TC Publication No. Service Manual TC /S1-1E. Model. Applicable Serial No ~ BQ-TADANO LTD. PRINTED IN CHINA BQ-TADANO LTD.

Transcription

1 Publication No. TC /S1-1E Service Manual 01 TC /S1-1E Crane Carrier (Chassis) Model TC Applicable Serial No ~ 2009 BQ-TADANO LTD. PRINTED IN CHINA BQ-TADANO LTD.

2 Foreword Model: TC Serial No ~ VIN: LE7D This publication is intended to provide preliminary information concerning the use of BQ-TADANO Chassis Service Manual. It contains the composition of the chassis, the methods of repair,checks and adjustment. the descriptive contents and scope of individual volumes, definitions of the terms used, a list of recommended lubricants. BQ-TADANO reserves the right to make changes for improvement at any time without notice. Accordingly, some of the descriptions contained in this manual may not be applicable to your particular vehicle. We reserve the right to modify the design without notice for improvements, etc. 1 WA E

3 Group Index A B C D Outline PTO System Hydraulic Power Generating System Outrigger System E F G H I J K L Cab Control System M N Electrical System O P Q R S Driving Power Transmission System Steering System T U Suspension System V W X Y Z Data, Adjustment and Checks System Diagrams 2 WA E

4 Conversion Table Conversion Table Length millimeter, mm centimeter, cm meter, m inch, in, foot, ft, mile, mi kilometer, km Speed Area km/h mile/h square millimeter, mm 2 square centimeter, cm 2 square meter, m 2 square inch, in 2 square foot, ft 2 Volume cubic centimeter, cm 3, cc cubic meter, m 3 cubic inch, in 3 cubic foot, ft 3 gallon, gal cubic inch, in 3 liter, lit, L Force Mass N kgf lbf gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t WA E

5 Conversion Table Pressure Pa kpa MPa kgf/cm 2 lbf/in 2, psi Torque bar MPa kgf/cm N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf inch-pound, in-lbf N-m kgf-m ft-lbf Centigrade-Fahrenheit F C F C F C F C F C F C Conversion equation: t C=5(T o F-32)/9, T F=(9 t C+160)/5 4 WA E

6 A A Outline Contents A-1 Outline Name of each parts Carrier Carrier control device Inside cab Switch Combination meter...4 i

7 A-1 A-1 Outline A-1 Outline 1. Name of each parts 1.1 Carrier Step Step Fuel tank Coolant reserve tank Engine (inside the cover) Air cleaner Battery (inside the cover) (inside the cover) Right Rear Left Muffler Hydraulic oil tank (common to crane part) Step Step Front jack Rear outrigger Axle (1st axle) Axle (2nd axle) Front outrigger Axle (3rd axle) Axle (4th axle) F E 1 WA E

8 CC+ CCh CC/ON CC/OFF A-1 A-1 Outline 2. Carrier control device 2.1 Inside cab Fuse box Air blow louver AM/FM radio Sunshade Mirror switch Steering wheel Instrument panel HOUR METER Air blow louver Storage box Steering wheel adjustment switch Clutch pedal 53 Brake pedal 57 P. Accelerator pedal Seat P. 34 Air blow louvers Shift lever 53 Air conditioner panel Parking brake lever Cigarette lighter Fuse box F E Alarm buzzer 2 WA E

9 A-1 A-1 Outline 2.2 Switch PTO switch Clearance lamp switch Differential lock switch Suspension down switch Suspension lock switch Suspension leveling switch PTO hourmeter E lectric window switch HOUR CC+ CC- METER h CC/ON CC/OFF Air horn Battery main switch Cruise control switch Rear fog lamp switch Cruise adjustment switch Mirror Heating switch HOUR CC+ CC- METER h CC/ON CC/OFF Emergency switch OFF R L PASS UP UP OFF ON HI LO OFF INT Washer switch Lamp switch Turn signal lever Harzard warning lamp switch Wiper switch E xhaust brake lever 3 WA E

