Publication No.

GR-700EXL-1/S2-2E

02

Rough Terrain Crane

GR-700EX-1
Model
GR-700EXL-1
Applicable Serial No. 545870 --
 Safety

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

Safety precautions and recommendations are outlined

in this section and are also included in the operation
and maintenance instructions given in subsequent
sections. Warning labels are also provided on the
machine.
The cautionary instructions in this manual are
identified as "DANGER", "WARNING", "CAUTION" or
"NOTICE". These terms are defined as follows:

DANGER
DANGER indicates an imminently hazardous
situation, which, if not avoided, will result in death
or serious injury.

WARNING
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.

CAUTION
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
a minor or moderate injury.

1 WA01-0041E
 Safety

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

vehicle loses its balance and falls down on a
Servicemen inexperienced in the units of this machine worker in a dismounting process of certain units.
should be cautious about safety operations. They
must acquire sufficient knowledge about the 7.When the working is done on a team of more than
equipment before dismounting and disassembling it. one person, make arrangements about
Before dismounting each component, a serviceman co-operation and communication between workers
should read this service manual thoroughly and find beforehand. Give a sign without fault and make
out the weight of the component, then lift it by proper sure that the sign has been transmitted to other
means. workers before starting the next operation.
The following are cautions to be observed all the time. 8.When it is inevitable to measure oil pressure,
rotational speed, and temperature for machine
1.Before starting repairs, find out the origin of the
inspection without stopping the engine, be careful
problem. When it becomes clear that
not to be caught or pinched in rotating or moving
disassembly and maintenance are necessary, first
parts such as a fan, fan belt. Make sure that
of all read this manual and parts catalog and
there is no obstruction or no person around the
thoroughly understand the principle of operation
machine before operating it.
and construction. Then carefully check and
examine each portion. Don't disassemble
portions unrelated to the problem. Unless taking
all possible measures before starting disassembly, 2. Cautions in working
new troubles or decline in performance may be
induced. 2.1 General
2.Before operating the machine, oiling or repairing, 1.When hoisting up components weighing more than
read warning labels and instructions on the 20 kg, use hoist or the like to prevent injury to your
machine and understand the contents. lumbar or spine. For specific components, their
weights are listed on the chapter for "service data"
3.Wear a safety helmet and safety shoes whenever
in this manual.
you carry out maintenance operation around the
machine. Be sure to wear safety goggles when 2. When using eyebolts, lift parts vertically so that
you hit the machine or its attachments with a only tension is applied to them.
hammer. In welding operation, wear safety gears
such as leather gloves, helmet, goggles, apron 3.Protect wire ropes and plastic lifting slings by
and proper working clothes, but don't wear loose covering corners with pads so that they are not
or torn clothes. Take a ring and so on off your bent sharply by directly contacting corners.
finger when you conduct maintenance or repair. Keep the sling angle of wire ropes within 60°and
as vertical as possible.
4.Park the machine on as level and hard ground as
possible. Place chocks under wheels to prevent 4.Be careful about hot or heated portions when
the vehicle from moving when doing maintenance conducting repair or maintenance just after the
on or below the machine. vehicle has stopped or the machine operation has
been finished or interrupted.
5.Before starting maintenance, remove cables to the
battery and allow the capacitors to discharge. 5.When hitting parts, be sure to either hit on a pad
Pull out the ignition key and hang a tag saying, placed on the parts or use a plastic hammer.
"Don't start the engine." in the cab.
6.Put units, especially similar parts, in order. Mark
6.Don't carry out maintenance while lifting the them with tags or marker if necessary.
vehicle with only a jack or a hoist. Sustain the
vehicle positively with blocks and so on to prevent

2 WA01-0041E
 Safety

7.Put disassembled parts in order so that parts such In case that the position of the center of gravity is
as bolts are not left behind in the machine. And not clear and there is a possibility of swing of load
check that no parts run short at assembly. after removing, use two hoists.

