Publication No. TR-500M-3/S1-1E. Rough Terrain Crane TR-500M-3. Model. Applicable Serial No

Transcription

1 Publication No. TR-500M-3/S1-1E 01 Rough Terrain Crane Model TR-500M-3 Applicable Serial No

2 Foreword Foreword This material is the one that Publication No. TR-500M-3/R-01 was replaced from Japanese with English. This service manual describes the systems and components of the Model TR-500M-3 rough terrain crane, its repair, check and adjustment methods and other relevant matters. Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the crane in conjunction with this manual. When carrying out repairs, check the parts catalog for structure and sales units of the parts beforehand. 1. Applicable spec. No. The spec. Nos. of the cranes to which this manual is applicable are listed below. Check the spec. No. of your crane on the nameplate attached to the crane before using this manual. SPEC. NO. SERIAL. NO. MFG.DATE. KAGAWA, JAPAN ISA Spec. No. Applicable serial No. TR-500M TR-500M TR-500M Please note that, for product improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1

3 Foreword 2. Outline of specifications No. Item Spec. No. TR-500M TR-500M TR-500M No. of boom sections 6 2 No. of jib stages 2 3 Jib type Quick turn power tilt jib Quick turn jib 4 Single top 5 Winch No. of motors 2 No. of drums 2 6 Winch brake Automatic brake + Foot brake 7 Drum lock device 8 Drum rotation indicator 9 Color multi-display (AML-V) 10 Retarder (directly mounted on transmission) 11 Outrigger type X type 12 Air conditioner 13 Oil cooler 14 Outrigger Control Outside Cab 15 Emergency steer system 16 Auto. stop solenoid valve energizing type normally energized 17 Engine model PF-6T : Fitted : Not fitted 2

4 3. Group index B C D Hydraulic Power Generating System Outrigger System Swing System B C D F G H Winch System Boom Telescoping System Safety System F G H K L Cab Control System K L N Electrical System N R S T U Driving Power Transmission System Steering System Brake System Suspension System R S T U 3

5 Foreword 4. Contents Chapter Section Spec. No. TR-500M TR-500M TR-500M Hydraulic Power Generating System System Components B-1 Hydraulic Pump (Variable Displacement Pump) B-2 Hydraulic Pump (Gear Pump) B-3 B Solenoid Control Valve B-4 Hydraulic Pilot Control Valve B-5 B-6 B-5 Rotary Joint B-7 Flow Control Valve B-8 Outrigger System System Components C-1 C Solenoid Valve C-2 Pilot Check Valve (for Jack Retraction Prevention) Pilot Check Valve (for Jack Drop Prevention) C-3 C-4 C-5 Swing System System Components D-1 Hydraulic Pilot Control Valve D-2 D Swing Drive Unit D-3 Swing Bearing D-4 Solenoid Control Valve (for Swing Brake, Accumulator Circuit Pressure Control, Jib Extension Device, Pilot Vent) D-5 4

6 Foreword Chapter Section Spec. No. TR-500M TR-500M TR-500M Winch System System Components F-1 System Overview F-2 Hydraulic Motor F-3 Winch (for Main) F-4 Winch (for Auxiliary) F-5 F Counterbalance Valve F-6 Winch Clutch F-7 Winch Brake Band F-8 Master Cylinder (for Winch Brake) F-9 Accumulator F-10 Hydraulic Valve F-11 Solenoid Control Valve (See Chapter D.) D-5 Boom Telescoping System System Components G-1 System Overview G-2 Boom G-3 G Hydraulic Valve G-4 Flow Control Valve G-5 Hose Reel (for No. 2 Cylinder) G-6 Hose Reel (for No. 3 Cylinder) G-7 5

7 Foreword Chapter Section Spec. No. TR-500M TR-500M TR-500M Hose Reel (for Power Tilt Jib) G-8 G-8 G Solenoid Control Valve (See Chapter D.) Solenoid Valve (for Boom Telescoping/Jib Elevation Control Pilot Select) Counterbalance Valve (for Boom Telescoping Cylinder) Counterbalance Valve (for Power Tilt Jib) Pilot Check Valve (for Quick Turn Jib(Jib Extension Device)) D-5 G-9 G-9 G-10 G-11 G-11 G-12 Safety System System Overview H-1 H-2 H-1 Color Multi-Display (AML-V) H-3 H-4 H-3 Boom Length/Angle Detector H-5 H Jib Angle Detector(for Power Tilt Jib) H-6 H-6 Outrigger Extension Length Detector H-7 Solenoid Valve(for AML Vent) H-8 Solenoid Control Valve (See Chapter D.) D-5 Cab K Crane Cab Glass K-1 Control System System Components L-1 L Remote Control Valve (for Swing, Telescoping, Jib) Remote Control Valve (for Swing, Telescoping) Remote Control Valve (for Elevation, Winch) L-2 L-2 L-2 L-2 6

8 Foreword Chapter Section Spec. No. TR-500M TR-500M TR-500M Solenoid Control Relief Valve(for Elevation, Telescoping (Retraction) Stop) L-3 Throttle Valve (for Accelerator) L-4 L Air Cylinder (for Accelerator) L-5 Solenoid Valve (for Speed Limiter, Governor Select, Exhaust Brake, 2/4 Wheel Drive Select) L-6 Solenoid Valve (for Outrigger Accelerator) L-7 Electrical System N Cord Reel N-1 N-1 Driving Power Transmission System System Components R-1 R System Overview R-2 Torque Converter and Transmission R-3 Steering System System Components S-1 Hydraulic Pump (for Emergency Steer) S-2 Hydraulic Valve S-3 S Priority Valve S-4 Orbitrol S-5 Solenoid Valve (for Changing Steer Modes) S-6 Solenoid Valve (for Steer Lock) S-7 Air Cylinder (for Steer Lock) S-8 7

9 Foreword Chapter Section Spec. No. TR-500M TR-500M TR-500M Brake System System Components T-1 System Overview T-2 Brake (Service Brake) T-3 Brake Valve T-4 Booster T-5 T Air Dryer T-6 Pressure Regulator T-7 Reducing Valve T-8 Solenoid Valve (for Parking Brake, Auxiliary Brake) (See Chapter L.) L-7 Brake Chamber (for Parking Brake) T-9 Parking Brake T-10 Suspension System System Components U-1 Solenoid Valve (for Suspension Select) U-2 U Solenoid Valve (for Suspension Cylinder Up/Down Select) Solenoid Valve (for Suspension Lock) U-4 U-3 Pilot Check Valve(for Suspension Cylinder) U-5 Accumulator U-6 8

10 B B Hydraulic Power Generating System Contents B-1 System Components... 1 B-2 Hydraulic Pump Construction and Function Construction Operation of the regulator... 5 B-4 Solenoid Control Valve Construction B-5 Hydraulic Pilot Control Valve Construction and Function Disassembly Disassembling the regulator Disassembling the pump main body Reassembly Reassembling the pump main body Reassembling the regulator Maintenance Standard Test B-3 Hydraulic Pump Construction Disassembly B-6 Hydraulic Pilot Control Valve Construction and function B-7 Rotary Joint Construction Disassembly and Reassembly Calibration of Potentiometer B-8 Flow Control Valve Construction and Function Reassembly Test i

11 B-1. B-1. B-1. B-1 System Components Hydraulic pump (variable pump) Rotary joint Oil cooler Hydraulic pump (gear pump) Oil tank Solenoid control valve Flow control valve Oil filter Front Hydraulic pilot control valve 1 B

12 B-2 B-2 B-2 Hydraulic Pump 1. Construction and Function 1.1 Construction This hydraulic pump is a variable displacement piston pump, and the angle of its swash plate is controlled by the regulator. Maximum flow adjustment screw Hydraulic symbol Minimum flow adjustment screw

13 B-2 B-2 Hydraulic Pump [Regulator] [Main body]

14 B-2 B-2 Hydraulic Pump 111. Shaft (F) 436. Hexagon socket head bolt 629. Cover 756. O-ring 113. Shaft (R) 438. Hexagon socket head bolt 630. Lock nut 763. O-ring 114. Spline coupling Sleeve 774. Oil seal 123. Roller bearing 468. Plug 641. Pilot cover 789. Backup ring 124. Needle bearing 490. Plug 643. Pilot piston 792. Backup ring 127. Bearing spacer 496. Plug 644. Spring seat 801. Nut 141. Cylinder block 531. Tilting pin 645. Adjustment rod 806. Nut 151. Piston 532. Servo piston 646. Pilot spring 808. Nut 152. Shoe 534. Stopper 651. Sleeve 814. Snap ring 153. Set plate 535. Stopper 652. Spool 824. Snap ring 156. Spherical bush 541. Seat 653. Spring seat 836. Retaining ring 157. Cylinder spring 543. Stopper 654. Return spring 858. Locking ring 158. Spacer 544. Stopper 655. Set spring 874. Pin 211. Shoe plate 545. Steel ball 756. Blanking cover 885. Pin 212. Swash plate 548. Feedback pin 702. O-ring 885. Valve plate pin 214. Tilting bush 601. Casing 708. O-ring 886. Spring pin 251. Swash plate support 611. Feedback lever 710. O-ring 887. Pin 261. Seal cover (F) 612. Lever (1) 717. O-ring 897. Pin 263. Seal cover (R) 613. Lever (2) 722. O-ring 898. Pin 271. Pump casing 614. Fulcrum plug 724. O-ring 901. Eye bolt 312. Valve block 615. Adjustment plug Hexagon socket set screw 313. Valve plate (R) 621. Compensation piston 727. O-ring 925. Adjustment screw (B) 314. Valve plate (F) 622. Piston case 728. O-ring 953. Adjustment screw 325. Assist casing 623. Compensation rod 730. O-ring 954. Adjustment screw 401. Hexagon socket head bolt 624. Spring seat 732. O-ring 981. Name plate 406. Hexagon socket head bolt 625. Outer spring 733. O-ring 983. Drive pin 407. Hexagon socket head bolt 626. Inner spring 734. O-ring 984. Pin 412. Hexagon socket head bolt 627. Adjustment rod 735. O-ring 413. Hexagon socket head bolt 628. Adjustment screw (A) 755. O-ring

15 B-2 B-2 Hydraulic Pump 1.2 Operation of the regulator Pin (A) Pin (B) Lever (1) Lever (2) Feedback lever Pin (C) Note: Lever (2) does not work on this pump. Sleeve Spool Adjustment screw (A) Adjustment screw (B) Piston case Compensation piston Compensation rod Servo piston Tilting pin Inner spring Outer spring Fig

16 B-2 B-2 Hydraulic Pump Pump casing Servo piston Servo piston Lever (1) Pin (A) Lever (2) Compensation piston Pin (B) Pin (C) Feedback lever

17 B-2 B-2 Hydraulic Pump The pressure oil (P) delivered from the pump main body flows to the portions [A] and [B] shown in Fig. 3 and Fig. 4 through the passages in the regulator casing. The oil flows also to the small diameter chamber [H] of the servo piston. The pressure oil (P) flowing to the portion [A] flows to the oil chamber [F] through the clearance between the compensation piston and the piston case, and acts as a force to press the compensation piston rightward. When the discharge pressure (P) is below a certain pressure, the force of compensation piston to press the compensation rod rightward is smaller than the reaction force of the outer spring, therefore, the lever (1) does not move. (When the compensation rod moves rightward, the lever (1) moves via the pin [C].) Thus, the feedback lever is pressed leftward, and the seat portion [E] opens as the spool moves leftward, and then the pressure oil in the large diameter chamber [G] of the servo piston flows to the drain from the port [D], and the maximum discharge rate position is retained by the pressure oil on the small diameter chamber [H] side and the outer spring. Then, when the discharge pressure (P) rises exceeding the 1st turning point pressure P1 shown in Fig. 5, the force of the compensation piston to press the compensation rod rightward overcomes the reaction force of the outer spring, transmitted to the lever (1) via the pin (C) as the compensation rod moves rightward, causing the lever (1) to rotate around the pin (A) fixed to the casing. Since the pin (B) fixed to the feedback lever sticks out through the large hole portion of the lever (1), the feedback lever rotates around the point (J) as a fulcrum as the lever (1) rotates, and the spool moves rightward. As the spool moves, the seat portion [E] closes and the seat portion [C] opens, causing the pressure oil (P) flowing to the portion [B] to flow to the large diameter chamber [G] of the servo piston from the port [D], allowing the servo piston to move rightward, to reduce discharge rate. Then the servo piston s rightward movement is transmitted to the feedback lever via the point (J), causing the feedback lever to rotate around the pin (B) as a fulcrum and the spool to move leftward. The seat portion [C] (and [E]) of the spool is opened at a position where the oil pressures of the large diameter chamber and the small diameter chamber of the servo piston balance each other. In the range where only the spring force of the outer spring acts on the compensation rod, discharge pressure is between P1 and P2, and in the range where the spring force of both the outer spring and inner spring acts on the compensation rod, discharge pressure is between P2 and P3. (P2 is the 2nd turning point pressure.) On the other hand, when the discharge pressure changes from a high pressure to a low pressure, the compensation rod is pressed back due to the reaction force of the outer spring, and the lever (1) rotates around the pin (A). With the rotation of the lever (1), the feedback lever rotates around the point (J) as a fulcrum, and the spool moves leftward. As the spool moves, the seat portion [C] closes and the seat portion [E] opens, causing the pressure oil in the large diameter chamber [G] of the servo piston to flow to the drain, allowing the servo piston to move leftward, to increase discharge rate. The servo piston s movement is transmitted to the spool by the feedback mechanism, and the seat portions [C] and [E] are opened at a position where the oil pressures of the large diameter chamber and the small diameter chamber of the servo piston balance each other. As described above, the change of discharge rate of the variable pump is controlled by the balance between the force acting on the compensation rod and the force of the outer and inner springs for setting horsepower, and the balance between the oil pressures of the large diameter chamber and the small diameter chamber of the servo piston that depends on the former balance. The maximum discharge rate position is set by the adjustment screw [954], and the maximum discharge rate position is set by the adjustment screw [953]. For setting horsepower, the 1st turning point is set at the tightening position of the adjustment screw (A) for the outer spring, and the 2nd turning point is set at the tightening position of the adjustment screw (B) for the inner spring. The slope of the horsepower curve is determined by the spring constant of the spring. Discharge rate Discharge pressure

18 B-2 B-2 Hydraulic Pump 2. Disassembly NOTE Disassembly and reassembly are explained separately for the regulator and the pump main body. Never disassemble the adjustment screws of the regulator unless it is necessary. Doing so may change the set horsepower, resulting in dissatisfaction with the specifications. Before disassembling, discharge the oil in the pump, and remove dust and mud adhering to its surface. Make match marks on the joined portions for correct reassembly. The regulator, and the rotary group and the swash plate group in the pump main body are composed of two sets of parts respectively. Be careful not to confuse the parts on the front side and the parts on the rear side. 2.1 Disassembling the regulator 1. Remove the drain plug [468], and drain the oil. 2. Unscrew the hexagon socket head bolts [412] and [413], and remove the regulator main body from the pump main body. (Fig. 6) 4. Take out the outer spring [625], inner spring [626], and spring seat [624] from the casing [601]. Also take out the adjustment rod [645], pilot spring [646], and spring seat [644]. 5. Unscrew the hexagon socket head bolts [436] and [438], and remove the pilot cover [641]. Then remove the set spring [655]. (Fig. 8) 3. Unscrew the hexagon socket head bolt [438], and remove the cover [629]. (Fig. 7) CAUTION Do not loosen the adjustment screw (A) [628] and adjustment screw (B) [925]. Doing so will change the set horsepower. 6. Remove the snap ring [814], and remove the spring seat [653], return spring [654], and sleeve [651]. (Fig. 9) CAUTION When removing the snap ring [814], be careful not to allow the return spring [654] to spring out

19 B-2 B-2 Hydraulic Pump 8. Remove the lever (2) [613]. (Fig. 12) 7. Remove the locking ring [858], and remove the fulcrum plug [614] and adjustment plug [615]. (Fig. 10, 11) NOTE The fulcrum plug [614] and adjustment plug [615] can be pulled out easily using a M6 bolt. The pin [875] for fulcrum of the lever (2) [613] is press-fitted in the fulcrum plug [614]; they will be removed together. 9. Remove the pin [874] (φ4) from the fulcrum plug hole by pushing it using a thin steel rod, and remove the feedback lever [611]. (Fig. 13, 14) NOTE When removing the pin [874] by pushing it out, be careful not to allow the pin to come in contact with the lever (1) [612]

20 B-2 B-2 Hydraulic Pump 10. Remove the lever (1) [612]. NOTE Do not remove the pin [875] from the casing [601]. 11. Pull out the pilot piston [643] and spool [652]. 12. Pull out the piston case [622], compensation piston [621], and compensation rod [623]. NOTE The piston case [622] can be removed by pushing the compensation rod [623] from inside of the casing [601] to outside. 2.2 Disassembling the pump main body 1. Unscrew the hexagon socket head bolt [401] that tightens the swash plate support [251], pump casing [271], and valve block [312]. 4. Unscrew the hexagon socket head bolt [406], and remove the seal cover (F) [261]. (Fig. 17) NOTE It can be removed easily using a removal tap (M6) located on the seal cover (F) [261]. 2. Place the pump horizontally on a work bench with the regulator mounting surface facing downward, and separate the pump casing [271] and valve block [312]. (Fig. 15) 5. Lightly tap the mounting flange portion of the swash plate support [251] from the pump casing side, and separate the swash plate support and the pump casing. (Fig. 18) 3. Pull out the cylinder block [141] from the pump casing [271] horizontally against the shaft (F) [111]. (Fig. 16) NOTE Remove the piston [151], set plate [153], shoe [152], spherical bush [156], and cylinder spring [157] at the same time

21 B-2 B-2 Hydraulic Pump 6. Remove the shoe plate [211] and the swash plate [212] from the pump casing [271]. 3. Reassembly NOTE 7. Lightly tap the shaft end of the shaft (F) [111] using a plastic hammer, and pull out the shaft from the swash plate support [251]. (Fig. 19) In principle, replace all the sealing parts with new ones. When reassembling sliding portions, apply hydraulic oil, and when reassembling sealing parts, apply grease lightly. For some packings and thread portions of plugs, liquid packing or adhesive is used. Fully clean the mating surfaces of the case and the tapped holes for degreasing. 3.1 Reassembling the pump main body 8. Remove the valve plate (F) [314] from the valve block [312]. (Fig. 20) 1. Install the needle bearing [124] and spline coupling [114] in the valve block [312], and install the servo piston [532], tilting pin [531], and stoppers [534] and [535] in the pump casing [271]. NOTE Apply Loctite to the thread portion of the servo piston [532] and tilting pin [532]. 2. Place the pump casing [271] with the regulator mounting surface facing downward, and install the swash plate [212] in the swash plate support [251]. 3. Place the pump casing [271] with the regulator mounting surface facing downward, and install the swash plate [212] in the swash plate support [251]. (Fig. 21) 9. Remove the stoppers [534] and [535], servo piston [532], tilting pin [531] from the pump casing [271], and remove the needle bearing [124] and spline coupling [114] from the valve block [312]. NOTE NOTE Install correctly so that the head of the tilting pin [531] is inserted in the hole of the swash plate [212]. After installation, check that the swash plate [212] moves smoothly. To remove the tilting pin [531] from the servo piston [532], turn the servo piston counterclockwise by inserting an Allen wrench in the hole on the side surface of the servo piston while keeping the tilting pin fixed. Note that Loctite is applied to the thread portions. 10. Disassemble the rear pump in the same manner as above

22 B-2 B-2 Hydraulic Pump 4. Install the shaft (F) [111] on which the bearing [123], bearing spacer [127], and snap ring [824] are mounted, in the swash plate support [251]. (Fig. 22) 7. Install the valve plate [314] in the valve block [312]. (Fig. 25) 5. Install the seal cover (F) [261] in the swash plate support [251], and secure the seal cover (F) with the hexagon socket head bolt [406]. (Fig. 23) CAUTION Be careful not to confuse the suction and discharge directions of the valve plate [314]. NOTE Apply grease lightly to the oil seal [774] in the seal cover (F). 6. Install the shoe plate [211], and then install the cylinder [141], piston [151], set plate [153], spherical bush [156], spacer [158], and cylinder spring [157] in the pump casing [271] at the same time. (Fig. 24) 8. Install the valve block [312] in the pump casing [271], and secure the valve block with the hexagon socket head bolt [401]. (Fig. 26) NOTE Installing the rear pump earlier makes reassembly easier. Pay attention to the direction of the valve block [312] against the pump casing [271]

23 B-2 B-2 Hydraulic Pump Lever (1) side Lever (2) side (Fulcrum plug side) 5. Install the pilot piston [643]. 6. Install the lever (2) [613], and insert the pin [984] press-fitted in the lever (2), in the groove of the pilot piston. (Fig. 29) 3.2 Reassembling the regulator 1. Install the compensation rod [623] in the casing [601]. 2. Insert the pin [984] press-fitted in the lever (1) [612], in the groove of the compensation rod, and install the lever (1) in the pin [875] press-fitted in the casing. 3. Install the spool [652] and sleeve [651] in the casing [601]. NOTE Install the spool in the direction shown in Fig Insert the fulcrum plug [614] so that the pin [875] press-fitted in the fulcrum plug is inserted in the fulcrum pin hole of the lever (2) [613], and attach the locking ring [858]. 8. Install the adjustment plug [615], and attach the locking ring [858]. (Fig. 30) Spool Feedback lever NOTE Check that the feedback lever [611] moves smoothly. Be careful not to confuse the insertion holes of the fulcrum plug [614] and adjustment plug [615]. 4. Install the feedback lever [611], and connect the spool [652] and the feedback lever by inserting the pin [874]. CAUTION Install the feedback lever in the direction shown in Fig

24 B-2 B-2 Hydraulic Pump 9. Install the return spring [654] and spring seat [653] in the spool [652], and attach the snap ring [814]. (Fig. 31) 10. Install the set spring in the spool hole, and install the compensation piston [621] and piston case [622] in the compensation piston hole. Then install the pilot cover [641] using the hexagon socket head bolts [436] and [438]. (Fig. 32) 13. Install the cover [629] on which the adjustment screws [628] and [925], adjustment rod [627], lock nut [630], nut [801], and hexagon socket set screw [924] are set, using the hexagon socket head bolt [438]. (Fig. 34) 11. Install the spring seat [644], pilot spring [646], and adjustment rod [645]. 12. Install the spring seat [624], inner spring [626], and outer spring [625] in the compensation piston hole. (Fig. 33) 14. While inserting the feedback pin [548] of the tilting pin in the groove of the feedback lever [611] of the regulator, install the regulator in the pump casing using the hexagon socket head bolts [412] and [413]. (Fig. 35) NOTE Be careful not to confuse the front and rear regulators

25 B-2 B-2 Hydraulic Pump (3) Free length of the cylinder spring (L) Standard dimension: 41.1 mm Use limit: 40.3 mm 15. Install the drain plug [468]. 4. Maintenance Standard 1. Standard for replacing wear parts If any significant damage is found on the appearance, or if the following standard values are not satisfied, replace or re-adjust such parts. (1) Clearance between the piston and the cylinder bore (D - d) Standard dimension: mm Use limit: mm (2) Backlash between the piston and the shoe caulked portion (δ), and thickness of the shoe (t) [δ] Standard dimension: 0 to 0.1 mm Use limit: 0.3 mm [t] Standard dimension: 5.0 mm Use limit: 4.8 mm (4) Combination height of the set plate and the spherical bush (H - h) Standard dimension: 9.8 mm Use limit: 8.8 mm 2. Standard for correcting wear parts - Plane roughness of the valve plate (sliding portion), shoe plate, and cylinder (sliding portion) Standard plane roughness: 0.4 Z max. (lapping) Plane roughness requiring correction: 3-Z 3. Tightening torque Part name Size Tightening torque (kg m) M5 0.7 M6 1.2 M8 3.0 Hexagon socket M head bolt M12 10 (SCM435) M14 16 M16 24 M18 34 M20 44 PT1/ PT1/ PT plug PT1/ (S45C) PT3/8 3.5 PT1/2 5.0 PF1/4 3.0 PF1/2 10 PF plug PF3/4 15 (S45C) PF11/4 19 PF11/4 27 PF11/

26 B-2. Hydraulic Pump B Test 1. Operation test CAUTION In order to prevent malfunction or damage of rotation portions, be sure to loosen the plug to discharge air in the case before starting operation. Plug Before starting the pump, check if oil is delivered from the line on the suction side or the delivery port in the tank by inching the pump several times. Running the pump with oil not delivered may seize the pump. 1. Run the pump at idle speeds without load for 15 to 20 minutes, and check the following. - Excessive rising of oil temperature (Normally, oil temperature rises little.) - Abnormal noise - Abnormal vibration - Oil leakage 2. If the pump is free from abnormal conditions, gradually apply load and raise the pressure to the maximum. Then recheck the four conditions in No Run the pump at the maximum pressure for 1 to 2 minutes. When no abnormal condition is observed, start normal operation

27 B-3 B-3 B-3 Hydraulic Pump This manual describes the disassembly and reassembly procedures for the PHS and PLS Series gear pumps, using the Model PHS **R pump (a two-section gear pump, rotating clockwise) as the representative of the Series. When servicing the other models of the PHS and PLS Series, use the information in this manual, making necessary alterations. 1. Construction 1. Body 20. Coupling 2. Bearing 21. O-ring 3. Bearing 22. Hexagon socket head bolt 4. Front cover 23. Spring washer 5. Side plate 24. Body 6. Backup ring 25. Bearing 7. Rubber string 26. Bearing 8. Hexagon socket head bolt 27. Front cover 9. Hexagon socket head bolt 28. Side plate 10. Spring washer 29. Backup ring 11. O-ring 30. Packing 12. Oil seal 31. Hexagon socket head bolt 13. Dust seal 32. Spring washer 14. Retaining ring 33. O-ring Drive gear Driven gear 17. Drive gear 36. Rear cover 18. Driven gear 37. Dowel pin 19. Rear cover 38. Spring washer 2. Disassembly NOTE Fig.1 Before starting to disassemble or reassemble, be sure to read the disassembly and reassembly cautions in General Cautions (Hydraulic Units) in Chapter A, and proceed correctly. Put disassembled parts aside in an orderly arrangement, preserving the assembled condition as far as possible. 1. Make match marks on the sections to be separated for correct reassembly. 2. Using copper or aluminum sheets on the vise jaws, clamp the main body port flange portion in a vise, and unscrew the hexagon socket head bolt [22] and remove the rear pump ass y. NOTE Tighten the vise jaws only lightly to prevent deformation and damage. 3. Clamp the rear pump ass y in a vise, unscrew the hexagon socket head bolt [31], and remove the rear cover [36]

28 B-3 B-3 Hydraulic Pump 4. Push in the drive gear [34] to remove the bearing [26]. Pull out the drive gear [34] and driven gear [35] together with the side plate [28]. 6. Disassemble the front pump ass y in the same manner as above. NOTE Before pulling out the drive gear [17], wind tape around the splines to prevent damaging the oil seal lip. 7. When replacing the oil seal [12] and dust seal [13], clamp the front cover [4] in a vise, drive out the dust seal [13], remove the retaining ring [14], and then drive out the oil seal [12]. NOTE Be careful not to damage the oil seal mounting surface of the front cover. 5. Remove the inner side plate [28] and bearing [25]. If they cannot be pulled out in the direction shown in Fig. 8 due to burr on the body bore, unscrew the hexagon socket head bolt [31], remove the front cover [27] by tapping it off with a wooden mallet, and remove the bearing [25] and side plate [28] in the same direction. 3. Reassembly NOTE Do not reuse disassembled sealing parts; use only new parts. When installing them, apply grease and install carefully to prevent damage. When used parts are unavoidably used, wash them using a chemically neutral detergent, dry and grease before installation

29 B-3 B-3 Hydraulic Pump 1. Deburr the mating surfaces of the body and the cover using oilstone. Excepting sealing parts, wash all the parts in kerosene and blow with compressed air. 3. Install the retaining ring [14], and install the dust seal [13] in the same manner as the oil seal. NOTE Install the dust seal in the opposite direction to the oil seal. 4. Insert the two front cover-side bearings [25] together in the body [24] until they are slightly inward of the body surface, and then push in them together with the side plate [28]. Side plate [28] Delivery side Suction side 2. When replacing the oil seal [12], apply grease to the O.D. and the lip of the new seal and push it in by hand without tilting, and then lightly tap it in using a suitable jig. 5. Oil the bore of the bearing [25] and the gear contact surface of the side plate [28], and then insert the drive gear [34] and driven gear [35]

30 B-3. Hydraulic Pump B Insert the side plate [28] in the body [24] until it is slightly inward of the body surface. Push in the two rear cover-side bearings [28] together with the side plate. NOTE After installation, if the distance from the bearing end to the body surface is 1 mm or above, this indicates the packing [30] is protruding from the normal position. Disassemble and correct. 4. Test 1. Operation test NOTE Before starting the pump, check if oil is delivered from the line on the suction side or the delivery port in the tank by inching the pump several times. Running the pump with oil not delivered may seize the pump. (1) Run the pump at idle speeds without load for 15 to 30 minutes, and check the following. - Excessive rising of oil temperature (Normally, oil temperature rises little.) - Abnormal noise - Abnormal vibration - Oil leakage 7. Install the rear cover [36] using the hexagon socket head bolt [31]. Tightening torque: M kg m M kg m M kg m 8. After reassembling the front pump ass y in the same manner, install the coupling [20], and clamp the front pump ass y and the rear pump ass y together, with the hexagon socket head bolt [22]. Tightening torque: M kg m M kg m 9. Fill the pump with hydraulic oil through the port hole, and turn the drive shaft to spread the oil. (2) lf the pump is free from abnormal conditions, gradually apply load and raise the pressure to the maximum. Then recheck the four conditions above. (3) Run the pump at the maximum pressure for 1 to 2 minutes. When no abnormal condition is observed, start normal operation

31 B-4. B-4 Solenoid Control Valve B Construction Manual push pin Hydraulic symbol Relief valve (RV) 1. Cover 2. Valve ass y 3. Cover 4. Relief valve ass y 5. Tie rod 6. Nut

32 B-5 B-5 B-5 Hydraulic Pilot Control Valve 1. Construction and Function This valve is the direction control valve, comprising the selector valves for the jib (power tilt), elevating, telescoping, main winch, and auxiliary winch bolted together in an inline arrangement. It also includes relief valves, flow control valves, and port relief valves as devices to control the circuit. These valves operate as follows. 1. Relief valve (RV1) This valve controls the pressure in the P1 pump circuit. It also acts as an unload valve by working as follows: When any of the crane safety devices such as AML or the overwind cutout device operates, the solenoid valve is switched over to open the vent line of the relief valve, to discharge the pressure oil to the tank. 2. Relief valve (RV2) This valve controls the pressure in the P2 pump circuit, and also acts as an unload valve like the relief valve (RV1). 3. Port relief valve They control the pressure in the respective circuits to improve the operation and protect the hydraulic components. (PR1): Auxiliary winch hoist-down circuit (PR2): Main winch hoist-down circuit (PR3): Telescoping extending circuit (PR4): Telescoping retracting circuit (PR5): Elevating lowering circuit (PR6): Power tilt jib lowering circuit (PR7): Power tilt jib raising circuit 4. Flow control valve The flow control valve regulates the flow rate of oil to the actuator according to the amount of spool displacement whatever the pressure applied to the actuator circuit is. It serves to enable smooth inching operation of each device. The flow control (FC) valve also allows the P2 circuit oil to flow to the winch circuit when no telescoping/elevating/jib operation is performed (or it allows excess oil during telescoping/elevating/jib operation to flow to the winch circuit). (FC1): For auxiliary winch (FC2): For main winch (FC3): For telescoping (FC4): For elevating (FC5): For jib (FC): For junction circuit Jib Elevating Telescoping Main winch Auxiliary winch Hydraulic symbol

33 B-5 B-5 Hydraulic Pilot Control Valve Operation detection port (1 place) (Telescoping) Operation detection port (2 places) (Auxiliary, main) Auxiliary winch Main winch Telescoping Elevating Jib Operation detection port (1 place) (Jib)

34 B-5 B-5 Hydraulic Pilot Control Valve

35 B-5 B-5 Hydraulic Pilot Control Valve 1. Control valve ass y (Winch) 6. O-ring 11. Port relief valve ass'y 16. Port relief valve ass'y 2. Control valve ass y (Telescoping) 7. O-ring 12. Port relief valve ass'y 17. Plug 3. Control valve ass y (Elevating) 8. Hexagon socket head bolt 13. Port relief valve ass'y 18. Eye bolt 4. Control valve ass y (Jib) 9. Relief valve ass'y 14. Port relief valve ass'y 19. Plug 5. End cover 10. Hexagon socket head bolt 15. Port relief valve ass'y 20. O-ring Control valve ass y [[1]] (Winch) Operation detection port Loctite #242 C -C (Auxiliary winch) Loctite #270 Operation detection port Loctite #242 D -D (Main winch) Loctite #

36 B-5 B-5 Hydraulic Pilot Control Valve Note: The double-circled number shown in the figure is the same as that shown in Fig. 2. For its part name, refer to that used in Fig. 2. (This is also applied to the double-circled numbers shown in Fig. 4 to Fig. 6.) 1. Valve body 9. O-ring 17. Plug 25. Cover 2. Spool 10. Pilot cover 18. O-ring 26. Plug 3. Spool 11. Pilot cover 19. Restriction 27. Plug 4. Spool end 12. Hexagon socket head bolt 20. Bleeder screw 28. O-ring 5. Spring seat 13. Flow control valve 21. Cap 29. Washer 6. Spring seat 14. Flow control valve 22. Spring 30. Spring washer 7. Spring 15. Spring 23. Check valve 8. Spring 16. Cover 24. O-ring Control valve ass y [[2]] (Telescoping) Loctite #270 Operation detection port Loctite #242 Loctite #270 Loctite #

37 B-5 B-5 Hydraulic Pilot Control Valve 1. Valve body 9. O-ring 17. Plug 25. Spring 2. Spool 10. Pilot cover 18. Flow control valve 26. O-ring 3. Spring seat 11. O-ring 19. Plug 27. Cover 4. Spring 12. Pilot cover 20. O-ring 28. Bleeder screw 5. Spring 13. Hexagon socket set screw 21. Restriction 29. Cap 6. Spring seat 14. Hexagon socket head bolt 22. Spring 30. Washer 7. Spool end 15. Steel ball (Shuttle valve) 23. Plug 31. Spring washer 8. Plug 16. O-ring 24. Check valve Control valve ass y [[3]] (Elevating) Loctite #270 Loctite #242 Loctite #270 Loctite # Valve body 9. O-ring 17. Plug 25. Cover 2. Spool 10. Pilot cover 18. Flow control valve 26. Bleeder screw 3. Spring seat 11. O-ring 19. Plug 27. Cap 4. Spring 12. Pilot cover 20. O-ring 28. Plug 5. Spring 13. Hexagon socket set screw 21. Restriction 29. O-ring 6. Spring seat 14. Hexagon socket head bolt 22. Spring 30. Washer 7. Spool end 15. Steel ball (Shuttle valve) 23. Plug 31. Spring washer 8. Plug 16. O-ring 24. O-ring

38 B-5. Hydraulic Pilot Control Valve B-5. Control valve ass y [[4]] (Jib) Loctite #270 Operation detection port Loctite #242 Loctite # Valve body 8. Plug 15. Flow control valve 22. Cover 2. Spool 9. O-ring 16. Plug 23. Bleeder screw 3. Spring seat 10. Pilot cover 17. O-ring 24. Cap 4. Spring 11. O-ring 18. Restriction 25. Washer 5. Spring 12. Pilot cover 19. Spring 26. Spring washer 6. Spring seat 13. Hexagon socket set screw 20. Plug 7. Spool end 14. Hexagon socket head bolt 21. O-ring