10 A-1 A-1 Outline 2.3 Combination meter Fuel gauge Front fog lamp indicator lamp (green) Rear fog lamp indicator lamp High beam indicator lamp (blue) (yellow) Turn signal indicator lamp (green) Turn signal indicator lamp (green) Speedometer Engine tachometer Air pressure gauge (Front brake circuit) oo Coolant temperature gauge Odometer/tripmeter Select/reset button Engine hourmeter Range position indicator lamp (green) Range position indicator lamps (blue) Air pressure gauge (rear brake circuit) Battery charge warning lamp (red) Steering circuit 1 abnormality warning lamp (red) Engine hydraulic pressure warning lamp (red) Engine warning lamp (red) Engine check lamp (yellow) Low air pressure warning lamp (red) Exhaust brake indicator lamp (green) Suspension lock indicator lamp (red) PTO indicator lamp (red) Cruise control indicator lamp (green) oo Unused Low coolant warning lamp (red) Air cleaner warning Unused Low engine oil warning lamp (red) lamp (yellow) Steering circuit 2 abnormality warning lamp (red) Parking brake Low fuel warning lamp (yellow) warning lamp (red) Unused CPU error warning lamp (red) Suspension leveling status indicator lamp (blue) Differential lock indicator lamp (yellow) F E 4 WA E

11 B B PT O System Contents B-1 PTO System Outline Transmission Transmission overview Interior of transmission Power flow in transmission with PTO driving hydraulic pump PTO engage/disengage mechanism Air pressure circuit Electric circuit Electric circuit Transmission range lamp PTO lamp External view of interlock system Neutral interlock system Neutral interlock system components Transmission neutral interlock system Cautions when using the PTO Operating procedure and operation of the range interlock system i

12 B-1 B-1 PTO System B-1 PTO System 1. Outline The transmission comprises two integrated sections, with 9 forward gears and one reverse gear. The first section comprises 6 gear assemblies selected with the shift lever. The second section comprises 2 gear assemblies selected by air pressure, with Hi, N, and Lo ranges. The PTO driving the main pump is mounted on the rear of the transmission, and provides engine power via the countershaft when the N range is selected for the second section. 1 WB E

13 B-1 B-1 PTO System B-1 2. Transmission 2.1 Transmission overview 2 WB E 2

14 B-1 B-1 PTO System 2.2 Interior of transmission 3 WB E

15 B-1 B-1 PTO System 2.3 Power flow in transmission with PTO driving hydraulic pump First section: Power transmitted to Lo range 4th axle gear train. Second section: N range selected, and power transmitted to countershaft driving the PTO. A neutral interlock system is incorporated to ensure that the driveshaft driving the axles does not rotate when the PTO is driven. 4 WB E

16 B-1 B-1 PTO System 5 WB E

17 B-1 B-1 PTO System 6 WB E

18 B-1 B-1 PTO System B PTO engage/disengage mechanism 7 WB E 7

19 B-1 B-1 PTO System B-1 3. Air pressure circuit Air pressure system diagram and interlock system Interlock range position; N range From 37) Air dryer 16) Safety valve 18) 14-way circuit protection 26) Air valve (PTO) L 1 5) Hand brake valve 27) Mobil-stationary select valve Y L S205 Range N switch 15) Reservoir tank (protection valve / rear service brake valve) L 19) Reservoir tank (aux. equipment) N port Y050 Plunger lock solenoid 48) Reservoir tank (spring brake) 46) Parking brake indicator lamp switch 3rd axle 4th axle S206 Range Lo switch 28) Regulator Lo port Hi port 20.0 L Hi Lo 29) Range valve 30) 3-way valve 47) Low pressure switch 53) 54) Spring brake chamber Parking brake 45) Over Load Protection Relay Valve Spring brake chamber 41) 42) 44) Quick release valve 1) Master valve Air PTO flange 33) Air cylinder (PTO) (Engage / disengage cylinder)) Oil S318 PTO detection switch Clutch pedal IWB E25 8 WB E 8

