- 3
Tightening torque
N-m kgf-m ft-lbf
A G3/4 167 17 123
P.P G3/8 49 5 36
2-1 - 177 - 196 18 - 20 130 - 145
2-15 - 127 - 147 13 - 15 94 - 108
3-1 - 108 - 127 11 - 13 80 - 94
3-7 - 59 - 78 6-8 43 - 58
Mounting bolt M8 23.5 - 27.4 2.4 - 2.8 17 - 20
5 W119-0213E
E-3. E-3.
2. Function
a
P.P B
b
A
IW119-021003
This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the 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
6 W119-0213E
E-4. E-4.
Pressure Sensor
E-4 Pressure Sensor

[NOTICE]
1. Structure
1.1 Internal section
1. Joint (G3/8) Circuit diagram

2. O-ring
3. Diaphragm
4. Feed-through condenser
5. Connector
6. Circuit (board)
1.2 Connection diagram

Extension side (361-801-10000) Retraction side (361-801-60000)
1.3 Specification
Pressure sensor Pressure sensor AML control
Working power
1 Pressure range 0 - 35 MPa 4 5.0 ± 0.5V (DC) 4.5V DC
supply voltage Vs
Permissible max. Max. power supply
2 52.5 MPa 5 6.0V (DC) -
pressure voltage
Transmission 0.5 - 4.5V (DC) 0.45 - 4.05V DC
3 3 wire system 6 Output voltage
system (Vs=5V DC) (Vs=4.5V DC)
1.4 Conversion used by AML from sensor output voltage into hydraulic pressure
361-801-60000 △
0
Output voltage ( V DC) = 3.6 / 35×P + 0.45 (P: MPa) 361-801-10000 △
1
7 W337-0013E
F
Winch System
F
Contents
F-1 Winch System .................................. 1 3. Principle of operation................................11

3.1 When control valve is in neutral................ 11
1. Function ..................................................... 1 3.2 Hoisting up ................................................ 11
1.1 Hydraulic motor .......................................... 1 3.3 Hoisting down ........................................... 11
1.2 Counterbalance valve................................. 1
1.3 Hydraulic valve (winch brake) .................... 1
1.4 Pressure sensor (for gauge isolator).......... 1 F-5 Hydraulic Valve
(Winch Brake Release) ..........12
1. Structure .................................................. 12
F-2 Winch ................................................ 2

F-6 Accumulator (Winch Brake) ..........14
1. Structure .................................................... 2
1.1 General view............................................... 2 1. Structure .................................................. 14
1.2 Reducing assy ............................................ 4
F-7 Pressure Sensor.............................15

F-3 Hydraulic Motor (Winch) ................. 6
1. Structure .................................................. 15
1. Structure .................................................... 6 1.1 Internal section..........................................15
1.2 Connection diagram..................................15
2 Air bleeding procedure............................... 8 1.3 Specification..............................................15
1.4 Conversion used by AML from
sensor output voltage into
F-4 Counterbalance Valve (Winch) ....... 9 hydraulic pressure ..............................15
1. Structure .................................................... 9
2. Function ................................................... 10
2.1 Balancing and holding functions............... 10
2.2 Overload relief function ............................ 10
i
F-1 F-1
Winch System
F-1 Winch System 2. Hydraulic system description

(Refer to hydraulic circuit in Chapter Z.)
1. Function
[NOTICE]
1.1 Hydraulic motor
The main and auxiliary winches use control system
1. Energy of high pressure oil supplied from the of almost the same type. The following describes
the operation of the main winch control system.
pump is converted into rotational force of the
winch motors and transmitted to speed reducers. 1. Two speeds (1st/2nd) are available for both
2. Variable-displacement swash-plate type axial hoist-up and hoist-down operation.
piston motors are employed in this system. Each 2. While only the main winch is operated at the 1st
hydraulic motor has a built-in mechanical wet speed, only the pressurized oil from the pump
multi-disc brake. (P1) is used and the oil from the pump (P2) is
1.2 Counterbalance valve returned to the tank.
1. During hoisting-down, back pressure is applied to 3. While only the main winch is operated at the 2nd
the return-side circuit, preventing the winch from speed, the pressurized oil from the pump (P1) and
accelerating under the weight of the load. the pressurized oil from the pump (P2) via the
Hoist-down speed is determined by the amount of merging flow control valve merge, then the
oil supplied to the hydraulic motor. merged oil is supplied to the valve block for the
main winch.
2. When the lever is operated abruptly during
hoisting, high trapping pressures are generated in 4. The inlet pressure and outlet pressure affect the
the winch between the winch motor and flow control valve for the main winch. The oil
counterbalance valve. At this time, the overload whose amount corresponds to the operated stroke
relief valve opens, allowing pressure to return to of the main winch lever is supplied to the hydraulic
the tank and preventing damage to the device. motor for the main winch.
1.3 Hydraulic valve (winch brake)
During hoisting, the operating pressure of the

hydraulic pilot control valve switches this valve.
This directs accumulator pressure to the winch
automatic brake cylinder, releasing the automatic
brake.
1.4 Pressure sensor (for gauge isolator)
It detects the highest circuit pressure among three

circuits connected to the check valve (gauge
isolator), and sends the voltage corresponding to
the highest circuit pressure to the AML.
1 WF02-0490E
F-2 F-2
Winch
F-2 Winch
[NOTICE]
1. Structure
1.1 General view
2 W526-0382E
F-2 F-2
Winch
1.Air breather 5.Plug 9.Drum 13.Bearing stand

2.Coupling 6.Support 10.Bolt
3.Long nipple 7.Elbow joint 11.Ball bearing
4.Bolt 8.Reducer assy 12.Snap ring
Tightening torque
N-m kgf-m ft-lbf
4 (*1) M22 617 63 455
10 (*1) M16 215 22 159
T1 (Mounting bolt) M24 632 64.5 466
T2 (Mounting bolt) M20 431 44 318
(*1): Apply THREE-BOND 1305 to threaded sections.
3 W526-0382E
F-2 F-2
Winch
1.2 Reducer assy
3 2 1 29 28 27 26 25
*2
*1
4
5
*3
7
10
11
12 24
13,14
15 16 17 18 19 20 21 22 30
23 IW526-029002
4 W526-0382E
F-2. F-2.
Winch
[NOTICE]
(*1):Apply THREE-BOND 1215 to the mating face of the end cover(12) and the wheel(15).
(*2) (*3):When installing the oil seals(26), apply THREE-BOND 1215 to the external periphery and inject
lithium based grease to the internal periphery.
Do not disassemble the king pin(6), the king pin(20) and the sleeve(27).
1.Carrier 9.Sun gear 17.Plate 25.Bushing

2.Plate 10.Thrust plate 18.Idle gear 26.Oil seal
3.Planetary gear 11.Sun gear 19.Needle roller bearing 27.Sleeve
4.Thrust plate 12.End cover 20.King pin 28.Snap ring
5.Snap ring 13.Bolt 21.Plate 29.Ball bearing
6.King pin 14.Spring washer 22.Snap ring 30.Plug
7.Needle roller bearing 15.Wheel 23.Plug
8.Plate 16.Carrier 24.Spindle
Tightening torque
N-m kgf-m ft-lbf
13 (*1) M8 24 - 27 2.4 - 2.8 18 - 20
(*1): Apply THREE-BOND 1303 to threaded sections.
360-737-20000 △
0
5 W526-0382E
F-3 F-3
Hydraulic Motor (Winch)
F-3 Hydraulic Motor (Winch)
[NOTICE]
1. Structure

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

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

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

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

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

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

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

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

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

automatically adjust the oil passage area in land d
to prevent the load from falling at speeds faster
than the motor drive speed.
366-633-10050 △
0
11 W119-0561E
F-5 F-5
Hydraulic Valve (Winch Brake Release)
F-5 Hydraulic Valve (Winch Brake Release)
[NOTICE]
1. Structure
12 W123-0390E
F-5. F-5.
Hydraulic Valve (Winch Brake Release)
1.Body 6.Cover B 11.O-ring 16.Bleeder

2.Spool A 7.Spool B 12.O-ring 17.Cap
3.Adapter 8.Stopper 13.O-ring
4.Spring A 9. --- 14.Plug
5.Cover A 10.Plug 15.Hexagon socket head bolt

Tightening torque
N-m Kgf-m ft-lbf
A1,A2,B1,B2 G 1/4 29.4 3 22
PA1,PA2,PB1,PB2,
G 1/4 17.4 1.8 12.8
C1,C2,T,DR,Ac
10 G 3/8 45 - 55 4.6 - 5.6 33.2 - 40.6
14 NPTF 1/6 6-8 0.6 - 0.8 4.4 - 6
15 M6 10.5 - 13 1.1 - 1.3 7.7 - 9.6
16 M8 11 - 13 1.1 - 1.3 8 - 9.6
Mounting bolt
M10 21.6 - 24.5 2.2 - 2.5 16 - 18
(2 places)
367-416-30000 △
1
13 W123-0390E
F-6. F-6.
Accumulator (Winch Brake)
F-6 Accumulator (Winch Brake)
1. Structure
1.Shell 3.Valve poppet 5.Seal ring 7.Protecting cap

2.Diaphragm 4.Retainer 6.Valve screw
Tightening torque
N-m kgf-m ft-lbf
Piping mounting
G1/4 29.4 3 22
section
366-733-00000 △
0
14 W182-0090E
F-7. F-7.
Pressure Sensor
F-7 Pressure Sensor

[NOTICE]
1. Structure
1.1 Internal section
1. Joint (G3/8)
Circuit
2. O-ring
3. Diaphragm
4. Feed-through condenser
5. Connector
6. Circuit (board)
1.2 Connection diagram
1.3 Specification
Pressure sensor Pressure sensor AML control
Pressure Working power
1 0 - 29.4 MPa 4 5.0 ± 0.5V (DC) 4.5V DC
range supply voltage Vs
Permissible Max. power
2 44.1 MPa 5 6.0V (DC) -
max. pressure supply voltage
Transmission 0.5 - 4.5V (DC) 0.45 - 4.05V DC
3 3 wire system 6 Output voltage
system (at Vs=5V DC) (at Vs=4.5V DC)
1.4 Conversion used by AML from sensor output voltage into hydraulic pressure
Output voltage ( V DC) = 3.6 / 29.4×P + 0.45 (P: MPa) 361-801-30000 △

0
15 W337-0022E
G
Boom Telescoping System
Contents G
G-1 Telescoping System ........................ 1 3. Check ..................................................... 15
3.1 Boom ............................................................15
1. Function ..................................................... 1 3.2 Slide plate .....................................................15
1.1 Telescoping cylinder....................................... 1 3.3 Sheave..........................................................15
1.2 Counterbalance valve .................................... 1 3.4 Boom telescoping wire rope .........................15
1.3 Hose reel........................................................ 1
1.4 Hydraulic valve (top cylinder selection).......... 1 4. Reassembly............................................. 15
1.5 Hydraulic valve (for protection of top cylinder 4.1 Greasing .......................................................15
retraction) ............................................. 1 4.2 Installing anti-buckling bolts for telescoping
1.6 Jib lock pin cylinder ........................................ 1 cylinders..............................................15
1.7 Jib offset cylinder ........................................... 1
1.8 Solenoid control valve (jib set) ....................... 1 5. Adjustment............................................... 16
1.9 Solenoid control valve (jib set and 5.1 Boom fitting and shim adjustment ................16
counterweight cylinder) ........................ 1 5.1.1 Shim adjustment at lower oblique sides
1.10 Pilot check valve (jib set)................................ 1 of the rear end ....................................16
5.1.2 Shim adjustment at the sides
2. Boom telescoping mechanism................... 2 of the rear end ....................................16
5.1.3 Slide plate adjustment at the lower part
3. System description .................................... 3 of the top end......................................17
3.1Extension circuit ................................................ 3 5.1.4 Clearance adjustment at top
3.2Retraction circuit ............................................... 4 of the boom head................................18
5.1.5 Shim adjustment at top
of the boom tail end ............................18
G-2 Boom (Five-Section Boom) ............. 5 5.2 Adjustment of boom telescoping
wire ropes ...........................................18
1. Structure .................................................... 5
1.1 Boom assy ..................................................... 5 6. Test ..................................................... 19
6.1 Operation Test ..............................................19
2. Disassembly .............................................. 8 6.2 Boom lateral warp test..................................19
2.1 Removing the 2nd–top boom sections........... 8 6.3 Other functional test .....................................19
2.2 Removing the 3rd–top boom sections ........... 9
2.3 Removing the 4th–top boom sections.......... 12
2.4 Removing the top boom section .................. 13
i
G-3 Jib ................................................ 20 G-8 Jib Lock Pin Cylinder.....................36
1. Structure .................................................. 20 1. Structure .................................................. 36

1.1 Location of jib ............................................... 20
1.2 Jib main body ............................................... 22
G-9 Jib Offset Cylinder .........................37
2. Adjustment............................................... 24
2.1 Adjusting jib 1-2 connecting spring pin ........ 24 1. Structure .................................................. 37
2.2 Adjusting jib inclination................................. 24
2.3 Adjusting inclination of jib 2.......................... 25
G-10 Solenoid Control Valve (Jib Set)...38
G-4 Telescoping Cylinder..................... 26 1. Structure .................................................. 38
1. Structure .................................................. 26
G-11 Pilot Check Valve (Jib Set) ............44
G-5 Counterbalance Valve 1. Structure .................................................. 44

(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

1.6 Jib lock pin cylinder
1. Function This cylinder fixes the jib to the bracket on the
boom to prevent fall of the jib due to misoperation
1.1 Telescoping cylinder
during jib mounting and stowing.
These cylinders are installed inside the boom, and
are connected to the boom by pins. They function 1.7 Jib offset cylinder
to extend and retract the boom.
This cylinder is useed to kill the offset between the
jib and the boom in order to connect the jib with
1.2 Counterbalance valve
top part of the boom.
These valves are directly installed onto the
telescoping cylinders. They prevent cylinder 1.8 Solenoid control valve (jib set)
retraction when the control lever is in the neutral
This valve is a set of the solenoid valve for the jib
position, and prevent acceleration due to the
lock pin cylinder and jib offset cylinder when jib
boom’s own weight when the control lever is used
mounting / stowing is operated.
for boom retraction. In addition, they prevent
sudden cylinder retraction in the event that the 1.9 Solenoid control valve (jib set and
telescoping circuit hoses or other parts are counterweight cylinder)
damaged.
This valve is for GR-1000-2-00103.
1.3 Hose reel For This valve ,the solenoid valve (for
This hose reel winds in or unwinds the hose counterweight cylinder)is incorporated additionally
according to the boom telescoping condition and to the solenoid control valve (1.8).
secures a hydraulic circuit to the No.2 telescoping
1.10 Pilot check valve (jib set)
cylinder all the time.
This valve ensures the offset position of the jib
1.4 Hydraulic valve (top cylinder selection) and the lock of the lock pin position.
This valve controls the boom telescoping
sequence.
1.5 Hydraulic valve (for protection of top cylinder

retraction)
This valve controls to protect the top cylinder

retraction while the telescoping mode II selected.
1 WG02-0620E
G-1 G-1
Telescoping System
2. Boom telescoping mechanism

1. Order of boom extension 2. Order of boom retraction
2.1 Telescoping mode I

1.1 Telescoping mode I
First the 3rd, 4th and top boom sections retract
First the 2nd boom section extends. simultaneously.
Then the 3rd, 4th and top boom sections extend Then the 2nd boom section retracts.
simultaneously.
2.2 Telescoping mode II
1.2 Telescoping mode II First the 2nd boom section retracts.
First the 3rd, 4th and top boom sections extend Then the 3rd, 4th and top boom sections retract
simultaneously. simultaneously.
Then the 2nd boom section extends.
Boom extension Boom retraction

2nd
Extended by No.1 telescoping cylinder. Retracted by No.1 telescoping cylinder.
boom
3rd
Extended by No.2 telescoping cylinder. Retracted by No.2 telescoping cylinder.
boom
Extended by wire-rope mechanism which is Retracted by wire-rope mechanism which is
interlocked with No.2 telescoping cylinder’s interlocked with top boom section’s retraction.
extension.
4th
boom
Extended by wire-rope mechanism which is Retracted by wire-rope mechanism which is

interlocked with 4th boom section’s extension. interlocked with 3rd boom section’s retraction.
Top
boom
2 WG02-0620E
G-1 G-1
Telescoping System
3. System description
Telescoping mode II
(The 3rd through top boom sections extend first.)
3.1 Extension circuit
1. When the boom telescoping lever (linked to the
Telescoping mode I
remote control valve) is operated to the extension
(The 2nd boom section extends first.)
side, pilot pressure is led to the hydraulic pilot
1. When the boom telescoping lever (linked to the control valve, shifting the telescoping control valve
remote control valve) is operated to the extension to extension side and delivering the pressurized
side, pilot pressure is led to the hydraulic pilot oil from the hydraulic pump to the selector valve.
control valve, shifting the telescoping control valve
2. The pressurized oil is sent to the No. 2
to extension side and delivering the pressurized
telescoping cylinder, making the 3rd boom section
oil from the hydraulic pump to the selector valve.
extend.
2. The pressurized oil is sent to the No. 1
3. The 4th and top boom sections are extended by
telescoping cylinder, making the 2nd boom section
the wire-rope mechanism linked to the No. 2
extend.
telescoping cylinder.
3. After the 2nd boom section is fully extended,
4. After the 3rd through top boom sections are fully
press the next section extension switch while
extended, press the next section extension switch
keeping the boom telescoping lever operated. The
while keeping the boom telescoping lever
hydraulic valve will be energized, the pressurized
operated. The hydraulic valve will be energized,
oil will be sent to the No. 2 telescoping cylinder
the pressurized oil will be sent to the No. 1
and the 3rd boom section will extend.
telescoping cylinder and the 2nd boom section will
4. In this case, you need not keep pressing the next extend.
section extension switch when the No. 2
5. In this case, you need not keep pressing the next
telescoping cylinder extends slightly because the
section extension switch when the No. 1
boom full retraction switch is shifted and the
telescoping cylinder extends slightly because the
solenoid self-holding circuit for the hydraulic valve
boom full retraction switch is shifted and the
is established.
solenoid self-holding circuit for the hydraulic valve
5. The 4th and top boom sections are extended by is set up.
the wire-rope mechanism linked to the No. 2
3 WG02-0620E
G-1. G-1.
Telescoping System
3.2 Retraction circuit

Telescoping mode II
Telescoping mode I (The 3rd through top boom sections extend first.)
(The 2nd boom section extends first.)
1. Pressurized oil for boom retraction is delivered
1. Pressurized oil for boom retraction is delivered from the hydraulic pilot control valve to the No. 1
from the hydraulic pilot control valve to the No. 1 and No. 2 telescoping cylinder directly.
and No. 2 telescoping cylinder directly.
2. While the No. 1 telescoping cylinder is extended,
2. While the No. 2 telescoping cylinder is extended, the solenoid of the selector valve is energized due
the solenoid of the selector valve is energized due to the boom full retraction detector switch.
to the boom full retraction detector switch. Consequently the return circuit of the No. 2
Consequently the return circuit of the No. 1 telescoping cylinder is closed and only the No. 1
telescoping cylinder is closed and only the No. 2 telescoping cylinder retracts, resulting in retraction
telescoping cylinder retracts, resulting in retraction of the 2nd boom section.
of the 3rd boom section.
3. When the No. 1 telescoping cylinder is almost fully
3. At the same time, the 4th and top boom sections retracted, the boom full retraction detector switch
retract by the wire-rope mechanism. is activated and disestablishes the solenoid
self-holding circuit for the hydraulic valve.
4. When the No. 2 telescoping cylinder is almost fully
Consequently the selector valve automatically
retracted, the boom full retraction detector switch
shifts, the No. 2 telescoping cylinder retracts and
is activated and disestablishes the solenoid
the 3rd boom section retracts.
self-holding circuit for the hydraulic valve.
Consequently the selector valve automatically 4. When the 3rd boom section retracts, the 4th and
shifts, the No. 1 telescoping cylinder retracts and top boom sections retract simultaneously by
the 2nd boom section retracts. means of the wire rope mechanism.
4 WG02-0620E
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
1.1 Boom assy
Boom assy (1/2)
5 W536-1330E 5
G-2 G-2 G-2
Boom assy (2/2)
6 W536-1330E 6
G-2 G-2
1. Base boom section 38. --- 78. Plain washer 118. Nut
2. Second boom section 39. Bolt 79. Pin 119. Plate
3. Third boom section 40. Pin 80. Support 120. Plate
4. Fourth boom section 41. Spacer 81. Pin 121. Plate
5. Top boom section 42. Plate 82. Support 122. Plate
6. Set screw 43. Roller assy 83. Support 123. Grease nipple
7. Nut 44. Roller assy 84. Machine screw 124. Cap
8. Plate 45. Support 85. Bolt 125. Sheave assy
9. Bolt 46. Bolt 86. Slide plate 126. Pin
10. Plate 47. Wire rope 87. Pin 127. Pin
11. Slide plate 48. Wire rope 88. Sheave assy 128. Split pin
12. Retainer 49. Wire rope 89. Plate 129. Hexagon socket head bolt
13. Set screw 50. Nut 90. Spacer 130. Support
14. Set screw 51. Nut 91. Spacer 131. Plate
15. Retainer 52. Pin 92. Support 132. Slide plate assy
16. Retainer 53. Plate 93. Slide plate 133. Slide pIate assy
17. Spacer 54. Bolt 94. Hexagon socket head bolt 134. ---
18. Pin 55. Spring washer 95. Nut 135. Spring washer
19. Guide 56. Plate 96. Tooth washer 136. Plate
20. Spring washer 57. Pin 97. Sheave assy 137. Plate
21. --- 58. Snap pin 98. Guide 138. Plate
22. Sheave assy 59. Spacer 99. Guide 139. Hexagon socket head bolt
23. Bolt 60. Spacer 100. --- 140. Bolt
24. Pin 61. Sheave assy 101. Plain washer 141. Bolt
25. Support 62. Spacer 102. Plain washer 142. Bolt
26. Bolt 63. Pin 103. Grease nipple 143. Sheave assy
27. Spring washer 64. Nut 104. Pin 144. Sheave assy
28. --- 65. Tooth washer 105. Retaining ring 145. Plate
29. --- 66. Cover 106. Spacer 146. Plain washer
30. --- 67. Bolt 107. Pin 147. Plain washer
31-1. Support (base) 68. Pin 108. Spacer
31-2. Support (second) 69. Bolt 109. Retaining ring
31-3. Support (third) 70. Nut 110. Spacer
31-4. Support (fourth) 71. Sheave assy 111. Spacer
32. Plate 72. Spacer 112. Pin
33. Plate 73. Spacer 113. Plain bearing
34. Plate 74. Pin 114. Set screw
35. Plate 75. Spap pin 115. Nut
36. Bolt 76. Bolt 116. Nut
37. Nut 77. Adjuster assy 117. Bolt
342-022-00000 △
5
7 W536-1330E
G-2 G-2
2. Disassembly 3. After removing the retaining ring, pull out the pin
that connects the base boom section to the No. 1
[NOTICE] telescoping cylinder.
◆The procedure to dismount the boom from the Then remove the anti-buckling bolt and nut for the
swing table is not described here.
No. 1 telescoping cylinder.
◆The procedure to remove the 2nd–top boom
sections is described here.
2.1 Removing the 2nd–top boom sections
1. Remove the wiring connector from the cable

leading to the boom length detector cord reel,
and loosen the wiring clip. Remove the cable
from the top boom section, and secure it
temporarily on the cable guide on the base
boom section using a tape.
4. Loosen the set screws, nuts (on the sides and

top) and bolts on the top of the base boom section
head for adjusting the slide plates in order to
2. Remove the boom-telescoping high-pressure make the clearance to the 2nd boom section.
hoses connecting to the No. 1 telescoping cylinder
and boom-extending high-pressure hose
connecting to the No. 2 cylinder.
Attach a cap on each opening.
[NOTICE]
◆Since the spring force for extra winding turns is
applied to the hose, hold the drum when
disconnecting the hose.
5. Pull out the 2nd boom section by approx. 1 m