39 B-6 B-6 B-6 Hydraulic Pilot Control Valve 1. Construction and function This valve is the direction control valve, comprising the selector valves for the elevating, telescoping, main winch, and auxiliary winch bolted together in an inline arrangement. It also includes relief valves, flow control valves, and port relief valves as devices to control the circuit. These valves operate as follows. 1. Relief valve (RV1) This valve controls the pressure in the P1 pump circuit. It also acts as an unload valve by working as follows: When any of the crane safety devices such as AML or the overwind cutout device operates, the solenoid valve is switched over to open the vent line of the relief valve, to discharge the pressure oil to the tank. 2. Relief valve (RV2) This valve controls the pressure in the P2 pump circuit, and also acts as an unload valve like the relief valve (RV1). (PR1): Auxiliary winch hoist-down circuit (PR2): Main winch hoist-down circuit (PR3): Telescoping extending circuit (PR4): Telescoping retracting circuit (PR5): Elevating lowering circuit 4. Flow control valve The flow control valve regulates the flow rate of oil to the actuator according to the amount of spool displacement whatever the pressure applied to the actuator circuit is. It serves to enable smooth inching operation of each device. The flow control (FC) valve also allows the P2 circuit oil to flow to the winch circuit when no telescoping/elevating operation is performed (or it allows excess oil during telescoping/elevating operation to flow to the winch circuit). (FC1): For auxiliary winch (FC2): For main winch (FC3): For telescoping (FC4): For elevating (FC): For junction circuit 3. Port relief valve They control the pressure in the respective circuits to improve the operation and protect the hydraulic components. Elevating Telescoping Main winch Auxiliary winch Hydraulic symbol

40 B-6 B-6 Hydraulic Pilot Control Valve Operation detection port (1 place) (Telescoping) Operation detection port (2 places) (Auxiliary, main) Auxiliary winch Main winch Telescoping Elevating

41 B-6 B-6 Hydraulic Pilot Control Valve

42 B-6 B-6 Hydraulic Pilot Control Valve 1. Control valve ass y (Winch) 5. O-ring 10. Port relief valve ass y 15. Eye bolt 2. Control valve ass y (Telescoping) 6. O-ring 11. Port relief valve ass y 16. Plug 3. Control valve ass y (Elevating) 7. Hexagon socket head bolt 12. Port relief valve ass y 17. O-ring 4. End cover 8. Relief valve ass y 13. Port relief valve ass y 9. Hexagon socket head bolt 14. Plug Control valve ass y [[1]] (Winch) Operation detection port Loctite #242 C - C (Auxiliary winch) Loctite #270 Operation detection port Loctite #242 D - D (Main winch) Loctite #

43 B-6 B-6 Hydraulic Pilot Control Valve Note The double-circled number shown in the figure is the same as that shown in Fig. 2. For its part name, refer to that used in Fig. 2. (This is also applied to the double-circled numbers shown in Fig. 4 and Fig. 5.) 1. Valve body 9. O-ring 17. Plug 25. Cover 2. Spool 10. Pilot cover 18. O-ring 26. Plug 3. Spool 11. Pilot cover 19. Restriction 27. Plug 4. Spool end 12. Hexagon socket head bolt 20. Bleeder screw 28. O-ring 5. Spring seat 13. Flow control valve 21. Cap 29. Washer 6. Spring seat 14. Flow control valve 22. Spring 30. Spring washer 7. Spring 15. Spring 23. Check vale 8. Spring 16. Cover 24. O-ring Control valve ass y [[2]] (Telescoping) Loctite #270 Operation detection port Loctite #242 Loctite #270 Loctite #

44 B-6. Hydraulic Pilot Control Valve B Valve body 9. O-ring 17. Plug 25. Spring 2. Spool 10. Pilot cover 18. Flow control valve 26. O-ring 3. Spring seat 11. O-ring 19. Plug 27. Cover 4. Spring 12. Pilot cover 20. O-ring 28. Bleeder screw 5. Spring 13. Hexagon socket set screw 21. Restriction 29. Cap 6. Spring seat 14. Hexagon socket head bolt 22. Spring 30. Washer 7. Spool end 15. Steel ball (Shuttle valve) 23. Plug 31. Spring washer 8. Plug 16. O-ring 24. Check valve Control valve ass y [[3]] (Elevating) Loctite #270 Loctite #242 Loctite # Valve body 8. Plug 15. Flow control valve 22. Cover 2. Spool 9. O-ring 16. Plug 23. Bleeder screw 3. Spring seat 10. Pilot cover 17. O-ring 24. Cap 4. Spring 11. O-ring 18. Restriction 25. Plug 5. Spring 12. Pilot cover 19. Spring 26. O-ring 6. Spring seat 13. Hexagon socket set screw 20. Plug 27. Washer 7. Spool end 14. Hexagon socket head bolt 21. O-ring 28. Spring washer

45 B-7 B-7 B-7 Rotary Joint 1. Construction Air pressure section Electric section Apply screw lock. (ThreeBond 1401 or equivalent) Apply grease at assembly. 2 places Apply grease (EP2). Apply grease at assembly. Apply grease (EP2) slightly. Apply grease (EP2) slightly. Circulate antifreeze to degrease circuit after assembly. *Spread silicon rubber all around. in 5mm range (including key). *Pack grease (EP2) all around. Apply grease to key. Care about slit direction Retain a holding torque of 90 to 120 kg cm. Apply grease at assembly Align 3 punch marks at assembling material [10]. Apply screw lock. (ThreeBond 1305 or equivalent) Pack grease (for waterproof). Apply screw lock. (ThreeBond 1401 or equivalent) Apply grease (EP2). Apply screw lock. (ThreeBond 1401 or equivalent) Align punch marks on materials [8] & [11] at installing material [11]. Spread silicon rubber and do wxater-proof treatment over wiring take out portion. Tapped hole for lifting devices to separate body and core View A-A Apply screw lock. (ThreeBond 1401 or equivalent) Apply screw lock. (ThreeBond 1401 or equivalent) Hydraulic section Press fit material [7] with slit angle slant against D-line of material [1]. Press fitting material [7]. Grease (EP2) View B-B Apply screw lock. (ThreeBond 1401 or equivalent) Apply screw lock. (ThreeBond 1401 or equivalent) Screw lock (ThreeBond 1401 or equivalent) View C Block Symbol Circuit Hydraulic P1 Winch section P1 Gauge P2 Elevating, telescoping, and jib P2 Gauge P3 Steering and swing P4 Steering (Left) P5 Steering (Right) P6 Accumulator, jib extension T1 Tank T2 Tank DR Drain Block Symbol Circuit Air A1, A1' Air supply pressure section A2 Service brake (primary) A3 Service brake (secondary) A4 Accelerator L.L.C. W1 Heater IN W2 Heater OUT

46 B-7 B-7 Rotary Joint 1. Core 11. Body 21. Seal ring 31. Spring washer 2. Support 12. Plate 22. O-ring 32. Clamp 3. Core 13. Plain bearing 23. Grease nipple 33. Spring washer 4. Support 14. Plain bearing 24. Bolt 34. Bolt 5. Flange 15. Plain bearing 25. Hexagon socket head bolt 35. Clamp 6. Plate 16. Plain bearing 26. Hexagon socket head bolt 36. Plain washer 7. Shaft 17. Packing 27. Bolt 37. Spacer 8. Body 18. Seal ring 28. Bolt 38. Bolt 9. Cover 19. Packing 29. Hexagon socket head bolt 39. Plug 10. Slip ring ass y 20. Seal ring 30. Bolt 40. Seal ring

47 B-7 B-7 Rotary Joint Details of electric section Slit Hole Install so that the terminal comes to this position. View G Punch mark Care about material [44] installation direction. Shield View H Potentiometer (Swing angle detection) Apply Hi-lock. (4 places) Apply Hi-lock. (8 places) 4 places Important adjustment location (Circumference) After tightening nut R at the specified tightening toque, press support [48] from above to let it come in contact with material [47]. Then, after bringing nut S into contact with material [48], give a turn upward, and fix at the specified torque. After adjustment, check if holder A has degree of freedom. If it has no degree of freedom, re-adjust. Clearance 1.25 mm is a pitch of M8 screw. Nut R Nut S Apply grease at assembly Assemble with 2 hole facing downward. (Apply grease.) Holder A Circuit No. Section B-B Apply screw lock. (ThreeBond 1401 or equivalent) After degreasing thoroughly, apply Loctite 648. Tightening torque 120 to 140 kg cm (12 places) Insert the material [68] hose in the material [59] hole by approx. 20mm. (4 places) Punch mark Section A-A Path for wiring III Path for wiring II Care about the punch mark position when installing material [60]. Path for wiring IV Path for wiring I Section C-C

48 B-7 B-7 Rotary Joint Block No. I II III Circuit No. Brush holder (upper wiring) Wire No. Type Remarks Circuit No. Slip ring (lower wiring); Upper terminal (View D) Wire No. Type 1 1AA 2W Power 1 1 2W 1 1 2W WR Power LY Power LY LR LR LB LB LO LO LG LG L L 2 1CC 2W Power 2 1 2W 2 1 2W YW Power Power GY Power GY GB GB GL GL G G GO GO 1 1DD 2W Power WR Power WR LY Power P Power P WL Power WL WY Power WY WG WG WB WB connector Lower terminal (View D) connector IV 2 1BB 2W Power YW Power YW YR Power YR YO Power YO YL YL YG YG YB Power YB 41. Screw 48. Support 55. Slip ring 62. Nut 42. Spring washer 49. Insulator 56. Spacer 63. O-ring 43. Potentiometer 50. Spacer 57. Ball bearing 66. Fastener 44. Lever ass y 51. Brush holder ass y 58. Support 67. Hose 45. Hexagon socket head bolt 52. Brush holder ass y 59. Support 68. Hose 46. Spring washer 53. Bolt 60. Support 69. Shaft 47. Plain bearing 54. Bolt 61. Hexagon socket head bolt

49 B-7. Rotary Joint B Disassembly and Reassembly Reassembling the slip ring ass y 1. Hydraulic and air pressure sections NOTE In principle, replace all the sealing parts with new ones. Observe General Cautions (Sealing Parts) in Chapter A in installing them, taking care to install in the correct orientation. When reassembling, take extreme care not to allow the entry of dust and other foreign matter. 2. Electric section NOTE Use the brush holder ass y [52] (30 A of allowable current) for the brushes of the brush holder wire Nos. 1, 3, 4, 5, 6, 907, 8, 10, 911, 12, 15, and 24. For other brushes, use the brush holder ass y [51] (6 A of allowable current). [Difference] Color of cap --- Brown: 30 A Color of cap --- Black: 6 A Bend the terminals of the brush holder ass ies [52] for circuit Nos. 1 through 7 (12 places); and cut the terminal of the brush holder ass y [51] for circuit No. 26 (1 place). Bend Brush holder ass y Brush holder ass y Cap Cut Connect two wires to the terminal of the slip ring for circuit Nos. 1 and 2. (1) Screw the bolts [53] and [54] to the supports [58] and [59]. (2) After installing the slip ring ass y [55], install the brush holder ass y [52] for blocks I and III. (Take out the wires of the slip ring ass y in the applicable positions according to their circuit numbers.) (3) After installing the slip ring ass y [55], install the spacer [56] and brush holder ass y [52] for blocks II and IV. (4) After installing the slip ring ass y [55], install the brush holder ass y [52] for blocks I and III. (5) After installing the slip ring ass y [55], install the brush holder ass y [52] for blocks II and IV. (6) After installing the slip ring ass y [55], install the brush holder ass y [52] for blocks I and III. (7) After installing the slip ring ass y [55], install the spacer [50] for block IV, and install the brush holder ass y [52] for block II. (8) Hereinafter, assemble in the same manner as above in the order of I, II, III, and IV. (9) Check all the circuits for continuity, and for the complete insulation among them. 3. Calibration of Potentiometer (See Fig. 2 view G.) 1. Align the hole of the plain bearing [47] and the slit of the support [48]. 2. Loosen the screw of the lever ass y [44]. Give the shaft of the potentiometer [43] some turns by means of a screwdriver to render the W-B resistance of the view H connector minimum between 1 and 10 Ω. 3. Secure the lever ass y [44] with the screw

50 B-8. B-8 Flow Control Valve B Construction and Function This valve serves both as a flow control valve and as a pressure control valve, and maintains the delivery flow rate at a constant level under varying loads and inlet flow rates. When oil enters through the port P, a pressure difference occurs across the orifice [a] in the spool [4], and as the flow rate increases, the pressure difference increases. When finally the differential pressure overcomes the force of the spring [3], it pushes the spool [4] downward to return the excess oil to the tank. When the pressure in the control line (port A side) tends to rise above the preset level, the relief valve ass y [8] opens to shift the spool [4] downward to increase the bypass flow rate and to maintain the control line pressure at the preset level. 1. Body Spring 4. Spool 5. Plug 6. Plug 7. O-ring 8. Relief valve ass y Hydraulic symbol

51 C Outrigger System C C-1 System Components... 1 Contents C-2 Solenoid Valve Construction... 2 C-3 Pilot Check Valve Construction... 3 C-4 Pilot Check Valve Construction Remounting... 4 C-5 Pilot Check Valve Construction... 5 i

52 C-1. C-1 System Components C-1. Solenoid valve: for rear right (For selecting outrigger jack/slide) Pilot check valve (For preventing jack falling) Shuttle valve Solenoid valve: for front right (For selecting outrigger jack/slide) Front Solenoid valve: for rear left (For selecting outrigger jack/slide) Solenoid valve: for front left (For selecting outrigger jack/slide) Jack cylinder Jack cylinder Pilot check valve Pilot check valve Extension cylinder Extension cylinder X-type outrigger H-type outrigger 1 C

53 C-2. C-2 Solenoid Valve C Construction Hydraulic symbol Electric symbol Manual push pin 1. Body 8. Nut 15. Solenoid coil 22. O-ring 2. Cover 9. Solenoid plunger 16. Coil case 23. O-ring 3. Spool 10. Solenoid guide 17. Coil yoke 24. O-ring 4. Retainer 11. Pin Hexagon socket head bolt 5. Spacer 12. Spacer 19. Screw 6. Spring 13. Solenoid stopper 20. O-ring 7. Name plate 14. Connector 21. O-ring

54 C-3. C-3 Pilot Check Valve C Construction 1. Body 4. Sleeve 7. Check valve 10. Plug 2. O-ring 5. O-ring 8. O-ring 11. O-ring 3. Piston 6. Backup ring 9. Spring 12. Backup ring

55 C-4. C-4 Pilot Check Valve C Construction Hydraulic symbol For outrigger jack For front jack 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 2. Remounting Tightening torque for valve mounting bolts: 440 to 500 kg cm

56 C Construction C-5 Pilot Check Valve C Valve body 9. O-ring 17. O-ring 2. Cover 10. Piston Valve 11. O-ring 19. Bite type fitting 4. Coil spring 12. Backup ring 20. O-ring 5. Stopper 13. O-ring 21. Plug 6. Snap ring 14. Cap 22. Bite type fitting 7. Valve 15. Hexagon socket head bolt 23. Stopper 8. Coil spring 16. Spring washer Injection-valve opening pressure B: 8 kg/cm 2 C: 2 kg/cm 2 D: 2 kg/cm 2 Hydraulic symbol

57 D Swing System D Contents D-1 System Components... 1 D-2 Hydraulic Pilot Control Valve Construction... 2 D-3 Swing Drive Unit Construction and Function... 5 D-4 Swing Bearing Remounting Maintenance Standard D-5 Solenoid Control Valve Construction Dismounting Remounting Disassembly Separating the hydraulic motor and reducer Disassembling the reducer Disassembling the hydraulic motor Washing and Checking Reducer Hydraulic motor Reassembly Reassembling the reducer Reassembling the hydraulic motor Maintenance Standard i

58 D-1. D-1 System Components D-1. Swing drive unit Solenoid control valve (For swing brake, accumulator circuit pressure regulation, jib extension device, pilot vent) Hydraulic pilot control valve Swing bearing 1 D

59 D-2 D-2 D-2 Hydraulic Pilot Control Valve 1. Construction View A (+) side lead color: Red (-) side lead color: Blue Tightening torque 2000 to 2400 kg cm View B (+) side lead color: Red (-) side lead color: Blue Tightening torque 1500 to 1800 kg cm Tightening torque 350 to 390 kg cm Tightening torque 55 kg cm Tightening torque 350 to 390 kg cm Air breather Tightening torque 160 kg cm PF1/4 (For P port pressure measurement Tightening torque 350 to 390 kg cm M Pressure measurement port (For installing pressure sensor) Tightening torque 2000 to 2400 kg cm M Pressure measurement port (For installing pressure sensor)

60 D-2 D-2 Hydraulic Pilot Control Valve Hydraulic symbol Section A-A Relief valve RV (Loctite #241) Section B-B (to #581474) Section B-B (# and after)

61 D-2. Hydraulic Pilot Control Valve D-2. (Loctite #241) (Loctite #241) (Loctite #241) Section C-C 1. Casing 14. O-ring 27. O-ring 40. Seat 2. Plug 15. O-ring 28. Air breather 41. O-ring 3. Plug 16. Restriction 29. Check valve (C1) 42. Overload relief valve 4. Restriction 17. Plug 30. Check valve 43. Electromagnetic relief valve 5. Spool 18. Plug 31. Spring 44. Relief valve (RV) 6. Spacer bolt 19. Electromagnetic inverse 32. Spring 45. Solenoid valve 7. Stopper proportional reducing valve 33. Cap (swing creep speed) 8. Cover (1) 20. O-ring 34. Plug 46. Solenoid valve 9. Cover (2) 21. Hexagon socket head bolt 35. O-ring (swing free/lock select) 10. Spring seat 22. Hexagon socket head bolt 36. O-ring 47. Name plate 11. Spring 23. Hexagon socket head bolt 37. Spring seat 48. Restriction 12. Spring 24. Plug 38. Spring 13. O-ring 25. Plunger 39. Steel ball 26. Spring

62 D-3 D-3 D-3 Swing Drive Unit 1. Construction and Function This unit consists of the hydraulic motor, brake, and reducer. Their functions are as follows. 1. Hydraulic motor The hydraulic motor is an opposed piton double swash plate type axial piston motor, and serves to convert pressure oil into turning force to be transmitted to the reducer. 2. Brake As the brake plunger is pressed onto the friction plate (splined to the cylinder block ass y) by the spring force, brake is applied to the hydraulic motor output shaft. When pressure oil is supplied into the brake releasing port, the brake plunger compresses the spring to disconnect the brake plunger and the friction plate, releasing brake. 3. Reducer The reducer has a two-stage planetary gear mechanism. The turning force of the hydraulic motor is transmitted to the sun gear A which is splined to the hydraulic motor output shaft, and reduced through the positional relationship of the gears shown in the figure below, to be transmitted to the output shaft. (Fig. 2) Planetary gear A Input shaft (Hydraulic motor output shaft) Sun gear A Brake plunger Brake releasing port Friction plate Spring Output shaft Planetary gear B Output shaft Sun gear B

63 D-3 D-3 Swing Drive Unit Oil inspection port Oil drain A, B (G 3/4) : Motor port P (G 1/4) : Brake releasing port U (G 3/8) : Drain port Filler port Removal screw (2-M10) Apply lithium-based grease to shaft Oil drain port Oil inspection port Caulking Pack lithium-based grease Caulking Section J-J ThreeBond

64 D-3 D-3 Swing Drive Unit 1. Spur gear 9. Roller bearing 17. Carrier (A) 25. Needle bearing 2. Retainer 10. Hexagon socket head plug 18. Hexagon socket head plug 26. Sheet steel bearing ring King pin (B) 19. Casing 27. King pin (A) 4. Roller bearing 12. Carrier (B) 20. Spacer (A) 28. Sun gear (B) Sheet steel bearing ring 21. Sun gear (A) 29. Snap ring Needle bearing 22. Bolt 30. Name plate Planetary gear (B) 23. Spring washer 31. Rivet 8. Oil seal 16. Spacer (B) 24. Planetary gear (A) 32. Hydraulic motor ass'y Hydraulic motor ass'y 1. Casing 13. Sleeve 26. O-ring 38. Hexagon socket set screw 2. Thrust retainer plate 14. Timing plate pin 27. O-ring 39. Hexagon socket head bolt 3. Bearing housing 15. Spring 28. O-ring 46. Cylinder block ass y 4. Cylinder block 16. Disc spring 29. O-ring 48. Hexagon bar 5. Thrust plate 17. Friction plate 30. Backup ring 49. Rotation detection shaft 6. End cover 18. Brake spring 31. Oil seal 50. Plain bearing 7. Retaining ring 19. Brake plunger 32. Tapered roller bearing 51. Plate 8. Shaft 21. Dowel pin 33. Tapered roller bearing 52. Oil seal 9. Piston 22. Shim 34. Bolt 53. O-ring 10. Slipper 23. Pin 35. Bolt 54. End cover 11. Timing plate 24. Spacer 36. Hexagon socket head bolt 55. Bolt 12. Retaining plate 25. O-ring 37. Hexagon socket head bolt

65 D-3 D-3 Swing Drive Unit 2. Dismounting WARNING Dismounting this unit may cause the swing table to turn. Be sure to secure the swing table before dismounting the unit. When the circuit is suspected to retain pressure oil, be sure to vent the contained pressure before dismounting the unit. 4.2 Disassembling the reducer 1. Remove the sun gear (A) [21]. 2. Remove the planetary gear (A) [24], needle bearing [25], and sheet steel bearing ring [26] sequentially from the carrier (A) [17]. 3. Remounting CAUTION After remounting, be sure to supply hydraulic oil from the hydraulic motor drain port to fill the housing with hydraulic oil. Ensure this step is performed because if the swing unit operation is started without filling the housing with hydraulic oil, sliding parts may be seized or damaged. Bleed the air in the brake circuit. 4. Disassembly NOTE Every part of the unit is precisely manufactured. Disassemble and reassemble the unit in a clean environment, and handle the parts with extreme care to avoid hitting or dropping. During disassembling, take care not to strike or pry parts by force. Doing so may cause burr to occur or parts to be damaged, resulting in impossible disassembly or performance deterioration. 3. Remove the carrier (A) ass y. NOTE The king pin (A) [27] is installed by shrink fitting. The spacer (B) [16] is fixed to the mating part by caulking the mating part after it is installed. Therefore, do not disassemble them. 4.1 Separating the hydraulic motor and reducer 1. Before disassembling, make match marks on all the mating surfaces. 2. Remove the hexagon socket head plug [10], and drain gear oil. 3. Unscrew the motor mounting bolt [22], and separate the hydraulic motor from the reducer using the removal screw (2-M10) set at the motor flange. 4. Remove the spacer (A) [20] from the hydraulic motor. 4. Remove the sun gear (B) [28]. 5. Remove the planetary gear (B) [15], needle bearing [14], and sheet steel bearing ring [13] sequentially from the carrier (B) [12]

66 D-3 D-3 Swing Drive Unit 6. Remove the carrier (B) ass y. NOTE The king pin (B) [11] is installed by shrink fitting. Therefore, do not disassemble it. 7. Remove the sheet steel bearing ring [26] from the spur gear [1]. 8. Remove the snap ring [29]. 9. Remove the spur gear [1] from the casing [19] using a press and the like. 10. Remove the roller bearing [4] and retainer [2] from the spur gear [1]. 11. Remove the roller bearing [9] and oil seal [8] from the casing [19]

67 D-3 D-3 Swing Drive Unit 4.3 Disassembling the hydraulic motor Jigs and tools for disassembly/reassembly No. Name Shape (1) Master (2) Bearing outer race driving jig (3) Bearing outer race driving jig (4) Stud (5) Top hat (6) Bearing outer race removal jig (for cylinder lock) (7) Oil seal driving jig (8)

68 D-3 D-3 Swing Drive Unit No. Name Shape (9) Piston retention jig (10) Assembly stand (11) Piston push-in bar (12) Torque measuring jig 1. Drain the hydraulic oil in the motor casing [1]. 2. Remove the bolt [55], end cover [54], plate [51], rotation detection shaft [49], O-ring [53], plain bearing [50], hexagon bar [48], and oil seal [52]. Remove the rotation detection shaft [49] and plain bearing [50] using the removal tap (M4) set at the rotation detection shaft [49]. Remove the plain bearing [50] at the back by tapping a tap (M14) female thread on the inside diameter of the bearing and using a M14 bolt. 3. Place the motor casing [1] on the assembly stand (10) with the shaft pointing upward, and secure it. 4. Insert the stud (4) in the plug hole at the center of the thrust retainer plate [2], screw the top of the stud in the female thread at the center of the cylinder block [4], and secure the cylinder block [4] to the assembly stand (10). Casing [1] Cylinder block ass y Thrust retainer plate [2] Assembly stand (10) End cover [6] Stud (4)

69 D-3 D-3 Swing Drive Unit 5. Make appropriate match marks on the end cover [6] and casing [1]. 6. Unscrew the hexagon socket head bolt [36], and remove the end cover [6] and O-ring [26]. NOTE When removing the end cover [6], take care not to damage the oil seal contact area of the shaft. 7. Remove the shim [22]. 8. Unscrew the hexagon socket head bolt [39], and remove the bearing housing [3]. Remove the brake spring [18], O-ring [28], pin [23], dowel pin [21], and outer race of the bearing [32]. 9. Pull out the brake plunger [19], and remove the O-rings [28] and [29], and, friction plate [17]. 10. Loosen the nut of the stud (4), and lift up the cylinder block ass y (shaft [8], cylinder block [4], and hexagon socket set screw [38]) until the spring [15] is fully extended. NOTE Support the shaft with your hand so that the top of the shaft [8] is located at the shaft center. 12. Remove the spring [15] and port-side piston [9] from the casing [1]. 13. Unscrew the hexagon bolts [34] and [35], and remove the casing [1]. 14. Remove the bearing [32] from the cylinder block ass y using a gear puller. 15. Remove the hexagon socket head bolt [37] from the thrust plate [5] and thrust retainer plate [2], and remove the retaining ring [7], retaining plate [12], and slipper [10]. 16. Remove the timing plate [11], sleeve [13], disc spring [16], and spacer [24]. Remove the O-ring [27] and backup ring [30] of the sleeve [13]. Remove the timing plate pin [14] at the same time. 17. Remove the O-ring [25] of the thrust retainer plate [2]. 18. Remove the bearing [33] from the thrust retainer plate [2] using a gear puller. 19. Remove the oil seal [31] of the end cover [6]. 20. Remove the outer race of the bearing [32] from the bearing housing [3]. 21. Remove the outer race of the bearing [33] from the cylinder block ass y using the removal jig (6). Cylinder block ass y Loosen this nut. 11. Pull out the stud (4), and remove the cylinder block ass y. At this time, the output shaft-side swash plate ass y (thrust plate [5], slipper [10], retaining plate [12], retaining ring [7], and hexagon socket head bolt [37]) is also removed. NOTE The output shaft-side piston [9] is also removed, which remains in the cylinder block; take care not to allow the piston to fall down. Outer race of bearing [33] 1. Hang [1] on the outer race of the bearing. 2. Hit [2] against [3] hard. 3. After the outer race moves slightly, shift the position of [1], and repeat the steps 1 and 2 above

70 D-3 D-3 Swing Drive Unit 5. Washing and Checking Check all the parts for scratches. If burrs or nicks and the like are observed, remove them using oilstone, and then wash such parts in kerosene and dry them with air. Check the following points, and correct or replace the relevant parts. 5.1 Reducer (1) Gears and splines Replace the parts if any sign of seizure or large scratches are observed. (2) Output shaft Replace the parts if any scratches or wear is observed on the seal surface of the oil seal. (3) Bearing Replace the parts if any scratches, even small ones, are observed on the rolling contact surface of the roller, ball, or needle. 5.2 Hydraulic motor (1) Piston [9] and cylinder block [4] Check that the piston slides lightly in the cylinder bore. Any parts with slight scratches can be used. However, grind sharp edges using oilstone. If the diameter clearance between the piston and the cylinder bore reaches mm, replacement is recommended. (Standard clearance: 0.01 to mm) (2) Shaft [8] Check for scratches on the oil seal lip contact area. If any slight scratches are observed, correct them using oil stone. Replacement is recommended for the parts with scratches reaching 0.5 mm width and 0.3 mm depth. If the depth of any nick reaches 0.1 mm, replacement is recommended. (3) Sliding surface of the timing plate [11] and cylinder block [4] Check for scratches. Correct the timing plate by rubbing it lightly with emery paper (4/0 or 6/0) placed on a flat plate. Correct the cylinder block by lapping with a lapping block. If surface roughness reaches 10 µ or scratch depth reaches 0.1 mm, replacement is recommended. (Standard surface roughness: 0.6 µ) (4) End surface of the slipper [10] Rub the area a few times with emery paper (4/0 or 6/0) placed on a flat plate, and check that no projection is present. If surface roughness reaches 10 µ or scratch depth reaches 0.1 mm, replacement is recommended. (Standard surface roughness: 0.6 µ) (5) Spherical surface of the slipper [10] and piston [9] Check that no scratch is present on the spherical surface. If light scratches are observed, lap both the piston and the slipper for correction. If scratch depth reaches 0.1 mm, replacement is recommended. (6) Orifice at the center of the slipper [10] Let air pass through the orifice to check that it is not clogged (7) Bearings [32] and [33] If corrosion, fatigue-caused small cracks, or temper color is observed on their inner or outer rings and roller, replace the parts because their life is shortened. If their roller edge wears out, replacement is recommended even when there are no other abnormalities. If wear is observed on the rolling contact surface of the outer ring due to edge loading, replacement is recommended. (8) Sleeve driven into the thrust retainer plate [2] Check for burrs or scratches, and correct or replace the parts if necessary. (9) Thrust retainer plate [2] and thrust plate [5] Lightly rub any slight scratches on the sliding surface using a large oil stone to remove projection. If surface roughness reaches 10 µ or scratch depth reaches 0.1 mm, replacement is recommended. (Standard surface roughness: 3 µ) If wear amount reaches 0.05 mm, replacement is recommended. (10) O-ring, oil seal, backup ring Replace all in principle. (11) Plain bearing [50] Replace all in principle

71 D-3 D-3 Swing Drive Unit 6. Reassembly 6.1 Reassembling the reducer 4. Invert it and press-fit the roller bearing [9], and then install the snap ring [29]. 1. Press-fit the retainer [2] and roller bearing [4] into the spur gear [1]. At this time, pack lithium-based grease on the bearing-side end surface of the retainer [2] in advance. 5. Insert the sheet steel bearing ring [26]. 6. Install the carrier (B) ass y. 2. Press-fit the oil seal [8] into the casing [19]. 3. Press-fit the spur gear ass y reassembled in the step 1 into the casing ass y reassembled in the step 2. At this time, apply lithium-based grease to the oil seal contact area of the spur gear in advance. 7. Install the sheet steel bearing ring [13], needle bearing [14], and planetary gear (B) [15] sequentially

72 D-3 D-3 Swing Drive Unit 8. Install the sun gear (B) [28]. 11. Install the sun gear (A) [21], and check that it turns lightly by hand. 9. Install the carrier (A) ass y. 12. Install the spacer (A) [20] to the hydraulic motor [32], and caulk the end surface at 8 places. 10. Install the sheet steel bearing ring [26], needle bearing [25], and planetary gear (A) [24] sequentially. 13. Check that clearance X in Fig. 3 is 1.15 to 2.95 mm and Y is 0.05 to 2.26 mm, and then apply ThreeBond 1215 to the mating surfaces, and install the hydraulic motor [32] using the bolt [22] and spring washer [23]. Bolt [22] tightening torque: 440 to 500 kg cm

73 D-3 D-3 Swing Drive Unit 6.2 Reassembling the hydraulic motor 1. Reassemble the thrust retainer plate [2] according to the following procedure. (1) Secure the thrust retainer plate [2] to the assembly stand (10). (2) Install the O-ring [25] in the thrust retainer plate [2], and apply grease to the O-ring [25]. (3) Apply hydraulic oil to the sliding surface of the thrust retainer plate [2]. 14. Wind sealing tape around the plug [10] of the oil drain and install. 15. Supply approx. 2.3 L of gear oil in the casing [19] of the reducer from the gear oil filler port. (Check that gear oil is loaded up to the oil inspection port.) 16. Wind sealing tape around the plug [18] of the oil inspection port and the plug [10] of the filler port and install. (4) Over the thrust retainer plate [2], insert the slipper [10] in the retaining plate [12]. (5) Install the retaining ring [7] to the thrust retainer plate [2] using the hexagon socket head bolt [37] (Loctite applied). (Bolt [37] tightening torque: 17 kg cm) (6) Install the bearing [33] in the thrust retainer plate [2] by shrink fitting. Shrink fitting temperature shall be 130 C or lower. (7) Insert the timing plate pin [14] in the thrust retainer plate [2]. 2. Drive the outer race of the bearing [33] into the cylinder block ass y using the bearing outer race driving jig (3). At this time, apply Loctite 601 or RC75 to the outer diameter of the outer race. Apply hydraulic oil to the cylinder block bore. Outer race driving jig (3) Assembly stand Cylinder block ass y

74 D-3 D-3 Swing Drive Unit 3. Reassemble the timing plate [11] according to the following procedure. (1) Place the timing plate [11] solely on the thrust retainer plate [2], and install the cylinder block ass y, and then measure the dimension to the shaft end. (Left side in Fig. 24) (5) Insert the disc spring [16], spacer [24], and sleeve ass y reassembled in the step (4) above, in the 4 holes on the timing plate [11]. NOTE Take care not to confuse the direction of the disc spring and the sleeve. Backup ring [30] O-ring [27] Cylinder block ass y Sleeve [13] Timing plate pin [14] Timing plate [11] Master (1) (4 pcs.) Timing plate [11] Spacer [24] Disc spring [16] (3 pcs. for each hole; take care about direction.) Thrust retainer plate [2] When the master (1) is not inserted in the timing plate [11] When the master (1) is inserted in the timing plate [11] 4. Install the cylinder block ass y according to the following procedure. (2) Remove the cylinder block ass y, insert the master (1) in the timing plate [11], and install the timing plate [11] and cylinder block ass y in the thrust retainer plate [2:], and then measure the dimension to the shaft end. (Right side in Fig. 24) Piston retention jig (9) (3) Determine the number of spacers to be inserted in the 4 holes on the timing plate [11], from the dimension difference A between (1) and (2) above. Cylinder block ass y Dimension difference A Number of spacers Total thickness 1.30 to 1.40 mm to 1.30 mm mm 0.70 to 1.00 mm mm 0.40 to 0.70 mm mm 0.20 to 0.40 mm mm Stud (4) (4) Install the O-ring [27] and backup ring [30] in the sleeve [13], and apply grease

75 D-3 D-3 Swing Drive Unit (1) Apply hydraulic oil to the port-side bore of the cylinder block [4], and insert the piston [9]. NOTE If you feel roughness, check for scratches. Remove them using oil stone. (2) Set the timing plate ass'y and the cylinder block ass y on the thrust retainer plate ass y. (3) Insert the stud (4) through the center hole of the thrust retainer plate [2], and secure the cylinder block ass y and the thrust retainer plate ass'y. At this time, align the stud (4) with the position of the slipper [10] and the cylinder block bore. (4) Insert the spring [15] in the cylinder block ass y. (5) Install the piston retention jig (9) to the cylinder block ass y. NOTE (1) Apply hydraulic oil to the sliding surface of the thrust plate [5]. (2) Over the thrust plate [5], insert the slipper [10] in the retaining plate [12]. (3) Install the retaining ring [7] to the thrust plate [5] using the hexagon socket head bolt [37]. (Bolt [37] tightening torque: 17 kg cm) 6. Install the thrust plate [5] in the cylinder block [4] according to the following procedure. Top hat (5) Thrust plate [5] Cylinder block ass y Install with the position of the claw aligned with the bore. (6) Push in the piston [9] using the piston push-in bar (11), and fix the piston [9] using the claw of the piston retention jig (9). (7) Apply hydraulic oil to the spherical surface of the piston. 5. Reassemble the thrust plate [5] according to the following procedure. Countersunk holes (2 places) face the thicker side of the thrust plate [5]. R portion faces upward. (1) Set the thrust plate [5] in the cylinder block [4]. (2) Put the top hat (5) over the output shaft, and fit the top hat (5) to the socket and spigot portion of the thrust plate [5]. Then, tighten the top hat (5) with bolts using the screw holes on the end surface of the output shaft. NOTE Set the thicker side of both the thrust plate [5] and thrust retainer plate [2] in the same direction. (3) Loosen the nut of the piston retention jig (9), and remove the piston retention jig (9)