20 B-1 PTO System B-1 B-1 4. Electric ciruit 4.1 Electric circuit 101 5W 106 5W F033 10A F034 10A F037 10A F038 10A A1 102C 5Y 11 A2 12 B1 21 B2 22 E1 E2 F1 F2 618 YB (30) PTO-synchronized power supply (upper PTO control) F001 5A F002 15A F003 5A F004 10A A1 A2 B1 B2 C1 C2 D1 601A WB D2 601B WB FUSE HOLDER F061 30A F058 30A G002 AVf85B BATTERY G001 BATTERY AVf85B 104 5L AVf85B X016 Slip ring F059 (carrier key switch synchronization power supply) 1 8W 50A 101 8W Elestric circuit (crane) AV15B 101A 3W F060 50A AV15B AVf85B 88 88a 101B 3W 630 LR 86 K003 BATTERY RELAY carrier YAZAKI305 type (2P) F X012 M 104 5L L W W 101 2W W 101 2W W 101 2W W YAZAKI250 type (4P) F X011 M AMP070(20P) M X013 F 1 cab Electric circuit (control) K W 102A 5Y LB K a A 5Y 101 2W 0 B 0 B YG R 17 LW Power supply relay (energized when KEY ON) T K049(M) 608A 1.25RY S021 Power supply hold relay (timer : 10 sec.) SWF(8P) M S021 F 630 LR 625 LB 1 F041 10A F042 10A F047 10A F048 15A F051 10A F052 5A R a R Engine stop relay (from upper) 0:OFF 1:OFF 2:ON 3:START AMP250(6P) F S002 M Y 639 YG 50 A1 A2 B1 B2 C1 C2 D1 D2 0 B SWF(2P) M S021 F 0 Battery switch YG G Y G2 H1 H2 625 LB 626 LW L 640 L Y P S002 Starter switch 0:UP OFF 10 9 S317 PTO switch 1:DOWN ON A WB RG K043(M) Power supply relay (upper PTO) (energized when PTO-ON) 0 B 635 RG 87a R 102C 5Y A 5Y B S317 PTO switch ON F009 10A F010 10A F013 10A F014 10A 635 RG A1 A2 B1 B2 608A 1.25RY E1 E2 608B RY F1 F2 AMP040 Ⅱ (20P) F X067 P001 Combination meter 626 LW 11 BATT GUAGE_LU GUAGE_LD HL1 HL2 HL3 HL4 SPEED L1 L2 L3 L4 L5 L6 TURN L L7 L YG Hi BEAM FFOG RFOG SIFT 5 SIFT 4 SIFT 3 SIFT 2 SIFT 1 L9 L YO 773 Y TURN R L11 L12 L13 L14 PTO ON Parking brake ON condition L17 L Y/B 770 YG 9 2 TACHO L15 L16 L17 L18 L19 L20 Transmission N Transmission L 20 SIFT2 19 SIFT3 773 Y 772 YO 606 Y/B 91 GUAGE_RU GUAGE_RD K719(M) RW R B B a R R Engine start relay (energized : key "ON") X050 F B Engine 6 DIAG Cab Carrier AMP070(12P) M X021 F GY RW GY RW F X55 M RW 15 KL GY 8 KL A 3W 101A 2W 5 KL30 101B 3W 101B 2W 6 KL30 Electric circuit 7 (power supply) WR 12 ANLA 01 3B 01 2B 02 3B 02 2B 9 KL31 11 KL31 AMP JPT(21P) F X52 M 1.(21 pin connector) YG 1 KL.30 supply voltage(12v/24v) RW 2 KL.15 ignition switch(terminal15) B 3 KL.31 battery ground AMP JPT(18P) F X53 M 3.(18 pin connector) YB 7 FG_WAHL throttle select 636 YB 10 PTO remote PTO 636 YB 11 LIM0 limiter Engine main body A013 MR A014 ADM2 AMP JPT(12P) 2.(12 pin connector) F X51 M GY 1 KL.50 engine start,terminal terminal15(ignition) terminal50(start) starter ground ground (15 pin connector) 11 transmission neutral NE Battery voltage Battery voltage 709 LgB A015 DCU RG Do20(-) Do22(-) Do23(-) Parking Lo Parking Lo Di20(-) 83 BL Di22(-) Di23(-) LgB N N 564 LgW Do38(-) PTO PTO detection Di37(-) BL 562 LgB 698 LgR 637 G AMP070(18P) F X022 M LgB 698 LgR 637 G AMP070(14P) F X023 M 1 83 BL BL G G LgB 017 B 698 LgR YAZAKI 62Z(2P) F S206 M B 1 B 2 YAZAKI 62Z(2P) F S205 M 1 B LgR B B 2 YAZAKI 62Z(2P) F S203 M 637 G B B 2 0 B G YAZAKI SWP(6P) F X024 M B B G 2 0 B 1 YAZAKI 62Z(2P) F Y052 M Transmission S206 Range L (contact closes at range L) S205 Range N (contact closes at range N) S203 Shift N (contact closes at shift N) Y050 Plunger Lock (energized : lock release) S318 PTO (contact closes at PTO ON) Air unit Y052 Stationary Mobile SOL WR AVf85B AVf85B 50(S) 30(B+) M M 31(GND) B+ 4 BS 5 1 W 2 L 3 15 B- AMP 250 F M002 M G 1 M001 Starter motor G003 Alternator M002 Compressor clutch 564 LgW V LgB 709 LgB 675 Lg 0 2B V YB 634 BL 637 G (Range N) (PTO detection) 564 LgW 0 B K079(M) a 0 B 698 LgR R Range N (contact "ON" when range N) 635 RG 674 GL 30 K078(M) 87 87a 649 LB 635 RG R Parking relay (contact "ON" when "PARK") 649 LB 83 BL V013 (parking) YAZAKI SWP(3P) M S201 F 608B RY 675 Lg 0 B S201 Clutch switch (energized when clutch pedal is depressed) Br B L 674 GL 676 LB 675 Lg 674 GL K075(M) a K076(M) R 674 GL 676 LB B 676 LB 87a R 676 LB 648 G K077(M) a 676 LB PTO select relay Clutch relay (shift R : PTO-OFF) (contact "ON" when clutch pedal is depressed) R 83 BL 063 B S042 Parking brake switch (contact closes at parking brake operation) (contact closes at low air pressure P<0.37MPa) IWB E WB E