(3.28 ft).
6. Remove the retainer and slide plates.
8 W536-1330E
G-2 G-2
7. Remove the support (which holds the slide plates) 2.2 Removing the 3rd–top boom sections
on the bottom of the base boom section head by
1. Detach the ends of the wire ropes (for the top
loosening the bolts.
boom section extension/4th boom section
While lifting up the 2nd boom section slightly,
retraction) from the top of the 2nd boom section
remove the slide plates (upper and lower) for the
head by loosening the nuts.
rounded face and the slide plate retainer.
Temporarily attach the ends of the wire ropes to
the sheave of the 4th boom section using a cord.
[NOTICE]
◆Before loosening the nuts, measure the length of
each wire rope protrusion (L1) as a guide for
reassembly.
Wire rope Nut L1
IW536-0620E06
8. Lift up and pull out the 2nd–top sections together
using a crane, and place them on a platform. Put
stoppers to keep balance of the boom assy. 2. Remove the adjuster assy from the 2nd boom
section by loosening the bolts 1 (2 pcs.) and the
bolts 2 (4 pcs.) located on the top of the 2nd boom
section head.
Temporarily attach the adjuster assy to the head
of the 3rd boom section using a cord.
[NOTICE]
◆Before loosening the nuts, measure the length of
adjuster assy protrusion (L2) as a guide for
reassembly.
9 W536-1330E
G-2 G-2
3. Remove the pin and detach the end of the wire 5. After removing the retaining ring, pull out the pin
rope (for the top boom section retraction) at the that connects No.2 telescoping cylinder to the 2nd
tail end of the top boom section by loosening the boom section.
bolt 2. Then remove the anti-buckling bolt and nut for the
Temporarily attach the end of wire rope to the tail No. 2 telescoping cylinder.
end of the 3rd boom section using a cord.
4. Remove the support assy which guides the No. 1

telescoping cylinder from the top of the 3rd boom
section tail end by loosening the bolts.
6. Detach the end of the wire rope (for 4th boom
section extension) located on the top of the 2nd
boom section tail end together with the support by
loosening the nut on its end.
Temporarily attach the end of the wire rope to the
rod of the 2nd telescoping cylinder using a cord.
And also prevent the wire rope from hanging from
the telescoping cylinder.
[NOTICE]
◆Before loosening the nut, measure the length of
each wire rope protrusion (L3) as a guide for
reassembly.
10 W536-1330E
G-2 G-2
7. Loosen the set screws, nuts (on the sides and 11. Lift up and pull out the 3rd–top sections together
top) and bolts on the top of the 2nd boom section using a crane, and place them on a platform. Put
head for adjusting the slide plates in order to stoppers to keep balance of the boom assy.
make the clearance to the 3rd boom section.
8. Pull out the 3rd boom section by approx. 1 m

(3.28 ft).
9. Remove the retainers and slide plates.
10. Remove the support (which holds the slide

plates) on the bottom of the 2nd boom section
head by loosening the bolts.
While lifting up the 3rd boom section slightly,
remove the slide plates (upper and lower) for the
rounded face and the slide plate retainer.
11 W536-1330E
G-2 G-2
2.3 Removing the 4th–top boom sections 3. Loosen the set screws, nuts (on the sides and
top) and bolts on the top of the 3rd boom section
1. Lift up the No.2 telescoping cylinder using a crane
head for adjusting the slide plates in order to
and keep it suspended.
make the clearance to the 4th boom section.
After removing the retaining ring, pull out the pin
that connects No.2 telescoping cylinder to the 3rd
boom section.
Remove the anti-buckling bolt and nut for the No.
2 telescoping cylinder.
4. Pull out the 4th boom section by approx. 1 m

(3.28 ft).
6. Remove the support (which holds the slide plates)

on the bottom of the 3rd boom section head by
2. Lift up the No. 2 telescoping cylinder using a While lifting up the 4th boom section slightly,
crane. Pull the telescoping cylinder assy all the remove the slide plates (upper and lower) for the
way out of the 3rd boom section while pulling the rounded face and the slide plate retainer.
end of the wire rope (for 4th boom section
extension) together with the support.
[NOTICE]
◆Prevent the wire rope from hanging from the
12 W536-1330E
G-2 G-2
7. Lift up and pull out the 4th–top sections together 2.4 Removing the top boom section
using a crane, and place them on a platform. Put
1. Remove the support by loosening the bolts 2 (4
stoppers to keep balance of the boom assy.
pcs.) located on both sides of the 4th boom
section head.
Draw out the wire ropes (for top boom section
extension/4th boom section retraction) forward by
approx. 0.5 m (1.64 ft). Then detach the pin and
separate the wire rope from the support.
Temporarily attach the ends of the wire ropes to
the head of the top boom section using a cord.
2. To prevent damage to the wire rope (for top boom

section extension/4th boom section retraction),
secure it to the head of the top boom section
using a jig.
13 W536-1330E
G-2 G-2
3. Loosen the set screws, nuts (on the sides and 7. Lift up and pull out the top boom section using a
top) and bolts on the top of the 4th boom section crane, and place it on a platform. Put stoppers to
head for adjusting the slide plates in order to keep balance of the boom assy.
make the clearance to the top boom section.
4. Pull out the top boom section by approx. 1 m

(3.28 ft).
6. Remove the support (which holds the slide plates)

on the bottom of the 4th boom section head by
While lifting up the top boom section slightly,
remove the slide plates (upper, middle, and lower)
for the rounded face and the slide plate retainer.
14 W536-1330E
G-2 G-2
3. Check 4.2 Installing anti-buckling bolts for telescoping

cylinders
3.1 Boom
Check the boom for twist, deformation warp, and

cracks.
3.2 Slide plate
Replace ones with any cracks or excessive wear.
3.3 Sheave
Replace any broken, deformed or excessively

worn ones.
3.4 Boom telescoping wire rope

Wire ropes in the condition described below must
not be used.
a: Deformation or corrosion
b: Kinking
c: 10% or more broken wires (filler wires excluded)

in one lay of the wire rope
d: Diameter reduction exceeding 7% of the nominal • Connect the boom and telescoping cylinder using
diameter the pins A and B.
e: Evidence of any heat damage from any cause • Set the corresponding boom sections horizontal
and fully retracted.
4. Reassembly • Choose suitable plates among [119], [120], [121],

and [122] to make the clearance X between the
[NOTICE]
cylinder and the support on the boom 1 mm
◆For the reassembly of the boom, understand
(0.04 in) or less.
enough the notes in "1. Structure".
◆Reassemble the boom in a reverse order described • Adjust the bolt C locked with the nuts D and E so
in "2. Disassembly".
that it can be turned by hand and the axial
clearance (S) from the head of the bolt C is
4.1 Greasing
0.5 mm (0.02 in) or less. (Apply thread locking
When installing unplated pins, ally grease agent.)
beforehand.
Apply TNR-2 Grease sufficiently to the sliding
surfaces on the slide plates, the boom sections,
and telescoping cylinders.
15 W536-1330E
G-2 G-2
5. Adjustment 5.1.2 Shim adjustment at the sides of the rear end
1. Measure the inner dimension of the outer boom

5.1 Boom fitting and shim adjustment box at the sliding position of the slide plates at
[NOTICE]
approx. 1.5 m (4.92 ft) from the rear end opening.
◆All adjustment procedures are the same from the
Then divide the dimension evenly between right
top to 2nd boom sections.
and left sides, and insert shims so that the gaps
◆The term "minimum clearance" means the
clearance to which the thinnest provided shim become the minimum clearance.
cannot be inserted.
2. Apply thread locking agent (ThreeBond 1401 or
5.1.1 Shim adjustment at lower oblique sides of the equivalent) to the hexagon socket head bolts.
rear end Then tighten the bolts lightly and then turn them
back for a quarter turn.
1. Construct this part with standard number of shims
Standard number of shims
inserted to both right and left plates. 2nd boom section 1-mm shim: 2, 0.6-mm shim: 1
[NOTICE] 3rd boom section 1-mm shim: 2, 0.6-mm shim: 1
◆Only when the cylinder connecting pin [104, 109] 4th boom section 1-mm shim: 2, 0.6-mm shim: 1
cannot be inserted, make an adjustment by Top boom section 1-mm shim: 5, 0.6-mm shim: 1
removing the shims.
Standard number of shims
2nd boom section 0.6-mm shim: 2
3rd boom section 0.6-mm shim: 2
4th boom section No shim adjustment
Top boom section No shim adjustment
2. Apply thread locking agent (ThreeBond 1401 or

equivalent) to the threaded area of the fixing
support. Then tighten the nuts lightly and then turn
them back for a quarter turn.
342-021-60900 △
2
16 W536-1330E
G-2 G-2
5.1.3 Slide plate adjustment at the lower part of the 4. For the 4th boom section top end, it is allowed to
top end use the slide plates of different thickness in the
[NOTICE]
upper parts. (For the lower part, use the slide
◆Make this adjustment with each boom section
plates with thickness "0" only.)
retracted almost fully.
5. It is allowed to use the slide plates with different
1. Insert the stopper plates before inserting slide
thickness in left/right sides.
plates.
However, the difference of the clearance between
2. As a rule, use the slide plates of standard the boom sections (dimension X) shall be 2 mm
thickness "0". When the plates of standard (0.08 in) or less between the left and right sides.
thickness "0" cannot be inserted, use those of
6. Insert the shims [15] and [16] to the position
thickness "-2". When the plates of thickness "-2"
shown in the figure so that the horizontal
cannot be inserted, use those of thickness "-3".
clearance on the upper slide plates is adjusted to
3. For the top ends of the base, 2nd and 3rd boom minimum (0.6 mm (0.024 in) or less). (The total
sections, select and use the slide plates of the thickness of shims shall be 1.8 (0.07 in) mm or
same thickness for both upper and lower slides. less and the shims of (t0.6) shall be 3 or less.)
Slide plate and shim (1 mm = 3.93701 × 10-2 in)

Size (mm) Size (mm) Size (mm)
1 “0” 240 × 250 7 “0” 139 × 200 Right 13 “0” 50 × 190
2 “-2” 240 × 250 8 “0” 139 × 200 Left 14 “-2” 48 × 190
3 “0” 220 × 250 9 “0” 117 × 200 Right 15 70 × 240 × t0.6 (shim)
4 “-2” 220 × 250 10 “-2” 117 × 200 Right 16 50 × 190 × t0.6 (shim)
5 “0” 200 × 200 11 “0” 117 × 200 Left
6 “-2” 200 × 200 12 “-2” 117 × 200 Left
342-021-60700 △
0
17 W536-1330E
G-2 G-2
5.1.4 Clearance adjustment at top of the boom 5.1.5 Shim adjustment at top of the boom tail end
head
1. After the adjustment of the head as explained in
1. Extend the boom section for approx. 0.5 m (1.64 steps (5.1.3) and (5.1.4), perform the following
ft), and then lift the boom head slightly to the adjustment.
extent that the inner boom section to be adjusted
does not rise up. 2. Check that the difference of the upper rear end
[NOTICE] clearance (dimension B) between the right and left
◆If the boom section head is not lifted, the rear end sides is 3 mm (0.12 in) or less.
part cannot follow and the rear end is twisted
against the head, and the adjustment in the step
(5.1.5) cannot be performed correctly.
2. Set the slide plates along the curve of the inner

boom section without inclination, and then the
upper-side adjustment bolts to let the slide plate
touch the retainer.
[NOTICE]
◆If it exceeds 3 mm (0.12 in), go back to the step
(5.1.4) and adjust again.
3. Insert shims until the clearance (C) on the upper

slide plate is minimum.
[NOTICE]
◆If the boom is constructed without correcting the
tilting of the slide plates, the load can move the
slide plates and the fixing of the retainer can come
loose.
3. Adjust the dimension A using the side adjustment

bolts so that the right-side dimension is 1 mm [NOTICE]
(0.04 in) greater than that of the left side. ◆When using 1.2-mm shims, always put them under
Ex: When the dimension A on the right is 21 mm the 0.23-mm shims.
(0.84 in), the dimension A on the left shall be 20
mm (0.8 in). 4. Apply thread locking agent (ThreeBond 1305 or
equivalent) to the retainer bolt. And tighten it with
4. After the above adjustment, retighten the upper tightening torque of 74–82 N·m {7.6–8.4 kgf·m}
and side adjustment bolts at both left and right (54.6–60.5 ft·lbf).
sides for a quarter turn, and then fix them using
nuts. 5.2 Adjustment of boom telescoping wire ropes
5. Finally, pull and fix the retainers with the fixing Refer to the "Y-6 Assembly Adjustment (Crane
bolts, and then bend the washer plate to stop bolt Operation)" in the Y section.
turning.
18 W536-1330E
G-2. G-2.
6. Test
[NOTICE]
◆Bleed the telescoping cylinders completely and
apply grease to the boom sliding surfaces before
starting the test.
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
[Condition]
･Crane levelness : 6′ {0.1°} at max.
･Boom length : Full extension
･Boom elevation : Maximum
･Boom direction : Over-front, over-rear
over-right, over left
･Other condition : Free from solar heat and wind
1. The hook displacement (A in the figure) under the

above test conditions with no load lifted must be W
brought within 200 mm (7.9 in) in all boom A
IW536-001029
directions by shim adjustment.
2. After shim adjustment, the hook displacement (A

in the figure) under the above test conditions with
rated lifting capacity lifted must be brought within
500 mm (19.7 in) in all boom directions by shim
adjustment. When the displacement is more than
the above value, readjust the shim.
6.3 Other functional test
Check all the electric and electronic parts (boom

length & detector, etc.) that are influenced by
boom dismounting for function and accuracy.
19 W536-1330E
G-3 G-3 G-3
Jib
G-3 Jib
1. Structure
1.1 Location of jib
20 W537-0330E 20
G-3 G-3
Jib
1.Support assy 13.Support assy 25.End 37.Stopper

2.Plate 14.Plate 26.Pin 38.Support
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 43.Plate
8.Plain washer 20.Support 32.Support 44.Plate
9.Slide plate 21.Support assy 33.Spring 45.Plate
10.Shim 22.Support assy 34.Plate 46.Bolt
11.plate 23.Support 35.Pin assy 47.U-Nut
12.--- 24.--- 36.Plate 48.Support
49.Nut
50.Support assy
51.Plate
342-219-20100 △
4
342-219-50100 △
5
21 W537-0330E
G-3 G-3 G-3
Jib
1.2 Jib main body
22 W537-0330E 22
G-3 G-3
Jib
1.Jib 2 15.Pin 29.Spacer 43.Pin

2.Jib1 16.Spacer 30.Pin 44.Bolt
3.Support 17.Sheave assy 31.Plate 45.Spring washer
4.Snap pin 18.Plate 32.Pin 46.Roller assy
5.Pin 19.Pin 33.Split pin 47.Pin
6.Pin 20.Link 34.Plate 48.Spacer
7.Retaining ring 21.Plate 35.Pin assy 49.Snap pin
8.Sheave assy 22.Plate 36.Nut 50.Spacer
9.Grease nipple 23.Plate 37.Bolt 51.---
10.Pin 24.Pin 38.Plate 52.Spacer
11.Snap pin 25.Plain washer 39.Pin assy 53.Sheave assy
12.Guide assy 26.Split pin 40.Pin 54.Retaining ring
13.Bolt 27.Stopper 41.Support 55.Pin
14.Spring washer 28.Roller assy 42.Plate 56.Spap pin
342-219-22000 △
2
23 W537-0330E
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 In order to facilitate inserting and removing the jib
support and spring pin is 2 mm (0.08 in) while the lock pin, adjust the jib inclination by using a bolt
jib 1 supports the jib 2. and secure the bolt with a nut.
Support
Jib 2
X
Spring pin
Jib 1
Jib 1-2 connecting spring pin

IW537-0100E07
24 W537-0330E
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 W537-0330E
G-4 G-4
Telescoping Cylinder
G-4 Telescoping Cylinder

[NOTICE]
1. Structure
1. No.1 cylinder 4. Hexagon socket head bolt 7. --- 10. Split pin
2. No.2 cylinder 5. Spring washer 8. Plain washer
3.Support 6. Hose 9. Pin
Tightening torque
N-m kgf-m ft-lbf
A1, B G3/4 108 - 123 11 - 12.5 80 - 90
A2 G1/2 54 - 64 5.5 - 6.5 40 - 47
4 M12 68.6 - 82.4 7 - 8.4 50.6 - 60.7
26 W157-0640E
G-4. G-4.
Telescoping Cylinder
1.Plug 6.--- 11.Rod 16.Packing

2.Set screw 7.Packing 12.O-ring 17.Backup ring
3.Nut 8.O-ring 13.Rod cover assy 18.Plain bearing
4.Piston 9.Plain bearing 14.Damper ring 19.Dust seal
5.Backup ring 10.Cylinder 15.Support 29.O-ring
*1: Face the notch or the lip toward the pressurized side.
*2: After tightened, punching (2 places).
Tightening torque
N-m kgf-m ft-lbf
2 M8 13.2 – 16.2 1.35 – 1.65 9.7 – 11.9
360-185-10000 △
1
360-185-20000 △
2
27 W157-0640E
G-5 G-5
Counterbalance Valve (Telescoping)
G-5 Counterbalance Valve (Telescoping)

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

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

Tightening torque
N-m kgf-m ft-lbf
6 - 29 - 49 3-5 22 - 36
7 - 1 - 1.2 0.1 - 0.12 0.7 - 0.9
11 - 56 - 62 5.7 - 6.3 41 - 46
18 - 78 - 98 8 - 10 58 - 72
20 - 1 - 1.2 0.1 - 0.12 0.7 - 0.9
M M10 43.1 - 49 4.4 - 5.0 31.8 - 36.1
28 W119-0224E
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 W119-0224E
G-6 G-6
Hose Reel
G-6 Hose Reel
[NOTICE]
1. Structure
1.Drum plate 9.Nut 17.Set screw 25.Spacer

2.Drum plate 10.Bearing 18.Nut 26.O-ring
3.Seat packing 11.Bush 19.Spring washer 27.Bolt
4.Spring case 12.Bearing 20.Plate 28.Spring washer
5.Spring 13.Seal ring 21. Bolt 29.Stop Plate
6.Aux. spring 14.Backup ring 22. --- 30.Grommet
7.Special bolt 15.Pin 23.Retaining ring
8.Spring washer 16.Support 24.Oil seal
30 W183-0134E
G-6 G-6
Hose Reel
2. Dismounting 1) Remove the protection plate from the case 4

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

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

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

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

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

follows:
31 W183-0134E
G-6. G-6.
Hose Reel
2) With the lower side coated with grease,

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

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

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

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

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

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

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

surfaces of drum plates.
366-716-50000 △
3
32 W183-0134E
G-7 G-7
Hydraulic Valve
G-7 Hydraulic Valve
[NOTICE]
1. Structure
PP
P C T Dr
IW123-017001
PP
Dr
C P T
IW123-017002
Tightening torque
N-m kgf-m ft-lbf
P, C, T G3/4 167 17 123
PP, Dr G1/4 29.4 3 22
33 W123-0173E
G-7 G-7
Hydraulic Valve
19 6
17
15
C P T Dr
15 3 10 1 2 7 10
IW123-017003
1.Body 3.Cover 7.Spring 15.Hex. socket head bolt

2.Spool 6.Solenoid valve 10.O-ring 17.Plug
19.Orifice
Tightening torque
N-m kgf-m ft-lbf
Mounting bolt
M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
(for solenoid valve.6)
34 W123-0173E
G-7. G-7.
Hydraulic Valve
Solenoid valve assy
Connector
(+): Red
(-): Blue
+-
IW121-0542E01
T1 3
A P B
T T
T2 12 9 1 15 8 7 11 2
IW121-025003
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 kgf-m ft-lbf
2 - 44 - 49 4.5 - 5 32.5 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
366-497-50000 △
1
366-463-10000 △
1
35 W123-0173E
G-8. G-8.
Jib Lock Pin Cylinder
G-8 Jib Lock Pin Cylinder

[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 1194.
Tightening torque
N-m kgf-m ft-lbf
A, B G1/4 29.4 3 22
360-531-60001 △
1
36 W180-0140E
G-9. G-9.
Jib Offset Cylinder
G-9 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

*2 : Apply adhesive (Loctite 638) to the 3rd - 5th threads of rod [7] beyond the tip of the piston [4].
Tightening torque
N-m kgf-m ft-lbf
A, B G1/4 29.4 3 22
3 M24 450 - 500 46 - 51 332 - 369
360-512-20000 △
3
360-512-20001 △
0
37 W180-0070E
G-10 G-10
Solenoid Control Valve (Jib Set)
G-10 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
38 W112-0224E
G-10 G-10
18.Name plate 27.Plug 31.Nut 33.Ball

21.Tie rod 29.Hexagon socket head bolt 32.Rivet screw 38.O-ring
50.Relief valve assy
Tightening torque
N-m kgf-m ft-lbf
P, T G1/2 98 10 72
A1, B1, A2, B2 G3/8 49 5 36
C•O G1/2 98 10 72
P•P G1/4 29.4 3 22
39 W112-0224E
G-10 G-10
6.Collar 16 28 34 19 38 23 27 33
7.Spring holder
8.Plug
9.Spring 8
16.Solenoid 7
19.Body
20.Spring 22
22.Spring 25
6
23.Filter 44
25.Spool end 35
35
27.Plug
33
33.Ball
34.O-ring
35.O-ring
37.O-ring
38.O-ring
44.O-ring
35 33
35
28
37
8
9
33
16 34 19 38 27 23 20
A-A
IW112-0220E03
40 W112-0224E
G-10 G-10
14.Spool
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
41 W112-0224E
G-10 G-10
Relief valve assy
C-C
IW112-0224E05
Relief valve assy
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
42 W112-0224E
G-10. G-10.
CO
D-D IW112-0220E06
366-489-20000 △
0
43 W112-0224E
G-11. G-11.
Pilot Check Valve (Jib Set)
G-11 Pilot Check Valve (Jib Set)

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

2.Sleeve 5.Piston 8.O-ring 11.Plug
3.Poppet 6.O-ring 9.O-ring 12.Plug
Tightening torque
Sign /port Thread size
N-m kgf-m ft-lbf
A,B,C,D G1/4 29.4 3 22
366-241-40000 △
1
44 W115-0272E
H
Safety System
Contents
H-1 Safety System .................................. 1 H-3 Outrigger Extension Length H

Detector ....................................8
1. Function of safety devices ......................... 1
1.1 Moment detector (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 Swing angle detector.................................. 1
1.5 Other detectors and switches..................... 1 3. Reassembly............................................. 10
1.6 AML (load moment indicator) main body.... 1
1.7 Overwind cutout (anti-twoblock) device ..... 1
1.8 Solenoid valve (AML vent).......................... 1 H-4 Solenoid Valve (Auto Stop) ...........12
2. System description .................................... 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 AML (load moment indicator) main body
1. Function of safety devices 1. AML main body calculates the total moment being
generated on the crane based on signals from the
1.1 Moment detector (pressure sensor) pressure sensor and the boom length and angle
detector.
1. An extension pressure sensor and a retraction
pressure sensor are incorporated in the elevating 2. The calculation result is compared with the rated
cylinder. moment. When it reaches 90% and 100% of the
rating, AML sends alarm and auto. stop signals,
2. They convert the elevation pressure into the
respectively, to prevent the crane from being
electric signal and transmit it to AML (load
overloaded.
moment indicator) main body, making the limiter
calculate the total moment created by the lifted 3. The currently lifted load is calculated from the
load and the mass of the boom. above total moment.
(For the pressure sensor, refer to “Pressure
sensor” in the chapter E.) 1.7 Overwind cutout (anti-twoblock) device
This device prevents damage to the crane that