8.Watch your step in the following cases: 8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
When stepping up to or stepping down from the
hinder removing.
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble 2.3 Remounting and assembling
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder 1.Before assembling, clean all the parts and repair
When checking engine oil, radiator coolant, or or replace defective parts.
battery fluid.
2.As dirt and soil adversely affect sliding portions
When replacing a filter of air cleaner
and they may decrease the life of the machine,
When getting on and off the cab
pay special attention to avoid intrusion of dirt and
Be careful not to slip in the above operations in soil.
winter as snow and ice may attach to the exterior
3.Use special tools for parts when specified to do so.
of boom and it becomes very slippery.
4.Remove dirt, soil, water, and resin completely from
2.2 Dismounting and disassembling surfaces where liquid gasket will be applied.
1.Before dismounting and disassembling, make sure 5.After remounting, be sure to inspect the machine
of the construction and part sales unit by reading and verify that there is no error by oversight. If
this manual and the separate parts catalog, then adjustment or air bleeding is required, conduct it
understand the procedures of dismounting and according to instructions. Conduct function and
remounting and disassembling and reassembling. performance test to verify its integrity.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging 3. Cautions in operation
the confined pressure.

3.Before removing, clean the part to be dismounted 3.1 Brake fluid replenishment
and the area surround it. Seal the opening with a
1.When the brake-warning lamp (for fluid level) is
plug or tape, etc. to prevent foreign material from
lighted, replenish brake fluid and check and make
entering it.
sure of the thickness of disk brake pads. (Refer
4.Measure and record the data such as shim to Chapter Y for periodical inspection periods.)
thickness adjustment and pre-load at disassembly
2.Check the thickness of disk brake pads whenever
that will be required at reassembly.
brake fluid is replenished.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling. 3.2 Handling of battery

6.If a part cannot be removed after removing bolts or 1.Erroneous handling of a battery may cause it to
nuts fixing it, don't apply too much force to it but catch fire and explode.
check the part for the cause. Only after relieving Be extremely sure to avoid short circuits, sparks
the cause, proceed disassembling. and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
7.Use lifting slings appropriate for the weight and Charge up batteries and use them only in well
characteristics of a part. Lift up it in balanced ventilated places.
condition.

3 WA01-0041E
 Safety

2.Battery fluid (dilute sulfuric acid) may cause loss of 4.1 Gasoline
sight or burn injury.
1.Spill or leak: Review fire and explosion hazards
If battery fluid stains an eye, skin, or clothes,
before proceeding with clean up. Use appropriate
immediately wash down them with a great deal
personal protective equipment during clean up.
of water.
Dike spill. Prevent liquid from entering sewers,
If battery fluid enters into an eye, immediately
waterways, or low areas. Soak up with sawdust,
wash it down with water and see a doctor for
sand, oil dry or other absorbent material. Shovel or
medical aid.
sweep up.
3.When removing terminals, remove the minus (－)
2.Remove source of heat, sparks, flame, impact,
terminal first. When connecting terminals,
friction or electricity including internal combustion
connect minus (－) terminal last.
engines and power tools. If equipment is used for
spill cleanup, it must be explosion proof and
3.3 Handling of radiator
suitable for flammable liquid and vapor.
1.Don't open the radiator cap while the coolant is still
Note: Vapors released from the spill may create an
hot.
explosive atmosphere.
2.Check the coolant at the reservoir tank.
3.Waste disposal method: Treatment, storage,
3.If high-pressure water is used for radiator cleaning, transportation and disposal must be in accordance
fins may be damaged. with applicable federal, state, provincial, and local
regulations. Do not flush to surface water or
3.4 Cooling fan sanitary sewer system.

1.Stop the engine completely before checking the 4.By itself, the liquid is expected to be a RCRA
tension of the engine fan belt. ignitable hazardous waste.