76 D-3 D-3 Swing Drive Unit 7. Install the casing [1] according to the following procedure. (1) Install the casing [1] by putting it over the cylinder block ass y. (2) Fix the casing [1] and the thrust retainer plate [2] by tightening the bolts [34] and [35] to which Loctite 262 is applied. (Tightening torque for bolts [34] and [35]: 500 kg cm) 8. Install the friction plate [17]. 9. Install the O-rings [28] and [29] to which grease is applied, to the brake plunger [19], and insert the brake plunger in the casing [1] so that the two pin holes on the brake plunger [19] are located in the direction of the port and in the opposite direction to the port. 15. Perform shim adjustment according to the following procedure. (When the disassembled casing [1], cylinder block [4], thrust retainer plate [2], bearings [32] and [33], and end cover [6] are used without any change, shim adjustment is not required and the existing shims can be used.) (1) Drive the outer race of the bearing [32] into the bearing housing [3] using the bearing outer race driving jig (2). Check that the outer race is in contact with the bearing roller, and measure dimension A using a dial depth gauge, and then make adjustments so that mutual error among the dimension A at 3 places on the circumference is 0.05 mm or smaller. Dial depth gauge 10. Install the O-ring [28] to which grease is applied in the bearing housing [3], and insert 16 brake springs [18] in the positions marked with X shown in the figure below. (To prevent the brake springs from falling, apply grease fully to the spring ends before inserting.) (2) Measure dimension B of the end cover [6] using a dial depth gauge. (Fig. 30) (3) Temporarily determine the shim thickness according to the following formula. Shim thickness = A - B + α (A: Average of 3 places on the circumference) (α: to mm) 11. Drive the dowel pin [21] into the bearing housing [3]. Install the positioning pin [23] to the thrust plate [5]. 12. Align the center of the shaft [8] with the center of the casing [1], and install the bearing housing [3] in the casing by tightening the hexagon socket head bolt [39]. (Bolt [39] tightening torque: 900 kg cm) 13. Remove the top hat (5) and stud (4). 14. Install the bearing [32] by shrink fitting. Shrink fitting temperature shall be 130 C or lower. (4) Finally determine the shim thickness according to the following procedure. Install shims suitable to the thickness temporarily determined in the step (3), fit the end cover [6] to the socket and spigot portion of the bearing housing [3], and measure torque T1 at the time when the shaft starts rotating using a torque wrench. Then, fix the end cover by tightening the hexagon socket head bolt [36]. (Tightening torque: 300 kg cm) Measure T2 at the time when the shaft starts rotating in this condition. Readjust the shim thickness that satisfies T2 - T1 =

77 D-3. Swing Drive Unit D-3. Torque measuring jig (12) Torque wrench 7. Maintenance Standard 1. Hydraulic motor drain amount (1) During starting kg/cm 2, 37 cst) Standard value: 3.5 L/min max. (2) During running kg/cm 2, 37 cst, 500 rpm) 16. Install the end cover [6] according to the following procedure. Standard value: 1.5 L/min max. (1) Remove the end cover [6], and drive the oil seal [31] using the oil seal driving jig (7). Apply grease to the lip of the oil seal. Oil seal driving jig (7) (2) Install the O-ring [26] to the end cover [6], and apply grease. (3) Place the specified shim [22] on the outer race of the bearing [32], and fix the end cover [6] to the bearing housing [3] by tightening the hexagon socket head bolt [36]. (Bolt [36] tightening torque: 300 kg cm) (4) Rotate the output shaft, and measure torque. Check that the shaft rotates smoothly. Standard torque value - Torque when the shaft starts rotating: 1.2 to 1.4 kg m - Torque during rotation: 0.8 to 1 kg m 17. Remove the motor from the assembly stand (10), and install the plain bearing [50], hexagon bar [48], rotation detection shaft [49], plate [51], O-ring [53], and end cover [54] (to which oil seal [52] has already been installed), to the thrust retainer plate [2] using the bolt [55]. (Bolt [55] tightening torque: 20 kg cm) 18. Fill the motor casing with hydraulic oil from the hydraulic motor drain port

78 D-4. D-4 Swing Bearing D Remounting 1. Remove fouling and foreign objects on the bolt holes by inserting the tap in the bolt holes on the frame and the swing table. Replace bolts, nuts, washers, and bend washers with new ones, and apply torque coefficient stabilizer (TORUKON KOGYO) to the threads of the bolts. 2. Install the swing bearing to the frame with the S mark on the inner ring pointing rearward of the vehicle. Inner ring 6. Lower the swing table ass y slowly, align the bolt holes and tighten the bolts in the order of the side, front left and front right, rear left and rear right, the rear, and left and right sides, using a wrench. NOTE Take extreme care not to damage bolt threads. 7. Temporarily tighten all the bolts to 50% of the specified torque, and then apply the specified torque in diagonal order. Check that the bolts threads project from the nut by a pitch or more. Tightening torque: 120 to 130 kg m (M27) NOTE S mark Take special care to avoid difference in tightening torque among the bolts. 3. Tighten the specified bolt to fix the swing bearing to the frame. When tightening the bolt, temporarily tighten it to 50% of the specified torque, and then apply the specified torque in diagonal order. Bend the bend washer so that it is attached firmly to the bolt side surface. Check that the bolt threads project from the nut by a pitch or more. Tightening torque: 120 to 130 kg m (M27) NOTE Take special care to avoid difference in tightening torque among the bolts. 2. Maintenance Standard 1. Bolt tightening torque Check tightening torque at 300 hours after starting operation. Thereafter, check regularly at every 600 hours. 2. Greasing Grease the bearing races and gear teeth regularly (every week). 4. Pack grease from the grease nipple on the bearing side surface until the grease is extruded from the mating surface between the inner and outer rings. 5. Lift up the swing table ass y with a crane with its front lowered slightly, and move it to over the frame. Set the S mark on the outer ring pointing rightward of the swing table. S mark Outer ring

79 D-5 D-5 D-5 Solenoid Control Valve 1. Construction Port symbols and solenoid symbols P : Pump port Pp : External pilot port T : Tank port Dr : Drain port SOL 1a : For jib extension V : Carry-over port SOL 1b : For jib stowing A1, B1 : Jib extension cylinder port SOL 2a : For pilot vent Pa : Accumulator circuit port SOL 2b : For swing brake cancel Pb : Swing brake port Pc : Pilot circuit port Hydraulic symbol Relief valve RV - side Lead color: Black + side Lead color: Red Relief valve RV Unload valve UN Reducing valve RDV

80 D-5 D-5 Solenoid Control Valve 1. PT cover ass y 5. End cover 9. Nut Unload valve ass y 6. O-ring Plug 3. Pilot valve block ass y 7. O-ring 11. Plug 16. O-ring 4. Selector valve block ass y 8. Stud bolt 12. Reducing valve 21. Relief valve ass y (RV) Loctite #

81 D-5 D-5 Solenoid Control Valve 1. Valve body 6. O-ring 11. Sequence valve 16. Plug 2. Socket 7. O-ring 12. Filter 17. Reducing valve (RDV) 3. Spring 8. Spring seat 13. O-ring 18. Plug 4. Valve 9. O-ring 14. O-ring 5. C-shaped retaining ring 10. Spring 15. Plug Loctite # Valve body 8. O-ring 15. O-ring 22. Valve seat 2. Nut 9. O-ring 16. Spool 23. Spring 3. Adjustment screw 10. Valve seat 17. Spacer 24. O-ring 4. Spring 11. O-ring 18. Plug 25. Plug 5. Nut 12. Stopper 19. O-ring 26. Plug 6. Poppet 13. O-ring 20. Spool 27. Hexagon socket head bolt 7. Body 14. Socket 21. Spring

82 D-5 D-5 Solenoid Control Valve (Loctite #242) 1. Valve body 6. O-ring 11. Check valve Solenoid valve 7. O-ring 12. Check valve Socket 8. Plug 13. Plug 18. Socket 4. Valve 9. O-ring 14. Connector 19. Valve 5. Spring 10. Spring

83 D-5. Solenoid Control Valve D-5. (Loctite #262) 1. Valve body 7. Spring seat 13. Solenoid valve 19. Connector 2. Spool 8. Spring 14. Socket Stopper 9. Body 15. Valve 21. Relief valve ass y (RV) 4. O-ring 10. Hexagon socket head bolt 16. Spring Check valve 11. O-ring 17. O-ring 23. Plug 6. Spring 12. O-ring 18. O-ring 24. O-ring Relief valve ass'y (RV) [21] 1. Socket 5. Body 9. Spring 13. O-ring 2. Valve 6. Poppet 14. Backup ring 10. Spring 3. Piston 7. Adjustment screw 11. O-ring 15. O-ring 4. Body 8. Nut 12. O-ring

84 F Winch System F Contents F-1 System Components... 1 F-2 System Overview Description of System... 2 F-3 Hydraulic Motor Construction and Function Dismounting and Remounting Disassembly and Reassembly Maintenance Standard F-4 Winch Construction Disassembly Reassembly F-5 Winch F-6 Counterbalance Valve Construction F-7 Winch Clutch Construction Disassembly Checking Reassembly Adjustment Clutch burning F-8 Winch Brake Band Construction and Function Disassembly and Reassembly Adjustment Brake burning Construction Disassembly Reassembly i

85 F-9 Master Cylinder Construction Disassembly Washing Checks Reassembly Test Adjustment F-10 Accumulator Construction and Function Dismounting Disassembly and Reassembly Refilling Nitrogen Gas Maintenance Standard F-11 Hydraulic Valve Construction ii

86 F-1. F-1 System Components F-1. Winch brake band Hydraulic motor, counterbalance valve Auxiliary winch Winch clutch Winch clutch Main winch Hydraulic motor, counterbalance valve Hydraulic valve Accumulator Master cylinder (Auxiliary) Master cylinder (Main) 1 F

87 F-2 F-2 F-2 System Overview 1. Description of System 1. Operations of main winch and auxiliary winch 1. Connection of winch clutch (Main winch is used as the representative) Usually, the winch clutch, to which accumulator pressure is led, is in the connected condition except during free-fall operation. As the automatic brake cylinder circuit of the winch brake band leads to the drain circuit via the hydraulic valve, the brake band is in the automatic braking condition. Accumulator circuit Winch circuit pressure Tank circuit Hydraulic valve Pilot circuit Winch brake band Winch clutch (Main) (Auxiliary) (Main) Master cylinder (Auxiliary) Drain circuit 2. Hoisting up and hoisting down (Main winch is used as the representative) When hoisting up/down operation is performed, the pressure in the winch circuit rises, allowing the hydraulic valve (B) to be switched. This causes the accumulator pressure to be led to the automatic brake cylinder, opening the winch brake band to perform hoisting up/down operation. When the winch control lever is returned to the neutral position, the winch circuit pressure is lowered to the tank circuit pressure, causing the switched hydraulic valve (B) to be returned by the spring force. This sets the brake band in the automatic braking condition again. Accumulator circuit Winch circuit pressure Tank circuit Hydraulic valve Drain circuit Pilot circuit Winch brake band Winch clutch (Main) (Auxiliary) (Main) Master cylinder (Auxiliary) 2 F

88 F-2. System Overview F Free-fall (Main winch is used as the representative.) When the winch brake pedal is pressed and the winch clutch select switch is set to the FREE position, the solenoid is energized, and the hydraulic valve (C) is switched, changing the circuit condition from that shown in Fig. 1 to Fig. 3. Thus, the pressure oil in the winch clutch circuit is returned to the drain circuit, setting the winch clutch disconnected. At the same time, the switched hydraulic valve (A) is returned by the spring force. This causes the accumulator pressure to be led to the automatic brake cylinder, releasing the automatic brake. Since, in this condition, the winch drum is locked only by the foot brake (master cylinder), returning the brake pedal to release the brake band sets the winch drum free, allowing the hook block to fall freely. Accumulator circuit Winch circuit pressure Tank circuit Hydraulic valve Drain circuit Pilot circuit Winch brake band Winch clutch (Main) (Auxiliary) (Main) Master cylinder (Auxiliary) 3 F

89 F-3 F-3 F-3 Hydraulic Motor 1. Construction and Function 1. Description of operation When pressure oil is supplied from one of the slits of the control plate, half numbers of the pistons in the cylinder block are pushed out by the pressure. The pushed out pistons presses the flange portion of the drive shaft upward, rotating the drive shaft. At this time, the cylinder block slides on the control plate. During rotation, seven pistons reciprocate between the top dead center (OT) and the bottom dead center (UT), and obtain stroke (h) depending on the tilt angle (a). During the piston stoke from UT to OT, oil of the amount of piston section area (F) piston stoke (h) is supplied from one of the slits of the control plate, and then during the piston stroke from OT to UT after the piston turns further, the oil is discharged from the other slit. 2. Description of construction The cylinder block [41] is retained in the rotatable condition by the center pin [43] and control plate [42]. During operation with no load, the cylinder block [41] is pressed against the control plate [42] by the disc spring [47]. When pressure rises, balance is achieved by the oil pressure, creating oil film between the cylinder block [41] and control plate [42] constantly. In the drive shaft [13], the bearings [19] and [20] are installed combined with the bearing case [14]. These bearings are subject to the load generated both in the axial and radial directions. For sealing the drive mechanism against the external portions, the oil seal [22] and O-rings [23] and [31] are used. Piston Drive shaft Cylinder block Control plate Slit

90 F-3 F-3 Hydraulic Motor (Note) The bushing and plug may be installed inversely depending on the hydraulic motor installation direction. 1. Bushing 19. Bearing 27. Machine screw 41. Cylinder block 2. Plug 20. Bearing 28. Housing 42. Control plate 13. Shaft 21. Retaining ring 29. Cover 43. Center pin 14. Case 22. Oil seal 30. Dowel pin 44. Piston 15. Case 23. O-ring 31. O-ring 45. Piston ring 16. Shim 24. Shim 32. Hexagon socket head bolt 46. Spring seat 17. Plate 25. Shim 33. Spring washer 47. Disc spring 18. Nut 26. Shim

91 F-3 F-3 Hydraulic Motor 2. Dismounting and Remounting (2) Remove the case [15]. Remounting cautions 1. Motor mounting bolt tightening torque: 1350 to 1575 kg cm 3. Disassembly and Reassembly Disassembly and reassembly cautions (1) Every part of the unit is precisely manufactured. Disassemble and reassemble the unit in a clean environment, and handle the parts with extreme care to avoid hitting or dropping. (2) During disassembling, take care not to strike or pry parts by force. Doing so may cause burr to occur or parts to be damaged, resulting in impossible disassembly or performance deterioration. (3) Visually check for scratches on the oil seal [22], case [15], shaft [13], housing [28], and O-ring [23]. (4) Remove the oil seal [22]. (3) Clean the hydraulic motor with white kerosene with all the ports plugged, and then make match marks on all the mating surfaces. (4) In the figures shown in the following description, the drive shaft with outer spline is used. However, the procedures described below can also be used for the inner splined-type drive shaft. (5) Press-fit a new oil seal in the case [15]. 1. Disassembling and reassembling the shaft seal portion (1) Remove the retaining ring [21]. (When the drive shaft has a key, remove the key in advance.) (6) Install a new O-ring, and apply grease to the O-ring and the lip of the oil seal

92 F-3 F-3 Hydraulic Motor (7) Install the case [15] in the housing [28], and then install the retaining ring [21] using a punch. 2. Disassembling and reassembling the cover plate seal portion (1) Make match marks on the cover [29] and housing [28], and then remove the bolt [32]. (8) Check that the retaining ring [21] is completely seated. (2) Remove the cover [29] while rotating it around the dowel pin [30]. (3) Record the position of the dowel pin [30]

93 F-3 F-3 Hydraulic Motor NOTE The position of the dowel pin varies as shown in the figures below depending on the case when the unit is used as a motor or when it is used as a pump. When used as a motor (7) Tighten the bolt [32] using a torque wrench. (For the torque value, see Table 3.) When used as a pump (4) Visually check for scratches on the O-ring [31], O-ring groove, or cover [29]. (5) Apply grease lightly to a new O-ring, and install it in the O-ring groove. 3. Removing the rotary group (1) Remove the cover [29] according to the procedure previously described in the step 2. Rotate and remove the control plate [42]. (6) Check that the dowel pin [30] is set at the correct position, and then install the cover [29] in the housing [28] with the match marks made in the step (1) aligned

94 F-3 F-3 Hydraulic Motor (2) Remove the case [15] according to the procedure previously described in the step Disassembling the rotary group (1) Loosen the machine screw [27], and remove the plate [17]. (Screw lock agent has been applied to the machine screw.) (3) Remove the shim. (2) Secure the shaft [13] using the special tool (Fig. 3), and remove the nut [18] using a socket wrench (Fig. 2). (4) Remove the rotary group using the special pull-out tool (Fig. 13). (3) Remove the bearings [19] and [20] slightly using the special tool (Fig. 4). (5) When transporting the rotary group as a set, secure the parts with a transportation clamp to prevent damage

95 F-3 F-3 Hydraulic Motor (4) Pull out the bearings [19] and [20] completely using the special tool (Fig. 5). (2) Checking the shaft [13]. [1] No rust or damage is allowed to the spline or key groove. [2] No wear or scratches are allowed on the outside diameters of the shaft. [3] No scratches or pitching is allowed on the piston end support portions. [4] Play in the piston axial direction (5) Pull out the outer ring using the special tool (Fig. 6). [5] Socket and spigot joint 5. Checking parts (1) Remove dust and soil from the shaft, bearing, and nut. Remove the adhering screw lock agent using a wire brush. (3) Checking the pistons [44] [1] No scratches or pitching is allowed

96 F-3 F-3 Hydraulic Motor (4) Checking the center pin [43] [1] No scratches or pitching is allowed on the end portion. [2] No scratches are allowed on the outside diameter portion. (7) Checking the housing [28] No damage or wear is allowed on the bearing mounting portion. 6. Reassembling the rotary group (1) Press-fit the outer ring of the small bearing [20] using the special tool (Fig. 7). (5) Checking the plate [17] [1] No scratches or wear is allowed. (2) Press-fit the inner ring of the large bearing [19] into the drive shaft [13] using the special tool (Fig. 6). (6) Checking the cylinder block [41] and control plate [42] [1] No scratches or wear is allowed on the hole of the cylinder block. [2] All surfaces shall be smooth and free from cracks or scratches. (3) Install the outer ring of the large bearing [19] and the case [14] (in which the outer ring of the small bearing [20] is installed), and then press-fit the inner ring of the small bearing [20] using the special tool (Fig. 8 and Fig. 9). NOTE The height of the socket and spigot joint portion at the shaft bottom is not included in the height of the distance ring; therefore, use a plate with a hole allowed for the socket and spigot joint portion, as the plate to be placed under the shaft

97 F-3 F-3 Hydraulic Motor (5) Place the case [15] on the bearing with no seal, O-ring, and shim installed. (4) Install the nut [18] with the screw lock agent applied lightly, and tighten the nut slowly until the working torque reaches the value shown in Table 1. NOTE Use the measuring device shown in Fig. 10 for the measurement of the working torque. If working torque excesses the specified value, the unit must be reassembled again after removing the bearing. Therefore, tighten the nut carefully. (6) Measure the thickness S of the retaining ring [21] and the thickness A of the bearing ass y, and add these measured values. Calculate the difference between the added value and the specified value (Table 2), and insert shims equivalent to the difference. NOTE The height (a) of the socket and spigot joint portion is not included in height A

98 F-3 F-3 Hydraulic Motor (3) Set the measuring device (Fig. 11 and Fig. 12) at the middle position. 7. Adjusting the rotary group (1) Replace the pistons [44] as a set. When other parts are replaced, the rotary group must be readjusted. (4) Set the rotary group to the measuring device. At this time, remove the disc spring [47] in advance to allow only the spring seat [46] to be kept. Also remove the plate [17] in advance. (2) Replace the cylinder block [41] and control plate [42] as a set. (5) Measure the length B, and compare it with the specified value (Table 2). Tolerance is between mm and mm. If the length B is outside the tolerance, replace the spring seat [46] with the one with appropriate thickness

99 F-3 F-3 Hydraulic Motor 8. Replacing the piston rings (1) Remove the old piston rings by breaking them. (3) Check that the marks of both the piston rings at the piston end can be seen. NOTE To prevent the piston ring chips from scattering, cover the piston rings with a waste cloth. 9. Installing the rotary group (2) Install the inner piston ring and then the outer piston ring using the assembling tool. (1) Insert the center pin [43] in the shaft [13], place the shim [16], and install the plate [17]. Apply small amount of screw lock agent to the machine screw [27]. NOTE Each piston ring has spherical surface and a mark. Install the piston ring so that the mark at the piston end can be seen. Inner piston ring Outer piston ring Mark (2) Apply grease sufficiently to the spring seat [46] and disc spring [47], and install them to the cylinder block [41] using a screwdriver

100 F-3 F-3 Hydraulic Motor (5) Tilt the cylinder block [41] to the maximum, and then install the transportation/assembling tool (Fig. 14) at the position where the cylinder block stops. (6) Check that a new oil seal [22] is installed, and then heat the housing [28] to 80 C using the heater (Fig. 15). (3) Insert the pistons [44] in the cylinder block [41]. (7) Insert the rotary group in the housing. (4) Align the centers of the cylinder block [41] and the shaft ass'y, and insert the head of each piston in the shaft hole. NOTE Since the top end of the rotary group projects from the housing, place a support with a hole under the housing

101 F-3 F-3 Hydraulic Motor (8) Insert the shims [24] to [26], and reassemble the shaft seal portion. (See the previously described steps (6) to (8) in 1. Disassembling and reassembling the shaft seal portion.) (9) Pull the rotary group to allow it to come in contact with the case [15]. NOTE Check that the case [15] does not move. Torque plate for shaft (10) Remove the transportation/assembling tool. Removal tool (11) Reassemble the cover plate seal portion. (See the previously described steps (5) to (7) in 2. Disassembling and reassembling the cover plate seal portion.) Removal tool (12) To prevent entry of foreign objects, put a cover on all the openings. 10. Special tools Removal ring Nut tightening socket wrench

102 F-3 F-3 Hydraulic Motor Pushing ring (Outer ring of the small bearing) Rotary group measuring device Distance ring Rotary group adjustment gauge Pushing ring (Inner ring of the small bearing) Rotary group removal tool Working torque measuring device Transportation/assembling tool

103 F-3. Hydraulic Motor F Maintenance Standard 1. Working torque value Table 1 Size Torque kg m Heater 12 / to / to to / to / to / to / to Rotary group adjustment dimensions Table 2 Size [S+A] [B]± / / / / / / Tightening torque value Table 3 Screw M 6 M 8 M 10 M 12 M 16 Torque kg m

104 F-4 F-4 F-4 Winch 1. Construction Oil drain plug Oil level plug Apply ThreeBond 1303 and tighten (3600 to kg cm), and then apply paint lock. Hoist-up direction Apply ThreeBond 1215 Apply ThreeBond 1215 at shrink fitting Apply ThreeBond 1215 Apply ThreeBond ~120kg cm Apply ThreeBond 1303 Detail of B (sensor mounting portion) Apply ThreeBond 1215 at shrink fitting After tightening them until the drum rotates hard, turn them backward by 1/8 to 1/4 turns and fix. Apply ThreeBond

105 F-4. Winch F Bolt 14. Gear 27. Retainer 40. Bearing 2. Gear case 15. Retainer 28. Spacer 41. Snap ring 3. Gear 16. Spacer 29. Sleeve 42. Copper packing 4. Bolt 17. Bearing 30. Oil seal 43. Cover 5. Spring washer 18. Hexagon socket head bolt 31. Bearing 44. Packing 6. Shim 19. Spring washer 32. Shaft 45. Hexagon socket head plug 7. Oil seal 20. Sensor shaft 33. Clutch ass y 46. Elbow 8. Sleeve 21. Sensor bush 34. Clutch boss 47. Plug 9. Nut 22. Oil seal 35. Bearing 48. Hexagon socket head plug 10. Washer 23. Retainer 36. Drum shaft 49. Bolt 11. Retainer 24. Spacer 37. Drum 50. Spring washer 12. Bearing 25. Bearing 38. Nut 51. Name plate 13. Spacer 26. Shaft 39. Washer 52. Joint 2. Disassembly 1. Remove the snap ring [41], bearing [40], nut [38], and washer [39] in this order, and remove the drum [37]. 2. Remove the joint [52] of the clutch ass y [33], and remove the clutch ass y together with the clutch boss [34]. 3. Remove the cover [43]. 4. Remove the retainer [11], and remove the nut [9] and washer [10]. 3. Reassembly Reassemble the winch according to the reverse procedure of disassembly, while paying attention to the notes described in Fig. 1. Gear oil amount: Approx. 7 L NOTE When installing the retainer [11], adjust the clearance in the axial direction to 0.1 to 0.3 mm using the shim [6]. 5. Remove the retainer [27], and pull out the drum shaft [36] to the drum side. 6. Take out the gear [3]. 7. Remove the retainer [15], and pull out the shaft [32] to the drum side. 8. Take out the gear [14]. 9. Remove the sensor bush [21]. 10. Remove the retainer [23]. 11. Remove the sensor shaft [20]. 12. Pull out the shaft [26] to the opposite side to the drum

106 F-5 F-5 F-5 Winch 1. Construction Apply ThreeBond 1303 and tighten (3600 to 4000 kg cm), and then apply paint lock. Hoist-up direction Apply ThreeBond 1215 Oil level plug Oil drain plug Apply ThreeBond 1215 at shrink fitting Apply ThreeBond 1215 Apply ThreeBond ~120kg cm Apply ThreeBond 1303 Detail of B (sensor mounting portion) Apply ThreeBond 1215 at shrink fitting After tightening them until the drum rotates hard, turn them backward by 1/8 to 1/4 turns and fix. Apply ThreeBond

107 F-5. Winch F Bolt 14. Gear 27. Retainer 40. Bearing 2. Gear case 15. Retainer 28. Spacer 41. Snap ring 3. Gear 16. Spacer 29. Sleeve 42. Copper packing 4. Bolt 17. Bearing 30. Oil seal 43. Cover 5. Spring washer 18. Hexagon socket head bolt 31. Bearing 44. Packing 6. Shim 19. Spring washer 32. Shaft 45. Hexagon socket head plug 7. Oil seal 20. Sensor shaft 33. Clutch ass y 46. Elbow 8. Sleeve 21. Sensor bush 34. Clutch boss 47. Plug 9. Nut 22. Oil seal 35. Bearing 48. Hexagon socket head plug 10. Washer 23. Retainer 36. Drum shaft 49. Bolt 11. Retainer 24. Spacer 37. Drum 50. Spring washer 12. Bearing 25. Bearing 38. Nut 51. Name plate 13. Spacer 26. Shaft 39. Washer 52. Joint 2. Disassembly 1. Remove the snap ring [41], bearing [40], nut [38], and washer [39] in this order, and remove the drum [37]. 2. Remove the joint [52] of the clutch ass y [33], and remove the clutch ass y together with the clutch boss [34]. 3. Remove the cover [43]. 4. Remove the retainer [11], and remove the nut [9] and washer [10]. 3. Reassembly Reassemble the winch according to the reverse procedure of disassembly, while paying attention to the notes described in Fig. 1. Gear oil amount: Approx. 7 L NOTE When installing the retainer [11], adjust the clearance in the axial direction to 0.1 to 0.3 mm using the shim [6]. 5. Remove the retainer [27], and pull out the drum shaft [36] to the drum side. 6. Take out the gear [3]. 7. Remove the retainer [15], and pull out the shaft [32] to the drum side. 8. Take out the gear [14]. 9. Remove the sensor bush [21]. 10. Remove the retainer [23]. 11. Remove the sensor shaft [20]. 12. Pull out the shaft [26] to the opposite side to the drum

108 F-6. F-6 Counterbalance Valve F Construction For air venting Hydraulic symbol Relief valve ass y 1. Valve body 8. Plunger 15. Hexagon socket head bolt 22. Spring 2. Spool 9. Bushing 16. O-ring 23. Spring 3. Piston 10. Plug 17. O-ring 24. Relief valve ass y 4. Orifice 11. Plug 18. O-ring Cover 12. Hexagon socket head bolt 19. O-ring 26. Bleeder valve 6. Cover 13. Hexagon socket head bolt 20. O-ring 7. Cover 14. Hexagon socket head bolt 21. Spring

109 F-7 F-7 F-7 Winch Clutch 1. Construction Shoe extension direction Clutch rotation direction during hoisting-up NOTE: This figure shows the shape of the clockwise rotation type ( ). For the counterclockwise rotation type ( ), the shape will be symmetrical to the A-A axis. 1. Backing plate 8. Adjusting screw 14. Shoe 23. Spring washer 2. Cylinder body 9. Bleeder screw 15. Lining 24. Bolt 3. Piston Rivet 25. Shoe hold pin 4. Cup 11. Screw 17. Return spring 26. Washer 5. Backup ring 12. Spring washer 18. Return spring 27. Shoe hold cup 6. O-ring 13. Stopper 22. Bolt 28. Shoe hold spring 7. Boot

110 F-7 F-7 Winch Clutch 2. Disassembly 1. Remove the return springs [17] and [18]. 2. Remove the shoe hold cup [27] by pressing and turning it 90 while keeping the shoe hold pin [25] from rotating. 3. Remove the shoe ass y. 4. Remove the pipe, and then remove the bolts [22] and [24] to remove the cylinder ass y. 5. To disassemble the cylinder ass y, remove the boot from the cylinder body groove to pull out the piston, and remove the cup, backup ring, O-ring, and boot from the piston. 3. Checking (1) Shoe ass y Check the lining. If there is significant wear, uneven wear, streaks, surface deterioration, or grease adhesion, replace the lining. When the remaining thickness from the lining surface to the rivet head is 1 mm or less, the lining can not be used. If torsion of the shoe or deformation of the end portions on the adjuster and anchor sides is significant, replace the entire assembly. (2) Return spring If spring force is weak, or if there is significant rust or scratches, replace the return spring. (Free length) Anchor side (3) Shoe hold parts If there is significant wear or deformation on the pin, washer, or cup, replace the part. If spring force is weak, or if there is significant rust or scratches on the spring, replace it. Spring free length: 25.5 mm (4) Cylinder ass y If there is wear, rust, or damage on the cylinder body inner surface or on the piston surface, replace the part. Replace the sealing parts regularly (every two years)

111 F-7. Winch Clutch F Reassembly 6. Clutch burning 1. Reassembling the cylinder ass y NOTE Take care not to allow vegetable oils such as brake oil to adhere to all the parts. (1) Spread hydraulic oil lightly on the boot mounting portion, and install the boot to the piston. (2) Apply hydraulic oil to the cup, backup ring, and O-ring, and install them in the piston. (3) Apply hydraulic oil to the cylinder body inner surface and the piston surface, and install the piston in the cylinder while taking care not to damage the lip of the cup. (4) Install the boot in the groove of the cylinder body. 2. Attaching the lining (1) Clean the lining back side and the shoe surface to ensure that no foreign objects or oils are there, and then align the rivet holes of the shoe and the lining. Since some of the holes are irregularly pitched to indicate lining direction, invert the direction if the holes are not aligned. (2) Caulk the lining securely using the specified rivets while taking care not to allow oils to adhere to the lining surface. 3. Installing the shoe ass y Before installing, apply lubrication grease to the following areas. Shoe and cylinder anchor portion Shoe and cylinder adjusting screw portion Perform clutch burning according to the following procedure after temporary adjustment in Chapter Y Procedure for adjusting winch clutch. (1) Turn the PTO ON, clutch ON and drum lock ON, and then wind down the winch at a creeping speed. (2) Check that the click of the drum lock fits in the drum. (3) Turn the winch lever to hoist-down 2nd, and press the accelerator pedal (increase the engine speed to the maximum). NOTE Press and hold the winch brake pedal. (4) While keeping the step 3, repeat turning the clutch ON/OFF every four seconds until smoke rises from the clutch lining (for approx. two or three minutes). (5) Stop the operation when smoke rises. (6) After leaving the machine alone for cooling (to approx. 50 C), perform the steps 3 to 5 once. (7) Further perform the step 6 once. (Number of clutch burning reaches three in total) (8) Perform final adjustment of clutch clearance. Perform the procedure above for main winch and auxiliary winch individually. 5. Adjustment After installing to the actual machine, perform air venting of the hydraulic system and shoe clearance adjustment, referring to Chapter Y Adjustment and Checks

112 F-8 F-8 F-8 Winch Brake Band 1. Construction and Function Description of operation 1. Automatic braking when control lever is neutral Braking 2. Automatic brake releasing during winch operation Automatic brake releasing during free-fall operation Released by spring [35]. Releasing NOTE: The shaded parts [18], [29], [37], and [46] are immovable parts, which are fixed to the support [32]. Accumulator pressure 3. Foot braking during free-fall operation Braking This figure shows the winch brake band for auxiliary winch. For the type for main winch, the parts [22], [41], [46], [47], and [48] are located symmetrically to the H-H axis. Accumulator pressure Brake pressure (master cylinder) Take care about installation direction For air venting Automatic brake release pressure inlet port For air venting Foot brake pressure inlet port

113 F-8. Winch Brake Band F Bolt 14. O-ring 26. Piston 38. Bolt 2. Spring 15. Backup ring 27. O-ring 39. Spring washer 3. Nut 16. Nut 28. Boot 40. Spacer 4. Band 17. Bolt 29. Rod 41. Indicator 5. Support 18. Support 30. O-ring 42. Bolt 6. Bolt 19. Shim 31. Cylinder 43. Spring washer 7. Spring washer 20. Shim 32. Support 44. Hexagon socket head bolt 8. Boot 21, Spring 33. Hexagon socket head bolt 46. Pin 9. Pin 22. Plug ass y 34. Nut 47. Plate 10. Spring 23. Cylinder 35. Spring 48. Split pin 11. Piston 24. Packing 36. Hexagon socket head bolt 49. Link ass y 12. Packing 25. Backup ring 37. Pin 50. Spacer 13. Backup ring 2. Disassembly and Reassembly NOTE Perform disassembly and reassembly with the hexagon socket head bolt (full thread M16 50) screwed into the A portion (see Fig. 4) and the spring compressed. Take care not to allow vegetable oils such as brake oil to adhere to the cylinder. 1. Reassembling the cylinder portion Before reassembling, apply lithium-based grease (Daphne Coronex grease EP1 or equivalent; use this for the grease hereafter) lightly to the cylinder inner surface (G1 and G2 ranges). Before reassembling, apply grease sufficiently to the circumference surface of the pistons [11] and [26]. Before reassembling, apply grease sufficiently to the slide portion (G3 and G4 ranges) 2. Selecting shims [19] and [20] (1) Screw the hexagon socket head bolt (M16 50) into the A portion, and tighten the bolt until the dimension X reaches 0 mm. (2) Press the support [18] rightward so that the dimension C is 0 mm. (3) Measure the dimension B, and select and install appropriate shims so that shim thickness is (B - 11)±0.3 mm. (4) Remove the hexagon socket head bolt. 3. Other Apply grease to [3] and [9] before installation. 3. Adjustment After installing to the actual machine, perform air venting of the brake circuit and winch brake band adjustment, referring to Chapter Y Adjustment and Checks. 4. Brake burning Perform brake burning according to the following procedure after temporary adjustment in Chapter Y Procedure for adjusting winch clutch. (1) Turn the PTO ON and clutch ON. (2) Turn the winch lever to hoist-up 2nd, and press the accelerator pedal (increase the engine speed to the maximum). NOTE Press and hold the winch brake pedal. The hook block will be wound up. Take care about the hook block position. (3) Perform brake burning while keeping the step 2, until smoke rises from the brake lining (for approx. two or three minutes). (4) Stop the operation when smoke rises. (5) After leaving the machine alone for cooling (to approx. 50 C), perform the steps 2 to 4 once. (6) Perform final adjustment of brake band clearance. Perform the procedure above for main winch and auxiliary winch individually