1.2 Boom length and angle detector
would be caused by the hook block pulled hard
The boom length and angle detector is installed into the boom head. When the hook block
on the boom side, and uses the potentiometer approaches the head of the boom, single top or jib,
inside the detector to convert the extended boom the overwind cutout device sends a signal to AML,
length and the angle of the boom relative to the which then stops any further crane action toward
ground into an electric signal that is transmitted to the critical condition.
AML main body.
1.8 Solenoid valve (AML vent)
1.3 Outrigger extension width detector
1. If AML system detects the trouble, the actual
It is installed on the rear end of each outrigger moment reaches 100% of the rated moment, or
outer case. The potentiometer in the detector the hook block is overwound, an electric signal
converts the outrigger extension width into the (auto. stop) is sent from AML main body to this
electric signal and transmits it to AML main body. valve. (Actually, 24V DC output is cut.)
1.4 Swing angle detector 2. Therefore, this solenoid valve is deenergized, and
directs the vent line of the unload relief valve (for
For swing angle detector, refer to “Center joint” in elevation and telescoping) and the unload relief
the chapter B. valve (for winch) mounted on the hydraulic pilot
control valve to the tank. This solenoid valve
1.5 Other detectors and switches
allows the pressurized oil from the pump to
The outer detectors and switches convert the escape through the relief valve to the tank, then,
crane operation modes and working conditions the crane operation stops.
into electric signals that are transmitted to AML
main body.
Refer to the service manual of AML-C.
1 WH02-0190E
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 W305-0700E
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 W305-0700E
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 2 clamps and remove the bolts and

cover.
3. Disconnect the cable, potentiometer and angle Nut IW305-0230E04
detector from the terminal, and remove the cover

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

0-marker.
Bolt
Sub-cord
Plate
Match marks
IW305-0230E03
2. Pass the new cord through the hole of the drum

6. Remove the nut and separate the drum assy from
assy. Solder it on the slip ring assy.
the plate.
[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 W305-0700E
H-2 H-2
Core wire original position after it is rotated a quarter turn by

Cord
finger and released. If it is not returned, loosen the
bolt and adjust the position of the bracket.
Shield wire
[NOTICE]
Drum assy
Vinyl tube If the potentiometer is faulty, replace it referring to
IW305-0230E07 the "Replacing the potentiometer (boom length
detector)" described later.
3. Install the slip ring assy so that the cord is not 10. Fix the gear in the notched section of the speed
slackened. reducer shaft using a set screw. Apply thread
locking agent to the set screw.
4. Wind the new cord around the drum assy while
taking up slack in the cord. When the 0-marker on Tightening torque :
the 8.83 m (29.0ft) point of the cord shows on the 1.18 N-m (0.12kgf-m) {0.87ft-lbf}
drum, wind the cord 13 turns more and fix it with
gummed tape to prevent slackening. 11. Take out the new cord from the guide hole of the
cord reel and draw it out completely. Then wind it
[NOTICE] again the drum. When the 0-marker comes to the
Wind the cord around the drum assy clockwise as edge of the cord guide, fix the cord there as
seen from the slip ring. shown in the figure.
0-marker
Slip ring
Gummed tape
IW305-0230E09
Gummed tape
IW305-0230E08 12. Apply voltage DC 5V to the potentiometer (for
boom length detector) as shown in the figure and
turn the gear using a screwdriver until the output
5. Insert the shaft of the drum assy into the boss
voltage between the red and white terminals is 0.5
hole of the plate and fix it with a nut.
± 0.06 V. Then fix the gear using a set screw.
6. Put the case over the drum assy, leading the Apply thread-locking agent to the set screw.
sub-cord outside through the hole of the case and
Tightening torque :
the cord end outside through the opening of the
1.18N-m (0.12kgf-m) {0.87ft-lbf }
cord guide.
Screwdriver
7. Secure the case and the plate with a bolt and Gear B
attach the retaining ring. Gear A Set screw
Bracket
8. Apply sealant agent thinly on the bottom of the Spring
speed reducer. Then install the speed reducer on
the case. White
Red +
9. Inset the gear on the shaft of the speed reducer. - Tester
Black
Loosen the set screw on the potentiometer side to - Applied
+ voltage
allow both gears to idle.
IW305-0230E10
Check that the gear is spring-returned to the
5 W305-0700E
H-2 H-2
13. Draw out the cord slightly from the drum and 2.4 Disassembling the potentiometer
make sure that the resistance between the red (for boom length detector)
and white terminals increases smoothly. [NOTICE]
14. Connect the cable to the terminals for the If both the cord and spiral spring are faulty, remove
the detector assy from the boom.
potentiometer and angle detector.
If only the potentiometer is faulty, it is not necessary
15. Attach the cover. to remove the detector.
16. Pull the cable to eliminate slack, and tighten the 1. Loosen the 2 clamps and remove the bolt and
clamp. (2 places) cover.
17. Install the cord lock on the cord end and install 2. Disconnect the lead wire terminals (3 pieces) and
the lead wires and the connector close to the cord cable terminal from the potentiometer, and
end. Completely insulate the soldered remove the potentiometer together with the
connections. bracket.
8.5 m (27.9ft) [NOTICE]

0.08 m
ft) (0.26ft) Before replacement, disconnect the wiring to the
(0.8
m boom angle detector from the pin terminal section to
0.25
disconnect the lead wires (red and black) from the
Cord lock boom angle detector.
0-marker
Wind HI-BOND tape for
Connector waterproofing and then Gear
wind insulating tape.
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 W305-0700E
H-2. H-2.
2.5 Reassembling potentiometer 2.6 Replacing the boom angle detector
1. Install a new potentiometer. Disconnect the lead wires to the boom angle
detector from the pin terminal section, and replace
[NOTICE]
the boom angle detector assy.
To avoid exposing the potentiometer to high
temperature for a long time, solder the
potentiometer terminal and the lead wires quickly.
3. Adjustment
Fix the potentiometer terminal including the lead
wires to the bracket using insulating sealant.
1. Adjust the cord lock so that the 0-marker on the
cord is on the edge of the cord guide when the
Recommended sealant: Shin-Etsu Silicone
boom is fully retracted.
KE45RTV (Shin-Etsu Chemicals Industry)
Bracket
0-marker Cord lock

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

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

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

step 12. and below of the "Installing the cord"
section. 361-322-80000 △
1
7 W305-0700E
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.
Electric symbols
Use silicon sealant to seal

the shaded part.
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 W305-0252E
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: 2k ± 5%
Potentiometer Mechanical rotating Screw
angle: 3600°
IW305-0250E05
2. Disassembly
1. Get the wire slowly rewound round the drum until 5. Remove bolt and separate drum assy and base
the spiral spring loses its force. 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 W305-0252E
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 gummed 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 ± 30 , 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
10 W305-0252E
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
increases 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 W305-0252E
H-4 H-4
Solenoid Valve (Auto Stop)
H-4 Solenoid Valve (Auto Stop)
[NOTICE]
1. Structure
1.Body
2.Retainer
3.Filter element
4.Plug
5.Solenoid valve assy
6.Name plate
7.Screw
Tightening torque
N-m kgf-m ft-lbf
A, B, T G1/4 29.4 3 22
2 G1/4 6.9 – 8.8 0.7 – 0.9 5.1 – 6.5
T1 M5 6.9 – 8.9 0.7 - 0.9 5.1 – 6.5
12 W121-0546E
H-4. H-4.
Solenoid Valve (Auto Stop)
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 (24V DC)
3.Spool 9.O-ring 15.Hexagon socket head bolt
Tightening torque
N-m kgf-m ft-lbf
2 - 44 - 49 4.5 - 5 32.5 - 36
15 M5 6.9 – 8.9 0.7 – 0.9 5.1 – 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
366-460-80000 △
2
13 W121-0546E
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 10.3 How to check air conditioner.....................28
air conditioner....................................... 8
3.5 Comparison with a household 11. Diagnosis table ........................................ 29
air conditioner....................................... 8 11.1 Car air conditioner system diagnosis table I
3.6 Receiver functions...................................... 9 (Refrigeration circuit) ..........................29
3.7 Reheat method ......................................... 10 11.2 Car air conditioner system diagnosis table II
3.8 Components ............................................. 11 (External causes other than insufficient
cooling and abnormal pressure) .........32
4. Layout ..................................................... 13 11.3 Car air conditioner system diagnosis table III
4.1 Overall layout............................................ 13 (Electrical system) ..............................34
4.2 Overall layout............................................ 14 11.4 Car air conditioner system diagnosis table IV
4.3 Evaporator section ................................... 15 (Electronic thermo system) .................36
5. Compressor Assy..................................... 16
6. Evaporator Assy....................................... 17
i
12. Compressor ............................................. 38
12.1 Compressor abnormal sound diagnosis
chart ................................................... 38
12.2 Compressor diagnosis chart (1/2) ............ 39
13. Troubleshooting ....................................... 41
14. Control table ............................................ 47
K-3 Hydraulic Motor

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

(Option) .................................. 50
1. Structure .................................................. 50
K-5 Relief Valve (Air Conditioner) ....... 52
1. Structure .................................................. 52
ii
K-1 K-1
Crane Cab Glass
K-1 Crane Cab Glass 6. Let the primer C coated surfaces dry for more
1. Glass replacement procedure than 15 minutes.
Follow the procedure described below to replace 7. Clean and degrease the bonding surfaces of the
the fixed windshield window glass, roof glass, new glass with a gauze soaked with white
front right window glass (quarter window glass) gasoline or acetone.
and rear right window glass of the crane cab. Leave it more than 1 minute to dry.
1. Remove the glass to replace and the adhesive [NOTICE]

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

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

9. Let the primer B coated surfaces dry for more
[NOTICE] than 15 minutes.
Shake the primer bottle well and then apply the
primer with a brush, while making sure that there is [NOTICE]
no portion left uncoated. Apply the POS seal to the cab interior side of the
Prevent the primer coated surfaces from any molding, to a point inner than the center.
contact with hand, brush hairs, dust, water drops,
etc. 10. Apply the POS Seal (Cemedine product) to the
The primer deposited on a surface other than the glass fitting groove of the molding.
glass bonding surfaces should be immediately
wiped away with a cloth soaked with white gasoline.
5. Apply a 5 to 20µm (0.0002 to 0.0008 inch) thick
coat of primer C to the glass bonding surfaces of
the cab body.
• Primer C:
AR Primer for cab (clear)
Cemedine Co., Ltd.
1 W587-0011E
K-1. K-1.
Crane Cab Glass
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 W701-0330E
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 W701-0330E
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.
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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.
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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.
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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 W701-0330E
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2. Large variations in compressor speed

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

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

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

cycle.
If moisture enters the cycle, it will cause corrosion
of functioning parts, and will freeze in the hole of
the expansion valve, inhibiting the flow of
refrigerant.
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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
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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
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WARNING Air outlet changeover switch

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

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

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

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

These switches are used to adjust the
temperature of the air from the air conditioner
among eight steps.
The current temperature is shown by the bargraph
on the display.
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4. Layout
4.1 Overall layout
345-112-42000 △
0
13 W701-0330E 13
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Air Conditioner
4.2 Overall layout
345-112-43000 △
0
14 W701-0330E 14
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Air Conditioner
4.3 Evaporator section
345-109-42000 △
2
345-107-02000 △
5
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5. Compressor Assy
16 W701-0330E
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Air Conditioner
6. Evaporator Assy
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7. Condenser Assy
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8. Electric
8.1 Electric circuit
363-205-60030 △
0
19 W701-0330E 19
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Air Conditioner
8.2 Main harness A
20 W701-0330E 20
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Air Conditioner
8.3 Main harness B
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9. Important points for assembly

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

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

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

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

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

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

10.1 Charging gas in automatic operation
Gas charging unit (Reference)
24 W701-0330E
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Air Conditioner
Flow Jigs and

Procedure Safety point
No. tools
1 Plug the power supply cord of the main unit.
2 Connect the coupler of the high-pressure side (red hose) and the Be careful to the
low-pressure side with the compressor main body sequentially. scaffold
Purge residual pressure before connecting because the
connection of coupler becomes firm if there is residual pressure in
the unit.
(Usually it has been performed at work end. Refer to Flow No.14.)
3 Attach all freon cans. (6 cans) Be careful that gas

Tighten as it is though the gas leaks a little when attaching. liquor does not splash
4 Turn ON the automatic gas sweep switch. (to increase degree of
vacuum)
(If the gas is insufficient, turning OFF is allowed.)
5 Set the time switch to "20 minutes".
(Set to longer period if there is a time.)
6 Turn the power switch to the automatic side. (starts vacuum)
7 Vacuum operation is finished when the buzzer sounds 15-20
minutes later. Starts gas charging.
8 Engine start is allowed when buzzer sound stops. (Turn ON the air Make sure to check
conditioner switch.) surroundings
(Keep idling for at least 10 minutes --- specified by DENSO.)
9 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
10 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 min-1
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
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: Low-High
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 200±50g (0.44 ± 0.11 lb) 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 min-1
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

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 Check point and
No.
tools
1 Illumination lamp check (for control panel)
1) The lamp lights with the working lamp switch ON. (Two lamps
Lights both 2 lamps.
on upper and lower of center in the panel.)
2) The lamp turns off with the working lamp switch OFF.
2 Cooler temperature control switch. (Check with blower "HI".)
1) The cooler operates by setting to "COOL". (With maximum Must be a cold blow
cooling.)
(The cooler will be hard to operate if the ambient temperature is
low. The checking becomes easy when raising the cabin
temperature to about 25°C (77°F).)
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 (77-95°F)
(The standard of temperatures fluctuate is about 10-17°C
(50-62.6°F).)
* 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.
31 W701-0330E
K-2 K-2
Air Conditioner
11.2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure)
Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Water leak is Cooling unit Leaks at normal operation. Water leak from cooling Drain hose for blocking, bend, or Install drain hose, grommets,
found. case. coming off failure. and heat insulators
Delivery valve blocking, bend, appropriately, or replace case
coming off, or opening at end. and failed components.
Blocking in outlet under case.
Crack under case.
Noise sounds. Inside cabin. Gas leakage sound is ------------------------------- Gas leakage between Seal with packing or packing
heard. evaporator unit and blower material.
motor heater unit.
Something is heard from ------------------------------- Abnormal sound from motor or Replace the one with large
blower motor fan relation. bearing. sound.
------------------------------- Foreign object intrusion in fan Remove foreign object.
case.
Refrigerant gas sound ------------------------------- Gas vibration sound (flow sound Remove interference between
(sound 'Goooo!') is heard. or pulse sound) refrigeration piping and vehicle
frame or hood, if there is.
Something is heard from Whistle sound. ------------------------------- Replace parts for the one with
TXV relation (whistle sound large whistle sound.
or gas flow sound). Gas flow sound Gas flow sound may be Check refrigerant level, and
generated at insufficient charge refrigerant.
refrigerant or at air/refrigerant
mixed condition.
------------------------------- Gas flow sound is generated
somewhat, and check sound
level, then replace if it is noisy.
Engine room side Sound is generated when ------------------------------- Clutch bearing or idle pulley Replace bearing and idle
compressor and bearing is failure. pulley. Longevity will be
electromagnetic clutch are shortened if belt is
OFF. over-tensioned.
------------------------------- Loosening of idle pulley Re-tighten screw.
mounting nut.
Sound is generated when ------------------------------- Compressor noise failure. Repair or replace in case of
compressor starts. failure.
32 W701-0330E
K-2 K-2
Air Conditioner
Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Noise sounds. Engine room side Sound is generated when -------------------------------- Vibration or slip by belt Tension belt, replace, or
compressor starts. looseness (continuous sound re-tighten screw.
'Quuuu!'). Screw looseness
failure.
Sound is generated from -------------------------------- Motor-fan shaft shaking, bearing Repair or replace.
radiator fan and condenser breakdown, fan damage, or
fan. fan/shroud come in contact.
Sound is generated from -------------------------------- Dropout of fixed bolt, looseness, Tighten appropriately, or
parts installation section or damage of brackets. replace brackets.
(shaking when touching).
Vehicle Condenser unit Condenser is set in front of Blocking in condenser fin. -------------------------------- Wash condenser fin.
overheats radiator. Revolution of condenser fan Condenser fan failure. Replace condenser fan motor.
easily. is slow.
High-pressure is high. (High Same cause as refrigeration Same measures as
pressure is high at idling.) circuit system-I. (Hot air flows in refrigeration circuit system-I
condenser.)
Vehicle Vehicle side Trouble around radiator. Blocking in radiator fin. Wash or replace radiator fin.
overheats -------------------------------- Dirt inside radiator. Check and replace.
easily. Radiator filler cap failure.
Water pump failure.
Blocking in water thermo.
Radiator coolant is -------------------------------- Check leakage and replenish,
shortage. or replace radiator.
Fan belt and water pump -------------------------------- Adjust belt tension or replace
belt are slippage. belts.
Revolution of radiator Radiator fan failure. Replace
cooling fan is slow, or
slippage.
Engine Vehicle side Engine revolution adjusting -------------------------------- Raising idling speed too much or Adjust idling speed to a
(revolutions) is device overheat. regulated value, and adjust
overrun. engine. Take measures for
overheat.
Smells Cooling unit -------------------------------- -------------------------------- Smoke of Tabaco, dust, and Wash evaporator.
unpleasant. mold, etc. are adhered or
deposited to the evaporator fin.
33 W701-0330E
K-2 K-2
Air Conditioner
11.3 Car air conditioner system diagnosis table III (Electrical system)
Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
1) Neither Check of fuse -------------------------------- No fuse blowing -------------------------------- Measures from diagnosis
compressor clutch blowing. (normal). of 2) and 4).
nor blower motor -------------------------------- Fuse blowing. Short-circuit of compressor clutch Repair
operate. or blower motor system wiring.
2) Only Connect battery Clutch does not suck. ---------------------------- Clutch failure. Replace
compressor clutch directly to clutch Clutch does suck. Clutch does suck. Either of thermo amp., pressure Check and replace parts.
does not suck. terminal. Short-circuit both ends SW, or thermistor is failure.
(Others are of thermo amp. bypass Clutch does not suck. 0 (zero) V Check parts, and repair or
operating.) connector, pressure SW, Check voltage of Either of clutch relay signal replace parts.
and thermistor. clutch relay connector. circuit or vehicle side electronic
control amplifier is failure.
Clutch does not suck. Approx. 12V Check parts, and repair or
Check voltage of Either of clutch relay or clutch replace parts.
clutch relay connector. power circuit (disconnection) is
failure.
3) Compressor Remove thermistor Clutch does not suck. ---------------------------- Thermistor failure. Replace
clutch suction does from thermo amp. Clutch does suck. Clutch does not suck. Thermo amp. failure. Replace
not stop. Remove thermo amp. Clutch does suck. Clutch relay contact failure. Replace
power supply connector.
4) Only blower Connect battery Blower motor does not ---------------------------- Blower motor failure. Replace
motor does not directly to "+" work.
work. terminal of blower Blower motor works. Blower motor works. Blower switch failure. Replace
motor. Connect L.M.H of blower Blower motor does not Blower system cords Repair
switch directly to battery work. disconnection.
terminal. Rresistor failure. Replace
5) Condenser fan Connect battery Fan motor does not work. ---------------------------- Fan motor failure. Replace
motor does not directly to "+" Fan motor works. 0 (zero) V Signal circuit is open, and thermo Check parts, and repair or
work. terminal of fan Check voltage of amp. failure. replace parts.
motor. condenser fan relay Approx. 12V Condenser fan relay contact Check parts, and repair or
connector. failure or fan motor power circuit replace parts.
open.
6) Compressor Check air gap. -------------------------------- ----------------------------- Air gap is large. Adjust air gap.
clutch slips.
34 W701-0330E
K-2 K-2
Air Conditioner
Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
6) Compressor Measure clutch -------------------------------- ---------------------------- Clutch suction voltage is low (7V Repair or replace parts.
clutch slips. suction voltage. or less).
Try to turn -------------------------------- ---------------------------- Compressor shaft does not turn Repair or replce parts.
compressor shaft smoothly.
manually.
35 W701-0330E
K-2 K-2
Air Conditioner
11.4 Car air conditioner system diagnosis table IV (Electronic thermo system)
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Compressor Check thermistor. Measure resistance of Resistance is small. Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. (Abnormal if resistance is
ON. about 7kΩ or less.)
Resistance is about 2kΩ Thermistor is normal. ----------------------------
(25°C).
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.)
36 W701-0330E
K-2 K-2
Air Conditioner
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp. internal Replace thermo amp.
cooling. (Clutch thermistor with not change. failure.
works ON and new one.
OFF.) Check installation Positioned correctly. -------------------------------- Thermistor failure. Replace thermistor.
condition of Incorrect position or comes off. -------------------------------- -------------------------------- Install thermistor in correct
thermistor. position.
Insufficient Refer to other -------------------------------- -------------------------------- -------------------------------- --------------------------------
cooling. (Clutch diagnosis tables.
stayed ON) (Excluding the
cause of
electronic thermo
system.)
37 W701-0330E
K-2 K-2 K-2
Air Conditioner
12. Compressor
12.1 Compressor abnormal sound diagnosis chart
38 W701-0330E 38
K-2 K-2 K-2
Air Conditioner
12.2 Compressor diagnosis chart (1/2)
39 W701-0330E 39
K-2 K-2 K-2
Air Conditioner
Compressor diagnosis chart (2/2)
40 W701-0330E 40
K-2 K-2
Air Conditioner
13. Troubleshooting
41 W701-0330E
K-2 K-2
Air Conditioner
42 W701-0330E
K-2 K-2
Air Conditioner
43 W701-0330E
K-2 K-2
Air Conditioner
44 W701-0330E
K-2 K-2
Air Conditioner
45 W701-0330E
K-2 K-2
Air Conditioner
46 W701-0330E
K-2. K-2. K-2.
Air Conditioner
14. Control table
Input Output
Input from Panel LCD display on panel
ON/OFF Blowout mode In/outside A/C switch In/outside air
M/A Blowout mode Air blow mode Relay
Air blow DOWN switch

change switch mode
Temp. control display

Temp. DOWN switch
Switch air switch
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
B/L
ON
ON
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 W701-0330E 47
K-3 K-3
Hydraulic Motor (Air Conditioner)
K-3 Hydraulic Motor (Air Conditioner)

[NOTICE]
1. Structure
2 16 12 1 8 11 A 10 4 B 3
24 19
A B
9 13 15 IW102-037001
48 W102-0372E
K-3. K-3.
Hydraulic Motor (Air Conditioner)
A-A Section B-B Section
5 7 6
Dr
IW102-037002
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
366-634-40003 △
0
366-634-40002 △
0
366-634-40001 △
0
49 W102-0372E
K-4 K-4
Solenoid Valve (Air Conditioner) (Option)
K-4 Solenoid Valve (Air Conditioner) (Option)

[NOTICE]
1. Structure
1. Solenoid valve assy 2. Body 3. Orifice
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/2 98 10 72
T1 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
50 W121-0952E
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.Hexagon socket head bolt 71.Spring 157.Solenoid (24V DC)