21 B-1 B-1 PTO System 4.2 Transmission range lamp N, Lo, and Hi transmission range statuses are indicated by lamps. Hi is lit when both the N and Lo detector switches are 0. The N lamp flashes if range N is not selected (deselected) despite the PTO being ON (OFF). The range N and Lo lamps flash rapidly if a malfunction occurs in the N or Lo detector switches (detected as both ON). Input status Output status Di8 (PTO operation) Di22 (Lo) Di23 (N) Do7 (Hi) Do22 (Lo) Do23 (N) /1_L /1_L /1_L /1_H 0/1_H Remarks 1: Operating switch ON H 0: Operating switch OFF L 1: Detector switch closed L 0: Detector switch open H 1: Transistor ON 0: Transistor OFF 0/1_L: 800ms cycle (400 msec ON, 400 msec OFF). 0/1_L: 400 ms cycle (200 msec ON, 200 msec OFF). Note 1 The lit/extinguished timing of all lamps with the same flashing cycle is synchronized if their output conditions are satisfied WB E

22 B-1 Chap.2 Carrier B-1 PTO System 4.3 PTO lamp The PTO lamp is lit when the PTO is connected. If the PTO operation switch status and the detector switch status do not match, the lamp flashes to indicate a PTO operation procedure error or malfunction. Remarks Input status Output status Di8 (PTO operation) Di37 (PTO detected) Do38 (PTO) Other than above 0/1 1: Operation switch closed H 0: Operation switch open L 1: Detector switch closed L 0: Detector switch open H 1: Transistor ON 0: Transistor OFF 0/1: ON/OFF in 800 msec cycle (400 msec ON, 400 msec OFF). Note 1 The lit/extinguished timing of all lamps with the same flashing cycle is synchronized if their output conditions are satisfied Revised Aug WB E

23 B-1 B-1 PTO System 5. External view of interlock system 12 WB E

24 B-1 B-1 PTO System 13 WB E

25 B-1 B-1 PTO System 14 WB E

26 B-1 B-1 PTO System 6. Neutral interlock system 6.1 Neutral interlock system components 15 WB E

27 B-1 B-1 PTO System 6.2 Transmission neutral interlock system Range position Description When the transmission shift position is R, Lo, 1st, 2nd, 3rd or 4th, Lo range is selected for the second section of the transmission, and engine power is transmitted from the output shaft to the rear axles. The range neutral piston is used to select the N range for the second section of the transmission to drive the hydraulic pump from the PTO. In this case, transmission of power to the output shaft (driving the rear wheels from the main shaft) is halted, and power transmitted only to the PTO. To ensure that power is properly transmitted, the range neutral piston is locked in the N range with dual interlock of neutral lock plunger (air pressure) and lock plunger (spring force). The solenoid (Y050) is energized only when releasing the lock plunger (when (S205) detects N range and (S203) detects transmission shift N). When the transmission shift position is 5th, 6th, 7th, 8th, or 9th, the Hi range is selected for the second section of the transmission, and engine power is transmitted from the output shaft to the rear axles. 16 WB E