114 F-9. F-9 Master Cylinder F Construction Clearance at installation 1. Body 3-4. Valve rod 6. Packing 2. Spring 3-5. Valve 7. Stopper bolt 3. Piston ass y 3-6. Valve spring 8. Dust cover 3-1. Piston 3-7. Retainer 9. Push rod 3-2. Secondary 4. Stopper 10. Nut cup 3-3. Piston cup 5. Clip ring 11. Joint 2. Disassembly 1. Remove the stopper bolt [7]. 2. Remove the dust cover [8], and remove the push rod [9] and joint [11]. 3. Remove the clip ring [5] using pliers for C-shaped retaining ring. 4. Take out the stopper [4], piston ass y [3], and spring [2] from the body [1]. 3. Washing NOTE Use kerosene. Never use vegetable oils such as brake fluid because they swell rubber parts, causing malfunction. 4. Checks (1) Body, piston Check the sliding surface. If there are any scratches, rust, or significant wear, replace the part. If the clearance between the body and the piston exceeds 0.15 mm, replace the entire ass y. (2) Sealing parts (cup, valve) If there are any scratches or wear, replace the piston ass y. Replace these parts regularly (every two years) even when no abnormality is observed. 5. Reassembly 1. Apply the oil to be used to the cylinder inner surface, piston sliding surface, and cups, and then install the spring [2] and piston ass y [3] in the body [1]. NOTE Insert the parts carefully while taking care not to damage the cylinder sliding surface, piston sliding surface, and cup seal portion. Install the parts so that the mounting hole of the stopper bolt [7] and the groove direction of the piston ass y [3] match with each other. 2. Screw the stopper bolt [7] with packing [6] with the piston ass y [3] pressed downward approx. 15 mm from the body [1] end surface. 3. Install the stopper [4], and install the clip ring [5] securely in the clip groove inside the body. After installation, check that the piston ass y [3] moves smoothly. 4. Install the dust cover [8], push rod [9], and joint [11]. 6. Test 1. Function test Install the reservoir tank, and apply air pressure of 0.5 to 1.0 kg/cm 2 from the delivery port with small amount of hydraulic oil put in the tank. Then, check that air flow to the reservoir tank stops when the piston is forwarded approx. 3 mm. 7. Adjustment After installing to the actual machine, perform brake pedal adjustment and air venting of the brake circuit, referring to Chapter Y Adjustment and Checks

115 F-10 F-10 F-10 Accumulator 1. Construction and Function The accumulator is divided into two sections (oil space and gas space) by the plug. It has a function to store pressure oil due to the compressibility of nitrogen gas, by filling the gas space with nitrogen gas. The filled pressure oil is released by the compression pressure of the gas as required. The accumulator operates as shown in Fig. 1 depending on the inflow or outflow of pressure oil. Before filling nitrogen gas After filling nitrogen gas Inflow of pressure oil Outflow of pressure oil 1. Shell 5. Cap 2. Cover 6. Packing 3. Bladder ass y Core 8. Spring pin 2. Dismounting NOTE Before dismounting, check that the accumulator accumulation pressure decreases to 0 kg/cm 2 using a pressure gauge. 3. Disassembly and Reassembly 4. Refilling Nitrogen Gas When refilling of nitrogen gas is required due to gas leakage, refill the gas as follows. 1. Preparation Charging ass y (VGS250-1-TSS150-2) Replacing the core Pressure gauge (1)Remove the cap [5], and release the gas in the bladder [3] by pressing the head of the core [4] using a core tool. Then, remove the core [4] using a core tool to replace it. Handle [A] Handle [B] Hose Reducer (W22, male thread) Joint (W23, female thread) Core tool (10568)

116 F-10. Accumulator F-10. (1) When the bladder [3] and shell [1] are dry, put hydraulic oil of approx. 5% of the capacity from the oil port so that the bladder can swell easily. (2) Remove the cap [5]. (3) Remove the TV8 joint and the fiber packing at the connection joint portion of the charging ass y. Fiber packing Rubber packing (4) Turn the handle [A] leftward, and pull it up until it stops. (5) Turn the handle [B] of the bleed plug leftward to achieve an open condition. (6) Install the charging ass y to the gas filler port of the accumulator. Rubber packing Accumulator (7) Connect the nitrogen gas cylinder to the charging ass y. Use a reducer depending on the cylinder type. 2. Refilling nitrogen gas (1) Open the valve of the nitrogen gas cylinder, and release the gas at 2 to 3 kg/cm 2 while taking care not to release the gas rapidly. When the gas is released from the handle [B] portion, turn the handle [B] rightward to prevent gas escape. (2) Turn the handle [A] rightward to open the core. At this time, stop the handle when you feel a slight resistance to prevent damaging the core. (3) Open the valve of the nitrogen gas cylinder gradually to fill the bladder with nitrogen gas slowly. Meanwhile, close the valve of the cylinder sometimes and read the indicated pressure when the pressure gauge of the charging ass y is stabilized. (4) When the gas is filled up to the specified pressure, close the valve of the nitrogen gas cylinder. If the gas is filled to a higher pressure, turn the handle [B] leftward to release the gas gradually to the specified pressure. (5) Turn the handle [A] leftward to set the core to the original position. Then turn the handle [B] leftward to achieve an open condition and release the gas remaining in the charging ass y and the hose. (6) Remove the charging ass y from the accumulator and the nitrogen gas cylinder. (7) Check for gas leakage from the core by applying water or soapy water. 3. Checking the filling pressure (1) Turn the handle [A] of the charging ass y leftward and pull it up until it stops. Turn the handle [B] rightward to achieve a closed condition. Install the pressure gauge to the gas filler port in this condition. (2) Turn the handle [A] rightward to open the core. The pressure indicated on the pressure gauge at this time is the filling pressure. (3) Turn the handle [A] leftward to set the core to the original position and the handle [B] leftward to release the gas remaining in the charging ass y. (4) Repeat the steps (1) to (3) a few times and check the pressure. After completing pressure check, remove the charging ass y. Accumulator N 2 cylinder 5. Maintenance Standard 1. Nitrogen gas filling pressure The specified pressure (see Chapter Y) shall be satisfied

117 F-11 F-11 F-11 Hydraulic Valve 1. Construction Hydraulic symbol (+) lead color: Red (-) lead color: Blue

118 F-11 F-11 Hydraulic Valve Section A Section B

119 F-11. Hydraulic Valve F Body A 9. Stop plug 17. O-ring 25. Hexagon socket head bolt 2. Body B 10. Guide 18. Check valve 26. Hexagon socket head bolt 3. Body C 11. Spring A 19. Sleeve 27. Hexagon socket head plug 4. Solenoid valve ass y 12. Spring B 20. O-ring 28. Hexagon socket head plug 5. Spool A 13. Spool B 21. Spring D 29. Plug 6. O-ring 14. O-ring 22. O-ring 30. O-ring 7. Backup ring 15. O-ring 23. Spool C 8. O-ring 16. Piston 24. Spring C Solenoid valve ass y [4] Electric symbol 1. Spool D 4. O-ring 6. O-ring 8. Name plate 2. Sleeve 5. O-ring 7. Solenoid 9. Nut 3. Spring

120 G Boom Telescoping System Contents G G-1 System Components... 1 G-2 System Overview Description of System Boom telescoping mechanism Boom extension circuit Boom retraction circuit... 3 G-3 Boom Construction Dismounting and Remounting Dismounting procedure Remounting cautions Disassembly and reassembly Disassembling procedure Checking Reassembling Adjustment Adjusting boom telescoping wire ropes Test Operation test Boom lateral warp test G-4 Hydraulic Valve Construction G-5 Flow Control Valve Construction G-6 Hose Reel Construction Remounting Disassembling Reassembling G-7 Hose Reel Construction Remounting Disassembling Reassembling i

121 G-8 Hose Reel Construction Remounting Disassembling Reassembling G-9 Solenoid Valve Construction G-10 Counterbalance Valve Construction G-11 Counterbalance Valve Construction G-12 Pilot Check Valve Construction ii

122 G-1. G-1. G-1. G-1 System Components Telescoping cylinder Hose reel (for power tilt jib) Boom Counterbalance valve Jib tilt cylinder Quick turn jib cylinder Pilot check valve Jib Counterbalance valve Jib Hose reel (for No. 3 cylinder) Hose reel (for No. 2 cylinder) Flow control valve Hydraulic valve Solenoid valve (For selecting telescoping/jib control pilot) 1 G

123 G-2 G-2 G-2 System Overview 1. Description of System (See the circuit diagram in Chapter Z.) 1.1 Boom telescoping mechanism Extension system 4th boom Extension system by means of telescoping cylinder section 4th boom section extension length (E 4 ) = L L: Cylinder telescoping quantity Retraction system Retraction system by means of telescoping cylinder 4th boom section retraction length (R 4 ) = L 5th boom section Extension system by means of wire rope by telescoping cylinder (No. 3) extension 5th boom section extension length (E 5 ) = 2L (extension length against 3rd boom section) Retraction system by means of wire rope by top boom section retraction 5th boom section retraction length (R 5 ) = 2/3R 6 = 2L (retraction length against 3rd boom section) No. 2 telescoping cylinder top sheave Top boom Extension system by means of wire rope by 5th boom section extension Top boom section extension length (E 6 ) = 3/2E 5 = 3L (extension length against 3rd boom section) Retraction system by means of wire rope by 4th boom section retraction Top boom section retraction length (R 6 ) = 3R 4 = 3L (retraction length against 3rd boom section) (The figure is a simplified one.) The extension and retraction systems for the 2nd and 3rd boom sections are by means of telescoping cylinder. Extension Retraction For top boom section extension and 5th boom section retraction For top boom section extension and 5th boom section retraction No. 2 cylinder top sheave Top boom section Top boom section For 5th boom section extension 5th boom section 4th boom section No. 3 cylinder 3rd boom section 5th boom section For top boom section retraction 4th boom section No. 3 cylinder 3rd boom section 2 G

124 G-2. System Overview G Boom extension circuit 1.3 Boom retraction circuit When the boom extends, the second and third boom sections extend first simultaneously, and then the fourth, fifth, and top boom sections extend simultaneously. Pressure oil from the hydraulic pilot control valve flows through the hydraulic valve, flow control valve, and counterbalance valve, and enters the No. 1 and No. 2 cylinders to extend the second and third boom sections. Then, just before the second and third boom sections are extended fully, a voltage is applied to the CN1 terminal 6 (telescoping control output No. 1) of the AML by the signal from the boom length detector. Therefore, when the 4th/5th/top boom section extension switch (S7) is pressed when the second and third boom sections are fully extended, the hydraulic circuit of the hydraulic valve is switched from the No. 1 and No. 2 cylinders to the No. 3 cylinder circuit, thus sending the pressure oil to the No. 3 cylinder via the hose reel and the counterbalance valve, to extend the fourth, fifth, and top boom sections. In the circuit energizing the solenoid (SL22), when the fourth, fifth, and top boom sections are extended slightly, the 4th/5th/top boom section full retraction detector switch (L7) is freed, causing the relay (R2) contact to form a holding circuit; therefore, during boom extension, the 4th/5th/top boom section extension switch (S7) may be released. The fifth and top boom sections are telescoped by the wire rope mechanism that follows the movement of the No. 3 cylinder (fourth boom section). The boom sections retract in the reverse order of extension. Although pressure oil is sent directly from the hydraulic pilot control valve to the No. 1, No. 2, and No. 3 cylinders, only the No. 3 cylinder is allowed to retract because the return circuit of the No. 1 and No. 2 cylinders are blocked by the hydraulic valve. When the No. 3 cylinder is retracted almost fully, the 4th/5th/top boom section full retraction switch (L7) is activated, shutting off the holding circuit to the solenoid (SL22). Therefore, the hydraulic valve is switched from the No. 3 cylinder to the No. 1 and No. 2 cylinder circuits, and the second and third boom sections retract automatically. If the hydraulic valve is switched before the No. 3 cylinder is retracted fully, the oil flows through the restriction during retraction of the No. 1 and No. 2 cylinders, to retract the No. 3 cylinder. 3 G

125 G-3 G-3 G-3 G-3 Boom 1. Construction Pin insertion directions are: From top end: Base, 2nd, 3rd, 4th From rear end: 5th Lock the screw with ThreeBond Section B (10 places) Section A Section E Use this in place of [22] when tightening of [26] is disabled. Install with caulking pointing downward View G Take care about [96] installation direction Secure 1 mm or more clearance on both sides Take care about installation direction Bend for securing so that it is not out of the bolt head. (4 places) Center of lower slide plate (26 places) Section F Let the stop shaft point inside of the boom. Apply ThreeBond Tightening torque kgf cm Apply ThreeBond 1305 It shall not be out of the boss. Adjust with spacers so that clearance is 0.6 mm max. Right Opposite side Top end of the 5th boom section Opposite side Top end of the 4th boom section Opposite side Opposite side Top end of the 3rd boom section Opposite side Top boom of the 2nd boom section Opposite side Opposite side Top end of the base boom section Rear end of the top boom section Rear end of the 5th boom section Rear end of the 4th boom section Rear end of the 3rd boom section Rear end of the 2nd boom section Rear end of the base boom section

126 G-3 G-3 Boom 1. Top boom 42. Support 83. Slide plate 124. Retaining ring 2. 5th boom 43. Pin 84. Plate 125. Pin 3. 4th boom 44. Retaining ring 85. Plate 126. Slide plate 4. 3rd boom 45. Slide plate ass'y 86. Retainer 127. Pin 5. 2nd boom 46. Shim 87. Slide plate 128. Pin 6. Base boom 47. Slide plate 88. Retainer ass y 129. Pin 7. Nut 48. Bolt 89. Retainer ass y 130. Plain bearing 8. Washer 49. Spring washer 90. Grease nipple 131. Set screw 9. Spacer 50. Retainer ass y 91. Support 132. Plate 10. Pin 51. Retainer ass y 92. Slide plate 133. Bolt 11. Sheave ass y 52. Slide plate 93. Hexagon socket head bolt 134. Spring washer 12. Pin 53. Plate 94. Sheave ass y 135. Pin 13. Holder 54. Plate 95. Pin Pin 55. Retainer ass y 96. Plate Shim 56. Slide plate 97. Bolt Plate 98. Spacer 139. Pin Plate 99. Spacer 140. Spacer 18. Bolt 59. Retainer 100. Slide plate 141. Spacer 19. Plate 60. Pin 101. Shim 142. Retaining ring 20. Grease nipple 61. Split pin 102. Shim 143. Guide 21. Nut 62. Nut 103. Hexagon socket head bolt 144. Sheave ass y 22. Spacer 63. Bolt 104. Slide plate 145. Plate 23. Spacer 64. Guide 105. Pin 146. Plate 24. Wire rope 65. Sheave ass y 106. Retaining ring 147. Plate 25. Wire rope 66. Bolt 107. Slide plate 148. Plate 26. Wire rope 67. Pin 108. Nut 149. Plate 27. Nut 68. Plate 109. Washer 150. Plate 28. Nut 69. Bolt 110. Bolt 151. Plate 29. Nut 70. Plain washer 111. Support 152. Plate 30. Plug 71. Slide plate ass'y 112. Retaining ring 153. Plate 31. Nut 72. Retainer ass y 113. Sheave ass y 154. Plate 32. Bolt 73. Retainer ass y 114. Pin 155. Plate 33. Pin 74. Retainer ass y 115. Bolt 156. Plate 34. Spacer 75. Retainer ass y 116. Guide 157. Plate 35. Guide 76. Retainer ass y 117. Guide 158. Pin 36. Sheave ass y 77. Slide plate 118. Slide plate 159. Guide 37. Bolt 78. Bolt 119. Retaining ring 160. Cover 38. Spring washer 79. Slide plate ass'y 120. Pin 161. Bolt 39. Bolt 80. Retainer 121. Support ass y 162. Split pin 40. Bolt 81. Retainer ass'y 122. Slide plate 163. Snap pin 41. Spring washer 82. Slide plate ass'y 123. Pin

127 G-3 G-3 Boom 2. Dismounting and Remounting 2.1 Dismounting procedure The following describes the procedure for removing an assembly of 2nd and after boom sections. 1. Set up the crane horizontally. 2. Remove the hook and the wire rope socket, and wind the main wire rope on the winch drum. NOTE After winding, secure the top end of each wire rope to a part of the swing table to prevent disorderly winding. Flange piping for extension Hose joint for No. 3 cylinder extension Flange piping for retraction Hose joint for No. 2 cylinder extension 3. After swinging the boom in a direction appropriate for work with the boom fully retracted, bring down the boom angle to 0, and stop the engine. Then, move the telescoping control lever back and forth several times to release the remaining pressure in the hydraulic equipment and the pipe lines. (In the case of the hydraulic pilot-type selector valve, perform operation after disconnecting the wiring connector of the solenoid valve for AML vent (AML vent state) with engine idling.) 4. Disconnect the wiring connector, release the wiring fixing piece, and secure the cable top end to the cable guide nearest to the cord reel using tape. Cable 6. Pull out the pin [129] that connects the base boom section and No. 1 telescoping cylinder. No. 1 telescoping cylinder Wiring fixing piece Cable guide Wiring connector Base boom 5. Remove the flange piping for extension and retraction connected to the No. 1 cylinder and also the high pressure hose on the hose reel connected to the No. 2 and No. 3 cylinders. Close all the openings with caps. 7. Loosen the nut [31] to remove the bolt [32]. NOTE Since the hose on the hose reel is under spring force due to extra winding, hold the drum when removing the hose

128 G-3 G-3 Boom 8. Remove the bolt [a] and pin [60], and pull out the slide plates [82] and [56] on the side surfaces of the base boom section (4 pieces in total on the right and left sides). (Before removing the pin [60], loosen the bolt [39].) 10. Pull the 2nd and after boom sections by approx. 6 m, and attach wire rope at two locations as shown in the figure below to lift them up with a crane. 11. Pull out the assembly of the 2nd and after boom sections fully, and lower them on a supporting block. Bolt 2.2 Remounting cautions Section B (1) Install the antibuckling bolt for the cylinder as follows. With the pin inserted, tighten the nut [a] until the bolt comes in contact lightly with the surface Y, and then lock with the nut [b]. Screw lock agent should be applied to the bolt. 9. Pull the 2nd and after boom sections by approx. 1 m. Then, with the 2nd boom section slightly lifted up, unscrew the bolt [78] and remove the slide Pin Nut Boom side plates [83] and [87] (with retainer assy's [81], [88], and [89]). Cylinder side Bolt (2) Since the cable for the boom length detector has been removed, check the boom length displayed on the AML again after remounting. Base boom top end

129 G-3 G-3 Boom 3. Disassembly and reassembly In the previous section Dismounting and Remounting, some steps of the procedure for disassembling and reassembling of the boom have been described. Therefore, this section describes the steps after that. 4. Remove the bolt [a] and pin [60], and pull out the slide plates [82] and [56] on the side surfaces of the 2nd boom section (4 pieces in total on the right and left sides). (Before removing the pin [60], loosen the bolt [39].) 3.1 Disassembling procedure 1. Hold the bosses of the No. 1 cylinder with a crane as shown in the figure below, and remove the retaining ring [119] and pull out the pin [127]. Bolt Section B 2. Pull out the pin [128] that connects the No. 2 cylinder and the 2nd boom section, and loosen the nut [31] to remove the bolt [32]. (See Fig. 4.) 3. Attach wire rope using the boss hole at the rear end of the 2nd boom section as shown in the figure below, and secure the other end to the heavy load such as a fork lift. 5. Pull the 3rd and after boom sections by approx. 1 m, and lift them up slightly. Then, unscrew the bolts [48] and [78], and remove the slide plates [83] and [77] (with retainer assy's [75]/[76] and [72]/[73]). (See the figure of the top end of the 2nd boom section shown in Fig. 1.) 6. Pull the 3rd and after boom sections by approx. 6 m in the manner shown in Fig Attach rigging wire rope to the 3rd boom section at two locations as shown in Fig. 7. Lift it up with a crane, and pull out the 3rd and after boom sections fully. 8. Remove the support ass'y [121] from the 3rd boom section. (See the figure of the rear end of the 3rd boom section shown in Fig. 1.) 9. While holding the telescoping cylinder with the crane, pull out the pin [123] that connects the No. 2 cylinder and the 3rd boom section. Then, pull out the pin [125] that fixes the No. 3 cylinder and the 3rd boom section. Loosen the nut [31] to remove the bolt [32]

130 G-3 G-3 Boom 12. Pull the 4th and after boom sections by approx. 1 m, and lift them up slightly. Then, unscrew the bolts [48] and [79], and remove the slide plates [83] and [77] (with retainer assy's [75]/[76] and [72]/[73]). (See the figure of the top end of the 3rd boom section shown in Fig. 1.) 13. Pull out the 4th boom section from the 3rd boom section in the same manner as the steps 6 and Remove the top boom section extension (and 5th boom section retraction) wire rope [26] and the 5th boom section extension wire rope [25] from the 3rd boom section, and secure them to the top boom section. 14. Loosen the nuts [21] on both sides of the end of the top boom section retraction wire rope [26] at the top end of the top boom section. (Be sure not to fully remove the nuts [21].) Wire rope (For top boom extension and 5th boom retraction) Wire rope (For 5th boom extension) NOTE Record the tightening amount of the extension wire rope adjusting nuts [29] and [27], and use the value for reference in reassembling and adjustment. 15. While holding the telescoping cylinder with the crane, pull out the pin [120] that connects the No. 3 cylinder and the 4th boom section. (See the figure of the rear end of the 4th boom section shown in Fig. 1.) Bolt 11. Remove the bolt [a] and pin [158], and pull out the slide plates [79] and [56] on the side surfaces of the 3rd boom section (4 pieces in total on the right and left sides). (Before removing the pin [158], loosen the bolt [39] in advance.) (See the figure of the top end of the 3rd boom section shown in Fig. 13 and Fig. 1.) 16. Remove the rope ends (both sides) of the top boom section retraction wire rope [26] located at the rear end of the 4th boom section together with the support [111]. (See the figure of the rear end of the 4th boom section shown in Fig. 1 and the subsequent figure.) NOTE Attach wire to the wire rope ends to keep them outside the boom

131 G-3 G-3 Boom Wire rope (Top boom retraction) 22. Unscrew the nuts [21] (both sides) at the top end of the top boom section, and remove the top boom section retraction wire rope [26] from the boom. (See Fig. 14.) 23. After removing the sheave ass y [65] at the top end of the 4th boom section, pull out the 5th boom section from the 4th boom section in the same manner as the steps 11, 12, and 13. (See the figure of the top end of the 4th boom section shown in Fig. 1.) NOTE 17. While pulling the rope end of the top boom section retraction wire rope [26], pull out the telescoping cylinder ass'y to the position approx. 900 mm before the rear end of the 4th boom section. (A distance where the sheaves [144] and [113] do not interfere with each other) (See Fig. 1.) When pulling out the 5th boom section from the 4th boom section, take care not to damage the wire rope [25]. 18. Remove the sheave assy's [113] (both sides). (See Fig. 15.) 19. Pull the telescoping cylinder ass'y until the sheave ass y [144] at the top end of the No. 2 cylinder comes out. 20. Remove the top boom section retraction wire rope [26] from the sheave ass y [144] at the top end of the No. 2 cylinder. (Remove guides [143] and [159] attached to the sheave ass y, and remove the wire rope.) Top end of No. 2 cylinder Bolt 24. Remove the sheave ass y [36], guide [35], spacer [34], and pin [33] at the top end of the 5th boom section. (See the figure of the top end of the 5th boom section shown in Fig. 1.) 25. Hold the wire rope, and then remove the support [42] for fixing the top boom section extension (and 5th boom section retraction) wire rope [24] on the side surface of the top end of the 5th boom section. Then, pull the wire rope end slightly to the boom top end side, and secure it to the top boom. 21. Pull out the telescoping cylinder ass'y fully from the 4th boom section

132 G-3 G-3 Boom (1) Before reassembling, apply grease to the boom sliding surfaces and telescoping cylinder sliding surfaces. During reassembling, apply grease to the cylinder fixing pins, slide plates, and wire ropes. (2) Install the antibuckling bolt [32] for No. 2 and No. 3 cylinders in the same manner as the nut for the No. 1 cylinder. (3) Install the support ass'y [121] so that the right and left clearances in the lateral direction with the telescoping cylinder are equal. Apply grease to the sliding surfaces. 26. Pull out the top boom section from the 5th boom section in the same manner as the steps 11, 12, and 13. (See the figures of Section F and the top end of the 5th boom section shown in Fig. 1.) NOTE When pulling out the top boom section from the 5th boom section, take care not to damage the wire rope [24]. 4. Checking (1) Boom Check for twist, deformation, warp, and cracks. (2) Slide plate Check for cracks and wear, and replace the part when these conditions are excessive. (3) Sheave Check for damage, deformation, and wear, and replace the part when these conditions are excessive. (4) Boom telescoping wire rope Do not re-use any wire ropes which fall under the following conditions. - Deformed or with evidence of corrosion - Kinked - 10% or more broken wires in one lay - With any portion where reduction from nominal diameter is more than 7% - With evidence of any heat damage 5. Reassembling NOTE Reassemble the boom in the reverse order of the disassembly procedure, while paying attention to the following. (4) Tighten the mounting bolts [110] and [115] of the support [111] at a tightening torque of kg cm after applying screw lock agent to the bolts. (5) Tighten the stopper bolt [93] of the slide plate at the upper side of the rear end of each boom section, with screw lock agent applied. (6) Tighten the bolts [69] and [103] lightly with screw lock agent applied, and then make a quarter turn backward to lock. (7) After installing the top and 5th boom sections in the 4th boom section, insert the top boom section retraction wire rope [26] to the top end of the top boom section, through the wire guides at the middle and rear end of the top boom section and at the rear end of the 5th boom section, and secure the wire rope to the top boom section. For how to lead the top boom section retraction wire rope [26] in reassembling, see the figure below. (8) When installing the telescoping cylinder, pull the rope to prevent the top boom section retraction wire rope [26] from sagging in the boom. (9) When installing the slide plates [118] and [100] on the side of the rear end of each boom section, adjust the clearance on each boom section side to approx. 0.5 mm using shims. To the top end of the top boom section Upper Lower Top end sheave of No. 2 cylinder (2nd) Rear end sheave of the 4th boom section (right) Wire rope Rear end sheave of the 4th boom section (left) To the rear end of the 4th boom section

133 G-3 G-3 Boom (10) Make an adjustment with shims for the slide plate at the top end of each boom section as follows. (See Fig. 1.) [1] Install the boom inner case to approx. 1 m before the full retraction position. (Make an adjustment sequentially from between the base and 2nd boom sections.) Measurement position A, C B Boom Between base and 2nd boom sections, 2nd and 3rd boom sections, 3rd and 4th boom sections Between 4th and 5th boom sections, 5th and top boom sections [2] Place the slide plates and the retainers on the right and left sides of the boom outer case tilt portion (Fig. 21), and place the boom inner case over them. [3] Measure the clearance D at the side of the outer and inner cases. (Measure on both right and left sides.) [5] Make a shim adjustment so that mm is added to the clearance measured in [4] above, and install the slide plate. For shim adjustment within 3 mm, insert shims between the slide plate and the retainer, and for shim adjustment over 3 mm, insert the plate under the retainer. Boom inner case Boom outer case Slide plate Retainer Shim Between base and 2nd boom sections, 2nd and 3rd boom sections - Insert shims between the retainer and the slide plate for adjustment so that the clearance on the right side (crane cab-side) is smaller than that on the left side (the inner case is slightly on the right), and that the difference of the right and left clearances is 3 mm or below. Inserting a 1 mm shim moves the inner case approx. 1.2 mm widthwise and 0.5 mm heightwise. Between 3rd and 4th boom sections, 4th and 5th boom sections, 5th and top boom sections - Insert shims between the retainer and the slide plate for adjustment so that there is no difference of the right and left clearances between the inner and outer cases. Inserting a 1 mm shim moves the inner case approx. 1.2 mm widthwise and 0.5 mm heightwise. [4] Measure the clearance at the bottom of the outer and inner cases. Measure at the top end and at 300 mm inside the top end, and choose the smallest value. Boom inner case Boom outer case Slide plate Shim Retainer (Plate) Measured value +0~0.5mm [6] Install the slide plate at the side surface by making a shim adjustment so that the clearance with the inner case is -0.3 mm to +0.3 mm. Slide plate Shim [7] Install the slide plate on the upper R portion by making a shim adjustment so that the clearance between the slide plate and the inner case allows play that enables the retainer fixing pin to enter smoothly. (Clearance: Approx mm)

134 G-3 G-3 Boom Shim Pin Retainer Lock nut (4) Tighten the right and left adjusting nuts for the 5th boom extension and the top boom extension (and 5th boom retraction) alternately until the values ([A] - [B]) and ([A] - [C]) reach approx. 10 mm. Adjusting nut for 5th boom extension Adjusting nut for top boom extension and 5th boom retraction Slide plate Adjustment bolt [8] Tighten the adjustment bolt until the slide plate on the R portion lightly comes in contact with the inner case, and lock with the lock nut. 6. Adjustment 6.1 Adjusting boom telescoping wire ropes NOTE Make the adjustment without load. Ensure the tightening amount of the adjustment bolts and nuts of each wire rope is loosened by 2-3 turns in reference to the positions recorded during disassembly. (5) Extend the 4th, 5th, and top boom sections again, and check that the values ([A] - [B]) and ([A] - [C]) are approx. 10 mm Adjusting the retraction wire rope (1) Retract the boom, and lower it to the horizontal. (2) Extend the 4th, 5th, and top boom sections by approx. 1 m, then retract them again. Measure the unretracted length A of the top boom section and the unretracted length B of the 5th boom section. 4th 5th Adjusting the extension wire rope (1) Retract the boom, and lower it to the horizontal. (2) Extend the 4th, 5th, and top boom sections by approx. 1 m, and measure dimensions [A], [B], and [C]. 4th 5th Top Stopper (3) Retract the boom fully. Stopper (3) Extend the 4th, 5th, and top boom sections by approx. 1 m. (4) Tighten the adjusting nut for top boom section retraction by a third of the length (A+B). Tighten also the adjusting nut for 5th boom section retraction (and top boom section extension) slightly. NOTE Top Loosen the lock nut before tightening the adjusting nut for top boom section retraction. Do not tighten the adjusting nut excessively. Tighten the lock nut after adjustment

135 G-3. Boom G-3. Do not tighten the adjusting nut for 5th boom section retraction (and top boom section extension) excessively. (Top boom section will not fully retract if the nut is tightened too far.) 7. Test NOTE Adjusting nut for top boom retraction Lock nut Bleed the telescoping cylinders completely. Apply grease to the boom sliding surfaces before starting the tests. 7.1 Operation test Telescope the booms several times, and make sure that the telescoping operation is in order. Adjusting nut for top boom retraction (5) Gradually retract the 4th, 5th, and top boom sections, and check that the 4th, 5th, and top boom section stoppers simultaneously and respectively come in contact with the previous section ends. 4th 5th 7.2 Boom lateral warp test [Condition] Crane levelness : Within 6 Boom length : Full extension Boom elevation : Maximum angle Measurement : Over-front, over-rear, over-right, direction over-left Other conditions : Free from solar heat and wind Top Stopper (6) If those stoppers do not simultaneously come in contact with the corresponding boom section ends, extend the 4th, 5th, and top boom sections, and then turn the adjusting nuts. When the 4th boom section stopper comes in contact with the previous section end first, further tighten the adjusting nut for top boom section retraction and the adjusting nut for 5th boom section retraction (and top boom section extension). When the top (or 5th) boom section stopper comes in contact with the previous section end first, loosen the adjusting nut for top boom section retraction (or the adjusting nut for 5th boom section retraction (and top boom section extension)). (7) Retract the boom fully. (1) Make a shim adjustment so that the hook displacement (A in the figure) under the above test conditions under no load is within 100 mm in all measurement directions. (2) After a shim adjustment, check that the hook displacement (A in the figure) under the above conditions under the total rated load is within the specified limit of 600 mm. When the displacement is more than the specified limit, correct by making a shim adjustment

136 G-4 G-4 G-4 Hydraulic Valve 1. Construction Hydraulic symbol (Blue) (Red) Electric symbol Red (+) + side Blue (-) - side Manual operation button

137 G-4. Hydraulic Valve G Spring seat 6. Plug 11. Spool 16. Plug 2. Body 7. Cover 12. Body 17. Spring 3. Spool 8. Hexagon socket head bolt 13. O-ring 18. Spring pin 4. O-ring 9. O-ring 14. Cover 19. Hexagon socket head bolt 5. Solenoid 10. Spring 15. Hexagon socket head bolt

138 G-5 G-5 G-5 Flow Control Valve 1. Construction Hydraulic symbol Tightening torque kg cm Tightening torque kg cm Apply Loctite Body 3. Solenoid valve 5. O-ring 7. Plug 2. Flow control valve 4. Hexagon socket head bolt 6. Hexagon socket head bolt 8. Orifice

139 G-5 G-5 Flow Control Valve Body [1] Flow control valve [2]

140 G-5. Flow Control Valve G Body 4. Spool 8. Orifice 11. Hexagon socket head bolt 2. End cover 5. Spring 9. O-ring 12. Plug 3. Spool 6. Bolt 10. O-ring Solenoid valve [3] Hydraulic symbol Electric symbol 1. Nut 6. O-ring 11. Packing 16. O-ring 2. O-ring 7. Plug 12. O-ring 17. Spring 3. Screw 8. Solenoid core ass y 13. Washer 4. Spool 9. Solenoid coil ass y 14. Body 5. Spring pin 10. Spring pin 15. O-ring

141 G-6 G-6 G-6 Hose Reel 1. Construction 1. Reel 2. Ball bearing 3. Retaining ring 4. Seal ring 5. Backup ring 6. Ball bearing 7. Nut 8. Spring washer 9. Shaft 10. Seal ring 11. Bolt 12. Spring washer 13. Wire 14. Spring 15. Case 16. Plate 17. Auxiliary spring 18. Grooved rubber Spacer 21. Oil seal 22. Set screw 23. O-ring 24. Oil seal 25. Retaining ring 26. Plate 27. Set screw 28. Bolt 29. Bracket 2. Remounting After winding the reel until the hose reel spring adheres together, return one to one and half turns backward. After making an adjustment to allow the hose to be pulled out by the length shown in Fig. 3 in this condition, connect it to the cylinder. In other words, make an adjustment so that the hose reel spring reaches a position one to one and half turns before adhering condition when the telescoping cylinder is at the extension-side stroke end. L= (Cylinder stroke: L m) m +mounting length (Mounting length between A and B) 3. Disassembling L: TR-350M m TR-500M-1, 2, m Telescoping cylinder Hose reel