4.Plug 21.Spool 113.Square ring 159.O-ring
9.O-ring 60.Spring seat 156.O-ring
Tightening torque
N-m kgf-m ft-lbf
4 - 44 - 49 4.5 - 5 32 - 36
15 M5 6.9 - 8.9 0.7 - 0.9 5.1 - 6.5
T1 - 38.3 - 41.2 3.9 - 4.2 28.3 - 30.4
T2 - 3.9 - 4.9 0.4 - 0.5 2.9 - 3.6
367-415-00000 △
0
51 W121-0952E
K-5. K-5.
Relief Valve
K-5 Relief Valve
[NOTICE]
1. Structure
1.Body 5.Spring 9.Adjuter 13.O-ring

2.Sleeve 6.Poppet 10.Cap 14.O-ring
3.Valve 7.Spring 11.Locknut 15.O-ring
4.Sheet 8.Plug 12.O-ring 16.Seal
Tightening torque
N-m kgf-m ft-lbf
P, T G1/2 98 10 72
366-068-80000 △
0
366-061-10000 △
0
52 W111-0360E
L
Control System
Contents
L-1 Control Device.................................. 1 L-5 Remote Control Valve (Pedal) .......15
1. Crane control ............................................. 1 1. Structure .................................................. 15
2. Driving control............................................ 3
L-6 Shuttle Valve (Lever / Pedal) .........18
3. Other control device................................... 5
1. Structure .................................................. 18 L
L-2 Shift Switch ...................................... 6
L-7 Solenoid Valve (Boom Telescoping
1. Structure .................................................... 6 / Aux. Winch) ..........................19
2. Electric circuit............................................. 9 1. Structure .................................................. 19
L-3 Solenoid Valve (Air) ....................... 10 L-8 Proportional Control Valve

(Elevation Slow Stop) ............21
1. Structure .................................................. 10
1. Structure .................................................. 21
L-4 Remote Control Valve (Lever) ..... 12
1. Structure .................................................. 12
i
L-1 L-1
Control Device
L-1 Control Device
1. Crane control
Inside cab
1 WL01-0270E
L-1 L-1
Control Device
Inside cab
Outside cab
2 WL01-0270E
L-1 L-1
Control Device
2. Driving control
Inside cab
3 WL01-0270E
L-1 L-1
Control Device
Inside cab
4 WL01-0270E
L-1. L-1.
Inside Cab Control Device
3. Other control device

Inside cab
5 WL01-0270E
L-2 L-2
Shift Switch
L-2 Shift Switch
[NOTICE]
1. Structure
6 W326-0280E
L-2 L-2
Shift Switch
1. Detent rod
2. Rod
3. Shift lever plate
4. Detent plate
5. Screw with washer
6. Shift lever sub assy
7. Pin
8. Plate
9. Upper indicator
10. Lower indicator
11. Switch valve
12. Control shaft
13. Spring
14. Knob
15. Button
16. Pin
18. Indicator plate
19. Nut
20. Slide cover
21. Sleeve
22. Bush
25. Spring washer
27. Clamp
28. Piston
29. Steel ball
30. Guide pipe
31. Spring
32. Shifter
35. Cord clamp
7 W326-0280E
L-2 L-2
Shift Switch
Detail of A Shift position
Tightening torque
Sign/Port Thread size
N-m kgf-cm ft-lbf
5 － 1.8 - 2.5 18 - 26 1.3 - 1.8
17, 35, 36 － 1.4 - 2.0 14 - 20 1.0 - 1.5
19 － 9.8 - 15.7 100 - 160 7.2 - 11.6
23 － 4.1 - 5.5 42 - 56 3.0 - 4.1
24 － 1.5 - 2.5 15 - 25 1.1 - 1.8
26 － 2.4 - 3.0 24 - 31 1.8 - 2.2
8 W326-0280E
L-2. L-2.
Shift Switch
2. Electric circuit
347-213-61001 △
0
9 W326-0280E
L-3 L-3
Solenoid Valve (Air)
L-3 Solenoid Valve (Air)

[NOTICE]
1. Structure
Connector
+-
IW210-0151E01
10 W210-0171E
L-3. L-3.
Solenoid Valve (Air)
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 kgf-m ft-lbf
IN, OUT Rc1/4 15 - 29 1.5 - 3 11 - 22
23 - 2-3 0.2 - 0.3 1.5 - 2.0
T1 M8x1.25 8 - 12 0.8 - 1.2 6-9
366-474-50000 △
3
11 W210-0171E
L-4 L-4
Remote Control Valve (Lever) (Right Side)
L-4 Remote Control Valve (Lever) (Right Side)

[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
IW135-0135E02
12 W135-0135E
L-4 L-4
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
IW135-0135E03
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
13 W135-0135E
L-4.
Tightening torque
N-m kgf-m ft-lbf
P, T G1/4 34.3 - 38.3 3.5 - 3.9 25 - 28
PORTS 1, 2, 3, 4 G1/4 34.3 - 38.4 3.5 - 3.9 25 - 28
125 M8 27.4 - 31.4 2.8 - 3.2 20 - 23
161 R1/4 19.6 - 23.6 2 - 2.4 14 - 17
172 M8 15.7 - 17.7 1.6 - 1.8 12 - 13
411 M12 27.4 - 31.4 2.8 - 3.2 20 - 23
445 M8 27.4 - 31.4 2.8 - 3.2 20 - 23
454 *1 M8 15.7 - 17.7 1.6 - 1.8 12 - 13
481 M6 10.8 - 12.8 1.1 - 1.3 8 - 9.4
366-349-20000 △
0
14 W135-0135E
L-5 L-5
Remote Control Valve (Pedal)
L-5 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
4 14
262
263
T
115
P
27 2 273
Port 1,2 Port 3,4 Port 5,6 102

10 1 10 3 A IW135-0156E02
15 W135-0156E
L-5 L-5
50 1 41 3 47 2 47 3 42 0
47 1
21 4
21 0
27 1
20 2
20 1
21 2
31 1
32 4
T
33 5
21 7
P
31 3
25 1
26 1
30 1
Port 1 ,3,5 Port 2 ,4 ,6
10 1
A-A IW135-0156E01
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.Lock nut 471.Ball
202.Plug 263.O-ring 323.Lever 472.Set screw
210.Seal 271.Hexagon socket head bolt 324.Spring 473.Hexagon socket head bolt
212.O-ring 272.Hexagon socket head bolt 335.Spring 501.Boot
16 W135-0156E
L-5. L-5.
Tightening torque
N-m kgf-m ft-lbf
272 M8 19.1 - 22.1 1.95 - 2.35 14.1 - 16.3
271 M6 8.7 - 8.9 0.89 - 0.91 6.4 - 6.6
251 G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
315 M12 56.3 - 61.3 5.7 - 6.3 41.5 - 45.2
5.9 - 7.9 0.6 - 0.8 4.4 - 5.8
472 M6
Apply LOCTITE 241.
473 M8 15.2 - 18.2 1.55 - 1.85 11.2 - 13.4
P, T G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
Port 1,2,3,4,5,6 G1/4 27.4 - 31.4 2.8 - 3.2 20.2 - 23.2
366-380-60000 △
2
366-377-50000 △
3
17 W135-0156E
L-6. L-6.
Shuttle Valve (Lever/Pedal)
L-6 Shuttle Valve (Lever / Pedal)

[NOTICE]
1. Structure
c d
e f
a b
IW128-011001
c d d(c)
2
f(e)
1
a b b(a)
IW128-011002
1.Body 2.Joint 3.O-ring 4.Steel ball
Tightening torque
N-m kgf-m ft-lbf
a, b, e, f G1/4 29.4 3 22
c, d G1/4 29.4 3 22
2 G3/8 49 5 36
366-236-90000 △
1
18 W128-0113E
L-7 L-7
Solenoid Valve (Boom Telescoping/Aux. Winch)
L-7 Solenoid Valve (Boom Telescoping / Aux. Winch)

[NOTICE]
1. Structure
H F G D B C
E T A
IW121-031001
Connector
+-
(+): Red
(-): Black
IW121-0542E01
19 W121-0315E
L-7. L-7.
Solenoid Valve (Boom Telescoping/Aux. Winch)
Cross section along the line X-X
3 1 14 16
B (F) D (H)
C (G)
11
T T
8
A (E)
4 16 7 15
X-X
IW121-031003
Note: Apply LOCTITE 262 (thread locking agent) to the threaded section of the seat (1).
1.Seat 5.Solenoid (24V DC) 11.Plain washer 16.Plug

2.Spring 7.Sleeve 13.Steel ball
3.Body 8.Stopper 14.Steel ball
4.Spool 10.Hexagon socket head bolt 15.O-ring
Tightening torque
N-m kgf-m ft-lbf
A, B, C, D G1/4 29.4 3 22
E, F, G, H G1/4 29.4 3 22
T G1/4 29.4 3 22
366-481-30000 △
1
20 W121-0315E
L-8 L-8
Proportional Control Valve (Elevation Slow Stop)
L-8 Proportional Control Valve (Elevation Slow Stop)

[NOTICE]
1. Structure
601
171
151
A2 A1
101.Casing P2 P1
151.Plug
601.Proportional reducing valve
101 T1 IW136-0250E01
Tightening torque
N-m kgf-m ft-lbf
P1, P2, T, A1, A2 G1/4 34 - 38 3.5 - 3.9 25 - 28
151 R1/16 6-8 0.6 - 0.8 4-6
171 M5 6-8 0.6 - 0.8 4-6
T1 M8 26 - 32 3.7 - 3.3 20 - 24
21 W136-0253E
L-8. L-8.
Proportional Control Valve (Elevation Slow Stop)
Proportional Reducing Valve
351 311 326 324 331
P A T
312 361 362 363 861 325 801 802
IW136-0250E02
311.Spool 326.Retaining ring 362.O-ring 861.O-ring

312.Sleeve 331.Spring seat 363.O-ring
324.Spring 351.Orifice 801.Proportional reducing valve
325.C-ring 361.O-ring 802.Seal nut
Tightening torque
N-m kgf-m ft-lbf
351 M3 0.5 - 0.7 0.05 - 0.07 0.37 - 0.52
802 M6 6.9 - 7.9 0.7 - 0.8 5.1 – 5.8
367-301-50000 △
0
22 W136-0253E
N
Electric System
Contents
N-1 Display Control Unit (DCU) ............. 1 3. Specifications........................................... 26

3.1 Speedometer.............................................26
1. System configuration ................................. 1 3.2 Tachometer ...............................................26
3.3 Odo/trip meter, hour meter........................26
2. Structure and function................................ 3 3.4 Odometer ..................................................26
3.5 Trip meter..................................................26
3. Connector (pin assignment)....................... 4 3.6 Hour meter ................................................26
3.7 Fuel gauge ................................................27
4. Input/output signal list ................................ 9 3.8 Coolant temperature gauge ......................27
3.9 Air pressure gauge....................................28
5. Error code list........................................... 13 3.10 Torque converter oil temperature
gauge ..................................................28 N
6. Data list .................................................... 14
6.1 Engine speed pulse output....................... 14 4. Electric circuit .......................................... 29
6.2 Vehicle speed signal pulse output............ 14
6.3 One-to-one correspondence input/output
function............................................... 15
6.4 Integration for hour meter......................... 16
6.5 Integration for odometer ........................... 16
6.6 Actual value conversion formula .............. 17
6.7 PWM output.............................................. 18
6.8 CAN communication................................. 19
6.9 Integrated value rewriting function ........... 19
6.10 DPF indicator function .............................. 20
6.11 DPF Indicator check function ................... 22
N-2 Combination Meter ........................ 23
1. System configuration ............................... 23
2. Display section......................................... 24
i
N-3 Signal Transmitter (STM-E) ........... 31 N-5 Telecommunications terminal.......66
1. System configuration ............................... 31 1. System configuration ............................... 66
2. Structure and function.............................. 33 2. ICF ..................................................... 67

2.1 External view.............................................67
3. Connector (pin assignment)..................... 34 2.2 Connector (pin assignment)......................67
4. LED display.............................................. 34 3. SCT (Satellite communication tarminal) .. 68

3.1 External view.............................................68
5. Input / output signal list ............................ 35 3.2 Connector (pin assignment)......................68
6. Error code list........................................... 37
7. Data list .................................................... 38

7.1 One-to-one correspondence
input / output function......................... 38
7.2 Integration function for remaining
fuel amont........................................... 39
7.3 CAN communication................................. 40
7.4 K-LINE communication specification........ 42
7.5 Error transmission .................................... 43
7.6 Communication between the lower MDT
and lower STM-E for machines
without DPF........................................ 45
7.7 Conversion of fuel consumption unit ........ 45
7.8 CAN and serial communication list........... 46
7.9 Specification of “DIAG on CAN”
communication ................................... 47
N-4 Engine Control Unit (ECU) ............ 48
1. System configuration ............................... 48
2. Diagnosis function ................................... 49

2.1 Check for a failure (user mode)................ 49
2.2 Diagnosis lamp lighting law when a failure
is detected .......................................... 49
2.3 How to call up faulty part .......................... 50
2.4 Diagnosis code display law ...................... 50
2.5 Clear of faulty part .................................... 50
2.6 Diagnosis lamp bulb burnt-out check ....... 50
2.7 Diagnosis code chart................................ 51
ii
N-1 N-1
Display Control Unit (DCU)
N-1 Display Control Unit (DCU)

[NOTICE]
The appearance or other items may differ from those of the parts for this machine. Even through the functions
and disassembly procedure will not differ so much, ensure to check the serial number of this machine and the
sales unit on the parts catalog before starting the disassembly work.
1. System configuration
The display control unit (DCU) is configured as shown in the configuration chart below.
1 W303-0590E
N-1 N-1
DCU type
Type Spec.
GR-350-2-00103
(0, 0, 0)
GR-300E-2-00102, 00104
(0, 0, 1) -
GR-1000-2-00101, 00103, 00104
GR-800E-2-00101, 00102, 00104, 00302
GR-750-2-00101, 00103
(0, 1, 0)
GR-600E-2-00102, 00104, 00302
GR-550-2-00101, 00104
GR-500E-2-00101, 00102, 00104, 00302
GR-1000-2-00201
GR-550-2-00201
(0, 1, 1)
GR-350-2-00101, 00102
GR-300E-2-00101
2 W303-0590E
N-1 N-1

The display control unit drives the combination meter and transmits the vehicle information (include error
history) to the information controller (ICF).
1. Base 3. Circuit board assembly 5. Silicon sheet 7. Cross-recessed round head

2. Cover 4. Nameplate 6. Cross-recessed round head screw
screw
3 W303-0590E
N-1 N-1
3. Connector (pin assignment)
4 W303-0590E
N-1 N-1
CN1 (1-1376430-1) (Section A)
Connector
Signal Signal name
pin No.
1 MB (+ 24V) Power supply input
4 GND GND
5 GND GND
6 GND GND
7 12V OUT 12 V output (300 mA)
8 Pi 1 Pulse input (0 to 12 V, MAX 600 Hz)
9 Pi 2 Pulse input (0 to 12 V, MAX 600 Hz)
10 Po 1 Pulse output (0 to 12 V, MAX 600 Hz)
13 GND GND
14 GND GND
15 GND GND
16 GND GND
17 GND GND
18 Ao 1 PWM output (with emergency circuit), 122 Hz
19 Ao 2 PWM output, 122 Hz
22 GND GND
23 GND GND
24 GND GND
25 GND GND
26 GND GND
27 GND GND
28 TXD + MDT communication
29 TXD - MDT communication
30 RXD + MDT communication
31 RXD - MDT communication
5 W303-0590E
N-1 N-1
CN1 (1-1376430-1) (Section B)
Connector
Signal Signal name
pin No.
32 Do 1 200 mA (Internal ground)
48 AVCC Analog power supply (5V)
51 AGND Analog GND
52 AGND Analog GND
53 AGND Analog GND
54 Ai 1 Analog input (0 to 5 V input)
57 Ai 4 Analog input (0 to 300 Ω connected)
60 SLD Shield
61 SLD Shield
62 SLD Shield
63 GND Maintenance communication GND
64 RSTXD Maintenance communication
65 RSRXD Maintenance communication
66 BOOT Boot signal
6 W303-0590E
N-1 N-1
CN1 (1-1376430-1) (Section C)
Connector
Signal Signal name
pin No.
67 CAN_H (High) CAN communication
68 CAN_L (Low) CAN communication
69 GND GND
94 Di 33 5 V source type
7 W303-0590E
N-1 N-1
CN1 (1-1376430-1) (Section D)
Connector
Signal Signal name
pin No.
102 GND GND
103 GND GND
104 Di 1 24 V sink type
8 W303-0590E
N-1 N-1
4. Input/output signal list

Digital input (Di) signal
The connection status of sink type and source type is showm in the figure below.
(*1): Voltage varies depending on unit equipment.
Digital output (Do) signal
The connection status of sink type is showm in the figure below.
9 W303-0590E
N-1 N-1
Input Signal Signal name Signal definition
Signal Signal name Signal definition 0:

Di28 Spare input
1:
Starter switch/ 0: Starter switch OFF/ACC
Di1 0:
ON signal 1: Starter switch ON/START Di29 Spare input
1:
Main winch 0: Main winch lever in operation
Di2 detection 0:
1: Main winch lever in neutral Di30 Spare input
1:
Aux. winch 0: Aux. winch lever in operation
Di3 detection 0:
1: Aux. winch lever in neutral Di31 Spare input
1:
Telescoping 0: Telescoping lever in operation
Di4 detection 0:
1: Telescoping lever in neutral Di32 Spare input
1:
Elevating 0: Elevating lever in operation
Di5 detection 0:
1: Elevating lever in neutral Di33 Spare input
1:
Swing 0: Swing lever in operation
Di6 detection 0:
1: Swing lever in neutral Di34 Spare input
1:
AML normal 0: AML abnormal
Di7 0:
input 1: AML normal Di35 Spare input
1:
AML override 0: Switch in neutral
Di8 0:
input 1: Switch in operation Di36 Spare input
1:
0:
Di9 Spare input 0:
1: Di37 Spare input
1:
0:
Di10 Spare input 0:
1: Di38 Spare input
1:
0:
Di11 Spare input 0:
1: Di39 Spare input
1:
0:
Di12 Spare input 0:
1: Di40 Spare input
1:
0:
Di13 Spare input Ai1 Air pressure
1:
0: Ai2 Spare input
Di14 Spare input
1:
Ai3 Spare input
0:
Di15 Spare input T/C hydraulic
1: Ai4 temperature
0:
Di16 Spare input
1: Ai5 Fuel gauge
0: Ai6 Spare Input
Di17 Spare input
1: Ai7 For internal 24 V
0:
Di18 Spare input Ai8 For internal 5 V
1:
0: Pi1 Engine speed
Di19 Spare input Vehicle speed
1: Pi2 singal
0:
Di20 Spare input
1:
0: • Di (Digital input) specifications
Di21 Spare input
1: Di1 to 8: 24 V sink input (battery voltage input)
0: (positive logic)
Di22 Spare input
1: Di9 to 40: 5 V source input (GND) (nagative logic)
0:
Di23 Spare input
1: • Ai (Analog input) specifications
0:
Di24 Spare input Ai1 to 3: 0 to 5 V input
1:
0: Ai4 to 6: 0 to 300 Ω connection
Di25 Spare input
1:
0:
• Pi (Pulse input) specifications
Di26 Spare input
1: (0 to 12 V, Max. 600Hz)
0:
Di27 Spare input
1:
10 W303-0590E
N-1 N-1
Output Signal Signal name Signal definition

Signal Signal name Signal definition 0: Indicator goes off
Do28 3
0: Indicator goes off 1: Indicator lights up
Do1 CPU error 0: Indicator goes off
1: Indicator lights up Do29 2
Water 1: Indicator lights up
0: Indicator goes off
Do2 separator 0: Indicator goes off
1: Indicator lights up Do30 1
Engine ECU 1: Indicator lights up
Do3 error (red) Reduction 0: Reduction speed solenoid OFF
1: Indicator lights up Do31 speed output 1: Reduction speed solenoid ON
Remaining 0: Indicator goes off
Do4 radiator
DPF warning
1: Indicator lights up Do32 lamp (manual
Engine hydraulic 0: Indicator goes off regeneration) 1: Indicator lights up
Do5 pressure alarm 1: Indicator lights up AML vent 0: AML vent solenoid OFF
Torque converter Do33 output
0: Indicator goes off 1: AML vent solenoid ON
Do6 hydraulic pressure
alarm 1: Indicator lights up 0: Indicator goes off
Do34 DPF level 1
Do7 Steering alarm
1: Indicator lights up Pilot vent 0: Pilot vent solenoid energized
Do35 output
Speed and 0: Indicator goes off 1: Pilot vent solenoid not energized
Do8 overrun alarm 1: Indicator lights up 0: Indicator goes off
Do36 DPF level 2
Do9 CHG External
1: Indicator lights up 0: Lamp not lit
Do37 indicator lamp
Remaining fuel 0: Indicator goes off 1: Lamp lit
Do10 output
alam 1: Indicator lights up
Low air 0: Indicator goes off Do38 DPF level 3
Do11 1: Indicator lights up
pressure alarm 1 : Indicator lights up
0: No sound
0: Indicator goes off Do39 Buzzer output
Do12 Low mode 1: Sound
1: Indicator lights up
0: Indicator goes off Do40 DPF level 4
Do13 3rd brake 1: Indicator lights up
Ao1 Air pressure
Do14 Parking brake T/C hydraulic
1: Indicator lights up Ao2 temperature
Do15 Exhaust brake Ao3 Fuel gauge
Engine ECU 0: Indicator goes off Coolant temp.
Do16 Ao4 gauge
error (yellow) 1: Indicator lights up
Differential 0: Indicator goes off Po1 Engine speed
Do17 lock 1: Indicator lights up Vehicle speed
Po2 signal
Do18 4WD
1: Indicator lights up Vehicle speed
Po3 signal For tachograph (1/5 dividing)
Suspension 0: Indicator goes off
Do19 lock 1: Indicator lights up
Special 0: Indicator goes off
Do20 steering 1: Indicator lights up • Do (Digital output) specifications
0: Indicator goes off Sink output (O.C., 200 mA) (negative logic)
Do21 PTO
O.C.: Open Collector
Do22 Working lamp
• Ao (Analog output) specifications
Do23 Lock pin (PWM output, 122 Hz)
0: Indicator goes off PWM: Pulse Width Modulation
Do24 Rear center
0: Indicator goes off • Po (Pulse output)specifications
Do25 R
1: Indicator lights up (0 to 12 V, Max. 600 Hz)
Do26 N
Do27 D
11 W303-0590E
N-1 N-1
Serial communication (current roup) input

Signal Signal name Signal definition
Di1 CPU error
Water
Di2 separater
Engine ECU
Di3 error (red)
Remaining
Di4 radiator
Engine oil
Di5 pressure alarm
Torque converter oil
Di6 pressure alarm
Di7 Steering alarm

Speed and
Di8 overrun alarm
Di9 CHG
Di10 Remaining fuel
Low air
Di11 pressure alarm
Di12 Low mode
Di13 3rd brake
Di14 Parking brake
Di15 Exhaust brake
Engine ECU
Di16 error (yellow)
Di17 Differential lock
Di18 4WD
Suspension
Di19 lock
Special
Di20 steering
Di21 PTO
Di22 Working lamp
Di23 Lock pin
Di24 Rear center
Di25 R
Di26 N
Di27 D
Di28 3
Di29 2
Di30 1
Spare Input
Di31
(not used)
DPF warning
Di32 lamp (manual
regeneration)
361-713-83040 △
1
12 W303-0590E
N-1 N-1
5. Error code list