28 B-1 B-1 PTO System 7. Cautions when using the PTO!WARNING! - FAILURE TO FOLLOW PROPER OPERATING PROCEDURES MAY CAUSE VEHICLE TO MOVE WHEN PTO IS ENGAGED. VEHICLE AIR SYSTEM PRESSURE MUST BE FULLY CHARGED AND PARKING BRAKES APPLIED. TRANSMISSION RANGE SELECTOR MUST BE IN N POSITION PRIOR TO SELECTING TRANSMISSION LO RANGE. PLACE THE TRANSMISSION SHIFT LEVER ONLY IN 4TH GEAR. IF A GEAR OTHER THAN 4TH IS SELECTED, THE VOLUMETRIC EFFICIENCY OF THE PUMP IS REDUCED, AND THE CAB COOLER AND OIL COOLER MOTORS MAY BE DAMAGED. APPLY VEHICLE BRAKES AND SLOWLY ENGAGE DRIVE CLUTCH TO ENSURE THAT VEHICLE REMAINS STATIONARY, AND BEGIN OPERATING PTO. STATIONARY PTO OPERATION FULLY CHARGE VEHICLE AIR SYSTEM. APPLY VEHICLE PARKING BRAKES. DISENGAGE DRIVE CLUTCH. PLACE TRANSMISSION LEVER IN NEUTRAL IN LO RANGE. SELECT PTO ON WITH PTO SWITCH. VERIFY PTO AND TRANSMISSION NEUTRAL INDICATORS ARE ON. PLACE TRANSMISSION SHIFT LEVER IN 4TH GEAR. APPLY VEHICLE BRAKES. SLOWLY ENGAGE DRIVE CLUTCH TO BEGIN OPERATING PTO. RESTORE MOBILE TRANSMISSION OPERATION DISENGAGE DRIVE CLUTCH PLACE TRANSMISSION LEVER IN NEUTRAL IN LO RANGE. DISENGAGE PTO CONTROL. VERIFY PTO AND TRANSMISSION N RANGE INDICATORS ARE OFF, AND TRANSMISSION LO RANGE INDICATOR IS ON. 17 WB E

29 B-1 B-1 PTO System B-1 8. Operating procedure and operation of the range interlock system The description of the system assumes that the engine is at low idle speed. Operating procedure Description of electrical system Description of air pressure system 1) Pressurize air tank. Spring brake reserve tank (48) is pressurized. Low-pressure switch (47) is turned OFF (lamp lit at 540 kpa). Brake air pressure low alarm switches (S052) and (S052) OFF. Combimeter brake air pressure low alarm lamp (Combimeter L7 (P001)) is extinguished, and alarm buzzer (B009) ceases. 2) Apply parking brake. Switch hand brake (5) to parking position. Parking brake chambers (41), (42), (53), and (54) are operated. Parking indicator contact (46) is turned ON (lamp lit at 373 kpa). Parking brake switch (S042) is turned ON. Parking brake relay (K078) is turned ON. Combimeter parking brake indicator lamp (Combimeter L10 (P001)) is lit. 3) Move shift lever to Neutral position. Transmission neutral detector switch (S203) ON (plunger lock solenoid (Y050) not yet energized). 4) Move range selector lever (fitted on shift lever) to Range Lo position. Master valve (range selector lever) (1) is set to Lo position. Lo port Hi port Pilot pressure is released, and range valve (29) is set to Lo position. Air pressure from regulator (28) acts on range neutral piston (32) Lo port via range valve (29). Air in range neutral piston (32) Hi port is exhausted from range valve (29) Hi port via pilot operated 3-way valve(30). Range neutral piston (32) moves to Lo range direction. 18 WB E 18

30 B-1 B-1 PTO System B-1 Operating procedure Description of electrical system Description of air pressure system Range Lo switch contact (S206) is turned ON. S206 DCU(A015) lights combimeter transmission L lamp (Combimeter SIFT13 (P001)). 5) Depress clutch pedal and set PTO switch ON. Proximity switch (S201) is turned ON. PTO-ON switch (S317) is turned ON. Clutch relay (K075): ON Clutch relay (K076): ON Hold Via PTO selector relay (K077) Stationary/mobile solenoid valve (Y052)/ (27) is energized. Stationary/mobile solenoid valve (27)/ (Y052) is switched to Station position. Range valve (29) Lo port pressure acts on valves (26) and (30), and Range neutral plunger (31). Pilot operated 3-way valve (30) is switched. Same pressure acts on Range neutral piston (32) Hi port as on Lo port. Piston moves in Hi Range direction due to left-right difference in its surface subject to pressure. Lo port Hi port 19 WB E 19

31 B-1 B-1 PTO System B-1 Operating procedure Description of electrical system Description of air pressure system Air pressure acting on N port presses Range neutral plunger (31) against Range neutral piston (32). Range N switch (S205) ON. Plunger lock solenoid (Y050) energized. Range Lo contact (S206) is turned OFF. DCU(A015) extinguishes combimeter transmission L lamp (Combimeter SIFT13 (P001)). Range neutral piston (32) is locked in a position equivalent to N range by plunger (31). Air valve (PTO) (26) is switched. Reservoir tank (19) air pressure acts on PTO selector cylinder (33) via Air valve (26). PTO is engaged. PTO ON detector switch (S318) is turned ON. PTO ON detector switch (S318) ON signal is received at Transmission neutral and Remote PTO on ADM2 (A014). ADM2 (A014) outputs MAP signal (e.g. torque, rpm) to engine via MR (A013). Combimeter PTO lamp (Combimeter L17 (P001)) is lit. PTO hour meter relay (K060) (electric circuit power supply) is turned ON. 20 WB E 20