142 G-6. Hose Reel G Remove the set screw [22] and retaining ring [3], and remove the spacer [20]. 2. Unscrew the nut [7], and remove the reel [1]. Guard 3. Secure the bracket [29] to a vise with the reel [1] installation side facing upward. 4. Attach protection plates as shown in the figure to prevent spring [14] from springing out using the case mounting holes, and then unscrew the bolt [28] on the shaft [9] side, and remove the case ass'y. Spring holder 4. Apply grease to the lower side of the spring [14], and then set it in the case [15], and install the protection plates. Protection plate 5. To replace the spring [14], remove it from the case [15] as follows: First, remove the protection plates from the case [15]; then, with the case [15] securely held in a sufficiently wide space, tie one end of a sufficiently long wire to the inner end of the spring, and pull the other end by hand to take out the spring [14]. NOTE Handling spring is very dangerous. Take extreme care in executing the operation. 4. Reassembling 1. Apply grease (Daphne Coronex FP2 from Idemitsu Kosan or equivalent product) to the seal ring [10], and install it in the case [15]. 2. Install the case [15] in the shaft [9]. 3. Install the spring [14] in the case [15] as follows: (1) With the spring [14] clamped by vise pliers, remove the spring holder restricting the spring. NOTE Allowing the spring to be free is very dangerous. Be sure to clamp it securely with vise pliers. Clamp the spring with vise pliers, taking care about the installation direction. 5. Install the spring [14] to the shaft [9] using the bolts [28], and lock the two bolts [28] with wire. 6. Remove the vise pliers on the outer end side of the spring [14], insert the auxiliary spring [17] and plate [16], and install the spring [14] in the case [15] using the bolt [11]. After installation, lock the two bolts [28] with wire. 7. Remove the other vice pliers, and then remove the protection plates, and apply grease to the upper side of the spring [14]. 8. Fit the grooved rubber [18] into the case [15]. 9. Install the seal ring [4], backup ring [5], and O-ring [23] in the shaft [9]. After installation, apply grease lightly on the shaft side. 10. Pack grease (Daphne Coronex EP2 from Idemitsu Kosan or equivalent product) in the clearance between the ball bearings [2] and [6], and the oil seals [21] and [24] which are installed in the reel [1]. Then insert the reel [1] in the shaft [9]. Before installation, apply adhesive to the mating surfaces of the reel [1] and grooved rubber [18]. 11. Secure the reel [1] and case [15] with the nut [7]. 12. Insert the spacer [20] in the shaft [9], and secure it with the retaining ring [3]. Then, lock the spacer [20] with the set screw [22] with screw lock agent applied

143 G-7 G-7 G-7 Hose Reel 1. Construction Apply sealing agent. View A View B, C Apply screw lock agent to [6], [14], [27], [29], and [31]. 1. Reel 9. Bearing 17. Pin 25. Split pin 2. Shaft 10. Seal ring 18. Spring 26. Spring 3. Spring 11. Backup ring 19. Arm 27. Set screw 4. Auxiliary spring 12. Cover 20. Arm 28. Roller ass'y 5. Collar 13. Bearing 21. Mount 29. Hexagon socket head bolt 6. Bolt 14. Bolt 22. Spacer 30. Roll pin 7. Spring washer 15. Spring washer Bolt 8. Bearing 16. Retaining ring Thrust washer 2. Remounting Connect the hose reel to the telescoping cylinder as shown in the figure with extra winding of 3.5 to 4 turns provided to the hose reel. If the start of winding is uncertain, wind the reel until the spring adheres together and return it 13 to 14 turns backward, which is equivalent to the extra winding of 4 to 5 turns. After connecting, check that hose pressing force F (see the figure) is 5 kg or above on the 1st layer, and 14 kg or above on the 2nd layer

144 G-7 G-7 Hose Reel 3. Disassembling 1. Remove the roller ass'y [28] and arm [20]. Remove the retaining ring [16]. 2. Pull out the shaft [2] to the mount side together with the mount [21] and arm [19]. NOTE Before pulling out the shaft [2], turn the shaft in the direction where no spring force is applied to allow the pin [17] to be pressed (see the figure below) by turning it further approx. 90 after a "click" is heard due to the activation of the spring breakage preventive mechanism. Collar Shaft NOTE Handling spring is very dangerous. Take extreme care in executing the operation. 4. Remove the spacer [22], and remove the spring [3] located inside from the reel [1] in the same manner as the step Reassembling 1. Install the spring [3] in the reel [1] as follows: (1) With the spring [3] clamped by vise pliers, remove the spring holder restricting the spring. NOTE Pin 3. To replace the spring [3], remove it from the reel [1] as follows: First, remove the cover [12] and collar [5] from the reel [1]. Then, with the reel [1] securely held in a sufficiently wide space, tie one end of a sufficiently long wire to the inner end of the spring, and pull the other end by hand to take out spring [3]. Allowing the spring to be free is very dangerous. Be sure to clamp it securely with vise pliers. Clamp the spring with vise pliers, taking care about the installation direction. Before installation, secure the spring inner end using the holder in advance as shown in the figure. This prevents deformation of the spring end when vise pliers are removed after the spring is installed in the reel

145 G-7. Hose Reel G-7. Spring Spring holder Holder (7) Install the upper spring [3] in the reel [1] in the same manner as the steps (1) to (6). (2) Apply grease to the lower side of the spring [3], set it in the reel [1], and install the protection plates. Protection plate (3) Remove the vise pliers on the outer end side of the spring [3], install the auxiliary spring [4], and secure it with the bolt [6] with screw lock agent applied. 2. Install the collar [5], and then install the cover [12] to the reel [1] using the bolt [14] with screw lock agent applied. 3. Install the seal ring [10] and backup ring [11] in the shaft [2], and apply grease lightly to the seal ring and its periphery, and the inner surface of the boss of the reel [1]. 4. Install the spring [18] and pin [17] in the collar [5], and then install the shaft [2] in the reel [1] with the chamfer facing the pin [17]. Chamfer (4) Remove the other vise plier. (5) Remove the holder installed in the step (1) above from the spring [3], and check that the inner end of the spring is shaped along the collar [5]. If it is deformed, correct it. (6) Remove the protection plates, and apply grease to the upper side of the spring [3]. Then, insert the spacer [22] in the reel [1]. NOTE After installation, turn the shaft [2] slowly to check that two "click" are heard due to the activation of the spring breakage preventive mechanism. 5. Install the retaining ring [16], and then install the arm [20] and roller ass'y [28] ,

146 G-8 G-8 G-8 Hose Reel 1. Construction Mark 1. Shaft 12. Snap ring 22. Retaining ring 2. Plate 13. Spring 23. Bolt 3. Body 14. Ball bearing 24. Bolt 4. Bearing case 15. Ball bearing 25. Hexagon socket head bolt 5. Drum plate 16. Plug 26. Hexagon socket head bolt 6. Drum plate 17. Dust seal 27. Hexagon socket head bolt 7. Drum 18. O-ring 28. Nut 8. Spacer 19. Backup ring 29. Spring washer 9. Spring case ass'y 20. Joint 30. Spring washer 10. Retaining ring Washer 11. Pin A portion in detail

147 G-8 G-8 Hose Reel 2. Remounting After winding the hose fully on the hose reel, for TR-500M-1, 2, and 3, pull out the hose from the free hose reel and attach the hose to the jib in the side up condition (equivalent to extra winding of 2 turns); for TG-500M-4, rewind the hose 1.5 to 2 turns from the free hose reel and attach the hose to the jib in the stowed condition (equivalent to extra winding of 0.8 to 1.3 turns). To connect the hose, for TR-500M-1, 2, and 3, connect the part where a yellow band is attached to the hose top end, to the joint on the lower side (lowering side); for JG-500M-4, connect that part to the joint on the inner side (retraction side). 5. Unscrew the hexagon socket head bolt [26], and remove the bearing case [4] from the body [3]. At this time, since the bearing case is bonded with sealing agent, remove it by inserting a flathead screwdriver at several locations on the circumference. Flathead screwdriver 3. Disassembling 1. Turn the shaft [1] counterclockwise as seen from the plate side to allow the pin [11] to come off from the spring hole and to be pressed into the shaft. When the pin [11] comes off from the spring hole, a sound as if a spring bounces in the spring case is produced. Check that sound. 2. Unscrew the bolt [24], and remove the spring case ass'y [9]. At this time, since the mating surfaces of the spring case ass'y [9] and body [3] are bonded with sealing agent, remove the spring case ass'y [9] by lifting while turning it alternately with the drum plate [5] secured. 3. Remove the pin [11], snap ring [12], and spring [13] from the shaft [1]. Be sure to remove the snap ring [12] in the axial direction. 4. Remove the retaining ring [10], and lightly hit the shaft [1] end with a plastic hammer to remove the shaft [1]. Plastic hammer 6. Remove the O-ring [18] and backup ring [19] while taking care not to damage the inner diameter of the body [3]. 7. If necessary, remove the ball bearing [15] and dust seal [17] from the bearing case [4]. 4. Reassembling 1. Apply grease lightly to the inner surface of the bearing case [4], and press-fit the dust seal [17] and ball bearing [15]. After press-fitting, apply grease to the lip of the dust seal. Dust seal press-fitting jig 2. Apply grease (Daphne Coronex EP2) to the inner diameter of the body [3], and then install the O-ring [18] and backup ring [19]

148 G-8. Hose Reel G Apply sealing agent (Silicon sealant KE45 from Shin-Etsu Chemical) to the bearing case [4] mounting surface. Install the bearing case to the body [3], and tighten them with the hexagon socket head bolt [26]. Sealing agent (applied to the entire circumference) 7. Apply sealing agent (Silicon sealant KE45 from Shin-Etsu Chemical) to the body [3] end surface in a ring shape (approx. φ4 mm). Sealing agent 4. Apply grease (Daphne Coronex EP2) to the part of the shaft [1] to be inserted in the body [3] (the dimension L part in the figure below), and then install the shaft in the body [3]. 8. Install the drum ass'y in the spring case ass'y [9] as if the drum ass'y covers the spring case ass'y. At this time, insert the shaft in the spring case ass y while pressing the pin [11] with a thin rod (approx. φ6 mm, and a length of 300 mm or longer). Thin rod 5. Install the retaining ring [10]. 6. Install the spring [13] and pin [11] with grease applied, in the shaft [1], and install the snap ring [12] by inserting from the axial direction. 9. Secure the spring case ass'y [9] to the drum plate [5] with the bolt [24]. NOTE Take care about the chamfer direction of the pin [11] in reassembling. (See Fig. 1.)

149 G-9 G-9 G-9 Solenoid Valve 1. Construction Hydraulic symbol (Blue) Red (+) Blue (-) + side - side (Red) Electric symbol

150 G-9. Solenoid Valve G-9. Manual operation button 1. Spring seat 5. Solenoid 9. Steel ball 13. Spring pin 2. Spool 6. Plug 10. Body 14. Hexagon socket head bolt 3. Body 7. O-ring 11. Spring 4. O-ring 8. Joint 12. Plug

151 G-10. G-10 Counterbalance Valve G Construction Cover Hydraulic symbol 1. Valve body 6. Spring 11. Orifice 16. O-ring 2. O-ring 7. Pilot spool 12. Backup ring 17. O-ring 3. Backup ring 8. Orifice 13. Spring (A) 18. Plug 4. Main spool 9. O-ring 14. Spring (B) 19. O-ring 5. Check valve 10. Backup ring 15. Plug 20. O-ring ,

152 G-11. G-11 Counterbalance Valve G Construction Hydraulic symbol 1. Spring 4. O-ring 7. Cap 10. Spring 2. O-ring 5. Backup ring 8. Check valve 11. Cap 3. Spool 6. Plug 9. O-ring 12. Body

153 G-12. G-12 Pilot Check Valve G Construction Hydraulic symbol 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. Breather screw

154 H Safety System H-1 System Overview Function of Units Color multi-display (AML-V) Solenoid valve... 1 Contents 3.1 Replacing the cord Replacing the recoil spring Replacing the potentiometer (for boom length) Replacing the boom angle indicator H 2. System Overview Adjustment H-2 System Overview Function of Units Color multi-display (AML-V) Solenoid valve System Overview... 2 H-3 Color Multi-Display (AML-V) Data... 3 H-4 Color Multi-Display (AML-V) Data... 4 H-5 Boom Length/Angle Detector Construction and Function Specifications Disassembly and Reassembly... 6 H-6 Jib Angle Detector Construction and Function Specifications Disassembly and Reassembly Disassembly procedure Reassembly procedure H-7 Outrigger Extension Length Detector Construction and Function Specifications Disassembly and Reassembly Disassembly procedure Reassembly procedure H-8 Solenoid Valve Construction i

155 H-1. H-1 System Overview H Function of Units (6) Moment limiter (AML-V) main body 1.1 Color multi-display (AML-V) (1) Moment detector This unit is incorporated in the elevating cylinder piston rod, and converts, by means of strain gauges, the total moment created by the hoisted load and the boom self-weight into an electric signal, which is transmitted to the moment limiter main body. (2) Boom length/angle detector This unit is installed on the boom side surface, and converts, by means of the potentiometer inside the detector, the boom extension length and the boom angle to the ground into electric signals, which are transmitted to the moment limiter main body. (3) Jib angle detector This unit is installed at the root of the jib tilt cylinder on the jib upper side, and converts, by means of the potentiometer inside the detector, the jib tilt cylinder extension length into an electric signal, which is transmitted to the moment limiter main body as an angle detection signal. (4) Outrigger extension length detector This unit is installed at the root of the extension cylinder, and converts, by means of the potentiometer inside the detector, the outrigger extension length into an electric signal, which is transmitted to the moment limiter main body via the multiplex data transmitter. (5) Other detectors The outer switches transmit the crane operation signals and working condition select signals to the moment limiter main body. This unit calculates the hoisted load using the input signals from the moment detector, boom length/angle detector, and jib angle detector. The calculated value is compared with the limit value for each operation condition, and when the calculated value is 90% and 100% of the limit value, this unit sends an alarm and automatic stop signal, to prevent the crane from being over-loaded. In addition, this unit has the slow stop function for the elevating, telescoping (retracting), and swing operations. When working range restrictions are provided or when the condition of automatic stop signal sending (the limit of working area, etc.) is met, this unit sends the slow stop signal before the operation is fully stopped, to stop the operation slowly. Slow stopping is enabled by controlling the vent flow rate of the solenoid control relief valve (see Chapter L) and the spool operation pilot flow rate of the hydraulic pilot control valve (see Chapter D for swing). 1.2 Solenoid valve If any AML malfunction occurs, or when the moment reaches 100% of the moment or the hook block is over-wound, the automatic stop signal is sent to this valve from the moment limiter main body. When the solenoid valve is of a regularly energized type, it is then de-energized. When it is of a irregularly-energized type, it is then energized. Irrespective of the type of solenoid valve, this valve serves to connect the vent passages for the relief valves (unload valves) incorporated in the hydraulic pilot control valve, to the tank, and to allow the pressure oil from the pump to flow to the tank through the relief valve, to stop crane movement. 2. System Overview See the service manual of the color multi-display (AML-V). 1 H

156 H-2. H-2 System Overview H Function of Units (5) Moment limiter (AML-V) main body 1.1 Color multi-display (AML-V) (1) Moment detector This unit is incorporated in the elevating cylinder piston rod, and converts, by means of strain gauges, the total moment created by the hoisted load and the boom self-weight into an electric signal, which is transmitted to the moment limiter main body. (2) Boom length/angle detector This unit is installed on the boom side surface, and converts, by means of the potentiometer inside the detector, the extension boom length and the boom angle to the ground into electric signals, which are transmitted to the moment limiter main body. (3) Outrigger extension length detector This unit is installed at the root of the extension cylinder, and converts, by means of the potentiometer inside the detector, the outrigger extension length into an electric signal, which is transmitted to the moment limiter main body via the multiplex data transmitter. (4) Other detectors The outer switches transmit the crane operation signals and working condition select signals to the moment limiter main body. This unit calculates the hoisted load using the input signals from the moment detector and the boom length/angle detector. The calculated value is compared with the limit value for each operation condition, and when the calculated value is 90% and 100% of the limit value, this unit sends an alarm and automatic stop signal, to prevent the crane from being over-loaded. In addition, this unit has the slow stop function for the elevating, telescoping (retracting), and swing operations. When working range restrictions are provided or when the condition of automatic stop signal sending (the limit of working area, etc.) is met, this unit sends the slow stop signal before the operation is fully stopped, to stop the operation slowly. Slow stopping is enabled by controlling the vent flow rate of the solenoid control relief valve (see Chapter L) and the spool operation pilot flow rate of the hydraulic pilot control valve (see Chapter D for swing). 1.2 Solenoid valve If any AML malfunction occurs, or when the moment reaches 100% of the moment or the hook block is over-wound, the automatic stop signal is sent to this valve from the moment limiter main body. When the solenoid valve is of a regularly energized type, it is then de-energized. When it is of a irregularly de-energized type, it is then energized. Irrespective of the type of solenoid valve, this valve serves to connect the vent passages for the relief valves (unload valves) incorporated in the hydraulic pilot control valve, to the tank, and to allow the pressure oil from the pump to flow to the tank through the relief valve, to stop crane movement. 2. System Overview See the service manual of the color multi-display (AML-V). 2 H

157 H-3. H-3 Color Multi-Display (AML-V) H Data Model TR-500M-3 Specifications 6 booms + 2 jibs (Power tilt jib) Boom length display adjustment (m) Power tilt jib angle display adjustment Outrigger extension length display adjustment (m) Moment span adjustment A Full retraction B Full extension B 2nd full extension Load radius (m) A Min. B Min A Full retraction Hook block to use B Full extension Hook block weight (ton) Number of part lines t

158 H-4 H-4 H-4 Color Multi-Display (AML-V) 1. Data Model TR-500M-3 Specifications 6 booms + 2 jibs Boom length display adjustment (m) Power tilt jib angle display adjustment Outrigger extension length display adjustment (m) Moment span adjustment A Full retraction B Full extension B 2nd full extension Load radius (m) A Min. B Min A Full retraction Hook block to use B Full extension Hook block weight (ton) Number of part lines t

159 H-5 H-5 H-5 Boom Length/Angle Detector 1. Construction and Function The boom length/angle detector consists of major parts of a recoil spring, cord, speed reducer, potentiometer (for boom length), and boom angle indicator. The cord wound on the drum is unwound and rewound by the recoil spring force following the extension and retraction of the boom. The resultant drum rotation is reduced to 1/50 by the speed reducer, which in turn rotates the shaft of the potentiometer. The electric resistance of the potentiometer varies proportional to the reduction of the shaft rotation, and the change in electric resistance is transmitted to the AML main body to detect the boom length. Core wire Shield wire Shield wire Core wire Potentiometer (for boom length) 1.Red 3 Black 2 White 2 White Shield Cable Green Red White Black Connection diagram Connector 1 Red 3 Black When the cord is drawn out in the direction of the arrow, the speed reducer, potentiometer, and the brush of the potentiometer rotate or move in the direction indicated by the arrow. Potentiometer (for boom angle) 2. Specifications Speed reducer Reduction ratio: 1/50 Potentiometer Resistance: 5000 ±750 Ω +2 (for boom length) Electrical turning angle: Mechanical turning angle: 360 continuous rotation Potentiometer Resistance: 500 ±100 Ω (for boom angle) Effective electrical angle: 120 ±

160 H-5 H-5 Boom Length/Angle Detector 1. Plate 15. Potentiometer 28. Packing Case 16. Spring 29. Connector 43. Angle indicator 3. Drum assembly 17. Cover 30. Connector 44. Set screw 4. Slip ring assembly 18. Clip 31. Cord lock 45. Plain washer 5. Contact point assembly 19. Clip Plain washer 6. Contact point assembly 20. Clamp 33. Screw 47. Spring washer 7. Bearing case Bolt 48. Spring washer 8. Bearing 22. Pin terminal (Cable terminal) 35. Bolt 49. Spring washer 9. Retaining ring 23. Pin terminal 36. Screw 50. Nut 10. Retaining ring (Potentiometer terminal) 37. Screw 51. Connector 11. Speed reducer 24. Cord guide Cable 12. Gear Screw 53. Cord 13. Gear 26. Packing 40. Screw 54. Nut 14. Bracket 27. Packing 41. Screw 55. Washer 3. Disassembly and Reassembly In the following description, repair items are divided into four groups: Replacing the cord, Replacing the recoil spring, Replacing the potentiometer (for boom length), and Replacing the boom angle indicator. Select applicable repair items according to the nature of the problem. 3.1 Replacing the cord (See the structural drawing.) Disassembly procedure 1. Remove the connector [29] and cord lock [31] at the top end of the cord, tie an auxiliary string of approx. 4.5 m to the cord, and let the drum wind the cord and the auxiliary string slowly until the recoil spring force is run out. 4. Loosen the set screw [44], and remove the gear [12]. Then, unscrew the screw [37], and remove the speed reducer [11]. NOTE Remove the speed reducer straight upward. Do not twist it while removing. 5. Remove the retaining ring [9] and bolt [35], and separate the case [2] from the drum assembly [3]. NOTE Make match marks on the case [2] and plate [1] to identify the direction for removing the sub cord. 2. Loosen the clamp [20], and remove the cover [17]. 3. Disconnect the cable [52] and potentiometer [15] from the terminal, and remove the cover and the cable together. Sub cord Match marks Terminal 6. Remove the nut [54], and separate the drum assembly [3] and plate [1]

161 H-5 H-5 Boom Length/Angle Detector Core wire Cord Shield wire Drum assembly Vinyl tube 3. Install the slip ring assembly to the cord while preventing sagging. 7. Remove the slip ring assembly [4] installed on the drum assembly. Then, remove the connection (soldered) of the slip ring and the cord. 4. Tie an auxiliary string of approx. 4.5 m, and wind the new cord around the drum assembly while preventing sagging. When the 0-marker on the 7.73 m point of the cord appears on the drum, wind the cord thirteen more times, and fix the cord with adhesive tape to prevent loosening. NOTE Cord Core wire Shield wire Wind the cord around the drum assembly clockwise as seen from the slip ring. Approx. 4.5 m Tape Auxiliary string 8. Remove the old cord completely from the drum assembly. Adhesive tape Reassembly procedure 1. Wind a yellow tape around a new cord as a 0-marker. Slip ring Auxiliary string Drum side 0-marker (yellow tape) 5. Insert the shaft of the drum assembly [3] in the boss hole of the plate [1], and secure them with the nut [54]. 2. Pass the new cord through the hole of the drum assembly. Solder the new cord to the slip ring assembly in the reverse procedure for disassembly. NOTE Connect the cord core wire to the inner slip ring. Connect the shield wire to the outer slip ring. Completely insulate the soldered portion. 6. Put the case [2] over the drum assembly [3]. At this time, lead the sub cord outside through the groove of the case [2] and the end of the auxiliary string through the opening of the cord guide [24]. 7. Secure the case [2] and plate [1] with the bolt [35], and install the retaining ring [9]. 8. Apply sealing agent lightly on the bottom of the speed reducer [11], and install it on the case [2]

162 H-5 H-5 Boom Length/Angle Detector 9. Fit the gear [12] into the shaft of the speed reducer [11], and loosen the set screw [44] of the gear [13] on the potentiometer side to allow both gears to idle. Turn the gear on the potentiometer side approx. a 1/4 turn with your finger, and check that the gear returns to its original position by the force of the spring [16]. If not, loosen the bolt [34], and adjust the position of the bracket [14]. If the potentiometer is faulty, replace the potentiometer here referring to Replacing the potentiometer (for boom length) described later. 10. Secure the gear [12] in the notched portion of the shaft of the speed reducer [11] with the set screw [44]. Apply screw lock agent to the set screw. Tightening torque: 12 kg cm 11. Take out the auxiliary string from the guide hole of the cord reel, and fully draw out the new cord. Then, let the drum wind the cord slowly. When the 0-marker appears at the edge of the cord guide, fix the cord at that position as shown in the figure. 0-marker 13. Draw out the cord slightly from the drum, and check that the resistance between red and white increases smoothly. 14. Connect the cable terminals [22] and potentiometer terminals [23]. (See the connection diagram.) 15. Bring the clamp [20] opposite to the potentiometer, and install the cover [17]. 16. Pull the cable [52] to eliminate sagging, and tighten the clamp [20]. 17. Install the cord lock [31] at the top end of the cord, and install the lead wires and the connector [29] to the top end of the cord. Completely insulate the soldered connection portion. 0-marker Wind a Hi-Bon tape to protect against water, and then wind an insulating tape. Adhesive tape (Yellow) (White) Lead wire Cord 12. Apply voltage of 5 V DC between the red and black terminals of the potentiometer (for boom length), and adjust the output voltage between red and white to 0.5 ±0.06 V by tuning the gear [13] with a screwdriver. Secure the gear [13] with the set screw [44] at that position. Apply screw lock agent to the set screw. Tightening torque: 12 kg cm 18. Test for continuity and short circuit between the terminals of the sub cord connector and the cord connector. Sub cord Cord Screwdriver Gear Set screw Bracket Spring 3.2 Replacing the recoil spring Red Black White Tester Power applied When the recoil spring is broken, replace the drum assembly [3]. For disassembly and reassembly of the recoil spring, see Replacing the cord previously described

163 H-5 H-5 Boom Length/Angle Detector 3.3 Replacing the potentiometer (for boom length) When both the cord and recoil spring are faulty, remove the detector assembly from the boom before replacement. If only the potentiometer is faulty, it is not necessary to remove the detector. Disassembly procedure 1. Loosen the clamp [20], and remove the bolt [34] and cover [17]. 2. Disconnect the lead wire (3 wires) terminals from the potentiometer and the terminals from the cable, and remove the potentiometer and the bracket [14] together. NOTE Since the lead wires (red and black) are connected also to the boom angle indicator, disconnect the wires to the boom angle indicator from the pin terminals prior to replacement. Reassembly procedure 1. Install a new potentiometer. NOTE Quickly solder the potentiometer terminals and lead wires to prevent the potentiometer from being exposed to unnecessary heat. Secure the potentiometer terminals including the lead wires to the bracket using an insulation sealing agent. Recommended sealing agent: Shin-Etsu Silicon KE45RTV from Shin-Etsu Chemical Bracket Potentiometer Insulation sealing agent Potentiometer To boom angle indicator Bracket Lead wire Black Red Pin terminal 2. Loosen the set screw [44] of the gear [12] on the speed reducer side and that of the gear [13] on the potentiometer side to allow the gears to idle. Turn the gear on the potentiometer side approx. a 1/4 turn with your finger, and check that the gear returns to its original position by the force of the spring [16]. If not, loosen the bolt [34] and adjust the position of the bracket [14]. Gear Gear Bracket 3. Remove the gear [13] and spring [16], and remove the potentiometer from the bracket. 4. Remove the connector [29] and cord lock [31] at the top end of the cord, tie an auxiliary string of approx. 4.5 m to the cord, and let the drum wind the cord and the auxiliary string slowly until the recoil spring force is run out. Spring Bolt 3. Secure the gear [12] in the notched portion of the shaft of the speed reducer [11] with the set screw [44]. Apply screw lock agent to the set screw. Tightening torque: 12 kg cm 4. Hereinafter, perform reassembly in the same manner as the steps 12 and after previously described in Replacing the cord

164 H-5. Boom Length/Angle Detector H Replacing the boom angle indicator When replacing the boom angle indicator, remove the lead wires of the boom angle indicator from the pin terminals, and then replace the boom angle indicator ass y. 4. Adjustment 1. With the boom fully retracted, adjust the cord lock so that the 0-marker on the cord reaches the edge of the cord guide. 0-marker Cord lock 2. Adjust the length display of the AML. (See the repair manual of the AML.)

165 H-6 H-6 H-6 Jib Angle Detector 1. Construction and Function The jib angle detector consists of major parts of a recoil spring, wire, and potentiometer. The wire wound on the drum is unwound and rewound by the recoil spring force following the extension and retraction of the jib tilt cylinder. The resultant drum rotation is reduced to 1/3.2 or 1/2.8 by the speed reducer, which in turn rotates the shaft of the potentiometer. The electric resistance of the potentiometer varies proportional to the reduction of the shaft rotation, and the change in electric resistance is transmitted to the AML main body to detect the jib angle. Potentiometer Red Green White Shield Cable Connection diagram Connector When the wire is drawn out in the direction of the arrow, the gear, potentiometer, and the brush of the potentiometer rotate or move in the direction indicated by the arrow. 2. Specifications 1/3.2 ( ) Reduction ratio 1/2.8 ( ) Resistance: 1 kω ±50 Ω Electrical turning angle: 350 ±1.5 Potentiometer Mechanical turning angle: 360 continuous rotation

166 H-6 H-6 Jib Angle Detector 1. Base plate 7. Potentiometer 13. Packing 19. Bolt 2. Packing 8. Bracket 14. Connector 20. Shaft 3. Case 9. Cord guide 15. Cap 21. Set screw 4. Drum ass'y 10. Clamp 16. Machine screw 5. Gear 11. Cable 17. Machine screw 6. Gear 12. Cover 18. Bolt 3. Disassembly and Reassembly 4. Unscrew the bolt [18], and remove the case [3]. 3.1 Disassembly procedure 1. Let the drum wind the wire slowly until the recoil spring force is run out. 2. Unscrew the machine screw [16], loosen the clamp [10], and remove the cover [12]. 5. Unscrew the bolt [19], and separate the drum ass y [4] and base plate [1]. 3. Unscrew the machine screw [17], and remove the potentiometer [7], gear [6], and bracket [8] together. 6. Remove the old wire completely from the drum ass y

167 H-6 H-6 Jib Angle Detector 3.2 Reassembly procedure 1. Wind a yellow tape around a new wire as a 0-marker. Drum side 0-marker (yellow tape) 6. Take out the wire from the guide hole of the reel, and fully draw out the wire. Then, let the drum wind the wire slowly. When the wire length reaches the value shown in the figure below, fix the wire to the case [3] at that position with adhesive tape. 2. Wind the new wire around the drum ass'y [4] to the position of the yellow tape. Wind the wire eight more times, and fix the wire with adhesive tape to prevent loosening. NOTE Wind the wire around the drum ass y counterclockwise as seen from the gear. Adhesive tape Wire Gear Boom length detector Wire length code No. [A] m Turn the gear [6] of the potentiometer [7] by hand, and engage the gears [5] and [6] at the position where the resistance between [C] and [D] is 100 ±12 Ω, then install the potentiometer. * When replacing the potentiometer with a new one, follow the procedure below. - Install a new potentiometer on the bracket, and solder the cable [11] wires to the terminals of the potentiometer. (See the connection diagram in the structural drawing.) NOTE 3. Install the base plate [1] on the drum ass'y [4] using the bolt [19]. 4. Apply grease (Moly Speed Grease No. 0) to the bearing of the case [3], and put the case [3] over the drum ass'y [4]. At this time, lead the wire end outside through the opening of the cord guide [9]. 5. Secure the case [3] and base plate [1] with the bolt [18]. Quickly solder the potentiometer terminals and wires to prevent the potentiometer from being exposed to unnecessary heat. Secure the potentiometer terminals including the wires to the bracket using an insulation sealing agent. Recommended sealing agent: Shin-Etsu Silicon KE45RTV from Shin-Etsu Chemical Install the potentiometer so that the potentiometer terminals point at the position shown in the figure below. Potentiometer Insulation sealing agent

168 H-6. Jib Angle Detector H Draw out the wire slightly from the drum, and check that the resistance between [C] and [D] decreases smoothly. 9. Bring the clamp [10] opposite to the potentiometer, and install the cover [12]. 10. Pull the cable [11] to eliminate sagging, and tighten the clamp [10]

169 H-7 H-7 H-7 Outrigger Extension Length Detector 1. Construction and Function The outrigger extension length detector consists of major parts of a recoil spring, wire, and potentiometer. The wire wound on the drum is unwound or rewound by the recoil spring force following the extension and retraction of the slide cylinder. The resultant drum rotation is reduced to 5/6 by the gear, which in turn rotates the shaft of the potentiometer. The electric resistance of the potentiometer varies proportional to the reduction of the shaft rotation, and the change in electric resistance is transmitted to the AML main body via the multiplex data transmitter, to detect the outrigger extension length. Green Red White Shield Potentiometer Cable Connection diagram Connector When the wire is drawn out in the direction of the arrow, the gear, potentiometer, and the brush of the potentiometer rotate or move in the direction indicated by the arrow. 2. Specifications Reduction ratio 5/6 Potentiometer Resistance: 2 kω ±100 Ω Mechanical turning angle:

170 H-7 H-7 Outrigger Extension Length Detector 1. Base plate 6. Nut 11. Screw 16. Screw 2. Drum ass'y 7. Potentiometer 12. Set screw 17. Clamp 3. Case 8. Cover 13. Screw 18. Connector 4. Packing 9. Shaft 14. Gear 19. Cable 5. Gear 10. Bolt 15. Bracket 3. Disassembly and Reassembly 4. Unscrew the screw [11], and remove the case [3]. 3.1 Disassembly procedure 1. Let the drum wind the wire slowly until the recoil spring force is run out. 2. Unscrew the screw [13], loosen the clamp [17], and remove the cover [8]. 5. Unscrew the bolt [10], and separate the drum ass'y [2] and base plate [1]. 3. Unscrew the screw [16], and remove the potentiometer [7], gear [5], and bracket [15] together. 6. Remove the old wire completely from the drum ass'y

171 H-7. Outrigger Extension Length Detector H Reassembly procedure 1. Wind a yellow tape around a new wire as a 0-marker. Drum side 0-marker (yellow tape) 6. Draw out the wire from the guide hole of the reel, and when the wire length reaches the value indicated in the figure below, fix the wire to the case [3] at that position with adhesive tape. 2. Wind the new wire around the drum ass y [2] to the position of the yellow tape. Wind the wire four more times, and fix the wire with adhesive tape to prevent loosening. NOTE Wind the wire around the drum ass y counterclockwise as seen from the shaft. Adhesive tape Wire Shaft 7. Turn the gear [5] of the potentiometer [7] by hand, and engage the gears [5] and [14] at the position where resistance between [C] and [D] is 200 ±30 Ω, then install the potentiometer. * When replacing the potentiometer with a new one, follow the procedure below. - Install a new potentiometer on the bracket, and solder the cable [19] wires to the terminals of the potentiometer. (See the connection diagram of the structural drawing.) NOTE 3. Install the base plate [1] on the drum ass y [2] using the bolt [10]. 4. Apply grease (Moly Speed Grease No. 0) to the bearing of the case [3], and put the case [3] over the drum ass'y [2]. At this time, lead the wire end outside through opening of the cord guide. 5. Secure the case [3] and the base plate [1] with the screw [11]. Quickly solder the potentiometer terminals and wires to prevent the potentiometer from being exposed to unnecessary heat. Apply an insulation sealing agent to the terminals of the potentiometer. Recommended sealing agent: Shin-Etsu Silicon KE45RTV from Shin-Etsu Chemical 8. Draw out the wire slightly from the drum, and check that the resistance between [C] and [D] decreases smoothly. 9. Bring the clamp [17] opposite to the potentiometer, and install the cover [8]. 10. Pull the cable [19] to eliminate sagging, and tighten the clamp [17]

172 H-8. H-8 Solenoid Valve H Construction Electric symbol Manual push pin Hydraulic symbol 1. Solenoid ass'y 6. Body 10. Square ring 14. Filter 2. O-ring 7. Hexagon socket head bolt 11. Plug 15. O-ring 3. Spring 8. Set screw 12. O-ring 16. Plug 4. Spring seat 9. Plug 13. Sleeve 17. Body 5. Spool

173 K Cab K-1 Crane Cab Glass Glass Replacement Procedure... 1 Contents K i

174 K-1 K-1 K-1 Crane Cab Glass 1. Glass Replacement Procedure Follow the procedure described below to replace the fixed windshield glass, roof glass, front right window glass (quarter window glass), and rear right window glass of the crane cab. 1. Remove the glass to be replaced and adhesive from the cab body, and clean it. 2. Fit a trim all around the glass bonding frame of the cab body. 3. Temporarily set a new glass on the cab, attach pieces of masking tape across the glass and frame at multiple places for positioning, and then remove the glass. NOTE Make an adjustment so that the glass and the rubber dam of the trim will make even contact with each other. (Example) Roof glass Roof Masking tape (for positioning) Front 4. Clean and degrease the glass bonding surfaces of the cab body with new gauze soaked with white gasoline or acetone. Wait for a minute or more to let them dry. 5. Apply 5 to 20 µm thick coat of primer C to the bonding surfaces of the cab body. 6. Dry the primer C coated surfaces for 15 minutes or more. 7. Clean and degrease the bonding surfaces of the new glass with gauze soaked with white gasoline or acetone. Wait for a minute or more to let them dry. 8. Apply 5 to 20 µm thick coat of primer B to the non-ceramic coated portion on the outer circumference of the new glass. Primer B: AR Primer For glass (Black) Cemedine Co., Ltd. Apply Ceramic coating Glass NOTE Shake the primer bottle well, and then apply the primer with a brush. While making sure that there is no portion left uncoated or blurred, apply the primer evenly. Prevent the primer coated surfaces from any contact with hand, brush hairs, dust, water drops, etc. Wipe away any primer deposited on a surface other than the coating surfaces immediately with white gasoline. 9. Dry the primer B coated surfaces for 15 minutes or more. Primer C: AR Primer Cemedine Co., Ltd. For cab (Clear) 10. Apply the POS seal (Cemedine product) to the glass fitting groove of the molding. NOTE Shake the primer bottle well, and then apply the primer with a brush, while making sure that there is no portion left uncoated. Prevent the primer coated surfaces from any contact with hand, brush hairs, dust, water drops, etc. Wipe away any primer deposited on a surface other than the glass bonding surfaces immediately with white gasoline. Exterior Interior POS seal (Glass) NOTE Apply the POS seal to the cab interior side of the molding, to a point lower than its center. Molding