Error code
Error code Error signal (DTC code)
Remedy for error
transmitted transmitted from CAN Error description and detection conditions
to MDT SPN FMI, CM OC Recovery conditions
No error -
(0,0) - - -
-
Open-circuit in MDT receiving line • Data received from MDT is not
In the case that DCU receives no communication data updated.
from MDT for 600 ms or longer • Do1 is turned on. Do2 to Do30
(0,1) 131329 0 1 At power on, no error detection is performed for 4 are held.
seconds. • Do32, 34, 36, 38 and 40 are held.
• Communication data from MDT is
received normally.
Error of data received from MDT • Data received form MDT is not
In the case that data received from MDT has a receiving updated.
error (parity/framing/overrun error, check sum error, (Except for transmission
error in number of received bytes, transmission time-out, time-out)
(1,0) 131330 0 1 and type error) for three successive times • Do1 is turned on. Do2 to Do30
are held.
• Do32, 34, 36, 38 and 40 are held.
• Communication data from MDT is
received normally.
Controller self-diagnosis error (voltage monitoring) Turn on Do1.
The battery voltage (24 V) and detector voltage (5 V) are

checked every cycle. Check result is normal.
In the case that all the six retries cannot satisfy the
(1,1) 131331 0 1 following conditions:
Battery voltage: 18 to 32 V, detector voltage: 4.5 to 5.5 V
A/D conversion error Do1 is turned on. A/D conversion
In the case that A/D conversion operation is not value is held.
completed by the end of the waiting time. A/D conversion is completed
successfully.
Controller self-diagnosis error (ROM sum check) All outputs are off and operation is
ROM sum check is performed at power on. stopped.
In the case that all the three retries show an error Turning on the power again
Controller self-diagnosis error (CPU error) All outputs are off and operation is
(1) Calculation with ADD, SUB, multiplication, and divide stopped.
commands and comparison with correct answers on
ROM are performed at power on. Turning on the power again
In the case that all the three retries show an error
No error (2) In the case that a detectable run away in software is
code detected
No error code
transmitted Controller self-diagnosis error (RAM check: At power on) All outputs are off and operation is
transmitted because of
because of The data items (1) to (4) shown below are written for 8 stopped.
operation stop
operation bytes on RAM, read, and compared with correct
stop answers on ROM at power on.
Turning on the power again
In the case that all the three retries show an error
(1)55h (2) AAh (3) FFh (4) 00h
Controller self-diagnosis error (RAM check: Every cycle) All outputs are off and operation is
The data items (1) to (4) shown below are written for 8 stopped.
bytes on RAM, read, and compared with correct
answers on ROM every cycle.
In the case that all the six retries show an error
(1) 55h (2) AAh (3) FFh (4) 00h
(NOTE) When the operation stops, the hardware (1) turns Do1 on, and (2) switches Ao output to emergency (hardware) output.
Transmission priority when multiple errors occur simultaneously: (0, 0) > (1, 1) > (0, 1) > (1, 0)
361-713-83090 △
0
13 W303-0590E
N-1 N-1
6. Data list
6.1 Engine speed pulse output
The engine speed pulse input frequency is divided

depending on the type selection signal from MDT,
and the engine speed pulse output is sent to the
meter.
Input status Output status

DCU type determined by the serial
Pi1 Po1 Remarks
communication data from MDT
(Engine speed) (Engine speed)
(0, 0, 0) N 1/1 dividing
(0, 0, 1) N/2 1/2 dividing
N
(0, 1, 0) N x 3/4 3/4 dividing
(0, 1, 1) N/4 1/4 dividing
Frequency (Hz) Frequency (Hz)
Note 1. Type selection is defined by upper MDT to DCU communication function.
Remarks
361-713-83070 △
0
6.2 Vehicle speed signal pulse output
The vehicle speed pulse input frequency from the

vehicle speed sensor and/or MDT is divided and
the vehicle speed signal pulse output is sent to the
meter.
For RC (rough terrain crane), the output for the
meter is one-to-one output (only for the hardware)
by means of the jumper setting in the hardware,
however, the software is to be installed.
The output for the tachograph is output after
divided by 1/5 of the meter output signal.
Input status Output status

Po Po
Pi2
(Vehicle speed signal (Vehicle speed signal
(Vehicle speed signal)
for meter) for tachograph)
N N N/5
Frequency (Hz) Frequency (Hz)
Remarks
361-710-53080 △
0
14 W303-0590E
N-1 N-1
6.3 One-to-one correspondence input/output function
If Di1 is "0" (starter switch: OFF/ACC), the following one-to-one correspondence is applied to Nos. 1, 3 and 16,
and "0 (OFF)" is applied to Nos. 2, 4 to 15 and 17 to 30.
If Di1 is "1" (starter switch: ON/START), the following one-to-one correspondence is applied.
No.16 is applicable to type (0, 0, 0), type (0, 0, 1) and type (0, 1, 0).
Signal to be output to the combination meter after one-to-one correspondence with the serial signal received
from MDT
1 Di1 (CPU error) → Do1 (CPU error)

2 Di2 (Water separator) → Do2 (Water separator)
3 Di3 (Engine ECU error (red)) → Do3 (Engine ECU error (red))
4 Di4 (Remaining radiator) → Do4 (Remaining radiator)
5 Di5 (Engine hydraulic pressure → Do5 (Engine hydraulic pressure
alarm) alarm)
6 Di6 (Torque converter hydraulic → Do6 (Torque converter hydraulic
pressure alarm) pressure alarm)
7 Di7 (Steering alarm) → Do7 (Steering alarm)
8 Di8 (Speed and overrun alarm) → Do8 (Speed and overrun alarm)
9 Di9 (CHG) → Do9 (CHG)
10 Di10 (Remaining fuel) → Do10 (Remaining fuel)
11 Di11 (Low air pressure alarm) → Do11 (Low air pressure alarm)
12 Di12 (Low mode) → Do12 (Low mode)
13 Di13 (3rd brake) → Do13 (3rd brake)
14 Di14 (Parking brake) → Do14 (Parking brake)
15 Di15 (Exhaust brake) → Do15 (Exhaust brake)
16 Di16 (Engine ECU error (yellow)) → Do16 (Engine ECU error (yellow))
17 Di17 (Differential lock) → Do17 (Differential lock)
18 Di18 (4WD) → Do18 (4WD)
19 Di19 (Suspension lock) → Do19 (Suspension lock)
20 Di20 (Special steering) → Do20 (Special steering)
21 Di21 (PTO) → Do21 (PTO)
22 Di22 (Working lamp) → Do22 (Working lamp)
23 Di23 (Lock pin) → Do23 (Lock pin)
24 Di24 (Rear center) → Do24 (Rear center)
25 Di25 (R) → Do25 (R)
26 Di26 (N) → Do26 (N)
27 Di27 (D) → Do27 (D)
28 Di28 (3) → Do28 (3)
29 Di29 (2) → Do29 (2)
30 Di30 (1) → Do30 (1)
361-713-83100 △
1
15 W303-0590E
N-1 N-1
6.4 Integration for hour meter

EEPROM: Electrical Erasable Programable Read
1. Time period when the "engine speed" signal in the Only Memory
serial communication data received from upper
MDT is on "1" status is integrated. CAN: Controller Area Network
2. The integrated time value is written in EEPROM MDT: Multiplex Data Transmitter
every 3 minutes after power on. I/O data: Input/Output data
3. The integrated value is output via CAN
(0.01 h/digit).
*For details, refer to the CAN specifications.
4. For correction, refer to “6.9 Integrated value

rewriting function”.
5. Only for the first time when the "engine speed"

signal in the serial data received from upper MDT
is changed from "0" to "1," 1 minute and 30
seconds are added to the integrated value.
6.5 Integration for odometer
1. The pulse input signal from Pi2 (vehicle speed

signal) input is converted to the actual distance
traveled and the distance traveled is integrated.
Conversion formula to actual value:

Distance traveled (km) = Number of Pi2 input
pulses x 7.85 (cm/pulse) x 10-5
2. The total distance traveled integrated every 3

minutes after power on is written in EEPROM.
To reduce the total count to write in EEPROM, the
writing is performed at the same time of that in the
hour meter.
3. The integrated value is output via CAN (0.125

km/Digit).
*For details, refer to the CAN specifications.
4. For correction, refer to “6.9 Integrated value

rewriting function”.
5. When the "I/O data 15" signal in the serial

communication data received from upper MDT is
changed from "1" to "0," the present value of the
distance traveled is written in EEPROM.
361-710-53110 △
1
16 W303-0590E
N-1 N-1
6.6 Actual value conversion formula
361-713-83050 △
1
17 W303-0590E
N-1 N-1
6.7 PWM output (PWM: Pulse Width Modulation)

Duty (%) = PWM output transistor ON time (second) x PWM frequency (122 Hz) x 100
If Di1 is "0," Duty = 0 (%), and if Di1 is "1," the following specifications apply.
(1) Ao1 (Air pressure)
Depending on the voltage value input to Ai1, this value is output from Ao1in the duty ratio calculated by the approximate
expression which linearly interpolates the points in the characteristics table below.
V: Ai1 input voltage (V)
Where V < 0.21 (V), Duty = 0%, and where V > 2.22 (V), Duty = 100%.
(Characteristics table)
Input voltage (V) 0.21 0.50 1.25 1.86 2.22
Duty (%) 0.0 17.6 50.3 69.2 100.0
(2) Ao2 (Torque converter oil temperature)

Depending on the resistance value of the sender connected to Ai4, this value is output from Ao2 in the duty ratio calculated by
the approximate expression which linearly interpolates the points in the charastristics table below.
The average value is calculated from Ai4 input values every second, and the output value is determined from the simple moving
average for 15 seconds calculated from the average value.
The average value in every second is calculated from the 64 sampling values at 15-ms intervals
R: Resistance value of sender connected to Ai4 (Ω)
Where R < 7 (Ω) Duty = 100%, and where R > 800 (Ω), Duty = 0%
Sender resi. value (Ω) 800.0 229.1 31.0 23.4 11.6 7.0
Duty (%) 0.0 17.3 51.7 56.2 68.2 100.0
(3) Ao3 (Fuel gauge)

Depending on the resistance value of the sender connected to Ai5, this value is output from Ao3 in the duty ratio calculated by
the approximate expression which linearly interpolates the points in the charastristics table below.
The average value is calculated from Ai5 input values every second, and the output value is determined from the simple moving
average for 60 seconds (*1) calculated from the average value.
(*1): Until 60 seconds elapse after power is turned ON, the output value is determined from the simple moving average
value in every 15 seconds.
The average value in every second is calculated from the 64 sampling values at 15-ms intervals.
R: Resistance value of sender connected to Ai5 (Ω)
Where R < 5.4 (Ω), R = 5.4 (Ω) (Duty = 74.7%)
Where R > 140 (Ω), Duty = 0%
Sender resi. value (Ω) 140.0 97.0 32.5 6.0 1.0
Duty (%) 0.0 20.0 48.7 71.3 100.0
(4) Ao4 (Coolant temperature)

Depending on the engine coolant temperature value which STM-E receives in CAN communication, this value is output from Ao4
in the duty ratio calculated by the approximate expression which linearly interpolates the points in the charastristics table below.
The engine coolant temperature data received from the upper structure is averaged simply at the number of times of reception,
and the output value is determined from the moving average for 15 seconds (15 values) calculated from the average value.
If a disconnection occurs, the output value (Duty) is assumed to be 0 % and all values for the moving average value is initialized.
When the communication is recovered, the average value is calculated again from the initial status.
Type (0, 0, 0) X: Engine coolant temperature of CAN communication specification
Type (0, 1, 0) Where X > 181.3 (˚C), Duty = 100%, and where X < 38.4 (˚C), Duty = 0%
Type (0, 1, 1)
Type (0, 0, 1)
Engine coolant tempertature (˚C) 38.4 67 103 106 135 181.3
Duty (%) 0.0 19.3 49.3 51.9 69.7 100
361-713-83060 △
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18 W303-0590E
N-1 N-1
6.8 CAN communication 6.9 Integrated value rewriting function
1. The vehicle information is sent/received via CAN 1. The integrated values for the hour meter and
according to the SAE J1939 specifications. odometer are rewritten to the values specified by
Data sent by DCU AML.
Data name 2. If a rewriting request for the integrated value is

1 Controller version sent from AML via CAN, the value is rewritten to
the specified value, and the response is sent
2 Engine speed
together with the rewritten value.
Engine coolant temperature
3 Remaining fuel 3. If a reading request for the present integrated
Torque converter oil temperature value is sent from AML via CAN, the present
integrated value is returned to AML.
4 Integrated fuel amount used
5 Hour meter 4. The rewriting request and reading request from
6 Odometer AML are sent with the same PGN (Performance
Group Number) both for the hour meter and
7 Ambient temperature
odometer, and the request flag and data
8 Torque controller pressure
identification No. in DF (Data Field) are used for
9 Traveling speed recognition.
10 Di/Do status
Machine operation status
Data name
11 Traveling status
Request flag
Engine overrun status
Data recived via CAN
1 Data identification No.

12 Error code
Integrated value rewriting data
13 Integrated value rewriting response (*1)
Request flag
Accumulation level in DPF
14 DPF regeneration status Data identification No.
2 Integrated value rewriting data
DPF warning lamp stasus
(for integer)
15 Fuel comsumption Integrated value rewriting data
(for decimal places)
*1: For the data identification number and integrated
value response data, refer to "Data sent via CAN " in
"6.9 Integrated value rewriting function." Data name
Request flag
1 Data identification No.
Data sent via CAN
Data received by DCU Integrated value rewriting data

Data name
Request flag
1 Integrated value rewriting request (*2)
Data identification No.
*2: For the request flag, data identification number, and 2 Integrated value rewriting data
(for integer)
integrated value rewritng data, refer to "Data
Integrated value rewriting data
received via CAN" in "6.9 Integrated value rewriting (for decimal places)
function."
361-713-83030 △
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19 W303-0590E
N-1 N-1
6.10 DPF indicator function
According to the DPF data received from upper MDT, DPF regeneration indicator and accumulation level
indicator (from level 1 to 4) are shown.
6.10.1 Accumulation level indicator
20 W303-0590E
N-1 N-1
6.10.2 DPF regeneration indicator

Type (0, 1, 0)
Type (0, 1, 1)
21 W303-0590E
N-1. N-1.
6.10.3 Engine ECU error (yellow)
The following truth table is applicable regardress of DI1 status.
Type (0, 1, 1)
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6.11 DPF indicator check function
1. When the starter SW signal turns from OFF into ON (that is Di1 turns from “0” into “1”), the
outputs Do1 to 30, 32, 34, 36, 38, and 40, which are determined in the DCU I/O list turn into “1”
for 2 seconds.
* When the controller is turned on, the indicators lights up for specified seconds to allow
check of indicator operation
361-713-83150 △
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22 W303-0590E
N-2 N-2
Combination Meter
N-2 Combination Meter

[NOTICE]
sales unit on the parts catalog before starting the disassembly work
The combination meter is configured as shown in the configuration chart below.
23 W339-0060E
N-2 N-2
Combination Meter
2. Display section
24 W339-0060E
N-2 N-2
Combination Meter
25 W339-0060E
N-2 N-2
Combination Meter
3. Specifications
3.1 Speedometer
1. Indicates 60 km/h when the input signal is:
637 min-1 x 20 pulses/rev
Indication standard (1km/h=0.6214MPH)
Standard indication (km/h) 20 40 60
+1.5 +3.5 +5.5
Tolerance (km/h)
0 +0.8 +1.6
Test temperature: 20±5°C
Response
Up to 90% of the max. scale 1.0±0.5 s
3.2 Tachometer
1. Input signal: Input pulse; 3 pulses/rev
Indication standard
Standard indication (min-1) 500 2000
Tolerance (min-1) ±50 ±100

Test temperature: 20±5°C
Response
Up to 90% of the max. scale 0.4±0.25 s
3.3 Odo/trip meter, hour meter

1. Display spc.: TN positive LCD 1/4-duty 1/3-bias
2. Odo/trip changeover: The display switches when the changeover switch is on for less than 1 second.
3.4 Odometer
1. Display method: 7 segments x 6 numerals + ODO
Zero surplus display
2. Integration rate: 1 km is integrated for every 12740 pulses.
3. Display range: 0 to 999999 km
4. Integrated value at delivery shall be 5 km or less.
3.5 Trip meter

1. Display method: 7 segments x 5 numerals + decimal point + TRIP
2. Integration rate: Same as odometer
3. Display range: 0.0 to 9999.9 km (Display is cycled.)
4. Trip setting: The displayed value changes to "0.0" when the odo/trip changeover switch is kept on for 1
second or longer with the trip meter displayed.
3.6 Hour meter

1. Display method: 7 segments x 6 numerals + decimal point
2. Display range: 0.0 to 99999.9 h (Display is cycled.)
When 9999.9 h is exceeded, the display returns to 0.0 h,
and the second time 9999.9 h is reached, the display is fixed.
3. Minimum display unit: 0.1 h
4. The displayed value at delivery shall be 0.1 h or less.
26 W339-0060E
N-2 N-2
Combination Meter
3.7 Fuel gauge

1. Indication method shall be movable magnetic type (MG-31).
2. Input signal: PWM signal (Reference frequency 128 Hz)
Indication standard
Scale E F
Tolerance (°) ±3.75 ±3.75
Reference duty 20% 69%
Test voltage: 27±0.1 V DC
Test temperature: 20±5°C (59-77°C)
Test sequence: After F is set, E
(Test is performed when at least 1 minute has passed.)
Response
Up to 90% of E to F travel: Within 4.0 s
3.8 Coolant temperature gauge

Indication standard
Scale C H
Tolerance (°) ±3.75 ±3.75
Reference duty 20% 67.4%
Test sequence: After C is set, H
Response
Up to 90% of C to H travel: Within 4.0 s
PWM drive circuit
27 W339-0060E
N-2 N-2
Combination Meter
3.9 Air pressure gauge

Indication standard (1kPa=1.45Psi)

Scale (kPa) 0 1000
Tolerance (°) ±3.75 ±3.75
Test sequence: After 0 kPa is set, 1000 kPa
Response
Up to 90% of 0 kPa to 1000 kPa travel: within 4.0 s
3.10 Torque converter oil temperature gauge

Indication standard
Scale C H
Tolerance (°) ±3.75 ±3.75
Test sequence: After C is set, H
Response
Up to 90% of C to H travel: within 4.0 s
28 W339-0060E
N-2 N-2
Combination Meter
4. Electric circuit
Signal connection assignment
No. Name No. Name

1 Air pressure gauge 13 Suspension lock
2 Parking brake 14 Not used
3 Exhaust brake 15 Low speed selected
4 Retarder 16 R
5 Inter-axle differential lock 17 N
6 4WD selected 18 D
7 T/C oil temperature gauge 19 3
8 Special steer selected 20 2
9 PTO 21 CHG error
10 Working lamp 22 Overrun, speed
11 Lock pin removed 23 1
12 Rear steer straight ahead detected 24 Low brake air pressure
25 Remaining fuel
26 Operation auxiliary brake
27 Fuel gauge
Signal connection assignment 28 Coolant temperature gauge
No. Name No. Name

1 GND 11 BATT
2 Engine oil pressure 12 IGN
3 Remaining coolant 13 Turn, RH
4 Steering failure 14 Turn, LH
5 T/C oil pressure 15 High beam
6 Controller error 16 Lighting
7 Water separator 17 Hour meter operation
8 Engine failure 18 SP input
9 Engine warning 19 TA input
10 Not used 20 Not used
29 W339-0060E
N-2. N-2.
Combination Meter
366-840-60000 △
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30 W339-0060E
N-3 N-3
Signal Transmitter (STM-E)
N-3 Signal Transmitter (STM-E)

[NOTICE]
The appearance or other items may differ from those of the parts for this machine. Even though the functions
The signal transmitter (STM-E) is configured as shown in the configuration chart below.
31 W303-0600E
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STM-E type
Type Spec.
(0, 0, 0) GR-1000-2-00101, 00103
GR-550-2-00101
GR-500E-2-00302
(0, 0, 1) -
(0, 1, 0) -
(0, 1, 1) GR-350-2-00103
GR-300E-2-00102, 00104
(1, 0, 0) GR-1000-2-00104
GR-800E-2-00101, 00102, 00104, 00302
GR-750-2-00101, 00103
GR-600E-2-00102, 00104, 00302
GR-550-2-00104
GR-500E-2-00101, 00102, 00104
(1, 0, 1) GR-1000-2-00201
GR-550-2-00201
GR-350-2-00101, 00102
GR-300E-2-00101
32 W303-0600E
N-3 N-3

The signal transmitter (STM-E) obtains the engine ECU information (error, fuel cosumption, etc.) and transmits it
to the lower MDT.
For GR-120N-2, it additionally transmits the speed limiter control signal to the engine ECU.
Molding material
(Note) This is not degradable because

of potting with compound.
Electrolytic
capacitor
Molding material filled
1. Case 3. Sealing plate (packing) 5. Circuit board assembly

2. Sealing plate (PC) 4. Molding material 361-206-21020 △
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33 W303-0600E
N-3 N-3
3. Connector (pin assignment)
CN1 (3-1437285-1)
Connector
pin No. Signal Signal name
1 ― ―
2 ― ―
3 TXD+ MDT communication
4 RXD+ MDT communication
5 CAN_H CAN communication
6 RSRXD Maintenance communication
7 Power supply (-) F-GND
8 Power supply (+) Power supply input
10 K-LINE K-LINE communication
11 TXD- MDT communication
12 RXD- MDT communication
13 CAN_L CAN communication
14 RSTXD Maintenance communication
18 CAN communication terminating resistor Terminating resistor
20 Do3 200 mA (internal ground)
22 ― ―
23 Di4 5 V source type
25 BOOT Boot signal
30 ― ―
31 ― ―
34 ― ―
Figure viewed from connection

361-206-11010 △
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361-206-21010 △
0
4. LED display
• Power supply LED: (LED1) lights up in green at power on.
34 W303-0600E
N-3 N-3
5. Input/output signal list

Digital input (Di) signal
The connection status of sink type and source type is shown in the figure below.
Digital output (Do) signal
The connection status of sink type is shown in the figure below.
35 W303-0600E
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Signal Output from Signal

Input to STM Signal name Signal name
definition STM definition
0: 0:
Di1 Spare input Do1 Spare output
1: 1:
0: 0: Input/output
1: 1: to/from
0: 0: external
Di3 Spare input Do3 Spare output circuit
1: 1:
0: 0:
1: 1:
Received from Signal Transmitted to Signal

Signal name Signal name
lower MDT definition lower MDT definition
0: 0:
Do1 Spare input Di1 Spare output
1: 1:
0: 0:
1: 1: Serial
0: 0: communication
1: 1:
0: 0:
1: 1:
Di (Digital input) specifications
Di 1to 4: 5V source input (GND)

Negative logic (1: GND, 0: OPEN)
Do (Digital output) (Tr output) specifications
Do 1 to 4: Sink output (O.C., 200 mA)

Negative logic (1: transistor ON, 0: transistor OFF)
O.C.: Open Collector
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36 W303-0600E
N-3 N-3
6. Error code list