32 B-1 B-1 PTO System B-1 Operating procedure Description of electrical system Description of air pressure system 6) Move shift lever to 4th. Shift N detector switch (S203) is turned OFF. Plunger lock solenoid (Y050) is de-energized. De-energized Plunger lock solenoid plunger (Y050) locks Plunger (31) at N Range with spring force to ensure that Plunger (31) locks Piston (32) firmly at N Range. 7) Release clutch pedal, and drive hydraulic pump from PTO. Check for sound indicating that engine is driving hydraulic pump from PTO. 21 WB E 21

33 C C Hydraulic Power Generating System Contents C-1 Hydraulic Pump Mounting Main pump and steering pump Emergency steering pump... 2 C-2 Hydraulic Pump (Variable Piston + Gear Pump) Structure General view Inside view... 4 C-3 Hydraulic Pump (Steering) (Gear)...13 C-4 Hydraulic Pump (Emergency) (Radial Piston)...15 C-5 Flow Control Valve Structure i

34 C-1 C-1 Hydraulic Pump Mounting C-1 C-1 Hydraulic Pump Mounting 1. Main pump and steering pump WB E 1

35 C-1 C-1 Hydraulic Pump Mounting 2. Emergency steering pump (Dismounted) WB E

36 C-2 C-2 Hydraulic Pump (Variable Piston + Gear Pump) B-2 Hydraulic Pump (Variable Piston + Gear Pump) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1.1 General view Hydraulic Symbols Symbol Name Size A1, A2 Delivery port SAE11/4 (High pressure type) A3, A4 Delivery port SAE1 (Standard type) S1 Suction port SAE3 (Standard type) S3, S4 Suction port SAE11/4 (Standard type) X1, X2 Pilot port G1/4 L1, L2 Drain port G3/4 U1, U2 Air bleeding port G3/8 (Plug) 3 W E

37 C-2 C-2 Hydraulic Pump (Variable Piston + Gear Pump) 1.2 Inside view Variable displacement piston pump 4 W E

38 C-2 C-2 Hydraulic Pump (Variable Piston + Gear Pump) 1.Control section (C.W. rotation) 9.shaft section (front) Plug 2.Control section (C.C.W rotation) 10.shaft section (rear) 18.O-ring 26.O-ring 3.Port plate section 11.Pump housing 19.O-ring 27.Hexagon socket head bolt 4.Rotary section (C.W. rotation) 12.Pump housing 20.O-ring 28.Adapter ring 5.Rotary section (C.C.W rotation) 13.Cover Coupling 6.Piston section 14.Coupling Gear pump 7.Hanger section (C.W rotation) Hexagon socket head bolt 40.Elbow joint 8.Hanger section (C.C.W right rotation) Plug Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf T2 G3/ T3 G3/ T4 (*1) T5 M T T7 M T8 M T9 (*2) Be careful to the direction when installing 7. and 8. (Refer to the hanger section in attached paper) 2. Be careful to the direction when installing 28. (Install 28. so that the discharge ports of the variable displacement pump and gear pump become same direction.) 3. Be careful to the falling when assembling 18. (*1):Apply LOCTITE 241 (*2):Apply THREE BOND W E

39 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Control Section (1), (2) (This view shows C.W rotation ) 1.Regulator cover section 10.Adjust screw 18.Parallel pin 26.Nut 2.Body 11.Arm 19.O-ring 27.Plug 3.Guide 12.Spring 20.O-ring 28.Hexagon socket head bolt 4.Barrel 13.Spring 21.O-ring 29.Orifice 5.Spool 14.Spring 22.O-ring 30.Shim 6.Spring seat 15.Spring 23.O-ring 31.Shim 7.Spring seat 16.Parallel pin 24.Hexagon socket head bolt 32.Shim 9.Guide 17.Parallel pin 25.Hexagon socket head bolt Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf T1 M T2 M T3 M T4 M W E

40 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Regulator cover section (Control section) 1.Cover 2.Piston 3.Plug 4.Hexagon socket head bolt 5.O-ring 6.O-ring Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf T1 M T2 M W E

41 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Port plate section (3) 1.Port plate 6.Plug 7.Hexagon socket head bolt 8.Parallel pin 9.O-ring 10.O-ring Thread size and tightening torque Tightening torque Sign / port Thread size N-m kgf-m ft-lbf T1 M Apply THREE BOND 1305 to the plug 5 (12 places) 8 W E