175 K-1 K-1 Crane Cab Glass 11. Fit the molding on the circumference of the new glass, and bond its start and end points with the glass with an instantaneous adhesive. Glass Molding 14. Set and press the new glass while aligning the match marks on the cab body (masking tape pieces put in the step 3 for positioning) with the glass. Glass Rubber dam Molding Trim NOTE Wipe away excessive adhesive. 12. Install the trim on the glass bonding frame of the cab body, and then apply adhesive to the glass bonding surfaces. Adhesive: S-511A (Black paste; when room temperature is 15 C or higher) S-511F-1 (Black paste; when room temperature is 15 C or lower) Cemedine Co., Ltd. Rubber dam backing paper (5 or above) NOTE When installing the glass, press it only once. Do not press it repeatedly to prevent forming air bubbles. Wipe away excessive adhesive with a spatula and white gasoline. 15. Bonding the joint between windshield glass and roof glass (1) Attach approx. 50 mm-wide pieces of masking tape to places 1 to 2 mm away from the glass edges at the joint of the windshield glass and roof glass. (2) Remove the rubber dam backing paper. (3) Set and press the new glass while aligning the match marks on the cab body with the glass. Rubber dam Trim NOTE (4) Secure the windshield glass and roof glass to the cab body with adhesive tape. (5) Fill the space between the windshield glass and roof glass with adhesive (S-511A or S-511F-1 from Cemedine), and reshape it with a spatula so that it is flush with the glass. Reshape the applied adhesive with a spatula so that its cross sectional form is as shown in Fig. 5. For any areas where clearance exists between the glass and rubber dam, apply adhesive beads of a height of 5 mm of higher. Install the glass within 30 minutes after application of the adhesive. 13. Remove the rubber dam backing paper. (See Fig. 5.) (6) Remove the masking tapes, and wipe away excessive adhesive with white gasoline or acetone. Masking tape Roof glass Trim Adhesive Windshield glass Rubber dam

176 K-1. Crane Cab Glass K After bonding the glass, allow a curing period of two or more hours. Do not move the glass. NOTE After bonding the glass, secure the glass to the cab body with adhesive tape or elastic cords

177 L Control System Contents L-1 System Components... 1 L-4 Throttle Valve... 9 L-2 Remote Control Valve Construction and Function Function Description of Operation Failure and Countermeasure Dismounting and Remounting Disassembly and Reassembly Disassembly procedure Assembly procedure... 6 L-3 Solenoid Control Relief Valve Construction and Function Construction and Function Dismounting and Remounting Disassembling Checking Reassembling Test Adjustment L-5 Air Cylinder (for Accelerator) Construction and Function L-6 Solenoid Valve L 1. Construction L-7 Solenoid Valve Construction i

178 L-1. L-1 System Components L-1. Remote control valve (For swing and telescoping (jib)) Remote control valve (For elevating and winch) Solenoid control relief valve Throttle valve (For accelerator) Air cylinder (For accelerator) Front Solenoid valve (For speed limiter, governor select, exhaust brake, 2/4-wheel drive select) Solenoid valve (For outrigger accelerator) 1 L

179 L-2 L-2 L-2 Remote Control Valve 1. Construction and Function This valve is a pressure reducing valve-type remote control valve, and contains four pressure reducing valves that control outlet pressure. The output pressure is controlled by regulating the slope of the control lever. In this manual, the description is made using a two-section remote control valve as a representative. When servicing the other models than the two-section models, use the information in this manual, making necessary alterations. For information of the valve without the detent ass y ([6] to [11]), also refer to this manual. Hydraulic symbol Apply Loctite #241 Apply grease to the bottom. Apply grease to the top Secondary pressure regulation shim design center value t=0.4, 1 piece 1. Hexagon socket head bolt 11. Detent plug 21. Spring pin 31. Washer 2. Hexagon socket set screw 12. Cover 22. Double nut bolt 32. Spring seat 3. Hexagon socket head bolt 13. Plug 23. Nut 33. Spring 4. Cam shaft 14. O-ring 24. O-ring 34. Spring 5. Disc 15. Boot Washer 6. Steel ball 16. Plug Spool 7. Holder 17. Seal ring Case 8. O-ring 18. O-ring 28. Lever 38. O-ring 9. Lock nut 19. Bush 29. Push rod 39. Cover 10. Spring 20. Bush 30. Hexagon socket head bolt 40. Case

180 L-2 L-2 Remote Control Valve 1.1 Function The spool [36] switches the oil passage either so that the oil pressure from the hydraulic pump is received by the P port, which is led to the output ports (A, B, C, and D), or so that the oil pressure in the output port is led to the tank (T) port. As the spring [33] acts on the spool and attempts to achieve balance, the output pressure is determined. The push rod [29] slides in the plug [16] to change the deflection of the spring. The push rod moves according to the operation of the lever [28] via the disc [5]. The lever can tilt to the right and left sides using the cam shaft [4] as a fulcrum. The spring [34], independently of the output pressure, acts on the push rod [29] to return it in the zero-displacement direction, returning the spool to the neutral position. It also serves as a reaction force spring to allow the operator to feel an appropriate sense of operation. 1.2 Description of Operation (1) Lever neutral position The force of the spring [33] that determines the output pressure of the pilot valve does not act on the spool [36]. The spool is pushed up by the spring [34], the inlet port and P are closed, and the output ports (A, B, C, and D) lead to the tank port T. Therefore, the output port pressure is equal to the tank pressure. (2) During operation When the lever is tilted, the spool [36] is pushed by the push rod [29], and moves downward via the spring [33]. First, the outlet port and the tank port are blocked, and then as the spool is lowered, the output port leads to the inlet port. The pressure of the output port pushes the spool upward, allowing the spool to stop at the position where balance with the output of the spring [33] is achieved. As the control lever is tilted further, the spring output increases, and also the output port pressure increases. When the lever is returned to the neutral position, the balance between the spring output and hydraulic pressure is lost, allowing the spool to move upward. Since the output port leads to the tank port, the output port pressure becomes equal to the tank pressure

181 L-2 L-2 Remote Control Valve 2. Failure and Countermeasure The table below shows causes and actions of general failures. It should be noted that other causes and actions may be considered in addition to the following in the table. Phenomenon Cause Action Output port pressure does not rise Output port pressure is unstable Output port pressure is high [1] Insufficient inlet port pressure [2] Breakage or settling of the spring [33] [3] Extremely large clearance between the spool and case [4] Backlash at the lever [1] Roughness of the sliding portion [2] Fluctuation of the tank line pressure [3] Air contamination in the piping [1] High tank line pressure [2] Roughness of the sliding portion [1] Ensure the inlet port pressure. [2] Replace with a new part. [3] Replace the spool and case assemblies. [4] Disassembly/reassembly and replacement of the lever [1] Correct rough portions. [2] Directly return the pressure oil to the oil tank [3] Perform operation several times to bleed air. [1] Directly return the pressure oil to the oil tank. [2] Correct rough portions. 3. Dismounting and Remounting 4. Disassembly and Reassembly WARNING When the circuit is suspected to retain pressure oil, be sure to vent the contained pressure before dismounting the valve. NOTE After remounting, bleed the air in the circuit and equipment, and then perform operation tests to make sure that there is no abnormality. CAUTION When disassembling or reassembling the valve, be sure to refer to General Cautions (Hydraulic Units) in Chapter A, and proceed correctly. When disassembling or reassembling the valve, take care to prevent damage to the threads, finished surfaces, and sealing parts, and avoid handling by force. While disassembling, take necessary measures to ensure that all the parts will be reassembled in their original positions. Wash the disassembled parts in kerosene, and check their sliding surfaces, sealing part mounting portions, and threads. Correct any minor dents, scratches, rust, or burr with fine abrasive cloth or oilstone. When dents, scratches, or wear is significant, replace the parts with new ones. In principle, replace all the sealing parts with new ones. Observe General Cautions (Sealing Parts) in Chapter A in installing them, taking care to install in the correct direction. When reassembling, take extreme care not to allow the entry of dust and other foreign matter. Apply hydraulic oil for lubrication to the sliding surfaces of the sliding parts. Insert the sliding parts straight, taking care not to pry, and then check their smooth movement

182 L-2 L-2 Remote Control Valve 4.1 Disassembly procedure 1. Valve main body (1) Set blanking plugs on all the ports, and wash the outer surface of the valve with kerosene. (2) Loosen the nut [23], and separate the cases [37] and [40]. (3) Clamp the valve installation flange in a vise using copper sheets, so that the lever is on the upper side. (4) Remove the lower end of the boot [15] from the cover [12] in the upward direction. (5) Loosen the hexagon socket head bolt [1], and remove the lever [28]. (6) Loosen the lock nut [9], and remove the detent plug [11]. At this time, the steel ball [6], holder [7], and spring [10] are removed together. Take care not to lose the steel ball. (7) Loosen the hexagon socket set screw [2] and remove the cam shaft [4] to take out the disc [5] upward. (8) Remove the cover [12]. At this time, remove the cover while keeping it level, by loosening the hexagon socket head bolt [3] alternately to prevent prying the spool [36]. (10) Clamp the valve in a vise so that the valve cover [39] is on the upper side. (11) Loosen the hexagon socket head bolt [30], and remove the cover [39], O-ring [38], and bush [19] from the case. 2. Pressure reducing valve ass y (1) Let the lower end of the spool [36] stand vertically on a flat workbench, lower the spring seat [32] downward, and then remove the semicircle washer [31] using the top of a small screwdriver. NOTE Handle the pressure reducing valve as an assembly until it is reassembled. Do not lower the spring seat 6 mm or above. (2) Separate the spool [36], spring seat [32], spring [33], and washer [35]. (3) Remove the push rod [29] from the plug [16]. (4) Remove the seal ring [17] and O-ring [18] from the plug [16]. Use a small flathead screwdriver to remove the seal ring. (9) Remove the plug [16] and push rod [29] coming up from the back of the cover. If the return spring [34] is weak, the plug [16] does not come out due to sliding resistance of the O-ring. In such a case, remove the plug by setting a flathead screwdriver at the outer circumference groove of the plug. NOTE Take care to prevent damaging the plug due to unbalanced load. The plug may spring out by the spring [34] when the plug is removed

183 L-2. Remote Control Valve L Assembly procedure 1. Pressure reducing valve ass y (1) Insert the washer [35], spring [33], and spring seat [32] in the spool [36] in this order. (2) Let the lower end of the spool vertically on a flat work bench, and push down the spring seat. (3) Insert the washers [31] over the spring seat so that the two washers do not overlap with each other and that the sharp edge side faces upward. At this time, do not push down the spring seat more than 6 mm. 2. Valve main body (1) Install the bush [19] and O-ring [38] in the case. (2) Install the cover [39] to the case using the hexagon socket head bolts [30]. At this time, tighten the two bolts alternately and slowly to keep balance. Tightening torque: 300±20 kg cm (3) Install the spring [34] and the pressure reducing valve ass y in the case. (4) Install the O-ring [18] and seal ring [17] in the plug [16], and insert the push rod [29] with hydraulic oil applied to the surface. (Fig. 2) (5) While pressing the plug ass y with the cover [12] equally on the both sides, tighten the hexagon socket head bolts [3] alternately. Tightening torque: 120±10 kg cm (6) Apply grease to the steel ball [6] contact surface on the disc [5], steel ball [6], and the top of the push rod [29]. (7) Attach the steel ball [6] to the disc [5], and press them against the push rod [29] to insert the cam shaft [4]. (8) Set the holder [7] to the steel ball [6], and install the spring [10] and detent plug [11]. (9) Lock the cam shaft [4] and the detent plug [11] with the hexagon socket set screw [2] and the lock nut [9] respectively. (10) Install the lever [28] using the hexagon socket head bolt [1]. Tightening torque: 300±20 kg cm (11) Put the boot [15] on, and install the cases [37] and [40] using the nut [23] to finish reassembling. Tightening torque: 160±10 kg cm Seal ring Plug O-ring Push rod Apply hydraulic oil

184 L-3 L-3 L-3 Solenoid Control Relief Valve 1. Construction and Function This valve is an electromagnetic proportional relief valve that provides a pressure proportional to the input current to the solenoid. Hydraulic symbol Tightening torque of the valve main body installation bolt : 300±30 kg cm

185 L-3. Solenoid Control Relief Valve L-3. Electromagnetic inverse proportional reducing valve Tightening torque: kg cm Body Plug Tightening torque kg cm

186 L-4 L-4 L-4 Throttle Valve 1. Construction and Function Exhaust 1. Body 7. Piston 13. O-ring 19. Machine screw 2. Plunger (A) 8. O-ring 14. C-ring 20. Mounting plate 3. O-ring 9. Valve spring 15. O-ring 21. Plunger 4. Return spring 10. Plate 16. Main spring 22. Boot 5. Spring support 11. Feed valve 17. Main spring shim 23. Bolt 6. Spring seat 12. Feed valve seat 18. Cover Descriptions of operation 1. When applying air pressure (1) During operation (See Fig. 2.) When the pedal is depressed, the plunger and plunger (A) are pushed down, and the plunger (A) comes in contact with the feed valve to close the exhaust port. When the plunger (A) is lowered, the feed valve opens, and the air pressure moves from the chamber a to the chamber b then escapes from the OUT port. Exhaust Plunger (A) Feed valve seat Piston Feed valve Main spring

187 L-4 L-4 Throttle Valve (2) When the pedal is stopped at a position (See Fig. 3.) When the pedal is stopped in the middle (at any position), the piston is pushed down by the air pressure in the chamber b that acts on the upper side of the piston, and the feed valve is closed. At this time, the force to push down the piston by the air pressure in the chamber b and the main spring force are balanced with each other, which keeps the air pressure on the OUT port side constant. Exhaust (3) During full stroke When the pedal is depressed again, the feed valve is opened, and the air pressure increases. When the pedal is depressed further, the spring support comes in contact with the stopper on the body side, which makes a full stroke. 2. When reducing air pressure (1) During operation for releasing (See Fig. 4.) Exhaust When the pedal is returned slightly, the plunger (A) rises by the return spring, separating from the feed valve. This allows the air on the OUT port side to escape. (2) When the pedal is stopped at a position When the pedal is stopped in the middle, the air pressure in the chamber b is exhausted, and the main spring force becomes larger than the force to push down the piston. This pushes up the piston and closes the seat on the exhaust side again, which makes a balanced state. Exhaust (3) When the pedal is released completely (See Fig. 5) When the pedal is returned to the original position, the plunger (A) is pushed up fully, and the exhaust port is opened fully, allowing the air pressure on the OUT port side to escape completely

188 L-4 L-4 Throttle Valve 2. Dismounting and Remounting 1. Dismount the valve after immobilizing the vehicle and discharging the compressed air from reservoir by opening the drain cock. 2. Tightening torque of the pipe fittings: 200 to 300 kgf cm 3. Disassembling 1. Remove the boot [22], and remove the plunger [21]. Then, unscrew the bolt [23], and remove the mounting plate [20]. 2. Push down the spring support [5], pull out the spring seat [6] from the notched hole, and remove the return spring [4]. 3. Unscrew the machine screw [19], and remove the cover [18]. 4. Take out the main spring [16], push down the plunger (A) [2] from the upper side, and remove the piston [7]. 5. Remove the C-ring [14], and take out the feed valve seat [12], O-ring [13], feed valve [11], and valve spring [9]. NOTE Take care not to expand the C-ring [18] excessively when removing it. 4. Checking Check all the disassembled parts, and replace any parts that fall under the following conditions, with new ones. Replace rubber parts (O-rings and feed valves) every year even when no abnormality is observed. 1. Body [1] When there are any scratches or significant wear on the sliding portions of the piston or plunger (A). 2. Plunger (A) [2] When there are any scratches on the valve seat or the sliding portions (outer diameter portion), or when there is significant wear. 3. Piston [7] When there are any scratches or significant wear on the sliding portions (inner and outer diameter portions). 4. Feed valve seat [12] When there are any scratches on the seat. 5. Feed valve [11] When there is any damage or aging on the rubber portions, or when there are any scratches or significant wear on the sliding portions. (Replace the part every year even when no abnormality is observed.) 6. O-rings When there are any scratches or significant wear. (Replace the parts every year even when no abnormality is observed.) 7. Springs When there are any cracks or breaks, or when significant rust is generated. 8. Plunger [21] When there are any scratches or significant wear on the sliding portions (outer diameter portion). 9. Mounting plate [20] When there are any scratches or significant wear on the plunger sliding portions

189 L-4. Throttle Valve L Reassembling 6. Test 1. Install the O-ring [3] with grease applied, in the plunger (A) [2]. 2. Apply grease to the plunger (A) [2] of the body [1] and the piston [7] sliding portions, and then install the plunger (A) [2]. 3. Install the return spring [4] in the body [1], and while pushing the return spring with the spring support [5], insert the notched hole of the spring seat [6] in the groove of the plunger (A) [2] from the side. 4. Install the O-rings [8] and [15] with grease applied, in the piston [7]. 5. Install the valve spring [9], feed valve [11] (with grease applied to the sliding portions), plate [10], O-ring [13], and feed valve seat [12] in the piston [7] in this order, and secure them using the C-ring [14]. NOTE Take care not to allow dust to adhere to the seat surface of the feed valve. Take care not to expand the C-ring [14] excessively. 1. Air leakage test (1) Supply air pressure of 8 kgf/cm 2 to the IN port while not allowing the plunger to stroke, and apply soapy water to the exhaust port to check that there is no air leakage. (2) Check that leakage from the exhaust port is 10 cm 3 /min or lower when the plunger is stroked fully. Also check that there is no leakage from all the portions of the body and the tightened portions. 7. Adjustment Set a pressure gauge on the OUT port. Supply air pressure of 7 kgf/cm 2 to the IN port, and make an adjustment so that the plunger stroke at the occurrence of pressure on the OUT port side is mm using the set bolt attached to the pedal. In addition check that the OUT port pressure is kgf/cm 2. When the pressure at the occurrence of OUT port pressure is not kgf/cm 2, make an adjustment by changing the number of main spring shims. 6. Apply grease to the sliding surfaces, and install the piston [7] in the body [1]. 7. Install the main spring [16], and install the cover [18] with the main spring shim [17] incorporated, to the body [1] using the machine screw [19]. 8. Install the mounting plate [20] using the bolt [23]. 9. Apply grease to the sliding portions of the mounting plate [20] and plunger [21], and install the plunger [21] and then boot [22]. OUT port pressure (kgf/cm 2 ) IN port pressure: 7 kgf/cm 2 Plunger stroke (mm)

190 L-5. L-5 Air Cylinder (for Accelerator) L Construction and Function This cylinder leads the compressed air from the throttle valve to the B port (cylinder port) and controls the engine speed by the action of the piston rod [10] which extends in proportion to the pressure of the compressed air. The piston rod [10] moves over the maximum stroke when the A port (limiter port) is open to the atmosphere by the solenoid valve. When the reservoir pressure is present at the A port, the piston rod movement is limited to the distance over which the piston [6] moves. In other words, by controlling the pressure at the A port, the air cylinder has a capacity of controlling the maximum speed of the engine depending on the different operating conditions, 1. Cylinder main body 8. Cylinder tube 15. Nut 22. Piston packing 2. Rod cover 9. Piston rod A 16. Nut 23. Gasket 3. Head cover 10. Piston rod B 17. Nut 24. Wear ring 4. Spring seat 11. Spring 18. Spring washer 25. Rod packing 5. Piston A 12. Clevis 19. Metal 26. Tie rod 6. Piston B 13. Bolt 20. Rod packing 7. Tie rod 14. Spring washer 21. Tube gasket

191 L-6. L-6 Solenoid Valve L Construction (Revolved view) Section B-B [N O] Section A-A [N C] (Revolved view) Circuit diagram 1. Packing holder 8. Plunger 15. Valve 22. Valve seat 2. Packing 9. Rod 16. Spring 23. Bolt 3. Coil ass y 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

192 L-7. L-7 Solenoid Valve L Construction Circuit diagram 1. Core 6. Coil ass y 11. O-ring 16. Cover 2. O-ring Valve seat 17. Filter 3. Case 8. Rod 13. Valve 18. Packing 4. Spring 9. Coil cover 14. Body 19. Packing holder 5. Plunger 10. O-ring 15. Spring

193 N Electrical System Contents H-1 Cord Reel Construction and Function Dismounting and Remounting Disassembling Reassembling... 4 N i

194 N-1 N-1 H-1 Cord Reel 1. Construction and Function The cord reel mainly consists of a recoil spring, cord (three-core + shield wire), ring (slip ring), contact point (brush), etc. The cord wound on the drum is unwound and rewound by the recoil spring force following the telescoping of the boom

195 N-1 N-1 Cord Reel 1. Frame 9. Holder plate 19. Clip 29. Screw 2. Drum ass y 10. Contact point 20. Bush 30. Screw 3. Cover 11. Packing 21. Collar 31. Nylon clip 4. Bearing case 12. Packing 22. Cable 32. Screw 5. Bearing 13. Nut 23. Cable 33. Screw 6. Collar 14. Washer 26. Screw 34. Bolt 7. Collar 15. Clamp 27. Hexagon socket set screw 35. Spring joint arm 8. Ring 16. Clamp 28. Screw 2. Dismounting and Remounting Remounting cautions Wind the cable fully on the drum, and then draw the cable in the condition of 0 kg spring winding force and fix the cable to the support at the top end of the top boom section*. (The number of extra winding turns at this time is shown in the table below.) Model Number of extra winding turns TG-1200M-2 TG-3600M-1 Approx. 5 TG-3600M-2 TG-800R-1 Approx. 4.5 TR-500M Approx. 13 TR-500M Approx. 9.5 TG-500M-4 Approx TG-1200M-4 Approx. 5 TR-500M-2 Approx. 9.5 (Note 1) After fully winding the cable on the drum, turn the drum nine more times for TR-500M and three or four more times for TR-500M and TG-500M-4, and draw the cable to fix it to the top boom section. (Note 2) *: For TG-3600M-1, fix to the support at the top end of the second boom section, to that of the third boom section, and to that of the fourth boom section. For TG-3600M-2, fix to the support at the top of the second boom section, to that of the third boom section, and to that of the fourth boom section. 3. Disassembling 1. Rewind the output cable [22] wound on the drum ass y [2]. 2. Unscrew the screw [30] of the nylon clip [19] that fixes the cable and the drum, and remove the nylon clip [19] from the cable. 3. Unscrew the nut of the clamp [15] attached to the cover [3] and release the cable clamp state of the inner bush rubber. (Fig. 2) Bush rubber Washer Nut 4. Unscrew the screw [29] that fixes the cover and packing [11]. 5. Remove the cover, and loosen the nut that fixes the cable terminal to remove the terminal. (Fig. 3) Nut Terminal Holder plate Contact point

196 N-1 N-1 Cord Reel 6. Unscrew the screw [32] of the nylon clip [31] that fixes the cable to the drum, remove the nylon clip from the cable, and pull out the cable from the cover and the drum plate. 7. Unscrew the screw [26] that fixes the holder plate [9], and remove the holder plate. (Fig. 4) 11. Remove the lead wire soldered on the ring [8] using a soldering iron, and remove all the collars [6] and [7] and rings [8]. (Fig. 7) Lead wire 12. Pull out the input cable from the frame. 8. Unscrew the screw [28] that fixes the contact point [10] to the holder plate, and remove the contact point. (Fig. 4) 13. Unscrew the screw [33], and remove the bearing case [4] and bearing [5]. (Fig. 8) 9. Lift the washer [14] claw bent along the nut [13] on the shaft thread of the frame [1] using a flathead screwdriver, and loosen the nut to remove it with the washer. (Fig. 5) Click Screwdriver 14. Place the main body as shown in Fig. 9. Unscrew the bolt [34] that fixes the drum plate and drum of the drum ass y [2], and remove the drum plate [A]. (Fig. 9) 10. Unscrew the nut of the clamp [16], and release the input cable [23] clamp state of the inner bush rubber. (Fig. 6) Nut Washer Bush rubber

197 N-1 N-1 Cord Reel 15. Remove one recoil spring (on the drum plate [A] side), and unscrew the hexagon socket set screw [27] on the recoil spring fixing shaft. 16. Pull out the frame from the drum ass y. (Fig. 10) NOTE When pulling out the frame, lightly press the recoil spring in the drum by hand to prevent the spring from springing out. 3. Reassembling the drum sub ass'y [1] Insert the bearing [5] in the bearing case, and install it to the drum plate [B] (on the frame side). [2] Install the bolt [34] to the drum plate [B]. [3] Place the drum plate [B] in the step [2] above horizontally, and then insert a grooved rubber in the drum, and place the drum on the drum plate [B]. [4] While inserting the hole at the outer end of the recoil spring (frame side) to the bolt [34], insert the recoil spring. (Fig. 12) NOTE Although there is a cover around the recoil spring to prevent the spring from separating, take extra care not to allow the spring to separate. Apply grease (Moly Speed Grease No. 0) lightly to the recoil spring in advance. 4. Reassembling 1. Install the clamp [16] to the frame [1], the clamp [15] to the cover [3], and apply waterproof sealing agent. (Fig. 11) Apply waterproof sealing agent. (entire circumference) Cover to prevent the spring from separating Spring outer end hole Apply waterproof sealing agent. (entire circumference) 2. Insert the collar [21] in the shaft of the frame. (Fig. 11) [5] Insert the spring joint arm [35]. (Insert the spring inner end hole to the notched portion of the spring joint arm housing.) 4. Insert the frame to the drum sub ass y reassembled in the step 3 above

198 N-1 N-1 Cord Reel 5. Insert the recoil spring fixing shaft in the shaft of the frame, and secure with the hexagon socket set screw [27]. (Fig. 13) Notch NOTE Take care about the direction of the notched portion of the recoil spring fixing shaft. When installing, ensure that the clearance with the spring joint arm is 3 mm. 7. Install the drum plate [A]. NOTE Install the drum plate [A] so that the rivet to prevent disorderly winding attached to the cable winding section of the drum plate [A] is displaced 180 from the rivet on the drum plate [B] side. 8. Insert the bearing [5] in the bearing case [4], and install them to the drum ass y [2] using the screw [33]. 9. Put the nut, washer, and bush rubber of the clamp [16] around the input cable [23], and then insert the cable in the shaft hole of the frame. (Fig. 15) Recoil spring fixing shaft 6. Insert the remaining recoil spring (drum plate [A] side). (At this time, insert the recoil spring outer end hole in the pin of the spring joint arm, and insert the spring inner end hole portion in the notched portion of the recoil spring fixing shaft.) (Fig. 14) Nut Bush rubber Washer Spring inner end hole Pin of the spring joint arm 10. Put the collar [6] and ring [8] around the shaft. Cut the wire 1 (red) of the input cable to appropriate length, and strip and solder it. Then, put the collars [7] and then rings [8]. Cut the wires to appropriate length and solder them to the rings respectively in the order of 1 (red), 2 (white), 3 (black), and 4 (blue -- a blue lead wire is soldered to a shield wire). (Fig. 16) (Red) (White) (Black) (Blue)

199 N-1 N-1 Cord Reel 11. Fit the washer [14] into the detent groove of the shaft, and tighten the nut [13] by hand to the maximum. Then further tighten it using the special tool by 1/2 to 3/4 turns, and bend the claw of the washer in the nut groove. (Fig. 17) Special tool 13. Install the holder plate to the drum ass y using the screw [26]. (Fig. 19) 14. Apply sealing agent to the flange surface of the cover [3], and attach the packing [11]. 15. Insert the output cable [22] through the drum ass y, clamp [15], and cover [3] in this order. (Fig. 20) NOTE When tighten the nut [13], secure the rings so that the corner of the shaft groove does not damage the lead wires. After the tightening process, apply grease (CRS Grease 701) lightly to the ring surface. (Fig. 18) Corner Drum ass y 16. Wrap vinyl tape around the clip [31] installation position of the output cable, and install the clip [31] using the screw [32]. Ring Shaft Lead wire Vinyl tape Output cable Holder plate 12. Install the contact point [10] to the holder plate [9] using the screw [28]. (Fig. 19)

200 N-1 N-1 Cord Reel 17. Cut the output cable lead wires to the length necessary to the terminal mounting threads, and strip them. Caulk the terminals with a crimp tool, and then install them to the terminal mounting threads using nuts. (Fig. 22) 19. Apply sealing agent to the drum plate contact surface of the packing [11] attached to the cover [3] in the step 14, and install it to the drum plate using the screw [29]. (Fig. 23) NOTE The order of wire colors are: 1 (red), 2 (white), 3 (black), and 4 (blue -- a blue lead wire is soldered to a shield wire) from the drum plate side. Vinyl tape 1 (Red) Drum plate 2 (White) 3 (Black) 4 (Blue) Holder plate 20. Tighten the nut of the clamp [15]. Wrap vinyl tape around the clip [19] installation position of the output cable, and install the clip [19] using the screw [30]. (Fig. 23) 18. Measure the insulation between each terminal and the drum main body and between the terminals, and measure the continuity between continuity between the connectors at the ends of the input and output cables using a tester, to make sure that there is no abnormality

201 R Driving Power Transmission System Contents R-1 System Components... 1 R-2 System Overview Description of System Torque converter circuit Transmission gear change... 4 R-3 Torque Converter and Transmission Construction Torque converter Transmission Remounting Oil Replacement... 9 R 4. Maintenance Standard... 9 i

202 R-1. R-1 System Components R-1. Transmission Torque converter Retarder Engine Axle Axle Torque converter Transmission Retarder Front Solenoid valve (For PTO clutch) Solenoid valve (For lock-up clutch) 1 R

203 R-2 R-2 R-2 System Overview 1. Description of System (See the circuit diagram in Chapter Z.) 1.1 Torque converter circuit 1. Oil circulation circuit The oil suctioned by the charding pump from the transmission oil tank via the strainer, flows into the torque converter via the main pressure regulating valve and the torque converter inlet relief valve. The oil flowing to the torque converter flows through the hole in the stator support and the clearance in the stator support sustaining bearing, and then flows into the converter circuit from between the impeller wheel and the stator wheel. The oil of which temperature has risen due to transmission of driving power, flows from between the turbine wheel and the stator wheel, and flows through the clearance between the turbine shaft and the stator support, and then flows out from the converter housing via the torque converter outlet regulating valve. The oil flowing out from the torque converter is cooled by the oil cooler and regulated by the lubricating oil relief valve. Then, the oil provides lubrication for every part of the transmission and returns to the oil tank. These are the circulation circuit. The oil regulated by the main pressure regulating valve also flows to the solenoid for PTO clutch, solenoid for lock-up, and modulating valve of the transmission. Each valve on the circuit functions as follows: Main pressure regulating valve Torque converter inlet relief valve Torque converter outlet regulating valve Modulating valve : Regulates the hydraulic pressure of the PTO clutch, lock-up clutch, and all the clutches of the transmission : Prevents abnormal rise of torque convertor internal pressure due to increased viscosity of oil in cold weather, or other reasons : Ensures that the hydraulic pressure in the torque converter is always constant : Mitigates shocks occurring when the transmission clutch is shifted 2. PTO clutch circuit The pressure oil regulated by the main pressure regulating valve is led to the solenoid valve for PTO clutch (SL62). (At the same time, it is also led to the solenoid valve for lock-up (SL61) and the modulating valve.) When the PTO switch is turned ON, the solenoid valve for PTO clutch (SL62) is energized, and the pressure oil passes through the solenoid valve, flowing into the PTO clutch to engage the clutch. 3. Lock-up clutch circuit The pressure oil regulated by the main pressure regulating valve is led to the solenoid valve for lock-up (SL61) via the restriction. When the solenoid valve is switched, the pressure oil is led to the lock-up clutch. The ON/OFF condition of the lock-up solenoid valve is as follows. Lock-up does not work in 4-wheel Lo (i) Economy driving mode Drive/speed select switch 2-wheel Hi or 4-wheel Hi Lock-up Clutch engaged F1 Hi F2 Hi F3 Hi ON (engaged) 15 km/h 23 km/h 33 km/h OFF (disengaged) 10 km/h 19 km/h 27 km/h (ii) Power driving mode Drive/speed select switch 2-wheel Hi or 4-wheel Hi Lock-up Clutch engaged F1 Hi F2 Hi F3 Hi ON (engaged) 17 km/h 28 km/h 39 km/h OFF (disengaged) 13 km/h 23 km/h 33 km/h 4. Transmission clutch circuit (1) Neutral The pressure oil delivered from the charging pump passes through the restriction S1, and flows to P1 of the modulating valve. The pressure oil in the circuit P1 flows into the spool, and then it flows from the circuit P2 to the hydraulic valves R, F3, F1, and F2, in this order, through these series circuits. Since the hydraulic valve is in the neutral state, pressure in the circuit is all equal. Therefore, the modulating valve is switched to the position shown in Fig. 1, causing the pressure oil in the circuit P1 to flow directly to P2 and then to the hydraulic valves (R, F3, F1, and F2). Since the pressure oil in P2 also flows to the accumulator from the circuit P6, the accumulator is in the accumulated state. 2 R

204 R-2 R-2 System Overview From charging pump To F3 clutch Modulating valve Hydraulic valve To F2 clutch To F1 clutch To R clutch (3) While the solenoid valve SOL (F3) is energized (When the transmission clutch piston pushes the clutch plate and the clutch pressure starts increasing) By the time when the transmission clutch piston pushes the clutch plate and the clutch pressure starts increasing, the oil accumulated in the accumulator has all been discharged and is started to be accumulated through the circuit P6. In addition, the pressure oil is supplied to the F3 clutch from the circuit P2 via the restriction, thus, increasing the clutch oil pressure gradually. From charging pump Modulating valve (2) While the solenoid valve SOL (F3) is energized (At the moment when the solenoid valve is switched) At the moment when the solenoid valve is switched, the hydraulic valve F3 is shifted to the position shown in Fig. 2, causing oil to flow through the circuit between the modulating valve, hydraulic valve F3, and F3 clutch, thus decreasing the pressure in the circuits P2 and M. Therefore, the modulating valve is shifted to the position shown in Fig. 2, limiting the circuit from P1 to P2 only to the circuit through the restriction, thus increasing the pressure to the F3 clutch gradually. The oil accumulated in the accumulator is also supplied to the F3 clutch via the circuit P6, eliminating the time lag in clutch engagement. From charging pump Modulating valve Hydraulic valve Hydraulic valve To F3 clutch To F2 clutch To F1 clutch To R clutch (4) While the solenoid valve SOL (F3) is energized (When the clutch pressure increases to the specified pressure) As the F3 clutch pressure increases, the pressure in the circuits P2 and M increases, shifting the modulating valve to the position shown in Fig. 4. This causes the pressure oil via the restriction and the pressure oil directly led from P1 to P2 are supplied to the F3 clutch. The accumulator becomes the accumulated state. From charging pump Modulating valve Hydraulic valve To F3 clutch To F2 clutch To F1 clutch To R clutch To F3 clutch To F2 clutch To F1 clutch To R clutch 3 R