Error detection function
(1) Perform the self-diagnosis and communication error check. If an error occurs, the corresponding error
code is transmitted to the lower MDT.
(2) If no error occurs, the error code (0, 0, 0, 0) is transmitted to the lower MDT.
Error code Remedy for error

transmitted Error description and detection conditions
to lower MDT Recovery conditions
No error ―
(0, 0, 0, 0)
―
Open-circuit in MDT receiving line • Data received from MDT is not updated.
No communication data is transmitted from MDT for 600 ms or longer • All Dos are turned off.
(0, 0, 0, 1)
At power on, no error detection is performed for 4 seconds. • Communication data from MDT is received
normally.
Error of data received from MDT • Data received from MDT is not updated.
Data received from MDT has a receiving error (parity/framing/overrun error, (Except for transmission time-out)
(0, 0, 1, 0) check sum error, error in number of received bytes, transmission time-out, • All Dos are turned off.
and type error) for three successive times.
Alternately, receiving error status (status with no normal receiving) • Communication data from MDT is received
continues for 600 ms or longer. normally.
Open-circuit in CAN receiving line Received data is not updated.
(0, 1, 0, 0) Status in which no communication data is transmitted from CAN continues
for 45 seconds. Communicaton data is received via CAN.
CAN reception data error (no detection) ―
(0, 1, 0, 1)
Code reservation only ―
Open-circuit in K-LINE receiving line Received data is not updated.
(0, 1, 1, 0) Status in which no response message is transmitted from K-LINE continues
for 45 seconds. Response message is received.
K-LINE reception data error Received data is not updated.
(0, 1, 1, 1) Reception data error or receiving of negative response message occurs
three successive times. Positive response message is received.
Controller self-diagnosis error (voltage monitoring) Errors (0, 0, 0, 1), (0, 0, 1, 0), (0, 1, 1, 1) are
When the battery voltage (24 V) is checked every cycle, all the six retries not detected.
cannot satisfy the following conditions: All Dos are turned off.
(0, 0, 1, 1)
Battery voltage: 18 to 32 V Check result is normal.
A/D conversion error A/D conversion value is held.
A/D conversion operation is not completed by the end of the waiting time. A/D conversion is completed successfully.
Controller self-diagnosis error (ROM sum check)
All outputs are off and operation is stopped.
When ROM sum check is performed at power on, all the three retries show
an error. Turning on the power again
Controller self-diagnosis error (RAM check: At power on)
When the data items (1) to (4) shown below are written for 8 bytes on RAM, All outputs are off and operation is stopped.
read and compared with correct answers on ROM at power on, all the three
No error retries show an error.
code (1) 55h (2) AAh (3) FFh (4) 00h
transmitted Controller self-diagnosis error (RAM check: Every cycle)
because of When the data items (1) to (4) shown below are written for 8 bytes on RAM, All outputs are off and operation is stopped.
operation read, and compared with correct answers on ROM every cycle, all the six
stop retries show an error.
(1) 55h (2) AAh (3) FFh (4) 00h
Controller self-diagnosis error (CPU error)
(1) When the calculation with ADD, SUB, multiplication, and divide All outputs are off and operation is stopped.
commands and comparison with correct answers on ROM are performed at
power on, all the three retries show an error.
(2) A detectable runaway in software is detected
Transmission priority when multiple errors occur simultaneously:
(0, 0, 0, 0) > (0, 0, 1, 1) > (0, 0, 0, 1) > (0, 0, 1, 0) > (0, 1, 0, 0) > (0, 1, 0, 1) > (0, 1, 1, 0) > (0, 1, 1, 1)
361-206-23090 △
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37 W303-0600E
N-3 N-3
7. Data list
7.1 One-to-one correspondence input/output function
(1) Signal to be output from the transmitter after one-to-one correspondence with the signal received from the
lower MDT.
1 Do1 (Spare input 1)* → Do1 (Spare output 1)

* The signal is the STM (Do) data received from the lower MDT on the serial communication.
(2) Signal to be transmitted to the lower MDT after one-to-one correspondence with the signal input to the
transmitter.
1 Di1 (Spare input 1) → Di1 (Spare output 1)*

* The signal is the STM (Di) data transmitted to the lower MDT on the serial communication.
361-206-13070 △
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38 W303-0600E
N-3 N-3
7.2 Integration function for remaining fuel

amount
Type (0, 0, 0), (0, 0, 1), (0, 1, 1), (1, 0, 0), (1,0,1)
1. The fuel consumption data (fuel consumption

per hour {L/H}) received via CAN is averaged
for 10 minutes. The averaged value is divided
by 6 and the result is integrated as the fuel
consumption.
2. The integrated value is transmitted to the lower

MDT as 4-byte data (0.5 L/digit).
3. The integrated value is updated every 10

minutes and written to EEPROM.
4. The fuel consumption data is received via CAN

every 20 ms for types (0, 0, 0), (0, 0, 1), and
(1, 0, 0); every 100 ms for type (0, 1, 1) and
(1, 0, 1).
5. If the received fuel consumption data has an

error or has not been defined yet, such data is
not be integrated. Only normal data is
integrated.
Type (0, 1, 0)
1. The fuel consumption data (fuel consumption

per second {mm3/s}) received via CAN every
100 ms is averaged for 10 minutes. The
averaged value is divided by 10 and the result is
integrated as the 10-minute fuel consumption
(converted to L).
2. The integrated value is transmitted to the lower

MDT as 4-byte data (0.5 L/digit).
3. The integrated value is updated every 10

minutes and written to EEPROM.
4. If the received fuel consumption data has an

error or has not been defined yet, such data is
not be integrated. Only normal data is
integrated. 361-206-43080 △
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39 W303-0600E
N-3 N-3
7.3 CAN communication Type (0, 1, 0)
1. The engine information is received via CAN, and Data name

1 Fuel consumption
Reception
also the necessary information is transmitted to
data
the engine ECU according to the SAE J1939 2 Engine coolant temperature
specifications. 3 Error code
mission
Trans-
2. The transmission/reception data depends on the
data
1 Diagnostic code request
type signal from the lower MDT (because the type
of engine ECU differs.)
Type (0, 1, 1)
Types (0, 0, 0), (0, 0, 1) Data name
Data name 1 Fuel consumption
Reception
Engine coolant temperature 2 Engine coolant temperature
data
1 Vehicle speed 3 Intake air temperature
Vehicle deceleration 4 Error code
Reception data
Engine type ID
Types (1, 0, 0)
Presence/absence of information for vehicle
speed limitation function Data name
2 Check of vehicle speed limitation function Engine coolant temperature
Vehicle speed echo back of vehicle speed
limitation 1 Vehicle speed
Fuel consumption Vehicle deceleration

Vehicle control integrated ECU monitoring Engine type ID
signal
3 Presence/absence of information for vehicle
Recognized vehicle speed for vehicle control speed limitation function
Reception data
Echo back of engine type ID 2 Check of vehicle speed limitation function

Vehicle speed echo back of vehicle speed
1 Vehicle speed filtering cut-off frequency limitation
Echo back of vehicle control integrated ECU
Transmission data
Fuel consumption
monitoring signal
Vehicle control integrated ECU monitoring
Vehicle speed override priority signal
3
Vehicle speed limitation control indication Recognized vehicle speed for vehicle control
Check of vehicle speed limitation function 4 DPF lamp information
Proportional gain for vehicle speed limitation Regeneration status No.

2 5
(*1) Integral gain or vehicle speed limitation PM accumulation level No.
Vehicle speed for vehicle speed limitation Echo back of engine type ID
Integral upper limit for vehicle speed limitation 1 Vehicle speed filtering cut-off frequency
Integral lower limit for vehicle speed limitation Echo back of vehicle control integrated ECU
monitoring signal
Transmission data
Vehicle speed override priority

*1: The transmission data:
Vehicle speed limitation control indication
not applicable to type (0, 0, 0).
applicable to type (0, 0, 1). Check of vehicle speed limitation function
For the details, refer to the "Speed limitter Proportional gain for vehicle speed limitation
2
function (vehicle speed limitation function)" Integral gain or vehicle speed limitation
described later. Vehicle speed for vehicle speed limitation
Integral upper limit for vehicle speed limitation
Integral lower limit for vehicle speed limitation
40 W303-0600E
N-3 N-3
Type (1, 0, 1)
Data name
1 Fuel consumption
2 Engine coolant temperature
Reception data
3 Intake air temperature

4 Error code
DPF lamp information
5 PM filter status
Exhaust temperature warning lamp
mission
Trans-
data
1 DPF deactivation switch status
361-206-43030 △
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41 W303-0600E
N-3 N-3
Speed limiter function (applicable to STM type of “0, 0, 1 (GR-120N-2)” only)
CAN transmission data
Data name Output data
Echo back of engine type ID The engine type ID in the CAN receiving data is transmitted as it is.
Vehicle speed filtering cut-off frequency 0Ah
1
Echo back of vehicle control integrated ECU
The ECU monitoring signal in the CAN reception data is transmitted as it is.
monitoring signal
Vehicle speed override priority 00
00: Vehicle
speed Determined from the vehicle speed signal of CAN reception
CAN transmission data
limitation data.
control off 01: Vehicle speed limitation control start
Vehicle speed limitation control indication 00: Vehicle speed limitation control off
01: Vehicle
speed 48 km/h 50 km/h
limitation
control start
2 While a STM error (0, 1, 0, 0) or (0, 1, 0, 1) occurs, "01" is
00: No error
Check of vehicle speed limitation function output. While normal status is recovered or another error
01: Error present
occurs, "00" is output.
Proportional gain for vehicle speed limitation 78h
Integral gain or vehicle speed limitation 00h
Vehicle speed for vehicle speed limitation 2FA8h
Integral upper limit for vehicle speed limitation 19h
Integral lower limit for vehicle speed limitation 00h
361-206-23060 △
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7.4 K-LINE communication specifications
The engine error code and maintenance information

are transmitted.
Only for the type selection signals (0, 0, 0) and

(0, 0, 1) from the lower MDT
Crane model Type

GR-120N-2 (0, 0, 1)
GR-250N-2 (0, 0, 0)
361-206-13040 △
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42 W303-0600E
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7.5 Error transmission number is supposed as 1, and they are sent with
the error code.
1. The controller sends through serial communication
the error data received through serial 7. When no errors occur, the error beginning flag and
communication and the errors of the controller the error ending flag are set as "1", error number is
itself together. (Among them the one with smaller supposed as 0, and they are sent with the error
SPN No. is given priority.) code "0".
2. 40 errors at a maximum can be sent, and sends Lower STM (STM-E)

the received errors are given priority. (Errors of the
controller itself may not be sent.) 1. Engine error codes received from K-LINE or CAN
are converted into SPN as follows, and are sent to
3. If there are more than 40 errors, the errors from the lower MDT.
the one received first through the 40th are sent as Types "0,0,0", "0,0,1" and “1,0,0”
valid error data. The highest 2-byte data of the 3-byte error code
data conforming to DIAG service (ISO14229-1) is
4. The controller stores each error with the beginning
assumed to be a 2-digit error code (HEX). Its value
flag of "1" and the ending flag of "1" in the buffer.
plus 30000h is assumed to be SPN. FMI and CM
If the number of the received error data and the
are supposed to be 0, and OC is supposed to be 1.
number of the transmitted error data in the
* If the code of no error (0000h) conforming to
received data do not agree in this case, the sum of
DIAG service (ISO14229-1) is received, SPN
the number of the received errors and the number
(30000h) is not sent to the lower MDT.
of errors of the controller itself is supposed as the
number of the transmitted error. Then the upper bit Type "0,1,0"
(b7) of the number of transmitted error data is set The 2-byte error data received from CAN is
as "1" and is sent. If the data with "1" as the upper assumed to be a 2-digit error code (HEX). The
bit of the transmitted error data is received, the value plus 30000h is assumed to be SPN.
upper bit of the number of the transmitted error FMI and CM are supposed to be 0, and OC is
data is set as "1" and the number of the supposed to be 1.
transmitted error data is sent.
Type "0,1,1" and “1,0,1”
5. When the controller sends the received errors and 4-byte data received from CAN is sent to the lower
the errors of the controller itself together, it makes MDT (because the transmitted error data is
the beginning flag of the error sent first "1" and received according to J1939).
makes the ending flag of the error sent last "1". It
sends the number of the sent errors as the number SPN=627 and FMI=2 (FC1117 power supply) are
of the transmitted error data. masked. (Regarding CM and OC, it is arbitrary
whether they are masked or not.)
6. When one error occurs, the error beginning flag
and the error ending flag are set as "1", error
43 W303-0600E
N-3 N-3
2. The error that occurs in the lower STM (STM-E) is sent as SPN to the lower MDT as follows:
FMI and CM are supposed to be 0, and OC is supposed to be 1.
Error code of lower STM (STM-E)
SPN
(EC3,EC2,EC1,EC0)
0,0,0,1 131345 Reception interruption from lower MDT
0,0,1,0 131346 Data reception error from lower MDT
0,0,1,1 131347 Self-diagnosis error
0,1,0,0 131348 CAN communication disconnection
0,1,0,1 131349 CAN reception data error
0,1,1,0 131350 K-LINE communication disconnection
0,1,1,1 131351 K-LINE reception data error
Lower MDT
1. The engine error code received from the lower

STM (STM-E) is sent to the upper MDT.
2. The error that occurs by the lower MDT is

represented by 4-digit failure code in hexadecimal
notation. Its value plus 20000h is assumed to be
SPN and sent to the upper MDT.
FMI and CM are supposed to be 0, and OC is
supposed to be 1.
Upper MDT
1. The engine error code received from the lower

MDT is sent to DCU.
2. The error that occurs by the upper MDT is

represented by 4-digit failure code in hexadecimal
notation. Its value plus 20000h is assumed to be
SPN and sent to the DCU.
supposed to be 1.
3. Error signals (DTC) are sent to DCU.

supposed to be 1.
(Ex.) Refer to "CHG lamp", etc. in the "Data table". 361-713-53520 △
1
44 W303-0600E
N-3 N-3
7.6 Communication between the lower MDT 7.7 Conversion of fuel consumption unit
and lower STM-E for machines
without DPF Type (0, 1, 0)
Type (0, 0, 0), (0, 0, 1), (0, 1, 0), (0, 1, 1) 1. The fuel consumption data (fuel consumption per
second {mm3/s}) received every 100 ms via CAN
1. Fixed data “0” is transmitted at the DPF data after is converted into fuel consumption per hour {L/h}.
5 bytes from the beginning of the structure for the The integrated value is transmitted to the lower
data transmitted from the lower STM-E to the MDT as 2-byte data.
lower MDT.
2. How to convert
1 mm3/s = 0.0036 L/h
Data range: 0 to 64225 mm3/s {0 to 231.32 L/h}
Minimum unit: 0.05 L/h
* The number is rounded off to two decimal places
As the DPF-related data are assigned to the first, then rounded with 0.05 intervals.
structure of the data transmitted between the lower 0.00–0.02 → 0.00
STM-E and the lower MDT in order to share the 0.03–0.07 → 0.05
structure of transmission data regardless of DPF 0.08, 0.09 → 0.10
function, fixed data “0” is transmitted on the
machines without DPF.
361-206-43110 △
0 361-206-23120 △
0
45 W303-0600E
N-3 N-3
7.8 CAN and serial communication list

The following description shows how the CAN signals received from the ECU are assigned to the serial
communication between the lower MDT and STM-E and how the serial signals received from the lower MDT are
assigned to the CAN communication between STM-E and ECU.
Type (1, 0, 0)
Data sent from the lower STM-E to the lower MDT (DPF data)
Type (1, 0, 1)
Data sent from the lower STM-E to the lower MDT (DPF data)
Data sent from the lower MDT to the lower STM-E (DPF data)
361-206-43130 △
0
46 W303-0600E
N-3. N-3.
Outrigger Control Box
7.9 Specification of “DIAG on CAN”  Communication procedure

communication
This specification is applicable only when the type 1. Shift to the diagnostic session by the Diagnostic
selection signal from the lower MDT is (1, 0, 0). Session service (ID: 10 h).
 Applicable standard 2. Execute Read Data ByIdentifier (ID: 22 h) and
Physical layer: ISO11898 Read DTC Information service (ID: 19 h)
Data link layer: ISO11898 alternately until the power is turned off, and
Application layer (DIAG service): ISO14229-1 receive the intake temperature data and DTC data.
Network layer: ISO15765-2  When communication abnormality occurs
 Transmission speed If the response from the ECU is absent for the
250.0 kbps period of P2 or longer or a negative message is
received, service request is performed again after
 Message structure (conforming to ISO14230-2) a 200-ms interval.
1. Header 1. If a response is absent for 10 second or longer,

Target address byte (Tgt): 00 h communication initialization is executed.
Source address byte (Src): F1h Thereafter, communication initialization is
repeated for every 5 seconds until a response
2. Data byte
comes.
The specification of each service conforms to the
ISO15765-2 and 14229-1. 2. If negative messages come 3 times (including the
first request), it is assumed that data abnormality
 Timing (Refer to ISO14230-2.)
in the diagnosis service (ISO14229-1) occurs.
P1 (inter-byte time for ECU response): (The error “0,1,1,1” is transmitted to the lower
0–20 ms unit.)
P2 (ECU response time after service request):
* Service request continues even an error occurs,
25–50 ms
and the error is reset when data is received
P3 (request start timing after ECU response):
normally.
200 ms
P4 (inter-byte time for service request):  Note
10 ms (20 ms at maximum)
1. Unlike the IS014229-1 specification, the DTC
 Service codes are sent from the ECU in the way that 1
DTC code is sent for 1 frame (because the ECU
1. Diagnostic Session service (service ID... 10 h;
can send up to only 8 bytes for each frame).
parameter ID... 01 h)
After the number of the DTC codes sent from the
2. Read Data By Identifier service (service ID: 22 h) ECU is confirmed (service ID... 19 h; parameter
Request data ID: 0209 h ID... 01 h; DTC Status Mask... 02h), DTC codes
Readout data: on 4th byte of the ECU response are read out in the above-mentioned parameter ID
data (EGR temperature) (02h).
0–7 bit: 1°C/dig, offset by -40°C If the number of the DTC codes is more than 40,
the first 40 codes sent from the ECU are treated as
3. Read DTC Information service (service ID... 19 h;
the codes to be handled. (The 41st code and later
parameter ID... 02 h; DTC Status Mask... 02 h)
ones are not recognized.)
361-206-43140 △
0
47 W303-0600E
N-4 N-4
Engine Control Unit (ECU)
N-4 Engine Control Unit (ECU)

[NOTICE]
The engine control unit (ECU) is configured as shown in the configuration chart below.
48 W314-0140E
N-4 N-4
2. Diagnosis function System display
A system error is indicated by lighting of the check

The ECU diagnoses a failure in various sensors
engine lamp in the combination meter.
every time the starter switch (M) is turned to "ON."
If an error is detected, the ECU commands the
check engine lamp to light up to warn the user,
stores the faulty part, and activates the backup
mode. The failure location can be confirmed by
turning on/off of the diagnosis lamps 1 and 2.
Refer to “2.7 Diagnosis code chart” for faulty parts
and backup.
2.1 Check for a failure (user mode)
• When a system error occurs, the engine control unit

(ECU) commands the check engine lamp on the Failure Lighting status of check engine
(Present) lamp
combination meter to light up, warning the user
(present failure). Normal Off
In addition, the control unit stores the location of Failed On
the present failure in the memory as the failure
• The present failure status is confirmad with the
information (past failure).
check engine lamp.
• Once turning on, the check engine lamp will not go
off even after the normal status is restored. With
the key removed, wait for approximately 10
seconds and turn the key to "ON" again. The lamp
will go off.
2.2 Diagnosis lamp lighting law when a failure is detected
Diagnosis lamp 1 Diagnosis lamp 2

Failure mode
[Recommended color: Red] [Recommended color: Orange]
Serious failure (engine stop) On Off

Minor failure
Off On
(operated in backup mode)
49 W314-0140E
N-4 N-4
2.3 How to call up faulty part
The diagnosis code represents a present or past

faulty part and is indicated with the diagnosis lamp
1 depending on the operation (release or close) of
the diag switch (connector) and the memory clear
switch (connector).
The diag switch and the memory clear switch are
located near lowew-section electrical unit.
Diag switch Memory clear switch Displayed diagnosis code

Off On Displays present failure(s)
Off Off Displays present + past failures
Note: If no error is present, displays the normal code "01."
2.4 Diagnosis code display law 2.5 Clear of faulty part
1. Stop the vehicle and turn the starter switch (M) to 1. Operating the memory clear switch can clear the
"ON." Release the diag switch for 1 second or faulty parts stored in the ECU.
longer. The display stays off for 2.4 seconds, and
2. Releasing the memory clear switch once and
then the code is displayed.
closing it again can clear all the faulty parts stored
2. The code is displayed in 2 digits. The tens place in the ECU.
stays on for 1.2 seconds, and off for 1.2 seconds.
1 second or longer 3 seconds
Memory clear switch
The units place stays on for 0.4 seconds, and off
Close
for 0.4 seconds.
Cleared here
3. The display repeats 3 times per 1 code. If no new

Release
code is followed, it returns to the first code.
Example 1: Code 12 [NOTICE]

Diagnosis lamp 1
Operation the memory clear switch only can clear
Tens place Units place
the data.
ON
If it is not desirable to clear the data, turn the starter
OFF switch (M) to "OFF" with the memory clear switch
s s s released, and then close the memory clear switch.
Example 2: Multiple codes (codes 12 and 13)

2.6 Diagnosis lamp bulb burnt-out check
The ECU commands the diagnosis lamps 1 and 2 to

light up when all the following conditions are met.
• Engine speed: 0 min-1

• Starter switch (M): "ON"
• Diag switch: Closed
• No error which lights up the diagnosis lamp
50 W314-0140E
N-4 N-4
2.7 Diagnosis code chart
51 W314-0140E
N-4 N-4
Diagnosis code generation conditions and inspection items
52 W314-0140E
N-4 N-4
53 W314-0140E
N-4 N-4
54 W314-0140E
N-4 N-4
55 W314-0140E
N-4 N-4
56 W314-0140E
N-4 N-4
57 W314-0140E
N-4 N-4
58 W314-0140E
N-4 N-4
59 W314-0140E
N-4 N-4
60 W314-0140E
N-4 N-4
61 W314-0140E
N-4 N-4
62 W314-0140E
N-4 N-4
63 W314-0140E
N-4 N-4
64 W314-0140E
N-4. N-4.
65 W314-0140E
N-5 N-5
Telecommunications terminal
N-5 Telecommunications terminal

[NOTICE]
sales unit on the parts catalog before starting the disassembly work.
The telecommunications terminal is configured as shown in the configuration chart below.
66 W340-0010E
N-5 N-5
2. ICF
2.1 External view
2.2 Connector (Pin assignment)
361-711-40000 △
0
67 W340-0010E
N-5. N-5.
3. SCT (Satellite communication terminal)
3.1 External view
3.2 Connector (Pin assignment)
361-711-50000 △
1
68 W340-0010E
R
Contents
R-1 Driving Power Transmission

System...................................... 1
1. Function ..................................................... 1
1.1 Engine ........................................................ 1
1.2 Torque converter ........................................ 1
1.3 Transmission .............................................. 1
1.4 Axles........................................................... 1
2. System description .................................... 1