42 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Rotary section (4), (5) Piston section (6) 1.Piston 7.Spring 1.Piston 4.Piston 2.Cylinder block 9.Pressure pin 2.Cylinder 5.Spring 4.Retaining plate 10.V ring 3.Cylinder 6.Retaining ball 11.Backup plate 9 W E

43 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Hanger section (7), (8) 1.Joint (control piston) 2.Hanger 3.Metal 4.Orifice 10 W E

44 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Shaft section (9) (front) Shaft section (10) (rear) 1.Shaft 6.Bearing 1.Shaft 4.Bearing 2.Seal case 7.Oil seal 2.Shim 5.Bearing 4.Shim 8.C-retaining ring 5.Bearing 9.O-ring 1. Apply the grease equivalent to MORITON GREASE NO.2 (Product by SUMICO ) to the lip of oil seal W E

45 C-2 C-2 Hydraulic Pump(Variable Piston + Gear Pump) Gear pump (30) 1.Frame 10.Side plate 19.C-retaining ring 28.Bolt 2.Body 3.Body 4.Case 5.Gear 6.Gear 7.Gear 8.Gear 9.Side plate 11.Seal ring 12.Coupling 13.Collar 14.Bolt 15.Bearing 16.Square ring O-ring 20.Plain washer 21.Plug 22.Plain washer 23.Nut 24.Parallel pin 25.O-ring 26.Bolt 27.Spring washer 29.Stud bolt Name plate Metal 36.Bush W E

46 C-3 C-3 Hydraulic Pump (Steering) (Gear) C-3 C-3 Hydraulic Pump (Steering) (Gear) 13 W E 13

47 C-3 C-3 Hydraulic Pump (Steering) (Gear) W E

48 C-4 C-4 Hydraulic Pump (Emergency) (Radial Piston) C-4 C-4 Hydraulic Pump (Emergency) (Radial Piston) W E 15

49 C-5 C-5 Manual Control Valve (Lower) C-5 Manual Control Valve (Lower) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 16 W E

50 C-5 C-5 Manual Control Valve (Lower) 1.Front cover assy 4.Control valve assy 7.Relief valve assy 10.Carry-over assy 2.Rear cover assy 5.Control valve assy 8.Check valve retainer 11.Control valve assy 3.Bolt 6.Nut 9.O-ring 12.Port relief valve assy Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf P, T, A1,V G1/ A3, A4, A5, A6, B1, B2, B3, B4, B5, B6, C G3/ Extension / retraction selector assy 1.2 Supply / drain assy 17 W E

51 C-5 C-5 Manual Control Valve (Lower) 1.3 Jack / slider selector assy 1.4 Relief valve assy 1.5 Port relief valve assy W E

52 C-6 C-6 Flow Control Valve C-6 Flow Control Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure PB 7 4 PA T IW E T PA PB IW E IW E03 1.Valve body 2.Spool 3.Spring 4.Plug 5.Plug 6.O-ring 7.Relief valve assy Thread size and tightening torque Sign / Port Thread size Tightening torque N-m kgf-m ft-lbf 4, PA G3/ T, PB G1/ W E

53 D Outrigger System D D-1 Jack Cylinder Structure... 1 Contents D-2 Pilot check Valve (Jack Cylinder Retracting Prevention) Structure... 2 D-3 Extension Cylinder Structure... 3 D-4 Front Jack Cylinder Structure... 4 D-5 Pilot Check Valve Construction... 5 D-6 Outrigger Extension Length Detector Structure and function Disassembly Reassembly... 8 i

54 D-1 D-1 Jack Cylinder D-1 Jack Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1.Cylinder 2.Rod 3.Bolt 4.Spring washer 5.Bolt 6.Stopper 7.Set screw 8.Piston 9.Packing 10.Backup ring 11.O-ring 12.Backup ring 13.O-ring 15.Rod cover assy 16.Packing 17.Backup ring 18.Dust seal 19.Damper ring 21.Backup ring 22.Plain bearing Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf 3,5 M T1 M18 (8.8) W E

55 D-2 D-2 Pilot Check Valve (Jack Cylinder Retracting Prevention) D-2 Pilot check Valve (Jack Cylinder Retracting Prevention) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 9 C D A B C D IW ,8 2 A B Valve body 2.Plug 3.O-ring 4.Valve 5.Spring 6.Piston 7.O-ring 8.Backup ring 9.O-ring IW Seat Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf A G1/ B G1/ Mounting bolt M W E