205 R-2 R-2 System Overview Fig. 5 shows the F3 clutch pressure rise graph when the solenoid valve is switched as previously described in (1) to (4). Oil pressure Time [A] : Neutral [B] : While the solenoid valve (SOL (F3)) is energized (At the moment when the solenoid valve is switched) [C] : While the solenoid valve (SOL (F3)) is energized (When the transmission clutch piston pushes the clutch plate and the clutch pressure starts increasing) [D] : While the solenoid valve (SOL (F3)) is energized (When the clutch pressure increases to the specified pressure) The table below shows the relationship between solenoid valves and gear change stages. Normal state 4-wheel Lo Shift lever position Solenoid valve D N R SOL (F1) SOL (F2) SOL (F3) - - * - - SOL (Hi) SOL (Lo) - SOL (R) : Energized -: Not energized *: 1st to 3rd + 4th (F1/Hi) Emergency 2-wheel Hi, 4-wheel Hi, or 4-wheel Lo Shift lever position Solenoid valve D N R SOL (F1) SOL (F2) SOL (F3) SOL (Hi) SOL (Lo) SOL (R) : Energized -: Not energized 2-wheel Hi or 4-wheel Hi Shift lever position Solenoid valve D N R SOL (F1) SOL (F2) SOL (F3) - - * - - SOL (Hi) - - SOL (Lo) SOL (R) : Energized -: Not energized *: 1st to 3rd + 4th (F3/Hi) 1.2 Transmission gear change You can select a driving mode of automatic transmission by switching the gear change pattern of the transmission between the economy driving mode and the power driving mode using the mode select switch, depending on the driving condition. The following shows the transmission gear change points in the economy and power driving modes. 4 R

206 R-2. System Overview R wheel Hi or 4-wheel Hi 2. 4-wheel Lo Economy driving mode Acceleration Deceleration 1st 2nd 3rd 4th 1st 2nd 3rd 4th The figures in parentheses show the speed meter indication at the gear change point. The figures in circles show the values at lock-up ON and OFF. Power driving mode 1st 2nd 3rd 4th Deceleration Acceleration Deceleration 1st 2nd 3rd 4th 1st 2nd 3rd 4th The figures in parentheses show the speed meter indication at the gear change point. No lock-up No economy/power mode change 3. Over shift preventive function This automatic transmission has a mechanism that allows the transmission gear to change only when the vehicle speed is below the specified speed when the change lever is shifted down, which prevents engine overrun. Acceleration 1st 2nd 3rd 4th The figures in parentheses show the speed meter indication at the gear change point. The figures in circles show the values at lock-up ON and OFF. The figure near * symbol is the value at manual 1st-speed shift down (13 km/h). *1: Lock-up ON at manual 1st speed *2: Lock-up OFF at manual 1st speed 5 R

207 R-3 R-3 R-3 Torque Converter and Transmission 1. Construction 1.1 Torque converter To T/M control valve Main pressure regulating valve PTO clutch pressure outlet port Torque converter relief valve Bypass drain port Solenoid valve for PTO clutch From line filter Solenoid valve for lock-up clutch Pump flange for crane View B Torque converter input pressure outlet port Delivery port (PF3/4) To line filter Suction port (PF1) TM suction Torque converter pressure regulating valve Charging pump Lock-up clutch pressure outlet port Oil level gauge T/C output pressure regulating valve Tightening torque Torque converter drain port Pick-up sensor Steering pump flange To oil cooler Drain plug Oil filler Line pressure outlet port View A

208 R-3 R-3 Torque Converter & Transmission 1.2 Transmission Pressure sensor 2/4-wheel drive select port Oil drain plug (retarder) Coolant drain plug Oil drain plug (oil cooler) Leak oil drain plug Air breather Air connection port Filler plug (With oil level gauge)

209 R-3 R-3 Torque Converter & Transmission Air breather Lo clutch pressure outlet port (PT1/4) Hi clutch pressure outlet port (PT1/4) F2 clutch pressure outlet port (PT1/4) R clutch pressure outlet port (PT1/4) From oil cooler (PF1) F1 clutch pressure outlet port (PT1/4) F3 clutch pressure outlet port (PT1/4) From T/C main pressure regulating valve (PF1/2) 2/4-wheel drive select air cylinder Emergency steering pump flange Speed meter output port Oil level gauge From T/C drain (PF1 1/4) Drain plug From T/C bypass drain (PF3/4) To T/C charging pump Coolant outlet Coolant inlet

210 R-3. Torque Converter & Transmission R Remounting Tightening torque 330~420kg cm Flywheel housing Flywheel Torque converter housing Torque converter Tightening torque 330~420kg cm flexible plate Tightening torque 970~1110kg cm Engine Transmission Torque converter Tightening torque 970~1110kg cm Tightening torque 970~1110kg cm Tightening torque 590~600kg cm E in detail View C Tightening torque 3000~3450kg cm 3. Oil Replacement 1. Draining oil Remove the drain plugs located at the lower sides of the torque converter and the transmission, and drain oil. 2. Filling with oil Add oil through the torque converter oil filler to the level "H" in the transmission oil level gauge, with the engine stopped. Then, run the engine at idle speeds, with the PTO switch OFF and the change lever in neutral. As the oil enters the converter, cooler, piping, etc., the oil level lowers. Add oil slowly while running the engine until the oil level becomes stable at a specified position (closer to "H" than the center between "H" and "L") in the oil level gauge. Check the oil level while the oil temperature is between 50 and 60 C. - Total oil quantity: Approx. 40 L Oil level gauge 4. Maintenance Standard Oil level adjustment range 1. Oil replacement and cleaning and replacement of the strainer and filter Perform the first replacement after 100 hours, and the second and after replacement every 1000 hours. At the same time, clean the strainer, and replace the line filter on the pump delivery section

211 S Steering System Contents S-1 System Components... 1 S-2 Hydraulic Pump Construction and Function... 2 S-3 Hydraulic Valve Construction... 3 S-4 Priority Valve Construction and Function... 4 S-6 Solenoid Valve Construction S-7 Solenoid Valve Construction Dismounting and Remounting S-8 Air Cylinder Construction S-5 Orbitrol Construction and Function Disassembly... 9 S 3. Checking Reassembly i

212 S-1. S-1 System Components S-1. Priority valve Orbitrol Hydraulic valve Steering cylinder Steering cylinder Front Air cylinder (For steering lock) Solenoid valve (For steering lock) Solenoid valve (For steering select) Hydraulic pump (for emergency steering) 1 S

213 S-2. S-2 Hydraulic Pump S Construction and Function This pump is a bidirectional rotation pump, of which suction port and delivery port change depending on the rotation direction. 1. Body 5. Backup ring 9. Dowel pin 13. Spring pin 2. Flange 6. Bush ass'y 10. Dowel pin 14. Ball 3. Drive gear 7. O-ring 11. Oil seal 15. Hexagon socket head bold 4. Driven gear 8. O-ring 12. Snap ring

214 S-3. S-3 Hydraulic Valve S Construction Hydraulic symbol Spool select pilot pressure - Injection-valve opening pressure: 5 kg/cm 2 - During full open: 7 kg/cm 2 Relief valve ass y 1. Body 2. Check valve 3. Spool 4. Check valve 5. Cover 6. Spring 7. Spring 8. Spring 9. O-ring 10. Hexagon socket head bolt 11. Hexagon socket head plug 12. Hexagon socket head plug 13. Spring washer 14. Hexagon socket head bolt 15. Relief valve ass'y

215 S-4 S-4 S-4 Priority Valve 1. Construction and Function This valve is an internal pilot-type priority valve, which 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. The operation illustration below shows the operation of the priority valve. When oil does not flow to the port P, the spool is pushed to the left end by the control spring Pc, letting EF be fully closed and CF be fully opened. Then, when oil flows to the port P, pressure difference occurs between before and after the variable orifice C 1, which is transmitted to the pressure chamber A and pressure chamber B. Therefore, the spool overcomes the control spring Pc and moves rightward as shown in the figure, allowing the oil flowing into the port P to flow to the both circuits of CF and EF. The branching ratio of the ports can be controlled between 0 and 100% without steps because the pressure difference before and after the variable orifice C 1 is changed by adjusting the opening of C 1. When the priority valve is used combined with the load sensing Orbitrol, the variable orifice C 1 is used as an orifice in the Orbitrol, of which opening is adjusted by the steering wheel rotation number. [Operation illustration] Pressure chamber A Pressure chamber B C 1 : Variable orifice Pc : Control spring CF : Steering circuit EF : Other actuator circuits LS : Pilot circuit P : Inlet circuit Spool Priority valve Hydraulic Hydraulic symbol symbol 1. Body 3. Control spring 5. Plug 7. Plug 2. Spool 4. Plug 6. O-ring 8. Air vent plug

216 S-4. Priority Valve S-4. Operation in combination with the Orbitrol Neutral Right steering Rotor set Orbitrol Spool To actuator Priority valve Spring Pressure chamber B Pressure chamber A 1. Neutral state While the engine is stopped, the spool [2] in the priority valve is pushed to the left end by the spring [3], letting the port CF fully opened and the port EF fully closed. When the engine is started, the hydraulic oil delivered from the hydraulic pump flows through the port P and port CF of the priority valve, to the port P of the Orbitrol. As the pressure in the circuit CF rises in this way, the pressure P5 in the pressure chamber A of the priority valve also rises. At this time, the pressure chamber B is connected to the tank line via the port LS of the Orbitrol, producing pressure difference (P 5 - P 6 ) between the pressure chambers A and B. When the difference exceeds the force of the spring [3], the spool moves rightward from the left end to a stable position, where the port EF is fully opened and the port CF is slightly opened, and the oil from the pump mostly flows to the port EF. 2. Right steering operation When the steering wheel is turned clockwise from the neutral state, the hydraulic oil passages in the Orbitrol are switched over, causing the oil entering through the port P of the Orbitrol to flow through the orifice C 1. Then, the pressure difference between before and after the Orifice C 1 is transmitted to the pressure chambers A and B. The stroke position of the spool becomes stable when the pressure difference (P 5 - P 6 ) becomes balanced by the force of the spring [3]. 3. Right steering to the end When the steering cylinder is moved to the stroke end and when the operator attempts to turn the steering wheel further, the relief valve in the priority valve is actuated, producing oil flow through the orifice C 2 in the line LS of the priority valve. As the pressure difference between before and after C 2 is transmitted to the pressure chambers A and B, the spool moves rightward to a stable position, where the port CF is slightly opened and the port EF is almost fully opened

217 S-5 S-5 S-5 Orbitrol 1. Construction and Function This Orbitrol is a load sensing type Orbitrol, the construction of which is shown in Fig. 1, and it consists of the following main components. Housing The housing has five piping ports of P, T, R, L, and LS. Spool and sleeve The spool [12] is connected to the steering wheel via spline grooves, and serves to switch over oil passages by its relative position to the sleeve [11]. The oil passages are combined in the three models as shown in Fig. 3. The spool [12] and sleeve [11] are mechanically connected at two positions, as shown in Sections C-C and D-D in Fig. 1. In Section C-C, the spring [13] is installed in the recess grooves in the spool [12] and sleeve [11], so that while the steering wheel is stationary, the spool [12] and sleeve [11] are kept in the neutral position relative to each other as shown in Section C-C by the force of spring [13]. In the area around Section D-D, the spool [12], sleeve [11], and drive [8] are connected by the pin [14]. Here, the sleeve [11] and drive [8] are connected by the pin [14] without looseness, but the spool [12] is oval shape enabling it to move to a certain angle against the pin [14]. The reason for this is to shift the spool [12] relative to the sleeve [11] to obtain the valve timing shown in Fig. 3. Drive The drive serves to transmit the motion of the star of the rotor set [3] to the sleeve [11] through the pin [14]. Rotor set The rotor set consists of a ring possessing seven internal teeth and a star internally in mesh with the ring, possessing six teeth. LS Ring Star

218 S-5 S-5 Orbitrol 1. Bolt 8. Drive 15. Plug 22. Bearing race 2. End cap O-ring 23. Bearing 3. Rotor set 10. Housing 17. Check seat 24. O-ring Sleeve 18. O-ring 25. Oil seal 5. Spacer 12. Spool 19. Check ball 26. Dust seat 6. Spacer 13. Spring 20. Check ball retainer 27. Snap ring 7. Plate 14. Pin 21. O-ring 28. Bushing Operation of Orbitrol (See Fig. 3.) The operation of this Orbitrol is linked with the priority valve, but in this section, the operation of the independent Orbitrol is described. For its operation in conjunction with the priority valve, see the section of Priority Valve. Neutral The hydraulic oil entering through the port P flows through the passages in the sleeve and the spool into the cavity in the spool, and flows out through the recess grooves in the spool and the sleeve, and to the port T. Right steering (Left steering) When the steering wheel is turned to the right (left), the spool is shifted relative to the sleeve to the right (left) to result in the valve timing shown in Fig. 3. In this state, the oil entering through the port P does not flow into the cavity in the spool, but flows through the sleeve holes, spool grooves, sleeve holes, and three holes of the seven holes of the housing, and then enters the three spaces formed between the star and the ring of the rotor set. At this time, the flow rate to the port P is determined by restriction C 1 in the Orbitrol. The restriction C 1 is for producing a pressure signal for actuating the spool of the priority valve. The restriction area changes in proportion to the steering speed (steering flow rate), outputting the pressure from the port LS for controlling the branching performance of the priority valve. As pressure oil enters the tooth spaces, the star is driven in the direction same as the spool to enlarge the tooth space. As the star rotates, the oil in the three discharge side tooth spaces flows to the port R (L) via the housing holes, sleeve holes, spool grooves, and sleeve holes, and eventually flows into the steering cylinder. The oil forced out of the steering cylinder enters though the port L (R), and returns to the port T via the sleeve holes, spool grooves, and sleeve holes. When the star is turned, the drive spline to it is turned, and the sleeve is also driven via the pin. Therefore, when the star is turned by pressure oil, the sleeve is turned to cancel the spool displacement relative to the sleeve. In other words,the sleeve follows the spool displacement, and as long as the steering wheel is turned, this relationship continues and oil is constantly discharged through the port R or L

219 S-5 S-5 Orbitrol High pressure oil from pump Discharge oil Return oil Neutral Steering wheel Neutral or entrapped Orbitrol Right turn Left turn

220 S-5 S-5 Orbitrol 2. Disassembly Disassembling rotor section 1. Clamp the mounting flange of the unit lightly in a vise, with the rotor facing upward. At this time, clamp over copper plate, and take care not to clamp too strongly. Disassembling control section 8. Remove the housing [10] from the vise, and place it on a piece of clean cloth, taking care not to damage the finished surface. Remove the snap ring [27] from the housing [10] by prying with a small screwdriver. 2. Unscrew the bolt [1] with a 5/16-12 point socket wrench. 3. Remove the end cap [2]. 9. Turn the spool [12] and sleeve [11] to bring the pin [14] into a horizontal position, and then push the spool [12] and sleeve [11] with the thumb to remove the bushing [28] from the housing [10]. 10. Remove the oil seal [25] from the bushing [28]. 4. Remove the O-ring [21] from the end cap [2]. 5. Remove the rotor set [3], taking care not to drop the star in the rotor set. 11. Remove the dust seal [26] from the bushing [28] using a screwdriver, taking care not to damage the bushing [28]. 12. Remove the bearing race [22] and bearing [23]. 6. Remove the O-ring [21] and spacers [5] and [6] from the rotor set [3]. 7. Remove the drive [8], plate [7], and O-ring [21]. 13. Remove the spool-sleeve ass y from the housing [10] in the opposite direction to the flange. NOTE Slowly turn in both directions while removing the spool-sleeve ass y to prevent its seizure in the housing

221 S-5 S-5 Orbitrol 14. Pull out the pin [14] from the spool-sleeve ass y. 15. Push the spool [12] in the sleeve [11] slightly forward, and carefully remove the spring [13] from the spool [12] by hand. Then, turn the spool [12] slowly and pull it out from the rear of the sleeve [11]. 2. Insert the O-rings [16] (ID: φ9.3) and [18] (ID: φ7.6) in the large diameter portion and the small diameter portion of the check seat [17]. (Fig. 14) 3. Insert the check seat [17] in the housing [10], with the holed side downward. (Fig. 14) 16. Remove the O-ring [24] from the housing [10]. 17. Remove the plug [15] from the housing [10] using a 1/4 Allen wrench. (Fig. 13) (Note that the plug has been locked by locking adhesive.) 18. Pull out the check seat [17] by screwing a #10-24 threaded bar (special tool). 19. Remove the O-rings [16] and [18] from the check seat [17]. 20. Take out the check ball [19] and check ball retainer [20] from the housing [10]. 3. Checking Check the mating surfaces of all the parts. Replace all parts containing scores or burrs, as they cause oil leakage. Wash all the metal parts in clean solvent, and dry by blowing air. Do not wipe with cloth or paper, as they contaminate with lint which is harmful to hydraulic systems. Do not file or sandpaper parts. Replace all the rubber parts with new parts, and apply small amount of grease to O-rings. 4. Reassembly 4. With Loctite #242 applied to the threads of the plug [15], tighten it using a 1/4 Allen wrench to approx. 1.2 kg m, and then make sure that the plug [15] is sunk slightly from the end surface of the housing [10]. 5. Insert the spool [12] in the sleeve [11] while turning and sliding the spool, and align all the spring grooves. Then, turn the spline of the spool [12] with fingers to make sure that it turns lightly in the sleeve [11]. When the spool and the sleeve are provided with alignment marks, bring the marks in alignment. Spring groove Sleeve Spring groove Spool Alignment marks 6. With the spring grooves aligned, place the spool [12] and sleeve [11] upright on a smooth flat plate, and insert the springs [13] into the spring grooves in the two parts, using a spring insertion tool # For this, put three springs [13] back-to back, and pinch them with the insertion tool, with the end notch facing downward. Lifting the spool [12] slightly in the sleeve [11] facilitates the process. Reassembling control section 1. Insert the check ball retainer [20] in the hole of the housing [10] using tweezers. After making sure that the retainer is not tilted, put the check ball [19] in the same hole

222 S-5 S-5 Orbitrol 7. Pinching the springs [13] with fingers, inset them into the spring grooves of the spool [12] and sleeve [11], while pulling the insertion tool at the same speed. 8. When the springs [13] are inserted in the center of the spool [12] and sleeve [11], align the spring with the ends of the spool and sleeve. Screwdriver Dust seal Snap ring Bushing Oil seal O-ring 9. Insert the pin [14] through the holes in the spool [12] and sleeve [11], and bring the pin ends flush with the outside surface of the sleeve. 15. Insert the snap ring [27] in the housing [10], and securely seat it in the groove by expanding its inner diameter with a screwdriver. 10. Insert the spool-sleeve ass y into the housing [10] from its rear end. NOTE When inserting the spool-sleeve ass y, take extreme care not to tilt and pry it. Insert it while turning it slowly in right and left directions, with the pin [14] kept horizontal. Bring the end of the spool-sleeve ass y flush with the rear surface of the housing. Do not insert it further, as then the pin may drop. Finally check that the spool-sleeve ass y rotates easily in the housing. 11. Place the housing [10] on a clean flat surface, and insert the O-ring [24], bearing race [22], and bearing [23]. Reassembling rotor section 16. Lightly clamp the flange of the housing [10] in a vise. NOTE Make sure that the spool-sleeve ass y is slightly sunk from the housing [10] end surface containing fourteen holes. Clean the housing end surface by wiping with a clean palm. Clean the mating surfaces of the plate [7] and rotor set [3] also by wiping with a palm. Do not wipe with cloth or paper. 17. Install the O-ring [21] in the housing [10]. 12. Install the dust seal [26] in the bushing [28] with the flat surface in contact with the bushing. 13. Install the oil seal [25] in the bushing [28] by pushing with fingers. 14. Insert the bushing [28] while turning it in the spool [12]. Seat it fully to the specified position by hammering with a plastic hammer. (Fig. 19) 18. Place the plate [7] on the housing [10], and align the bolt holes with the threaded holes of the housing. 19. Rotate the spool-sleeve ass y, and align the pin [14] parallel to the port surface of the housing [10]. (Fig. 21) Insert the drive [8] and engage the yoke of the drive with the pin. For this, mark the spline end surface of the drive with a marking pen as shown in Fig

223 S-5. Orbitrol S-5. Pin Port surface Drive Align the pin parallel to the port surface. 20. Install the O-ring [21] in the rotor set [3]. 21. With the O-ring side of the rotor set [3] toward the plate [7], position the rotor set by aligning the valleys of its star (A in Fig. 23) with the drive [8] (B in Fig. 23). At this time, make sure that the lines A, B, C, and D are parallel to each other as shown in Fig. 23. Align the bolt holes in the rotor set without disengaging the drive from the star. 22. Insert the spacers [5] and [6] in the rotor set [3]. The combination of the spacers is as shown in the table below. Spacer combination Displacement code Displacement (cm 3 / rev) Spacer length (mm) B 73 X - C 101 X 3.6 D 121 X 6.1 E 168 X 12.2 X 12.2 G 195 X 3.6 K 243 X 22.0 M 292 Y 24.4 P 390 Y 41.1 S 487 Z 53.7 T 583 Z 66.4 U 780 Z Put the end cap [2] on the rotor set [3], and align the bolt holes. 24. Oil the threads of the bolts [1], and screw them into the end cap [2]. First tighten all the seven bolts to a torque of approx. 1.5 kg m, and then tighten them to kg m in the sequence shown in Fig. 25. Install the steering wheel to the spool, and check that the spool rotates. NOTE This process is an important one for determining the valve timing of the unit. Valleys in star Drive [8] (marked by line) Pin Port surface

224 S-6 S-6 S-6 Solenoid Valve 1. Construction (Blue lead) Diode (Red lead) (-) side (+) side Electric symbol Hydraulic symbol Tightening torque 120±15 kg cm Tightening torque 55±5 kg cm Tightening torque 450±50 kg cm (-) side lead: blue (+) side lead: red Section A-A Tightening torque of valve main body installation bolt : 300 ±30 kg cm

225 S-6 S-6 Solenoid Valve Section B-B Tightening torque 70±10 kg cm (With sealing tape) Tightening torque 100±15 kg cm (With sealing tape) Section C-C

226 S-6. Solenoid Valve S-6. Section D-D 101. Casing 105. Spring seat 401. O-ring 502. Plug 102. Cover 201. Spring 402. O-ring 601. Solenoid valve 103. Spool (A) 301. Hexagon socket head bolt 403. O-ring 104. Spool (B) 302. Hexagon socket head bolt 501. Plug 15 S

227 S-7. S-7 Solenoid Valve S Construction Symbol 1. Body 4. Cylinder 8. Pilot valve ass y 11 Silencer 2. Spool 5. O-ring 8a. O-ring 13. Name plate 3. Seal ass'y 6. Piston ass'y 8b. Pilot valve body 15. Gasket 3a. Spacer 6a. Packing 8C. O-ring 16. Cap 3b. Packing 6b. Piston 8d. Manual shaft 17. Piston ass y 3c. Stopper 7. Plunger ass y 8e. O-ring 17a. Packing 3d. Packing 7a. Spring 9. Molded coil 17b. Piston 3e. Stopper 7b. Plunger 10. Terminal 18. Cylinder 2. Dismounting and Remounting Dismount the valve after securing the vehicle and opening the drain cock to discharge the compressed air in the reservoir S

228 S-8. S-8 Air Cylinder S Construction 1. Nut 6. Cylinder 11. Wear ring 16. Nut 2. Piston rod 7. Cushion rubber 12. Piston B 17. Toothed washer 3. Packing 8. Piston A 13. Head cover 4. Bush 9. Packing 14. Nut 5. Rod cover 10. Piston ring 15. Spacer

229 T Brake System Contents T-1 System Components Disassembling the body... 9 T-2 System Overview Description of System Service brake sircuit Parking brake and auxiliary brake circuits Washing and Checking Reassembly Reassembling the secondary section Reassembling the primary section Reassembling the mount plate T-3 Brake Construction and Function Checking the Pad Ass'y Test Maintenance Standard T-5 Booster Checking the Disc Plate Construction and Function Replacing the Pad Ass y Dismounting Disassembly Washing and Checking Reassembly Disassembly Disassembling the relay valve Disassembling the cylinder Checking T T-4 Brake Valve Construction and Function Dismounting and Remounting Disassembly Disassembling the mount plate Reassembly Relay valve Cylinder Reassembling the relay valve and cylinder Test Maintenance Standard i

230 T-6 Air Dryer Construction and Function Countermeasures against Failures Dismounting Remounting Disassembly Disassembling the cartridge Disassembling the body Washing T-8 Reducing Valve Construction and Function Dismounting Disassembly Washing and Checking Reassembly Test Maintenance Standard Reassembly Reassembling the cartridge Reassembling the body Reassembling the main body Test Maintenance Standard T-9 Brake Chamber Construction and Function Disassembly Washing and Checking T-7 Pressure Regulator Construction and Function Dismounting Disassembly Washing and Checking Reassembly Test Reassembly Test Maintenance Standard T-10 Parking Brake Construction Disassembly Checking Reassembly Adjustment

231 T-1. T-1 System Components T-1. Reducing valve (For rear wheel brake) Brake valve Front Air dryer Pressure regulator Solenoid valve (For auxiliary brake) Booster Solenoid valve (For parking brake) Reducing valve (For auxiliary brake) 1 T

232 T-2. T-2 System Overview T Description of System (See the circuit diagram in Chapter Z.) 1.1 Service brake sircuit When the brake valve pedal is depressed, the compressed air from the reservoir is regulated to a pressure depending on the pedal angle, and is applied to the relay valve mounted on the booster. The relay valve under control of the pilot pressure from the brake valve sends the compressed air in the reservoir to the air cylinder of the booster. The compressed air is converted to a fluid pressure here, which acts on the piston at the brake caliper, activating the disc brake. When the brake pedal is released, the compressed air acting on the relay valve is discharged through the exhaust port of the brake valve. This allows the relay valve to return to the non-operation position, and the compressed air sent to the booster to be discharged through the exhaust port of the relay valve, releasing the brake. 1.2 Parking brake and auxiliary brake circuits The solenoid for parking brake (SL79) and the solenoid for auxiliary brake (SL76) are energized as follows depending on the position of the parking brake switch. Parking brake switch Solenoid (SL79) (for parking brake) Solenoid (SL76) (for auxiliary brake) AUX OFF ON PARK OFF OFF OFF ON OFF 1. Parking brake (1) Braking When the parking brake switch is turned to PARK, the solenoid (SL79) is deenergized, releasing the compressed air sent to the spring chamber to the atmosphere through the solenoid valve. This frees the spring in the chamber, expanding the brake shoes to brake the drum. (2) Releasing When the parking brake switch is turned OFF, the solenoid valve (SL79) is energized and switched over, allowing the compressed air in the reservoir to enter the spring chamber through the solenoid valve. This compresses the spring in the chamber, releasing the brake. 2. Auxiliary brake (1) Braking When the parking brake switch is turned to AUX, the solenoid (SL79) is deenergized and the solenoid (SL76) is energized. This allows the compressed air in the reservoir to flow through the reducing valve, solenoid valve (SL76), and the shuttle valve and to act as pilot pressure on the booster relay valve, applying the service brake. At this time, the pilot pressure to the relay valve is regulated to a certain pressure by the reducing valve. In addition, since the compressed air sent to the spring chamber is released to the atmosphere by the solenoid (SL79), the spring is freed to apply the parking brake. (2) Releasing When the parking brake switch is turned OFF, the solenoid (SL79) is energized and the solenoid (SL76) is deenergized. This allows the relay valve to return to the non-operation position and allows the compressed air sent to the booster to discharge, releasing the service brake. In addition, the compressed air in the reservoir is sent to the chamber, releasing the parking brake. 1.3 Exhaust brake circuit When the exhaust brake switch is turned on, the exhaust brake indicator lamp lights up to indicate that exhaust braking is available. In this condition, if the engine speed decreases below approx. 700 rpm (idling switch ON) with the gearshift lever at other than the N position, the solenoid (SL73) is energized, activating exhaust braking. (If the D range is selected, SL73 is not energized when the vehicle speed decreases to 1 km/h or below with the idling switch turned ON.) When the gearshift lever is moved to the N position or the accelerator pedal is depressed, exhaust braking is released temporarily. 2 T

233 T-3 T-3 T-3 Brake 1. Construction and Function The brake is an opposed piston type disc brake that has pad ass ies on both sides of a disc plate to pinch it between them, as shown in the figure. The brake consists of a disc plate that turns together with the wheel and a caliper ass y that is fixed to the knuckle. The caliper ass y incorporates pistons. The pad ass ies at the top end of the pistons are forced on the disc plate from both sides by the brake pressure, braking the motion of the disc plate. The clearance between the pad ass y and the disc plate is maintained constant by means of the piston seals. Disc plate Pad residual thickness check hole Outer side Inner side Inner side Outer side Joint screw hole 1. Caliper ass y 5. Piston seal 9. Cap 13. Pad ass y 2. Lid 6. Boot ring 10. Bolt 14. Anchor pin 3. Lid 7. Boot 11. Washer 15. O-ring 4. Piston 8. Bleeder screw 12. Lock bolt 3 T

234 T-3 T-3 Brake Description of operation 1. When hydraulic pressure is applied The pistons apply pressure to the pad ass ies while deforming the piston seals. 2. Checking the Pad Ass'y Before checking the residual thickness of the pad, turn the parking brake switch to AUX. Then, insert the check gauge in the check hole on the caliper ass y to check the thickness. Caliper Piston seal Check gauge (Part No ) Piston Piston displacement Replace the pad ass y when Piston this distance becomes zero. Backing plate Pad ass y Wear lining Disc plate 2. When hydraulic pressure is not applied When hydraulic pressure is removed, the seals recover the original shape to push the pistons back, creating a certain clearance between the disc plate and the pad ass ies. Piston seal Piston NOTE When one of the pad ass ies is found to have worn to the use limit during the checking of residual thickness, all the other ones may also be worn to the same limit in most cases. It is recommended to replace the pad ass ies for the right and the left wheels or even four wheels simultaneously. A new pad ass y has a 9 mm thick backing plate and a 14 mm thick wear lining (total thickness of 23 mm). When the wear lining thickness becomes 4 mm (total thickness becomes 13 mm), the use limit is reached. Letting the pad ass y wear beyond the use limit will decrease braking force and damage the brake. Check the pad ass ies during start-up inspection. 3. When pad ass y wears The piston displacement distance increases beyond the seal deformation limit, and slip occurs by that amount between the pistons and the seals. Then the pistons are pulled back by the distance of deformation as above, maintaining a certain clearance. 3. Checking the Disc Plate Replace if the thickness becomes 28 mm or below (thickness of a new disc plate: 30 mm), or if the disc plate is unusably damaged

235 T-3 T-3 Brake 4. Replacing the Pad Ass y 1. Set the outriggers, and remove the tire. (To remove the brake ass y as a unit, unscrew the four mounting bolts in this state. When remounting it, tighten the mounting bolts to 95±9.5 kg m.) 2. Connect a vinyl tube to the bleeder screw [8] to loosen it. 3. Insert a piston return lever between the pad ass y [13] and the disc plate, and push all the pistons [4] fully to the end. Then, close the bleeder screw [8]. NOTE Take care that some brake fluid may overflow from the reservoir. Piston return lever Quenching HRC 45 or above 2. While taking care not to damage the boot [7], remove the boot ring [6] and then boot [7]. 3. Blow compressed air through the inlet of the caliper ass y, and remove the piston [4]. 4. While taking care not to damage the cylinder bore, remove the piston seal [5]. 5. Remove the bolt [10], and remove the lids [2] and [3] and piston seal [5]. 6. Loosen the lock bolt [12], and remove the anchor pin [14] and O-ring [15]. 6. Washing and Checking (1) Excluding rubber parts, wash the caliper ass y interior (cylinder) with brake fluid and wash other parts with light oil or wash oil. Then, rinse them with water and dry. For rubber parts, use alcohol for washing or only wipe off deposits. NOTE Replace rubber parts with new ones during overhaul. 4. Loosen the lock bolt [12], pull out the anchor pin [14] by the length equal to the pad thickness, and remove the pad ass y [13]. 5. Clean the caliper [1] and the end surfaces of the piston [4]. Then, install the pad ass y [13] and anchor pin [14], and tighten a new lock bolt [12]. NOTE Take care not to allow oils to adhere to the pad ass'y [13] and the disc plate. Take care not to allow the boot [7] to get caught between the piston [4] and pad ass y [13]. Replace the lock bolt [12] with a new one. 6. Bleed the air. 7. Bleed the brake circuits referring to Chapter Y Adjustment and Checks. 8. Mount the tire. Hub nut tightening torque: 60 to 70 kg m 5. Disassembly 1. Loosen the lock bolt [12], pull out the anchor pin [14] by the length equal to the pad thickness, and remove the pad ass y [13]. (2) Check the caliper ass y for deformation or cracks, and check the caliper interior (cylinder) for uneven wear, damage, or rust. Replace if defective. (3) Check the piston for uneven wear, damage, or rust. Replace if defective. (4) Check the pad for oil adhesion, deterioration, or uneven wear. Replace if defective. (5) Measure and record the thickness of the pad ass y. Replace if the measured value is below the use limit. Standard dimensions mm Use limit mm (6) Check the disc plate for damage or uneven wear. Replace if defective. (7) Measure and record the thickness of the disc plate. Replace if the measured value is below the use limit. Standard dimensions mm Use limit mm (8) Measure and record the deflection of the disc plate. Replace if defective. Maintenance standard mm or below

236 T-3. Brake T Reassembly 1. Install the piston seal [5], piston [4], boot [7], and boot ring [6] to the caliper ass y [1]. 4. Install the O-ring [15] in the caliper ass y, and install the anchor pin [14]. Tighten the lock bolt [12] to the specified torque. NOTE Apply Castrol H151/59 grease (red), enclosed in the seal kit, to all the surfaces of the piston seal, and install it in the seal groove securely. Apply brake fluid to the sliding surfaces of the piston, and insert it. When installing the boot, apply NIGLUBE RX-2 grease (orange), enclosed in the seal kit, to the seal portion and pack grease in the portion A in the figure below, and then install the boot in the boot grooves of the caliper and the piston. Boot NOTE Before installing the O-ring, apply AKB100 grease (yellow), enclosed in the seal kit, to the O-ring, and then install it in the caliper O-ring groove. Before installing the anchor pin, apply AKB100 grease (yellow), enclosed in the seal kit, around the anchor pin. Be sure not to apply this grease to other parts than the O-ring and the anchor pin. Grease application range Anchor pin 2. After installing the boot ring [6], check that the ring is installed properly. 3. Install the piston seals in the lids [2] and [3], and install them to the caliper ass y [1]. NOTE Before installing the piston seal, apply Castrol H151/59 grease (red), enclosed in the seal kit, to all the surfaces of the piston seal

237 T-4 T-4 T-4 Brake Valve 1. Construction and Function This brake valve is a dual, 2-circuit rubber spring type brake valve for air brake systems. It delivers air at pressures determined by the position of the brake pedal to two systems. Even when one of the systems fails and deactivates brakes, the other system remains operational to brake the vehicle by delivering pressurized air to the circuits of the other system. Primary section Supply port Delivery port Secondary section Supply port Delivery port Exhaust port 1. Upper body 13. O-ring 25. Spring washer 37. Exhaust cover 2. Upper valve 14. O-ring 26. Nut 38. Screw & 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 & washer 6. O-ring 18. Outer spring 30. Valve retainer 42. Mount plate 7. Special washer 19. Sleeve 31. Valve spring 43. Bolt & washer 8. Retaining ring 20. Stem washer 32. Retainer 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