2.1 Torque converter circuit .............................. 1
2.2 PTO clutch.................................................. 1
2.3 Lockup clutch.............................................. 2
2.4 Shift of drive mode...................................... 2
3. Installation.................................................. 3
3.1 Radiator ...................................................... 3
3.2 Power train ................................................. 4
i
R-1 R-1
R-1 Driving Power Transmission System 2. System description
1. Function (Refer to torque converter circuit in chapter Z.)
1.1 Engine 2.1 Torque converter circuit
The engine is the power source of vehicle 1. The pressurized oil discharged by the charging
traveling and crane operation. pump passes through a line filter, and enters relief
(When malfunction occurs, check for any valve (main pressure regulating valve), which is
abnormality in the crane. If none, contact a installed on the transmission.
distributor for the engine manufacturer.)
2. The pressurized oil adjusted by relief valve (main
pressure regulating valve) is provided to the PTO
1.2 Torque converter
and lockup clutch solenoid valve on the torque
1. The torque converter is directly connected to the converter, and to the solenoid valves on the
engine, and uses a fluid (torque converter oil) as a transmission.
medium to transmit power from the engine to the
3. The pressurized oil which is sent to the solenoid
transmission at variable speeds.
valve forms its path according to the operation of
2. In addition to transmitting torque to the the solenoid valves, and is led to the transmission
transmission, this device drives the crane clutches.
operation pump, steering pump, and charging
4. The pressure of the oil that passes through the
pump.
relief valve (main pressure regulating valve) is
1.3 Transmission regulated by torque converter inlet relief valve,
and the oil enters into the torque converter, and
1. The transmission uses a combination of gears to then the oil goes through the gap between the
select the speed among the 6 forward gears ((F1 inpeller wheel and stator wheel into the converter
to F3) of high range and (F1 to F3) of low range) circuit.
and the 2 reverse gears ((R) of high range and (R)
of low range), and transmits the power from 5. The oil heated after power transmission flows
torque converter to the axles. through the path between the turbine wheel and
stator wheel. The oil passes through the path
2. Switching the drive mode between 2- and 4-wheel between the turbine shaft and the stator support,
drive is available by air pressure. and flows out of the torque converter housing.
3. Switching the speed range between High and Low 6. The oil flowing out of the torque converter is sent
is also available by air pressure. to the oil cooler and becomes cooled in it, and
flows to the lubricating oil flow control valve
1.4 Axles
mounted in the transmission. The cooled oil
1. The axles transmit the power from the lubricates each transmission clutch and bearings,
transmission to the right and left wheels, driving then returns to the oil tank.
the vehicle. At the same time, they support the
vehicle’s weight. 2.2 PTO clutch
2. The steering cylinder performs steering control. When the PTO switch is ON, the PTO clutch
solenoid valve is energized. This allows
pressurized oil to enter the PTO clutch and
engages the clutch.
1 WR02-0200E
R-1 R-1
2.3 Lockup clutch 2.4 Shift of drive mode
1. When the lockup conditions are met, the lockup 1. Switching between 2-wheel and 4-wheel drive is
clutch solenoid valve receives a signal from the accomplished by turning the air ON (supplied) and
external device (MDT), and is energized. This OFF (shut off).
allows the pressurized oil to enter the lockup
2. A piston, shifter shaft and shifter fork are pressed
clutch and engage the clutch.
by the air pressure drawn from the air tank,
2. The power from the engine is directly transmitted moving the sleeve. This sleeve movement shifts
to the turbine shaft, without passing through the from 4-wheel to 2-wheel drive.
torque converter.
3. 2/4-wheel drive detection switch is provided in
the shifter shaft section.
2 WR02-0200E
R-1 R-1
3. Installation
3.1 Radiator
347-826-00000 △
4
349-225-20000 △
5
3 WR02-0200E
R-1 R-1
3.2 Power train
4 WR02-0200E
R-1. R-1.
347-825-70000 △
1
5 WR02-0200E
S
Steering System
Contents
S-1 Steering System............................... 1 S-4 Steering Cylinder .............................8
1. Function ..................................................... 1 1. Structure .................................................... 8

1.1 Priority valve ............................................... 1
1.2 Orbitrol........................................................ 1
1.3 Steering cylinder......................................... 1 S-5 Solenoid Valve
1.4 Solenoid valve (steering mode).................. 1 (Steering Mode)........................9
(rear steering hydraulic lock)................ 1 1. Structure .................................................... 9

S-6 Pilot Check Valve (Rear Steering
Hydraulic Lock)......................13
S-2 Priority Valve .................................... 2
1. Structure .................................................. 13
1. Structure .................................................... 2
2. Function ..................................................... 2
3. Principle of operation ................................. 3

3.1 Neutral state ............................................... 3
3.2 Right steering ............................................. 3 S
3.3 Right steering to the end ............................ 3
S-3 Orbitrol.............................................. 4
1. Structure .................................................... 4
2. Function ..................................................... 7
i
S-1. S-1.
Steering System
S-1 Steering System 2. Hydraulic system description

1. Function
1. The pressurized oil discharged by the hydraulic
1.1 Priority valve pump passes through the center joint and enters
The priority valve is a type of flow dividing valve. the priority valve.
Its first priority is supplying oil from the pump to
2. After the oil is regulated to a specified flow rate, it
the orbitrol, in proportion to the orbitrol speed and
enters the orbitrol, where its direction is controlled
capacity. It then sends oil which is not needed for
before it enters the steering cylinders.
steering operations to other actuators.
3. At this time, only the front wheel steering cylinders
1.2 Orbitrol are operated, forming the “2-wheel” steering
circuit when the solenoid valves for steering circuit
The orbitrol is linked with the steering wheel, and
directional control are all in the neutral position.
functions as a directional control valve when
pressurized oil from the pump is sent to the
steering cylinders.
1.3 Steering cylinder
The cylinders are attached to the axles and are

used for steering operation.
1.4 Solenoid valve (steering mode)
These valves switch the steering circuit to select

between 2-wheel, 4-wheel, crab, and other
steering.

(rear steering hydraulic lock)
This valve increases straightness of vehicle

traveling in addition to the conventional
mechanical lock.
4. If the shift switch has been switched and solenoid

SL30 or SL31 is energized, the rear wheel
steering cylinders operate, forming the “crab” or
“4-wheel” steering circuit.
1 WS02-0170E
S-2 S- 2
Priority Valve
S-2 Priority Valve

[NOTICE]
1. Structure
LS CF EF
P IW126-003001
6 9 12 13 10 14 11 7 8 3 2 1
P
LS
16 15
17 16 EF CF IW126-0060E01
1.Housing 7.Ring 11.Valve seat 15.Plug

2.Spool 8.Screen 12.O-ring 16.O-ring
3.Spring 9.Screw 13.Guide 17.Plug
6.Body 10.Spring 14.Popet
Sign / Tightening torque

Thread size
Port N-m kgf-m ft-lbf
T, LS 7/16 - 20UNF - 2B 20 - 24 2 - 2.4 15 - 18
P, EF 1•1/16 -12UN - 2B 78 - 88 8-9 58 - 65
CF 3/4 - 16UNF - 2B 54 - 66 5.5 - 6.7 40 - 48
2. Function
This valve serves to allow the hydraulic oil to flow to the Orbitrol only in the flow rate required by the steering
operation, and all the excess oil to flow to other actuators.
2 W126-0061E
S-2. S-2.
Priority Valve
3. Principle of operation
NEUTRAL RIGHT STEERING
The above figure is for illustrating the principle. The construction of the actual machine may differ from the figure.
3.1 Neutral state 3.2 Right steering

While the engine is standing still, spool 2 in the When the steering wheel is turned clockwise, the
priority valve is pushed to the left end by spring 3, hydraulic oil routes inside the Orbitrol are
fully opening port CF and fully closing port EF. switched over, causing the oil entering through
When the engine is started, the hydraulic oil port P of the Orbitrol to flow through orifice C1.
delivered from the hydraulic pump flows through Then, the pressures across orifice C1 are
port P and port CF of the priority valve to port P of transferred to pressure chambers A and B. The
the Orbitrol. As the hydraulic pressure in circuit CF spool is moved until the pressure difference (P5 –
rises in this way, pressure P5 in pressure P6) becomes balanced by spring 3.
chamber A of the priority valve also rises. At this
time, pressure chamber B is connected to the tank 3.3 Right steering to the end
line via port LS and port T of the Orbitrol, and When the steering cylinder piston is moved to the
when the pressure difference (P5 – P6) between stroke end, the relief valve in the priority valve
chamber A and chamber B rises to overcome the actuates, producing oil flow through orifice C2 in
force of spring 3, the spool moves towards right line LS of the priority valve. The pressure
until port EF becomes almost fully opened, and difference across C2 is transferred to pressure
port CF becomes slightly open. The spool remains chambers A and B and the spool is further moved
stable in this position, and the pump delivery oil towards right until it becomes stable with port CF
mostly flows through port EF. slightly open, and route EF almost fully open.
366-114-20000 △
1
3 W126-0061E
S-3 S- 3
Orbitrol
S-3 Orbitrol
[NOTICE]
1. Structure

Tightening torque
N-m kgf-m ft-lbf
P, T, L, R 3/4-16UNF-2B 53.9 - 65.7 5.5 - 6.7 40 - 48
LS 7/16-20UNF 19.6 - 23.5 2 - 2.4 15 - 18
T1 3/8-16UNC 34.3 - 44.1 3.5 - 4.5 25 - 32
4 W184-0014E
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 W184-0014E
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 kgf-m ft-lbf
1, 2 - 23.5 2.4 17.3
6 W184-0014E
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 W184-0014E
S-4. S-4.
Steering Cylinder
S-4 Steering Cylinder

[NOTICE]
1. Structure
1.Cylinder 7.Rod cover 13.Dust seal 19.Plain bearing

2.Set screw 8.O-ring 14.--- 20.Plain bearing
3.Piston 9.Damper ring 15.Plain bearing 21.Clip
4.--- 10.Packing 16.--- 22.Clip
5.O-ring 11.Backup ring 17.Boot
6.Rod 12.--- 18.---
Tightening torque
N-m kgf-m ft-lbf
A G1/2 98 10 72
B G3/8 49 5 36
C, D Rc1/8 9 - 12 0.9 - 1.2 6.5 - 9
2 M8 13.2 – 16.2 1.35 – 1.65 9.7 – 11.9
360-631-90000 △
1
360-632-00000 △
2
8 W160-0090E
S-5 S- 5
Solenoid Valve (Steering Mode)
S-5 Solenoid Valve (Steering Mode) Applicable serial No. △

4 ：547519 - -
[NOTICE]
1. Structure
9 W121-1070E
S-5 S- 5
Section A-A
Section B-B
10 W121-1070E
S-5 S- 5
Section C-C
Section D-D
11 W121-1070E
S-5. S-5.
101. Casing 105. Spring seat 302. Hexagon socket head bolt 403. O-ring
102. Cover 107. Cover 303. Screw 501. Plug
103. Spool 201. Spring 401. O-ring 502. Plug
104. Spool 301. Hexagon socket head bolt 402. O-ring 601. Solenoid valve assy
Tightening torque
Sign / port Thread size Remarks
N-m kgf-m ft-lbf
d(mounting bolt) M8 29.5±3 3±0.3 22±2.2 -
T1 - 2 or less 0.2 or less 1.5 or less Slit width 1.0
T2 - 5.4±0.5 0.55±0.05 4±0.4 Width across flat 12
T3 - 44±5 4.5±0.5 32.5±3.7 Width across flat 32
301 M6 11.8±1.5 1.2±0.15 9±1.1 Apply LOCTITE 241
302 M6 11.8±1.5 1.2±0.15 9±1.1 Width across flat 5
303 M5 3.9±0.5 0.4±0.05 2.9±0.37 Wrap sealing tape
501 - 6.9±1 0.7±0.1 5±0.7 Width across flat 4
502 - 9.8±1.5 1±0.15 7±1.1 Width across flat 5
P, A1, A2, B1, B2, T G 1/2 107.8±1 11±0.1 79.5±0.7 -
Pp, Dr G 1/4 36.3±2 3.7±0.2 26.8±1.4 -
367-415-50000 △
4
12 W121-1070E
S-6. S-6.
Pilot Check Valve (Rear Steering Hydraulic Lock)
S-6 Pilot Check Valve (Rear Steering Hydraulic 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 kgf-m ft-lbf
A, B, C, D G 1/2 98 10 72
Mounting bolt M8 14±1 1.4±0.1 10±0.7
366-254-50000 △
0
13 W115-0412E
T
Brake System
Contents
T-1 Brake System ................................... 1 4. Disassembly.............................................. 8

4.1 Disassembly of the mount plate .................. 8
1. Function .................................................... 1 4.2 Disassembly of the body ............................. 8
1.1 Brake .......................................................... 1
1.2 Brake valve ................................................. 1 5. Cleaning and checking .............................. 9
1.3 Booster ....................................................... 1 5.1 Cleaning ...................................................... 9
1.4 Air dryer ...................................................... 1 5.2 Checking ................................................... 10
1.5 Brake chamber ........................................... 1
1.6 Parking brake ............................................. 1 6. Reassembly ............................................ 10
1.7 Solenoid valve (Parking brake) .................. 1 6.1 Reassembly of the secondary side ........... 10
1.8 Pressure regulator ...................................... 1 6.2 Reassembly of the primary side ............... 10
6.3 Reassembly of the mount plate ................ 12
2. System Description ................................... 2
2.1 Service brake.............................................. 2 7. Test .................................................... 12
2.2 Parking brake ............................................. 2 7.1 Air leakage through supply valve and
2.3 Exhaust brake ............................................ 2 exhaust valve ...................................... 12
7.2 Air leakage in other parts .......................... 12
7.3 Operation test ........................................... 12
T-2 Brake Valve ...................................... 3 7.4 Performance test ....................................... 12
1. Structure and function ............................... 3 8. Maintenance standard ............................. 13

8.1 600-hour check ......................................... 13
2. Description of operation ............................ 5 8.2 1200-hour or 1-year check ........................ 13
2.1 Generation of air pressure.......................... 5
T
2.2 Stabilization of air pressure ........................ 5
2.3 Release of air pressure .............................. 6
2.4 Operation under piping rupture .................. 7
3. Dismounting and remounting .................... 7
i
T-3 Booster ........................................... 14 T-5 Brake Chamber............................... 36
1. Structure ................................................. 14 1. Structure ................................................. 36
2. Function .................................................. 17 2. Function .................................................. 37
3. Principles of operation ............................ 18 3. Disassembly............................................ 37

3.1 Relay valve ............................................... 18
3.2 Cylinder .................................................... 20 4. Cleaning and checking ............................ 38
4.1 Cleaning .................................................... 38
4.2 Checking ................................................... 38
T-4 Air Dryer ......................................... 21
5. Reassembly ............................................ 39
1. Structure ................................................. 21
6. Test .................................................... 39
2. Function .................................................. 25 6.1 Air leak test ............................................... 39
2.1 Dehumidification ....................................... 25
2.2 Regeneration ............................................ 26 7. Maintenance standards ........................... 39
2.3 Intake position .......................................... 27 7.1 1200-hour or 1-year check ........................ 39
2.4 Release position ....................................... 27
3. Precautions for handling ......................... 28 T-6 Solenoid Valve (Parking Brake)

(Air) ......................................... 40
4. Maintenance and inspection ................... 28
4.1 Daily inspection ........................................ 28 1. Structure ................................................. 40
4.2 Inspection and part replacement every
1 year or 100,000 km (62,140 mi) of
driving ................................................. 29
5. Disassembly ........................................... 29
5.1 Removing DU-3 ........................................ 29
5.2 Disassembly of cartridge .......................... 29
6. Reassembly ............................................ 31
6.1 Cartridge (lower) ....................................... 31
6.2 Tamping the desiccant .............................. 32
6.3 Cartridge (upper) ...................................... 32
7. Troubleshooting ...................................... 33
ii
T-1 T-1
Brake System
T-1 Brake System 1.6 Parking brake
The parking brake is a disc brake with the lever

1. Function
that is attached to the front axle.
The brake chamber spring force acts on the lever
1.1 Brake
to press the disc plate by the pad assy’s on both
Opposed-piston type disc brakes at which pad side of each disc plate and generate braking
assy’s on both sides of each disc plate press the force.
plate. For details, see the separate service manual
For details, see the separate service manual “Driving Axle”.
“Driving Axle”.
1.7 Solenoid valve (Parking brake)
1.2 Brake valve
This valve controls the supply of compressed air
1. The compressed air from the air tank is regulated to the brake chamber, making the parking brake
to air pressure (signal pressure) which released.
corresponds to the pedal depression angle
(pressing force), and is then sent to the relay 1.8 Pressure regulator
valve on the booster.
The pressure regulator operates to regulate the
air tank pressure within a specific range.
1.3 Booster
1. Relay valve
This valve supplies compressed air from the air
tank to the air cylinder, at the same pressure as
the air pressure (signal pressure) that is regulated
by the brake valve.
2. Air cylinder, fluid cylinder

The air pressure from the air tank is converted to
fluid pressure and magnified before being sent to
the wheel cylinder to operate the disc brakes.
1.4 Air dryer
The air dryer removes moisture from the

compressed air, preventing rust and extending
devices’ lifetimes.
1.5 Brake chamber
Parking brake is operated by the force from the

powerful spring inside the brake chamber, and
the compressed air is supplied to release the
parking brake.
1 WT02-0220E
T-1 . T-1 .
Brake System
2. System Description 2.3 Exhaust brake

(Refer to pneumatic circuit in chapter Z.) 1. When the exhaust brake switch (combination
switch) is pulled down, the exhaust brake indicator
2.1 Service brake lamp lights up, indicating that the exhaust brake is
1. When the pedal of the brake valve is depressed, ready for function.
compressed air from the air tank is regulated to air 2. If the shift lever is out of the “N” position and the
pressure (signal pressure) that corresponds to the accelerator switch is in the “ON” position, the
angle of pedal depression. This air then acts on solenoid valve SL54 is energized, allowing the
the relay valve which is attached to the booster. compressed air from the air tank passing through
2. The relay valve sends the compressed air at the the solenoid valve and entering the exhaust brake
pressure as same as the air from the air tank cylinder, then the exhaust brake works.
(signal pressure) to the booster air cylinder. There However, if the shift lever is in “D” position and the
it is converted to fluid pressure, which acts on the vehicle speed is lower than 1 km/h, the solenoid
wheel cylinders to operate the service brakes. valve SL54 is deenergized, and the compressed
air goes out of the exhaust port of the solenoid
3. When the pedal is released, the air pressure valve instead of being sent to the exhaust brake
(signal pressure) that had been acting on the relay cylinder, thus making the exhaust brake
valve is discharged through the exhaust port of inoperative.
the brake valve.
And the relay valve return to its non-operating
position. The compressed air goes out of the relay
valve exhaust port instead of being sent to the air
cylinder, thus making the service brake released.
2.2 Parking brake
Braking
When the parking brake switch is turned to the
“PARK“ position, solenoid valve SL50 is
deenergized, and the compressed air that has
been sent to the brake chamber is discharged
through the solenoid valve exhaust port.
And the brake shoes in the drum are expanded to
operate the parking brake by the spring inside the
brake chamber.
Releasing
When the parking brake switch is turned to the
“OFF” position, solenoid valve SL50 is energized.
The compressed air from the air tank passes
through the solenoid valve and enters the brake
chamber.
And the spring in the chamber is compressed, and
the parking brake is released.
2 WT02-0220E
T-2 T-2
Brake Valve
T-2 Brake Valve
[NOTICE]
1. Structure and function It delivers air to two systems at pressures

determined by the position of the brake pedal,
This brake valve is dual-circuit rubber-spring type
even when one of the systems fails, the other
for air brake systems.
system remains operational to brake the vehicle.
T1
46 45 16 26
25
24
T2
43
42
T3
23 19
27 21
Primary side
22 20
3 15
Supply port Delivery port
18
17
1 4
9 5
10 14
40
Supply port 11 Secondary side
7
6
13
Delivery port
8
2
28,41 T4
12
Exhaust port
36 34 37,38 39 29 35 33 32 31 30 IW202-001001E
T5
3 W202-0015E
T-2 T-2
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 kgf-m ft-lbf
T1 (26) - 3.9 - 6.9 0.4 - 0.7 2.9 - 5.1
T2 (43) - 8.8 - 13.7 0.9 - 1.4 6.5 - 10.1
T3 (19) - 3.9 - 6.9 0.4 - 0.7 2.9 - 5.1
T4 (41) - 3.9 - 6.9 0.4 - 0.7 2.9 - 5.1
T5 (38) - 1.3 - 2.5 0.13 - 0.25 1 - 1.8
Pipe port Rc 3/8 29.4 - 39.2 3-4 21.7 - 28.9
4 W202-0015E
T-2 T-2
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
brake in the primary system. Discharge valve sheet
Discharge air passage
Lower valve
Return spring Plunger IW202-0010E03
Spring sheet
Rubber spring 2.2 Stabilization of air pressure

Piston
1. When the pedal is depressed to a certain extent
and kept stationary at that position, the air
pressure is stabilized at a level corresponding to
Inlet valve sheet
that pedal position as follows:
2. As the pedal is depressed, the discharge valve

closes and the inlet valve opens to deliver air to
Discharge valve sheet
the system.
Upper body
3. This air also exerts upward pressure on the
Upper valve
underside of piston.
4. With the pedal maintained at a certain depressed

IW202-0010E02 position, the air under piston pushes up piston by
compressing rubber spring above the piston.
5. On the other hand, as the primary system
becomes operational, part of its pressurized air 5. Piston, while keeping contact with upper valve,
flows through the passage in the upper body into rises until upper valve comes into contact with the
the space above the relay piston in the secondary inlet valve seat to stop the delivery of air.
system. This pushes the relay piston down.
6. Then, with the discharge valve seat in contact with
6. The discharge valve seat at the bottom of the upper valve, the air pressure remains stable.
relay piston comes into contact with the lower
valve, closing the discharge passage at the
center.
5 W202-0015E
T-2 T-2
Brake Valve
Rubber spring
Piston
Discharge valve sheet
Relay piston
Inlet valve sheet
Upper body
Upper valve Discharge valve sheet
Inlet valve sheet

Lower body Lower valve
IW202-0010E05
IW202-0010E04
7. In the secondary air system, relay piston lowers in 2.3 Release of air pressure
proportion to the air pressure in the primary
1. As the pedal is released, the plunger and piston
system to generate air pressure in the secondary
are pushed up by the return spring and by the
system. The generated pressure is applied also 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 from 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.
6 W202-0015E
T-2 T-2
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 make the secondary system
Relay piston
operate in the same way as the primary system in
Upper valve
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

When the secondary brake system is broken, the Piston
primary system remains operational, because
relay piston separates it from the secondary
system.
Relay piston
Lower valve
IW202-0010E08
3. Dismounting and remounting

1. Dismount the valve after immobilizing the vehicle
Relay piston
and discharging the compressed air from the
reservoir by opening the drain cock.
2. Tighten the pipe fitting: 29.4 - 39.2 N-m (3 - 4 kgf-m)

(21.7 - 28.9 ft-lbf)
IW202-0010E07
7 W202-0015E
T-2 T-2
Brake Valve
Upper body Stem

4. Disassembly
[NOTICE]
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.
Place the disassembled parts in neat order to
facilitate reassembly.
4.1 Disassembly of the mount plate Relay piston
1. Remove three bolts and washers, and remove

IW202-0010E11
mount plate, plunger, and plunger boot.
Plunger Plunger boot

3. Unscrew nut at the top of piston, and remove
Bolt and washer
piston, return spring, relay piston, spring, and
Mount plate stem.
[NOTICE]
At this time, hold the piston to prevent it from being
popped out by the return spring.
Nut
Piston
IW202-0010E09
Return spring
4.2 Disassembly of the body
1. Clamp the body in a vise, with lower body facing

upward; unscrew four bolts, and remove the lower
body assembly from upper body.
Lower body
Bolt
Upper body Relay piston
IW202-0010E10
Stem
2. Clamp a screwdriver in a vise, pass it through the

discharge passage of relay piston and place the
blade in the slit in the stem. IW202-0010E12
8 W202-0015E
T-2 T-2
Brake Valve
4. Remove the O-ring fitted between the upper body

and lower body. Clamp the lower body in a vise, Retaining ring
with the exhaust check facing upward.
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.
9 W202-0015E
T-2 T-2
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
Eponex SR2, 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 Eponex
SR2) and fill the O-ring groove with grease in
advance. 6.2 Reassembly of the primary side
Apply lithium base grease containing MoS2
1. Place the upper valve on the work bench with the
(Bearing Grease No.3 by Nippon Molybdenum, or
equivalent) to the sliding surfaces of the plunger, valve seat side down.
and to the 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 Upper valve assy

IW202-0010E16
IW202-0010E15
10 W202-0015E
T-2 T-2
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 sufficiently 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.
11 W202-0015E
T-2 T-2
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 released 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