56 D-3 D-3 Extension Cylinder D-3 Extension Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1.Cylinder 4.Piston 7.O-ring 10.Dust seal 2.Nut 5.Rod 8.Packing 3.Seal ring 6.Rod cover 9.Backup ring Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf A, B, C G3/ D, E G1/ M W E

57 D-4 D-4 Front Jack Cylinder D-4 Front Jack Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1.Cylinder 8.Plain bearing 15.Dust seal 22.Plate 2.Set screw 9.Rod 16.Stopper 23.Rod 3.Piston 10.Rod cover ass'y 17.Bolt 24.Spring 4.Packing 11.O-ring 18.Spring washer 25.Plain washer 5.Backup ring 12.Damper ring 19.Bolt 26.O-ring 6.O-ring 13.Packing 20.Backup ring 27.O-ring 7.Backup ring 14.Backup ring 21.Limit switch 28.Washer W E

58 D-5 D-5 Pilot Check Valve D-5 Pilot Check Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Construction 1.Valve body 2.Plug 3.O-ring 4.Valve 5.Spring 6.Piston 7.O-ring 8.Backup ring 9.O-ring 10.Seat 11.Plug Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf A, B G 1/ Mounting bolt M W E

59 D-6 D-6 Outrigger Extension Length Detector D-6 Outrigger Extension Length Detector [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure and function 1. The detector consists of the following major components: a spiral spring, wire, and potentiometer. 2. The wire wound around the drum is unwound or rewound by the action of the spiral spring as the cylinder extends or retracts. 3. The consequent rotation of the drum drives the potentiometer shaft through gears which reduce the speed to 5/6. 4. The rotation of the shaft causes a proportional change in the electrical resistance of the potentiometer. This change is supplied by the multiplex data transmission (MDT) system to the AML (Load Moment Indicator) unit for detection of the outrigger extension length. 5. When the wire is reeled out, the gears, potentiometer, and potentiometer brush either rotate or move. Electric symbols Potentiometer 1 B 3 R 2 W Black Red White 0V +5V (Power supply) Out put IW E01 1 Use silicon sealant to seal the part that is shaded V (Black) Power supply (Red) 19 IW E02 Output (White) 6 W E

60 D-6 D-6 Outrigger Extension Length Detector 1. Base plate 6. Nut 11. Screw 16. Screw 2. Drum assy 7. Potentiometer 12. Set screw 17. Clamp 3. Case 8. Cover 13. Screw 18. Connector 4. Packing 9. Shaft 14. Gear B 19. Cable 5. Gear A 10. Bolt 15. Bracket Specification Item Specifications 4. Remove screw to remove case. Case Gear ratio 6/5 Potentiometer Resistance: 2kΩ ± 5% Mechanical rotating angle: 360 Screw 2. Disassembly 1. Get the wire slowly rewound round the drum until the power spring loses its power. IW E05 5. Remove bolt and separate drum assy and base plate. 2. Remove screw and loosen clamp to remove cover. Cover Screw Clamp Cable IW E03 3. Remove screw and remove potentiometer and gear together with bracket. Potentiometer 6. Remove the wire from the drum assy. Gear Bracket Screw IW E04 7 W E

61 D-6 D-6 Outrigger Extension Length Detector 3. Reassembly 1. Put a zero marker on a new wire by winding a yellow tape on it. Then tie an auxiliary string of about 1.0 m (3.3 ft) in length to the terminal of the wire. 4. Apply grease (Molyspeed Grease No.0) to the bearing of case and put the case over drum assy. In this time, lead the end of the auxiliary string out through the opening of the cord guide. Case Drum side Zero marker (yellow tape) Aux. string Scrwe L3 L4 Approx. 1m (3.3ft) IW E05 L3 : 2.72 m (8.9ft) L4 : 0.08m (0.26ft) IW E10 2. Wind the wire round drum assy until the yellow tape position. Then wind it three additional turns an secure the wire with a packing tape to prevent it from getting loose. [NOTICE] The wire winding direction should be clockwise as viewed from the shaft end. 5. Secure case on base plate with screw. 6. Draw out the wire from the guide window of the reel. After the wire has been extended to the 0-point mark (yellow tape), secure the wire to the case with gummed tape. 7. Rotate gear A of the potentiometer by hand. At the position where the resistance between B and W is 200 ± 30Ω, mesh gears A and B, and install the potentiometer. Gear B Gear A Gear side Gummed tape IW E11 3. Mount base plate on drum assy with bolt. IW E09 Potentiometer 1 B 3 R 2 W Black Red White 0V +5V (Power supply) Out put IW E01 8 W E