238 T-4 T-4 Brake Valve Description of operation 1. Normal state (1) Generation of air pressure When the pedal is depressed, the depressing force is transferred to the piston [21] via the plunger [46], spring seat [23], and rubber spring [22], and the piston [21] moves downward while compressing the return spring [15]. Following this movement, the discharge valve seat at the bottom of the piston [21] comes in contact with the upper valve [2] to close the discharge air passage at the center. As the piston [21] further compresses the return spring [15], the upper valve [2] moves to open the air valve seat of the upper body [1], allowing the pressurized air coming from the primary supply port to flow through the delivery port to the brake chamber in the primary system. On the other hand, as the primary system becomes operational, a part of its pressurized air flows through the passage in the upper body [1] into the space above the relay piston [12] in the secondary system to push the relay piston [12] down. Thus, the discharge valve seat at the bottom of the relay piston [12] comes in contact with the lower valve [29] to close the central discharge passage. The lower valve [29] further moves down to open the air inlet valve seat of the lower body [28], allowing the pressurized air coming from the secondary supply port to flow through the delivery port into the brake chamber of the secondary system. compressing the rubber spring [22] above the piston. The piston [21], while keeping contact with the upper valve [2], rises, and when the upper valve [2] comes in contact with the inlet valve seat, the delivery of air is stopped. Then, with the discharge valve seat in contact with the upper valve [2], the air pressure remains stable. In the secondary system, the relay piston [12] lowers in proportion to the air pressure in the primary system to generate air pressure in the secondary system. The generated pressure is also applied to the underside of the relay piston [12]. As this secondary pressure applied to the underside of the relay piston [12] becomes balanced with the primary pressure applied to the top of the relay piston, it is no more pushed down, but moves up while keeping contact with lower valve [29]. As the lower valve [29] comes in contact with the inlet valve seat of the lower body [28], the air supply through the supply port is stopped. In this state, since the discharge valve seat is in contact with the lower valve [29], the air pressure stops rising and becomes stable. Thus, the air pressure in the secondary system is kept stable at a level equal to that of the primary system. The spring [11] serves to minimize the pressure difference between the two systems. Inlet valve seat Discharge valve seat Discharge air passage Inlet valve seat Discharge valve seat (2) Stabilization of air pressure When the pedal is depressed to a certain extent and kept stationary at that position, the air pressure generated by the pedal operation is stabilized at a level corresponding to that pedal position as follows: As the pedal is depressed as previously described, the discharge valve closes and the inlet valve opens to deliver air to the system. This air also exerts upward pressure on the underside of the piston [21]. With the pedal maintained at a certain depressed position, the air pressure under the piston [21] rises while (3) Release of air pressure As the pedal is released, the plunger [46] and piston [21] are pushed up by the return spring [15] and the primary air pressure, and the discharge valve seat at the bottom of the pistons [21] disengages from the upper valve [2] to open the discharge passage at the center, allowing the primary system air pressure to flow through the discharge passage and discharge from the discharge port. As the primary air pressure drops, the relay piston [12] is pushed up by the secondary air pressure and the springs [17] and [18], and the discharge valve seat at the bottom of the relay piston [12] disengages from the lower valve [29] to open the central discharge passage, allowing the secondary air pressure to flow through the discharge passage and discharge from the discharge port

239 T-4 T-4 Brake Valve the relay piston [12] to directly push the lower valve [29] to cause the secondary system to operate in the same ways as the primary system in the normal state, generating air pressure, stabilizing, and releasing it. 2. Operation under piping rupture (1) Operation with only the primary system When the secondary brake system is damaged, the primary system remains operational as in the normal state because the relay piston [12] separates it from the secondary system. 2. Dismounting and Remounting (1) Dismount the valve after securing the vehicle and opening the drain cock to discharge the compressed air in the reservoir. (2) Tightening torque for the pipe fittings: 3 to 4 kg m 3. Disassembly NOTE When disassembling, remove mud, dust, water from the outside surface to avoid their entry into the interior. Before disassembling, put alignment marks on all the joints to facilitate correct reassembly. Place the disassembled parts in an orderly arrangement to facilitate reassembly. 3.1 Disassembling the mount plate (2) Operation with only the secondary system When the primary brake system is damaged, no air pressure is generated in the primary system, therefore, no primary air pressure is available to work on the relay piston [12] for actuation of the secondary system. In this case, depressing the pedal further down brings the lower end of the piston [21] in contact with the top of the relay piston [12], causing the discharge valve seat of (1) Remove the three bolts & washers [43], and remove the mount plate [42], plunger [46], and plunger boot [45]. 3.2 Disassembling the body (1) Clamp the body in a vise with the lower body [28] upward, and unscrew the four bolts [41] that fix the upper body [1] and lower body [28] to remove the lower body ass y. (Fig. 7)

240 T-4 T-4 Brake Valve (2) Clamp a flathead screwdriver in a vise, and pass it through the discharge passage of the relay piston [12], allowing the blade to come in contact with the slit in the stem. Loosen the nut [26] at the top of the piston [21], and remove the piston [21], return spring [15], relay piston [12], spring [11], and stem [16]. At this time, hold the piston [21] to prevent it from being popped out by the return spring [15]. (Fig. 8) (5) Disassemble the upper valve ass y, lower valve ass y, and the stem ass y. Upper valve ass y Lower valve ass y Stem ass y (3) Remove the O-ring [40] from between the upper body [1] and lower body [28], and clamp the lower body [28] in a vise with the exhaust check [39] upward. Then, loosen the four screws [38] to remove the exhaust cover [37] and lower valve ass y. 4. Washing and Checking (1) Washing Clean the rubber parts by wiping off deposits on the surface with a cloth damped with alcohol. Wash all the metal parts, except the mount plate, with trichloroethylene or other suitable cleaning agents. The mount plate incorporates an oil impregnated metal bushing; wash it in light oil and dry with compressed air. (4) Remove the retaining ring [10] from the groove inside the upper body [1], and take out the upper valve ass y. (2) Checking Check all the parts for cracks, breaks, deformation and dents on their sliding surfaces. Replace any defective parts with new ones. Check the springs for corrosion, and replace if they are defective. 5. Reassembly NOTE Apply lithium base grease (Daphne Coronex Grease EP2 from Idemitsu Kosan or equivalent product) to the sliding surfaces of the valve, body, and relay piston

241 T-4 T-4 Brake Valve Before inserting the O-rings, be sure to apply lithium base grease (Daphne Coronex Grease EP2 from Idemitsu Kosan or equivalent product) to them and fill the O-ring grooves with grease. Apply lithium base grease containing molybdenum (Bearing grease No. 3 from Nippon Molybdenum (Daizo) or equivalent product) to the sliding surfaces, rollers, and fulcrums of the plunger. 5.2 Reassembling the primary section (1) Place the upper valve [2] on a work bench with the valve seal side downward. Install the valve retainer [3], valve spring [4], retainer [5] with O-rings [6] and [9], and special washer [7] in this order, and secure with retaining ring [8]. Before installing the O-rings [6] and [9], apply grease. 5.1 Reassembling the secondary section (1) Place the lower valve [29] on a work bench with the valve seal side downward. Install the valve retainer [30], valve spring [31], retainer [32] with O-rings [33] and [36], and special washer [34], and secure with retaining ring [35]. (2) Insert the upper valve ass y in the upper body [1], and secure with the retaining ring [10]. (2) Install the lower valve ass'y in the lower body [28]. (3) Install the springs [17] and [18], stem washer [20], and sleeve [19] in the stem [16], and tighten the sleeve [19]. Apply grease to the springs [17] and [18] in advance. (3) Install the exhaust cover [37], and secure with the screw & washer [38]. Pack grease in the groove at the joints between the lower body [28] and upper body [1], and then install the O-ring [40] with grease applied. (4) Install the O-rings [13] and [14] in the relay piston [12], and insert the spring [11], relay piston [12], and the stem ass y in this order in the upper valve [2] that has been installed in the upper body [1]. Apply grease fully to the O-rings and the O-ring sliding surfaces in advance. (Fig. 20) (5) While holding the relay piston [12] by hand to prevent it from being popped out by the spring [11], let the screwdriver slit of the stem [16] come in contact with the blade of the flathead screwdriver clamped in the vise. (Fig. 21)

242 T-4. Brake Valve T Air leakage through the supply valve and exhaust valve In the fully released state, the air leakage through the delivery port and the exhaust port should be 100 cm 3 /min or below. In the fully depressed state, air leakage through the exhaust port should be the same. 2. Air leakage in other parts In the fully depressed state, there should be no air leakage from the body, valve cap, and their joints. 3. Operation test Thrust the plunger speedily into the fully depressed position, and then release speedily. The delivery pressure should rise and fall smoothly. (6) Install the return spring [15], piston [21], rubber spring [22], spring seat [23], special washer [24], and spring washer [25] in this order, and secure with the nut [26]. 4. Performance test 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 pressure is at 1 kg/cm 2, the lower delivery port pressure should be 0.8 kg/cm 2 or above. If these criteria are not met, the cause may be lack of grease or weakened springs. Performance curve Maximum stroke: 11.8mm (7) Clamp the upper body ass y in a vise, put the lower body ass y on it, and secure them with the bolt & washer [41]. 5.3 Reassembling the mount plate Delivery pressure (kgf/cm 2 ) Plunger stroke (mm) (1) Insert the plunger boot in the plunger [46], install them in the mount plate [42], and install them in the upper body [1] using the three bolts & washers [43]. 6. Test Test the brake valve for air leakage and performance problems, with a pressure gauge measuring up to approx. 10 kg/cm 2 mounted on the deliver side, and with the supply pressure adjusted to 7 kg/cm 2. 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. 7. Maintenance Standard hour check Disassemble the parts above the mount plate, and wash and check them. Replace if defective, and apply grease to the sliding surfaces hour or 1-year check Disassemble the valve, and clean all the parts. Replace all the rubber parts. Replace the metal parts that are found worn or damaged. Execute all the tests specified

243 T-5 T-5 T-5 Booster 1. Construction and Function The booster converts the air pressure sent to its air cylinder from the relay valve to hydraulic pressure, and supplies a hydraulic pressure in proportion to the air pressure to the wheel cylinders and other members of the brake system. The booster consists of the following three major components. Air cylinder The air cylinder incorporates the air piston ass y [8] and return spring [11]. The return spring side is always subject to the atmospheric pressure, and the compressed air side on the opposite side is subject to the output pressure of the relay valve. Oil cylinder The oil piston ass y [14] is connected to the air piston ass y [8] by the piston pin [16] via the valve ass'y [15], and the pin holder [17] prevents the pin from coming off. The hydraulic pressure is sealed by tight fit between the valve in the valve ass y [15] and the oil piston [14a]. Relay valve This valve serves to make the brake applied and released quickly. Chamber E Relay valve Oil cylinder Chamber F Chamber J Air cylinder Service port Chamber A Path G Chamber D Chamber H Chamber B Path I Supply port Path C Delivery port Exhaust port

244 T-5 T-5 Booster 1. Case ass'y 14b. Backup ring 28. Exhaust pipe 33j. O-ring 2. Seal cup 14c. Piston cup 29. Pipe holder 33k. O-ring 3. Backup ring 15. Valve ass y 30. Seal rubber 33l. O-ring 4. Seal cup 16. Piston pin 31. O-ring 33m. Return spring 5. Support ring 17. Pin holder 32. Spring washer 33n. Piston 6. C-ring 18. End cap 33. Relay valve ass y 33o. O-ring 7. Air cylinder 19. Oil cylinder 33a. Body 33p. Cover 8. Air piston ass y 20. O-ring 33b. Valve retainer 33q. Bolt 9. Piston ring 21. Connector 33c. Valve spring 33r. Spring washer 10. Piston seal 22. Bleeder screw 33d. Valve holder 33s. Valve ass y 11. Return spring 23. Cap 33e. Valve spacer 34. Lock nut 12. Spring washer 24. Nut 33f. Holder plate 35. Screw 13. Cylinder seal 25. Cap 33g. Dust seal rubber 36. Nipple 14. Oil piston ass y 26. Lock washer 33h. C-ring 37. Bolt 14a. Oil piston 27. Nut 33i. O-ring Description of operation 1. Relay valve (1) Booster not in operation Fig. 1 shows the state of the relay valve when the booster is not in operation. Since the chamber A is open to the atmosphere via the brake valve, the piston [33n] is kept in its raised position by the return spring [33m]. In this state, the chamber B is also open to the atmosphere through the path C. (2) Booster in operation for assisting braking When the brake pedal is depressed, the signal pressure is applied to the service port. This pressure acts on the piston [33n] and the piston compresses the return spring [33m], bringing the piston seat in contact with the valve ass y [33s]. This causes the chamber B to shut off the path C, and simultaneously presses down the valve ass y. As a result, the body seat opens, allowing the compressed air to flow from the chamber D to chamber B, to the delivery port, and then to the air cylinder. (Fig. 2) Booster in operation Supply port Chamber D Path C Chamber B Delivery port When the signal pressure becomes higher, the above sequence is repeated, increasing the outlet pressure by the amount of increase in signal pressure. In this manner, the pressure in the chamber A is constantly balanced with that in the chamber B during operation. Pressure in balance Supply port Chamber D Chamber B Delivery port (3) Booster in operation for releasing brakes When the brake pedal is released slightly, the pressure in the chamber A becomes lower than that in the chamber B, causing the piston [33n] to rise. This separate the piston from the valve ass y [33s], and the compressed air in the chamber B is discharged to the atmosphere through the path C, decreasing the pressure in the air cylinder. (Fig. 4) When the compressed air is discharged until the pressure in the chamber A becomes balanced with that in the chamber B, the piston [33n] comes in contact with the valve ass y [33s] again. In this manner, the pressure in the chamber A is constantly balanced with that in the chamber B also when the air is discharged. When brakes are released Chamber B When the pressure in the chamber B reaches the signal pressure (pressure in the chamber A), the body seat comes in contact with the valve ass y [33s], shutting off the passage between the chamber D and chamber B. Therefore, the pressure in the chamber B does not increase. (Fig. 3) Supply port Path C Delivery port Air discharge

245 T-5 T-5 Booster (4) Brakes completely released When the brake pedal is released completely, the signal pressure becomes zero. The compressed air supplied to the air cylinder is discharged from the chamber B to the atmosphere through the path C. The relay valve becomes in the booster non-operation state. 2. Cylinder (3) Brakes are released When the compressed air in the chamber E of the air cylinder becomes open to the atmosphere through the relay valve, the air piston ass y [8], valve ass y [15], and oil piston ass y [14] are brought back to the positions corresponding to the booster non-operation state by the return spring [11], thus releasing brakes. (1) Booster not in operation When the booster is not in operation, since the chambers E and F of the air cylinder are open to the atmosphere, the air piston ass y [8] is pushed toward the left of the air cylinder [7] by the return spring [11] (as shown in Fig. 1). In this state, the valve ass y [15] is separated from the oil piston [14a], allowing the brake fluid from the oil reservoir tank to flow to the oil cylinder chamber J through the path G, chamber H, clearance between the oil piston [14a] and valve ass y [15], and path I. (2) Booster in operation When the compressed air flows from the relay valve to the chamber E, the air piston ass y [8] moves rightward due to air pressure. The valve ass y [15] connected to the end of the push rod of the air piston ass y is moved rightward together with the air piston ass y, and it comes in contact with the oil piston [14a], closing the central hole to shut off the passage between the oil reservoir and the chamber J. Then, against the pressure in the chamber E, a hydraulic pressure proportional to the ratio of the air cylinder diameter to the oil cylinder diameter is generated. 2. Dismounting 1. Dismount the booster after securing the vehicle and opening the drain cock to discharge the compressed air in the reservoir. Push rod

246 T-5 T-5 Booster 3. Disassembly 3.1 Disassembling the relay valve 1. Remove the exhaust pipe [28], and remove the seal rubber [30] and O-ring [31]. 2. Unscrew the nut [24], and remove the relay valve ass y from the cylinder. 3. Unscrew the bolt [33q], and remove the cover [33p] and O-ring [33l]. 4. Remove the dust seal rubber [33g], and then the C-ring [33h]. Then remove the valve spacer [33e], valve holder [33d], holder plate [33f], valve spring [33c], valve retainer [33b], and valve ass y [33s] in this order

247 T-5 T-5 Booster 5. While taking care not to damage the body seat and the air piston seat, push up the piston [33n] and remove it from the body [33a]. 3.2 Disassembling the cylinder 1. Loosen the lock nut [34], and remove the oil cylinder [19] from the case ass'y [1]. Then, remove the end cap [18] from the oil cylinder [19]. 2. Remove the bolt [37], then the air cylinder [7]. With the air piston ass y [8] downward, push down the case ass'y [1] to slacken the return spring [11] and let the oil piston ass y [14] protrude from the case ass y. Compress the pin holder [17] so that the piston pin [16] can be removed. After removing the piston pin, the oil piston ass y [14] and valve ass y [15] can be removed from the push rod of the air piston ass y [8]. Then, pull up the case ass y [1] slowly to separate the air piston ass y [8], return spring [11], and case ass y [1]. NOTE Since the spring has a tension of approx. 30 kg, take extreme care when removing parts. 3. Remove the C-ring [6], and take out the support ring [5], seal cup [4], backup ring [3], and seal cup [2] in this order, from the case ass'y [1]. 4. Checking Check all the disassembled parts. If parts are in any of the following conditions, replace them with new ones. All rubber parts, even if no defects are found, must be replaced with new ones every year. 1. Relay valve (1) Body [33a] Any part with damage or significant wear on the piston sliding surfaces, or a one with damage on the body seat (Any damage, even if not significant, may cause air leakage.) (2) Piston [33n] Any part with damage or significant wear on the sliding surfaces, or a one with damage on the piston seat (Any damage, even if not significant, may cause air leakage.) (3) Valve holder [33d] Any part with damage or significant wear on the valve sliding surfaces (4) Valve ass y [33s] Any ass y with damaged or fatigued rubber parts, or a one with damage or significant wear on the sliding surfaces (Replace every year even if no defects are found.) (5) O-rings Any damaged or worn O-rings (Replace every year even if no defects are found.) (6) Dust seal rubber [33g] Any deteriorated or damaged dust seal rubbers (7) Springs Any cracked or broken spring, or a one with a free length below the following use limit Spring Return spring [33m] Valve spring [33c] 2. Cylinder Code number Standard free length Use limit mm 55 mm mm 60 mm mm 25 mm (1) Air cylinder [7] Any part with damage or significant wear on the air piston ass y [8] sliding surfaces, or a one with damage which appears to be detrimental to its function (2) Air piston ass y [8] Any part with damage, even if it is slight, or wear on its push rod, or a one with detrimental damage in the piston seal [10] groove (3) Piston ring [9] Any part with detrimental damage or wear on the outer circumference (4) Case ass'y Any ass y with detrimental damage or wear on its bush, or a one with damage in the seal cup [2] and [4] fitting portions, O-ring [20], and sealing portions (5) Oil piston [14a] Any part with damage or significant wear on the outer circumference and the valve seat faces, or a one with damage in the piston cup [14c] fitting portion (6) Valve ass y [15] Any ass y with damaged or deteriorated valves (rubbers), or a one with wear which appears to be detrimental to its function (Replace every year even if no defects are found.) (7) Backup rings [3] and [14b] Any part with damage or significant wear

248 T-5 T-5 Booster (8) Oil cylinder [19] Any part with damage or significant wear on its bore, or a one with damage in the O-ring [20] fitting portion (9) End cap [18] Any part with damage in the O-ring [20] sealing portion (10) Piston pin [16] Any part with detrimental damage, wear, or deformation (11) Piston seal [10], seal cups [2] and [4], piston cup [14c], cylinder seal [13], dust seal rubber [33g], and O-ring Any part with damage, wear, or other defects which appear to be detrimental to its function (Replace every year even if no defects are found.) (12) Return spring [11] Any cracked or broken part, or a one with a free length below the following use limit. Standard free length Use limit Code number mm 357 mm mm 310 mm Reassembly NOTE The silicon grease and rubber grease used in the following reassembly procedure should be G30M from Shin-Etsu Chemical or equivalent product, and RG4 from Sanko Yushi or equivalent product, respectively. 5.1 Relay valve 1. Apply silicon grease to the stem of the valve ass y [33s]. Then, install the valve ass y in the body [33a] together with the valve retainer [33b] and valve spring [33c]. 2. Apply silicon grease fully to the O-ring groove and inner circumference of the valve holder [33d]. Then, install the O-rings [33i] and [33j] with silicon grease applied. 3. Install the holder plate [33f], valve holder [33d] fitted with the O-ring, and valve spacer [33e] in this order, and secure them with the C-ring [33h]. When setting the valve spacer, align the pipe port with the notch in the valve spacer so that the exhaust pipe [28] can be inserted. 4. Install the dust seal rubber [33g]. 5. Apply silicon grease to the piston [33n] sliding surfaces of the body [33a]. Install the O-ring [33l] with silicon grease applied. 6. Pack silicon grease into the O-ring groove of the piston [33n], and install the O-ring [33o]. Remove excessive silicon grease, and apply silicon grease to the outer circumference of the piston. Install the piston in the body [33a] together with the return spring [33m]. 7. Install the cover [33p], and secure it with the bolt [33q]. 8. Apply silicon grease to the O-ring [33k], and install it in the body [33a]. 5.2 Cylinder 1. Apply rubber grease to the bush of the case ass'y [1] and to the seal cups [2] and [4]. 2. Install the seal cup [2], backup ring [3], seal cup [4], and support ring [5] in the case ass y [1] in this order, and secure them with the C-ring [6]. 3. Install the pin holder [17] in the oil piston [14a]. Apply rust-preventive oil CCI#20 (from Chuo Chemicals (CCI)) to the piston cup [14c], and install it together with the backup ring [14b]. Set the backup ring so that the side with chamfered inner circumference is on the piston side. Backup ring Chamfer Piston cup Oil piston 4. Apply rubber grease to the push rod of the air piston ass y [8], and install the air piston ass y [8], return spring [11], and case ass'y [1]. With the air piston ass y downward, slacken the return spring to let the end of the push rod protrude from the case ass'y. In this state, install the valve ass y [15] and oil piston ass y [14] to the end of the rod, and compress the pin holder [17] to insert the piston pin [16]. Make sure that the piston is installed in the position and retained by the pin holder. 5. After installing the O-ring [20] in the oil cylinder [19], apply rust-preventive oil CCI#20 to the O-ring and the bore of the oil cylinder. Then, screw the end cap [18] to the end with flats

249 T-5 T-5 Booster 6. Screw the lock nut [34] to the oil cylinder [19], and install them in the case ass'y [1]. At this time, to ensure that the piston cup [14c] is inserted in the oil cylinder properly, install the oil piston ass y [14] and the oil cylinder with the oil piston ass y protruding from the case ass y as previously described in the step 4, and then screw them in the case ass y. Adjust the oil cylinder position by screwing the cylinder until it comes in contact with the stopper and then unscrew it within a turn to set its position properly. After the adjustment secure with the lock nut. 7. Pack silicon grease into the outer circumference groove of the air piston ass y [8]. Mount the piston ring [9] and piston seal [10] with silicon grease applied. 8. Apply silicon grease to the inner circumference of the air cylinder [7]. Install it in the case ass y [1] together with the cylinder seal [13]. Secure with the bolt [37] and nut [27]. 5.3 Reassembling the relay valve and cylinder 1. Make sure that the O-ring [33k] is installed properly, and install the relay valve in the air cylinder [7]. 2. Install the seal rubber [30] to the pipe port of the relay valve. Install the O-ring [31] in the case ass'y [1]. 3. Install the pipe holder [29] to the exhaust pipe [28], and insert the exhaust pipe in the relay valve and the case ass'y [1]. 4. Install the pipe holder [29] to the cover [33p]. 5. Apply ThreeBond 1401 to the threads of the screw [35], and secure the case ass y side of the exhaust pipe [28] with that screw. 6. Test 3. Airtightness test (1) Leakage when booster not in operation With the relay valve supply port side pressure at 8.5 kg/cm 2, and the signal pressure at 0 kg/cm 2, apply soapy water to the relay valve exhaust port. Check that there is no air leakage. (2) Leakage when booster in operation With the relay valve supply port side pressure at 8.5 kg/cm 2, and the signal pressure at 1 kg/cm 2 and then at 7 kg/cm 2, check the following. - Apply soapy water to the relay valve exhaust port, and check that air leakage is 2.5 cc or below within a 15-second period. - Under the above air pressure condition, check that the gauge does not show any variation in hydraulic pressure for 15 seconds. - Apply soapy water to all the tightened portions, and check visually that there is no air leakage. 4. Operation characteristics test (1) Follow-up performance With the relay valve supply port side pressure at 8.5 kg/cm 2, change the signal pressure in a range of 0 to 5 kg/cm 2 repeatedly. Check that the hydraulic pressure can follow the signal pressure changes smoothly. (2) Characteristics With the relay valve supply port side pressure at 8.5 kg/cm 2, increase the signal pressure from 0 kg/cm 2 gradually. Check that the characteristics curve shown below is achieved. Hydraulic pressure After reassembly is completed, check the assembly for leakage and performance problems as follows. 1. Hydraulic section airtightness test With the wheel cylinder side outlet closed, connect a vacuum gauge and vacuum pump to the connector [21]. Keep the vacuum level in the oil cylinder at or above 600 mmhg, and check that the reading of gauge does not vary. Specification: The reading of gauge should not vary for 15 seconds at or above 600 mmhg 2. Filling with oil and air bleeding Connect the oil reservoir tank to the connector [21], and connect a pressure gauge for approx. 200 kg/cm 2 to the wheel cylinder side outlet. Add oil, and bleed thoroughly from the bleeder screw. Air pressure In parentheses: Part No Not in parentheses: Part No ,

250 T-5. Booster T Air piston return time Remove the cap [25], and mount the stroke detection bar. With the relay valve supply port side pressure at 8.5 kg/cm 2, and the signal pressure at 8.5 kg/cm 2, check that the air piston is moved to the full stroke position using the stroke detection bar. Then, discharge the signal pressure rapidly and measures the time required for the air piston to return to the zero-point position. Make sure that the piston return time is 3.2 seconds or below. 7. Maintenance Standard 1. Daily check (1) Check the fluid level in the oil reservoir tank. (2) Check for fluid leakage on and around the oil cylinder. (3) With brakes applied, check for leakage from the relay valve exhaust port with sounds large enough to be heard by the human ear hour or 1-year check Disassemble the booster and check all the parts. Replace all the rubber parts. Also replace any parts with damage that can be detrimental to operation. Execute all the tests specified

251 T-6 T-6 T-6 Air Dryer 1. Construction and Function In automobiles, compressed air is used widely for various functions. When compressed air is cooled in the reservoir and piping, the moisture contained in the compressed air condenses, and the condensed water has adverse influence on the various units. The air dryer eliminates moisture in compressed air to prevent water condensation and to prevent ill effect of water

252 T-6 T-6 Air Dryer View A 1. Body 16. Gasket ring 31 Nut 46. Terminal 2. Valve body 17. Gasket ring 32. O-ring 47. Heater 3. O-ring 18. Filter plate 33. Screw with washer 48. Gasket 4. O-ring 19. Bolt 34. Purge chamber 49. Screw 5. Piston 20. O-ring 35. Plug 50. Clamp 6. O-ring 21. Spacer 36. O-ring 51. Screw 7. Valve ass y 22. Filter 37. Stopper ring 52. Bracket 8. Valve spring 23. Desiccant 38. Bolt with washer 53. Bolt 9. Spring washer 24. Filter plate 39. Plate 54. Spring washer 10. Bolt 25. O-ring 40. Plate 55. Nut 11. Exhaust body 26. Spring 41. Thermostat ass y 56. Harness 12. O-ring 27. Cover 42. Cover 57. Screw 13. Retaining ring 28. Check valve 43. Boot 58. Nut 14. Case 29. Bolt 44. Terminal 15. Oil filter ass y 30. Spring washer 45. Cover

253 T-6 T-6 Air Dryer Description of operation 1. Dehumidifying When the compressor is in a load cycle, the compressed air from the compressor enters the air dryer through its inlet port, and is cooled around the outer surface of the case [14], letting moisture and oil content accumulate at the bottom of the body [1]. The air further flows through the oil filter ass y [15] with oil mist separator to have minute oil droplets and dust particles removed, and flows into the case [14]. In the case, residual moisture in the air is eliminated by the desiccant [23]. As the air flows upward in the case [14], moisture decreases due to contact with drier desiccant, until the air becomes dry at the upper end of the case [14]. The dry air flows into the main tank via the check valve [28] and the purge chamber. Purge chamber Check valve Check valve Desiccant Pressure regulator Main tank Inlet port Compressor Body 2. Regeneration When the air pressure in the system reaches the upper limit, the compressor reaches the unload position by the instruction of the pressure regulator. By the same instruction sent to the control port of the air dryer, the valve [7] opens, causing the inside of the case [14] to become open to the atmosphere. Due to the rapid release, the oil filter ass y [15] is cleaned by the pressure in the case [14], and oil content and condensed water are released to the atmosphere. After the rapid pressure decrease, the dry air in the purge chamber flows through the orifice and is decompression-expanded, becoming super-dry air. Flowing backward in the case [14], the air removes moisture from the desiccant [23] and sends it to the atmosphere, regenerating the desiccant. When the system returns to the load cycle, the valve [7] is closed by the instruction of the pressure regulator, the dehumidifying process starts. Purge Check valve chamber Orifice Check valve Desiccant Pressure regulator Main tank Drain valve Air dryer Control line Exhaust port Compressor

254 T-6 T-6 Air Dryer 2. Countermeasures against Failures Defective phenomenon Condensed water discharges from the main tank Condensed water does not discharge from the drain valve The dryer interior freezes Air leaks from the drain valve Pressure in the main tank abnormally decreases Causal improper maintenance 1. In such a case when the dryer has been disassembled, it requires some time for saturated air to become dry. 2. A large amount of air consumption under a special condition provides no load or unload cycles to the compressor. 3. Low (5 kg/cm 2 or below) detaching pressure of the governor (pressure regulator) prevents the drain valve from opening. 4. The desiccant and the oil filter have not been replaced for a long period. Proper action 1. Ensure that discharge of condensed water is performed in the post-work inspection or other timings, until the air becomes completely dry. 2. Provide load and unload cycles to the compressor, or check the installation of the dryer. 3. Adjust the detaching pressure of the governor to 5 kg/cm 2 or above. 4. Replace the desiccant kit every year or every 100,000 km as described in the manual. 1. Heater does not work, and the dryer freezes. 1. * If the heater is faulty, replace the heater. * If the thermostat is faulty, replace the thermostat. 2. Low (5 kg/cm 2 or below) detaching pressure of the governor prevents the drain valve from opening. 3. Foreign matters get caught in the drain valve, disabling the valve. 1. Improper installation of the air dryer causes its temperature to reach -30 C or below while driving in winter. 2. Open circuit occurring in the heater prevents heat retention. 3. Inoperative thermostat disables operation of the heater. 4. Snow ice adheres to the drain port of the air dryer, preventing regeneration process. 5. Disconnection between the heater and the thermostat disables operation of the heater. * Foreign matters get caught in the valve, preventing complete seating of the valve. * When the compressor in unload state, the air in the main tank flows backward and discharges from the dryer if the check valve between the main tank and the dryer does not serve its function. 2. Adjust the detaching pressure of the governor to the specified 5 kg/cm Disassemble and check the valve, and replace the valve kit. 1. Change the installation position of the air dryer, or install a hood to block wind. 2. Check continuity using a tester for open circuit on the heater. * If the heater has an open circuit, replace the heater. 3. Check if the thermostat works as follows. a) Leave it at a temperature of 0 C or below and check continuity using a tester. b) Hold the thermostat in the hand and check that it is turned off. * If the thermostat does not work, replace the thermostat. 4. Remove snow ice while taking care not to damage the wiring of the heater, and change the position to install the dryer. 5. Connect the heater and the thermostat properly. * Disassemble and check the valve section and replace the valve, or if the sealing surface of the valve body is damaged, replace the valve body. * Disassemble and check the check valve between the main tank and the air dryer, and replace the check valve if necessary

255 T-6 T-6 Air Dryer 3. Dismounting WARNING Dismount the air dryer after securing the vehicle and opening the drain cock to discharge the compressed air in the reservoir. 2. By inserting a flathead screwdriver in the notched portion of the purge chamber [34], remove the stopper ring [37] fitted in the purge chamber. 4. Remounting NOTE When using sealing tape for air sealing, use it carefully, as it may be pinched in the check valve or other parts. 5. Disassembly 5.1 Disassembling the cartridge 1. Disconnect the harness [56] connected to the bracket [52] and bolt [53], loosen the bolt [38] of 10 mm width across flats to remove the plates [39] and [40]. 3. Pull the body [1] out of the purge chamber [34], and then loosen the four screws [33] that secure the case [14] using a cross slot screwdriver to remove the cartridges [14] to [31] from the body. 4. While holding the cover [27] from the upper side using a special jig, loosen the six nuts [31] that secure the cover using a 10 mm wrench

256 T-6 T-6 Air Dryer 5. Remove the spring [26], filter plate [24], filter [22], desiccant [23], and filter [22] in this order from the above. 7. Loosen the nut [31] using a 10 mm box end wrench or socket wrench from above the case [14], and remove the filter plate [18], gasket ring [16], oil filter ass y [15], gasket ring [17], spacer [21], and O-ring [20] to complete disassembly of the cartridge. 6. Invert the case [14], insert a 12 mm socket in the top of the central bolt [19], and clamp its handle in a vise. Components of cartridge 5.2 Disassembling the body 1. With the heater [47] and thermostat ass y [41] to [46] installed to the body [1] facing upward, remove the retaining ring [13] using pliers for C-shaped retaining ring (for holes), and pull out the exhaust body [11] and O-ring [12]

257 T-6 T-6 Air Dryer Components of body 2. Clamp the top of the bolt [10] with pliers, and pull out the valve ass y [2] to [10]. 3. While securing the piston [5] with a 10 mm Allen wrench, loosen the bolt [10], and remove the valve ass y [7] to complete disassembly. 6. Washing Components of valve body Wash all the disassembled parts, except rubber parts and desiccant, in clean kerosene, wipe off deposits, and dry. When rubber parts are re-used, wipe them cleanly with waste cloth. Replace the desiccant with a new one

258 T-6 T-6 Air Dryer 7. Reassembly 7.1 Reassembling the cartridge 1. Insert the O-ring [20] in the groove of the spacer [21], and put the gasket ring [16] over them. 3. Insert the bolt [19] in the central hole of the case [14], and secure it with the spring washer [30] and nut [31]. Tightening 締付けトルク torque: 40 to 70 kg cm 2. Put the gasket ring [17] on the filter plate [18], and fit the oil filter ass y to which the gasket ring [16], O-ring [20], and spacer [21] are pressed in the concave portion. Then insert the bolt [19] from the filter plate side. 4. With the softer side facing upward, insert the filter [22] into the case [14] fully, and add the desiccant [23] in the case [14]. (The standard filling amount is approx. 1.1 kgf, but if desiccant is purchased as a repair kit, use a whole bag of desiccant.)

259 T-6 T-6 Air Dryer 6. Install the O-ring [25] and check valve [28] in the cover [27]. (Applying grease to the central projection of the check valve in advance facilitates inserting process.) 5. While turning the case [14], tap the outer surface of the case with a plastic hammer to settle the desiccant, and then insert the second filter [22] with its softer side facing downward. 7. Place the filter plate [24] and spring [26] in the case [14] containing desiccant, and put the cover [27] over them. Then hold the cover with the special jig, and secure with the bolt [29], spring washer [30], and nut [31]. (Since the spring load at setting reaches 74 kg, take extreme care during installation.) Tightening torque: 40 to 70 kg cm

260 T-6 T-6 Air Dryer 7.2 Reassembling the body 1. Apply grease to the O-ring [6], and install it in the piston [5]. 2. Apply grease to the O-ring sliding surfaces of the valve body [2] and the guide of the piston [5], and push the valve spring [8], piston [5], and O-ring [6] into the valve body. Then, secure with the spring washer [9] and bolt [10]. 4. Secure the plates [39] and [40] with the bolt [38]. Finally, secure the harness [56] with the screw [57] and nut [58]. 3. Insert the valve body ass y [2] to [10], O-ring [12], and exhaust body [11] in the body [1] sequentially, and secure with the retaining ring [13]. 7.3 Reassembling the main body 1. Apply grease to the O-rings [36] and [32], and install them in the body [1]. 2. Insert the cartridge [14] to [31] in the guide of the body [1] to [13], and secure with the screw [33]. Tightening torque: 40 to 70 kg cm 3. Push the body [1] to [13] and cartridge [14] to [31] into the purge chamber [34], and secure with the stopper ring [37]. (Insert the stopper ring in the groove while prying the groove with a flathead screwdriver facing outside.)