2
Upper body pressure is at 98.1 kPa (1 kgf/cm ) {14.2psi}, the
IW202-0010E23
lower delivery port pressure is over 78.5 kPa
2
(0.8 kgf/cm ) {11.4psi}. If these criteria are not met,
the cause may be lack of grease on sliding parts
6.3 Reassembly of the mount plate
or weakened springs.
1. With the plunger boot on, install plunger in mount Performance curve
plate, and clamp them to upper body with three (Psi) (kgf/cm2) (kPa) Max. travel 11.8mm (0.46in)
1015 7 690
bolts and washers.
6 590
725 5 490
4 390
7. Test 435 3 290
2 200
[NOTICE] 145 1 98
Test the brake valve for leaks and performance, 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 (mm)
with a pressure gauge measuring up to 981 kPa (10
2
kgf/cm ) {142psi} or so connected to the delivery 0 0.1 0.2 0.3 0.4 0.48(in)
side, and with the supply pressure adjust to 687 Plunger travel
2
kPa (7 kgf/cm ) {100psi}. IW202-0014E24
First, in the fully released state, make sure that the

delivery pressure is zero for both upper and lower sides.
Then, check the following items for both upper and lower
sides.
12 W202-0015E
T-2 . T-2 .
Brake Valve
8. Maintenance standard
(Refer to Operation & Maintenance manual,
Periodic Inspection)
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 1200-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.
(Refer to Safety Parts Requiring Regular
Replacement.)
366-010-00001 △
1
366-045-10000 △
0
13 W202-0015E
T-3 T-3
Booster
T-3 Booster
[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
14 W404-0013E
T-3 T-3
Booster
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
15 W404-0013E
T-3 T-3
Booster
[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 kgf-m ft-lbf
18 - 118 - 147 12 - 15 87 - 108
21 - 20 - 39 2-4 14 - 29
22 - 12 - 20 1.2 - 2 9 - 14
25 - 20 - 29 2-3 14 - 22
27, 37 M10 25 - 29 2.5 - 3 18 - 22
33-17 M8 10 - 20 1-2 7 - 14
34 M50 118- 147 12 - 15 87- 108
35 M4 1.5 – 2.5 0.15 - 0.25 1–2
36 - 20 - 39 2-4 14 - 29
16 W404-0013E
T-3 T-3
Booster
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.
17 W404-0013E
T-3 T-3
Booster
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
18 W404-0013E
T-3 T-3
Booster
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.
19 W404-0013E
T-3 . T-3 .
Booster
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
20 W404-0013E
T-4 T-4
Air Dryer
T-4 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
21 W232-0034E
T-4 T-4
Air Dryer
View A
58
39
B B
59 Heater
2
C
A
IW232-0030E03
22 W232-0034E
T-4 T-4
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
23 W232-0034E
T-4 T-4
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. Desiccant 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 kgf - m ft - lbf
IN, OUT Rc 1/2 44 - 59 4.5 - 6 32.5 - 43.5
8 － 4-7 0.4 - 0.7 3-5
29 － 7-8 0.7 - 0.8 5-6
33 － 5-6 0.5 - 0.6 3.5 - 4.5
39 － 15 - 25 1.5 - 2.5 11 - 18
49 － 2-4 0.2 - 0.4 1.5 - 3
53 － 2-4 0.2 - 0.4 1.5 - 3
58 － 18 - 27 1.8 - 2.8 13 - 20.5
59 － 20 - 29 2-3 14.5 - 21.5
61 － 0.5 - 1 0.05 - 0.1 0.4 - 0.7
63 － 1 - 1.5 0.1 - 0.15 0.7 - 1.1
Mounting bolt M10 × 1.25 15 - 23 1.5 - 2.3 11 - 16.5
24 W232-0034E
T-4 T-4
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. The air
the atmosphere and the drain valve closes.
becomes dry air when it reaches the top of the
drying tube.
2.1 Dehumidification
5. This dry air passes through the check valve and
1. During the compressor load cycle, the air from the
purge chamber at the top of the drying tube, and
compressor enters the air dryer inlet port. The
is supplied to the governor chamber and main
compressed air is cooled down as it flows along
tank via the outlet port check valve.
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
25 W232-0034E
T-4 T-4
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. This pressure is
control pressure passes through the control line also ejected from the dryer into the atmosphere by
and opens the drain valve 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
26 W232-0034E
T-4 T-4
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 (pressure in air
(air tank pressurized air) travels through the tank) 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 shut 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 beyond
is released into the atmosphere. 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 (pressure in air tank)

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
pressurized air from control port passes through
the exhaust stem to be released into the
atmosphere.
This closes the drain valve.
27 W232-0034E
T-4 T-4
Air Dryer
3. Precautions for handling 4. Maintenance and inspection
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
Use the desiccant specified by NABCO (part No.
41213640010), and replace it with an amount that is openings, and other locations.
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 for
reduce the moisture-absorption capability of the any drainage.
dryer, but can lead to unsetlling 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 (60.6°F)).
Be aware that the desiccant used in DU-3 is of a
different type than the desiccant used in DR-41, 3. If a small amount of drainage occurs, in cases
DR-42, and DU-4.
other than the above (drainage resulting from
Be sure to tamp the desiccant after pouring it.
temperature change), check the precautions for
1. If the vehicle has been parked for several hours in handling again.
a cold location (-10°C (14°F) or below), wait at [NOTICE]
least 10 minutes before driving after starting the If the desiccant becomes steeped in oil or other
engine. (It takes time for the temperature to rise substance, its ability to absorb moisture is
after the heater turns ON.) decreased and dryer function is greatly affected. Be
sure to replace any steeped desiccant.
2. Make sure that the unload time is 50 seconds or It is recommended that you replace the filters at the
longer. same time as the desiccant.
(If the regeneration process is not performed, the
moisture-absorbing 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
steeped in oil or other impurities. If 1/5 or more of
3. During unloading, air is continuously discharged the total desiccant is steeped 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 earlier. accumulate in the compressor and dryer piping, and
inside the dryer itself. Because this oil may catch
5. If drainage occurs from the air tank, disassemble fire, be sure to perform cleaning periodically.
the dryer. Replace the desiccant if 1/5 or more of
5. Pay attention to the drainage from the air dryer
the total desiccant is seeped in oil.
exhaust port. If an abnormal amount of oil is
(If the desiccant is steeped in oil, its ability to
drained, inspect the compressor and take steps to
absorb moisture is decreased and dryer function
prevent increases in the amount of oil.
is greatly affected. Be sure to replace any steeped
desiccant.)
28 W232-0034E
T-4 T-4
Air Dryer
6. Use the in-vehicle air pressure gauge to check 5. Disassembly

that the pressure governor is operating at the
specified pressure. Also check for any 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 (8.8 - 9.3 kgf/cm )

2 2. Open the drain cock on the air tank. Discharge the
{129.4 - 132.2psi} air from the brake piping.
Unload → Load: 740 - 780 kPa (7.5 - 8 kgf/cm )
2
3. Disconnect the thermostat wiring.
{106.7 -113.8psi}
4. Disconnect all the wires (IN, OUT) from the air
4.2 Inspection and part replacement every 1 dryer.
year or 100,000 km (62,140 mi) of driving
5. Loosen the three bolts to remove the UD-3.
1. Disassemble the air dryer. Replace the desiccant,
oil filter, filter, and all rubber parts, with or without 5.2 Disassembly of cartridge
scratches or wear is visible on these parts.
1. Anchor the DU-3 body-1 in a vise. Unscrew the
2. Check for any abnormalities in the piping and bolts and washers that fasten the purge chamber
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
washers
These inspections and maintenance are to be
performed when either the travel distance or
installation time is reached, whichever occurs first. Purge chamber
Desiccant
3. Check all metal parts for corrosion. Repair or Bolts
and
replace them as necessary. washers
Body
IW232-0030E10
2. When the purge chamber is removed, cartridge

assy containing the desiccant is exposed. Directly
remove the cartridge assy upward by hand.
29 W232-0034E
T-4 T-4
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
removed. washer
The case cover can be extremely dangerous if
the set spring inside causes the cover to pop up
and strike a person in the face or other body Purge chamber
part. Desiccant
3. Use your hand and press from above on the case Bolt
and
cover attached to the desiccant case. At the same washer
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
spring IW232-0011E12
Filter 6. Press the cover with your hand, and lift the case
Filter
plate B Desiccant up to remove it. Remove the oil separator filter
Filter installed in the cover.
Filter
plate A
IW232-0030E11
5. Use a 4 mm hex wrench to unscrew and remove

the 4 hexagon socket head bolts and washers.
30 W232-0034E
T-4 T-4
Air Dryer
6. Reassembly 3. Put 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
Use the specified NABCO desiccant Filter
(41213640010). plate B
Desiccant Case
Use of a desiccant other than that specified is Desiccant
extremely dangerous. It can result in the Filter
desiccant deteriorating and being lost, with Filter
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. Pour the specified amount of desiccant.
3
The specified amount is 590 - 619 cm (36 -
3
37.8in ) [480g (1.06lb)]. When using desiccant
Case included in a repair kit, use a whole bag of it..
Oil separator Desiccant
filter
O-ring Hexagon soket DANGER
head bolts If desiccant less than the specified amount is
Cover
used, the desiccant may remain unsettled and
be lost, with pieces clogging the brake piping
and hindering normal brake operation. Be sure
to pour the specified amount.
5. Next insert the second filter with the soft surface

on the bottom. Then place filter plate B in position
and tamp the desiccant.
IW232-0030E12
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
(0.2 - 0.4 kgf-m) (1.5 - 2.9 ft-lbf)
31 W232-0034E
T-4 T-4
Air Dryer
6.2 Tamping the desiccant 6.3 Cartridge (upper)
[NOTICE]
DANGER Applying grease to the raised part of the check
valve will allow it to be inserted more easily.
If the desiccant is not tamped, it may remain
unsettled and be lost, with pieces clogging the Use NABCO grease (grease pack 45499030090,
brake piping and hindering 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
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 tamping, place two or three sheets of
shopcloth or other soft cloth on the workbench at pressing down on the case cover with your hand.
the tapping location to prevent the cover from being Tightening torque: 2.0 - 3.9 N-m
damaged.
(0.2 - 0.4 kgf-m) (1.5 - 2.9 ft-lbf)
Check valve Case cover

purge chamber
Set spring Screws
and
washers
O-ring
Case
Filter plate Desiccant
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, keep holding the case
with your hands and do not release it.
3. Repeat steps 1 and 2 approximately 30 times.

Check that the filter plate B sinks 4 - 6 mm (1.5 –
2.4in) from the initial position. When this is verified,
the work is complete.
32 W232-0034E
T-4 T-4
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 in the compressor is Replace the desiccant.

flows out of the abnormally large. 1/5 or more of the Also take steps to decrease the oil.
air tank. desiccant is steeped in oil and its ability to
absorb moisture has decreased.
Moisture-absorbing ability is insufficient Use the specified amount of desiccant.

due to short amount of desiccant. 3
(Specified amount: 590 - 610 cm (36 - 37.2in ))
3
Moisture-absorbing ability is insufficient Use the specified type of desiccant.

due to wrong type of desiccant. (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 per 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 does not open, and the Check the governor discharge pressure. If it
desiccant is not regenerated. differs from the specified value, adjust or replace
the governor.
• Disassemble and inspect the valve operation
parts. Remove any foreign substances that are
found.
• If the drain valve is frozen, check for any open
circuit in the heater, thermostat failure, missing
wire, or other problem. Replace parts or
connect wires securely.
The dryer inlet temperature is higher than Make arrangement to lower the inlet temperature
60°C (140°F), and moisture absorption is less than 60 °C (140°F).
insufficient.
The desiccant has not been replaced for a Replace the desiccant every 1 year or 100,000
long time, and 1/5 or more is steeped in km (62140mi) of travel, whichever occurs earlier.
oil, reducing its ability to absorb moisture.
33 W232-0034E
T-4 T-4
Air Dryer
Condensate The desiccant regeneration capability is Inspect the check valve and O-ring.
flows out from reduced due to short purge time. (Purge time should be approximately 35 seconds
2
the air tank. at the pressure of 890 kPa (9 kgf/cm ) (129psi)
2
through 0 kPa (0kgf/cm ) (0psi).)
The desiccant regeneration capability is Check the governor discharge pressure. If it is

reduced due to low pressure in the purge different from the specified value, adjust or
chamber. replace the governor.
No condensate The drain valve is frozen and fails to If there is an open circuit in the heater, replace
is discharged open. the heater.
from the (Check the conduction with a tester.)
exhaust port.
• If the thermostat is faulty, replace it.
(Leave it at 0°C (32°F) or lower, then check
the conduction with a tester.)
• Check that no wires have been disconnected.
• If the machine is 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 from
-20°C - 0°C (-4°F - 32°F)
The governor discharge pressure is 490 Check the governor discharge pressure. If it
kPa (71psi) or less, and the drain valve differs from the specified value, adjust or replace
does not 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 does not If there is an open circuit in the heater, replace
the exhaust close. the heater.
port.
• If the thermostat is faulty, replace it.
• Check that no wires have been disconnected.
• If the machine is 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.
34 W232-0034E
T-4 . T-4 .
Brake (Parking Brake)
Main tank The air dryer outlet check valve fails to Disassemble and inspect the air dryer outlet
pressure drops function, and 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
35 W232-0034E
T-5 T-5
Brake Chamber
T-5 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 kgf-m ft - lbf
7, 8 － 9.8 - 14.7 1 - 1.5 7.2 - 10.8
36 W576-0024E
T-5 T-5
Brake Chamber
2. Function DANGER
Never attempt to disassemble the brake
1. When compressed air is introduced behind the chamber without using the special jig. Doing so
diaphragm, it pushes the diaphragm, and the push is extremely dangerous.
rod to release the brake. The spring is powerful. Be sure to use the
special jig to pull the push rod out approximately
2. When the compressed air is released to the 5 mm before disassembling.
outside air, the push rod is pushed back by a
strong return spring, pulling the brake lever to
effect the parking brake. 3. Disassembly
[NOTICE]
Make alignment marks on the clamp bolts,
non-pressure plate, and pressure plate 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)
(1.1)
28
50
(0.59)24
15
9
100 (3.94) (0.35)
IW576-0021E02
37 W576-0024E
T-5 T-5
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 the 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. Wipe it with dry cloth,
3. Remove bolts by unscrewing two clamp ring nuts,
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.
38 W576-0024E
T-5 . T-5 .
Brake Chamber
5. Reassembly
5. Place diaphragm and pressure plate on
1. Set push rod vertically on a flat bench, with its end non-pressure plate, attach clamp ring on the
up. flange of the pressure plate by expanding the ring,
and align the marks.
2. Put spring and non-pressure plate over the push
rod. 6. Tighten 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. (1 - 1.5 kgf-m) (7.2 - 10.8 ft-lbf)
4. Attach clamp ring on the flange 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 1200-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 (5 - 8 as described above.
2
kgf/cm ) (72.5 - 116psi) to the inlet port, and check
for air leakage.
367-001-40000 △
1
367-001-80000 △
1
367-001-50000 △
1
367-000-10000 △
1
39 W576-0024E
T-6 T-6
Solenoid Valve (Parking Brake) (Air)
T-6 Solenoid Valve (Parking Brake) (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
40 W210-0125E
T-6 . T-6 .
Solenoid Valve (Parking Brake) (Air)
1.Core 6.Coil assy (24V DC) 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 kgf-m ft-lbf
IN, OUT Rc1/4 15 - 29 1.5 - 3 11 - 22
T1 M8x1.25 8 - 12 0.8 - 1.2 6-9
366-459-60000 △
5
41 W210-0125E
U
Suspension System
Contents
U-1 Suspension System......................... 1 U-5 Pressure Reducing Valve

(Pilot Pressure) ........................9
1. Function ..................................................... 1
1.1 Suspension lock cylinder............................ 1 1. Structure .................................................... 9
1.2 Pilot check valve......................................... 1
1.3 Solenoid valve (suspension lock) ............... 1
1.4 Solenoid control valve ................................ 1
1.5 Reducing valve ........................................... 1
2. System description .................................... 1
3. Suspension lock......................................... 2
4. Installation.................................................. 3
U-2 Suspension Lock Cylinder .............. 5
1. Structure .................................................... 5
U-3 Pilot Check Valve (Suspension

Lock Cylinder) ......................... 6
1. Structure .................................................... 6
U
U-4 Solenoid Valve (Suspension Lock)
(Free/Lock) ............................... 7
1. Structure .................................................... 7
i
U-1 U-1
Suspension System
U-1 Suspension System 1.3 Solenoid valve (suspension lock)
This valve sends or stops the pilot pressure to the

pilot check valve.
1. Function
1.4 Reducing valve
1.1 Suspension lock cylinder
This valve regulates (reduces) the pilot pressure
The cylinder side is linked with the lower frame,
that is directed to the solenoid valve (suspension
and the rod side is linked with the axle. The
lock).
hydraulic oil is sealed inside the cylinder. Thus
the axle and frame are joined.
This valve seals the hydraulic oil that is in the

suspension-lock cylinders or releases the
hydraulic oil to the tank circuit.
1. When the outrigger control is in the neutral 2. When suspension lock is activated, solenoid valve
position, pressurized oil from pump P4 is sent (SL02) operates. It seals pressurized oil in the
through the reducing valve to the solenoid valve. right and left suspension cylinders, locking the
cylinders, lifting up the axles, and joining the axles
to the frame. When suspension lock is deactivated,
the solenoid valve (SL03) operates, the
pressurized oil is released and directed to the tank,
and the cylinders are unlocked.
1 WU02-0310E
U-1 U-1
Suspension System
3. Suspension lock
(1km/h = 0.62mi/h)
Serial signal
Upper unit input status output status Lower unit output status
to DCU Remarks
Pi2 Di36 Di45 (over-front Do19 RY50 RY20
(main speed) (PTO) detection) (sus lock) (sus lock) (sus free)
Suspension
0 1 0 0 1
release
Vs<1 Suspension
1 ― 1 1 0
lock
0 0 Previous status is retained. *1
Vs 1 ― ― Previous status is retained. *2
1: switch contact 1: switch contact
Remarks
Vs: vehicle
closed (H) closed (H) 1: level “H” 1: relay contact ON
speed
0: switch contact 0: switch contact 0: level “L” 0: relay contact OFF
(km/h)
open (L) open (L)
NOTICE 1: If the main speed input signal is erroneous (error 01), the main speed is supposed to be Vs 1.
*1. The initial value in the reset operation is supposed to be the lock output (Do19 "1", RY50 "1", RY51 "0").
*2. The initial value in the reset operation is supposed to be "0" for all of the outputs Do19, RY50, and RY51.
1. When the PTO switch is turned ON, the 3. The switching operation is not accepted if the
suspension lock operation is activated. vehicle speed is over 1 km/h (0.62 mi/h).
2. When the PTO switch is turned OFF in the

forward position, the suspension lock is released.
361-713-03470 △
0
2 WU02-0310E
U-1 U-1
Suspension System
4. Installation
3 WU02-0310E
U-1. U-1.
Suspension System
347-907-10000 △
2
4 WU02-0310E
U-2. U-2.
Suspension Lock Cylinder
U-2 Suspension Lock Cylinder

[NOTICE]
1. Structure
1.Cylinder 4.Plain bearing 7.Rod 10.O-ring

2.Set screw 5.Packing 8.Rod cover 11.Packing
3.Piston 6.O-ring 9.Damper ring 12.Dust seal

*2 : Apply Three-bond 1104 or equivalent to threaded section.
Tightening torque
N-m kgf-m ft-lbf
A, B G3/8 49 5 36
2 M8 13.2 – 16.2 1.35 – 1.65 9.7 – 11.9
360-539-80001 △
0
5 W159-0090E
U-3. U-3.
Pilot Check Valve (Suspension Lock Cylinder)
U-3 Pilot Check Valve (Suspension Lock Cylinder)

[NOTICE]
1. Structure
1.Plug 4.--- 7.Valve 10.Plug

2.O-ring 5.O-ring 8.Valve 11.Plug
3.Plunter 6.Body 9.Spring
Tightening torque
N-m kgf-m ft-lbf
P, Pp, Pa, Pb G1/4 29.4 3 22
1, 10 M34×1.5 93 - 103 9.5 - 10.5 68.7 – 75.9
366-205-30002 △
1
6 W115-0670E
U-4 U-4
Solenoid Valve (Suspension Lock) (Free/Lock)
U-4 Solenoid Valve (Suspension Lock) (Free/Lock)

[NOTICE]
1. Structure
T
G A
P
IW121-0700E01
T P 5
2
A
3,4

2.Body
3.Plug
4.O-ring
G
T IW121-0700E02
Tightening torque
N-m kgf-m ft-lbf
A, P, T, G G1/4 34 - 38 3.5 - 3.9 25 - 28
5 M5 4.9 – 6.9 0.5 - 0.7 3.6 – 5.1
346-410-52500 △
0
7 W121-0704E
U-4. U-4.
Solenoid Valve (Suspension Lock) (Free/Lock)
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 kgf-m ft-lbf
8 - 5–7 0.5 - 0.7 3.6 – 5.1
366-498-90000 △
0
8 W121-0704E
U-5. U-5.
Pressure Reducing Valve (Pilot Pressure)
U-5 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 kgf-m ft-lbf
P G1/2 98 10 72
A1 G3/8 49 5 36
A2, Dr G1/4 29.4 3 22
366-054-90000 △
1
9 W120-0122E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan
Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785
History of revision
1
2
3
4
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Tadano - Manual de Sevicio 2-S1 (U) - 1E

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Tadano - Manual de Sevicio 2-S1 (U) - 1E

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Publication No.

Rough Terrain Crane

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

2.The oil cooler fan may rotate the moment the

1. Applicable spec. and serial number

Spec. no. / model Applicable serial number

2. Separate service manual

bar MPa kgf/cm2

N-m kgf-m ft-lbf

B Hydraulic Power Generating System B

R Driving Power Transmission System R

Y Data, Adjustment and Checks

Chapter Section GR-750-2-00101

A General Cautions Refer to separate service manual

Hydraulic Power Generating System

Hydraulic Power Generating System B-1

Flow Control Valve B-6

Solenoid Valve(Pilot Pressure) B-10

Solenoid Valve(Positive Control) B-11

Check valve (Gauge Isolator) B-12

Outrigger System C-1

Solenoid Control Valve (Outrigger) C-2

Solenoid Valve (Slide/Jack) (TOKIMEC) C-4

Jack Cylinder C-6

Chapter Section GR-750-2-00101

Swing System D-1

Hydraulic Pilot Control Valve (Swing) D-2

D Hydraulic Motor (Swing) D-3

Swing Speed Reducer D-4

Swing Assembly D-5

Boom Elevating System

Elevating System E-1

Elevating Cylinder E-2

Pressure Sensor E-4

Winch System F-1

Hydraulic Motor and (Winch) F-3

F Counterbalance Valve (Winch) F-4

Hydraulic Valve (Winch Brake Release) F-5

Accumulator (Winch Brake) F-6

Pressure Sensor F-7

Chapter Section GR-750-2-00101

Boom Telescoping system

Telescoping System G-1

Boom (Five-Section Boom) G-2

Telescoping Cylinder G-4

Counterbalance Valve (Telescoping) G-5

G Hose Reel G-6

Hydraulic Valve (Winch Brake Release) G-7

Jib Lock Pin Cylinder G-8

Jib Offset Cylinder G-9

Solenoid Control Valve (Jib Set) G-10

Pilot Check Valve (Jib Set) G-11

Safety System H-1

Load Moment Indicator (AML) Refer to separate service manual

H Boom Length and Angle Detector H-2

Outrigger Extension Length Detector H-3

Solenoid Valve (Auto Stop) H-4

Crane Cab Glass K-1

Air Conditioner K-2

Chapter Section GR-750-2-00101

Inside Cab Control Device L-1

Shift Switch L-2

Solenoid Valve (Air) L-3