2.The oil cooler fan may rotate the moment the

4.2 Hydraulic oil
engine is started. Be sure to pull out the ignition
key before accessing the cooling fan. 1.Spill of leak: Contain spill immediately in smallest
area possible. Recover as much of the product
itself as possible by such methods as vacuuming,
4. About waste disposal followed by soaking up of residual fluids by use of
absorbent materials. Remove contaminated items
1.Waste oils, used filters, and other such
including contaminated soil and place in proper
petrochemical-related products, if disposed of
containers for disposal. Avoid washing, draining or
thoughtlessly, will cause environmental
directing material to storm or sanitary sewers.
contamination.
2.Waste disposal method: Recycle as much of the
2.Obtain a proper-sized vessel before releasing
recoverable product as possible. Dispose of
waste oils from the machine. Never discharge
nonrecyclable material as a RCRA hazardous
waste oils on the ground or into rivers, lakes or
waste by such methods as incineration, complying
marshes.
with federal, state, and local regulations.
3.Follow all governing environmental rules and
regulations when disposing of oils, fuels, cooling 4.3 Motor oil
water, brake fluid, solvents, filters, batteries or any See HYDRAULIC OIL above.
other damaging substances.

4 WA01-0041E
 Foreword

Foreword
This service manual describes the composition of the Model GR-700EXL-1 and GR-700EX-1 rough terrain crane,
its repair, check and adjustment methods and other relevant matters. Note that this service manual does not
provide the information in the separate service manuals given below.

This service manual applies to the cranes with the specification numbers given below. Check the specification
number on the nameplate of your crane.

Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.

1. Applicable spec. No. / Crane model

SPEC. NO. SERIAL. NO.

MFG.DATE.

KAGAWA, JAPAN

ISA04-001601

Crane model Spec. No. Applicable serial No.

GR-700E-1-00211
GR-700EXL-1 545960 -- 546189
GR-700E-1-00212

GR-700E-1-00211 546199--
GR-700EX-1
GR-700E-1-00212 546190--

2. Separate service manual

Separate Service Manual Information No.
General Cautions SA01-01-2E
Overload Prevention Device (AML) W301-0215E
Multiplex Data Transmitter W303-0257E
Torque Converter
W561-0101E
Transmission
Driving Axle W563-0053E

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

1 WA04-2091E
 Foreword

3. Outline of specifications
Spec. No.
Item GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

No. of boom sections 5

No. of jib stages 2

Single top Option

Main winch Fitted

Auxiliary winch Fitted

Winch Winch brake Automatic brake (Neutral brake)

Visual-type Option
Drum rotation
indicator
Touch-type Option ―

Weight Counterweight Removable type

Overload Prevention Device (AML) AML-L B

Auto. stop solenoid valve energizing type Normally energized

AML external indicator lamp Fitted

AML external buzzer Fitted ―

Oil cooler Fitted

Emergency engine stop system Fitted ―

Reversing steering compensator Fitted ―

Air conditioner Option

Emergency steering Fitted Option

Steering pump warning lamp Fitted ―

Over-unwinding prevention Option ―

Outrigger control box (Both sides of carrier) Option ―

Engine model MITSUBISHI 6M60-TLA3B

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

2 WA04-2091E
 Foreword

4. Conversion table
Length
millimeter, mm centimeter, meter, m inch, in, ” foot, ft, ’ mile, mi kilometer,
cm km
1 1×10-1 1×10 -3
3.93701×10 -2
3.28084×10 -3
1 1.60934
-2 -1 -2
1×10 1 1×10 3.93701×10 3.28084×10 6.21373×10-1 1
3 2
1×10 1×10 1 3.93701×10 3.28084
-2
2.54×10 2.54 2.54×10 1 8.33333×10-2
3.048×102 3.048×10 3.048×10-1 1.2×10 1

Area
square millimeter, mm2 square centimeter, cm2 square meter, m2 square inch, in2 square foot, ft2
1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5
1×102 1 1×10-4 1.55×10-1 1.07639×10-3
1×106 1×104 1 1.55×103 1.07639×10
2 -4
6.4516×10 6.4516 6.4516×10 1 6.94444×10-3
9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1

Volume
cubic centimeter, cubic meter,
cm3, cc cubic inch, in3 cubic foot, ft3 gallon, gal cubic inch, in3 liter, lit, L
m3
1 1×10-6 6.10237×10-2 3.53147×10-5 1 2.31×102 3.78541
6 4 -3
1×10 1 6.10237×10 3.53147×10 4.329×10 1 1.63871×10-2
1.63871×10 1.63871×10-5 1 5.78704×10-4 2.64172×10-1 6.10237×10 1
4 -2 3
2.83168×10 2.83168×10 1.728×10 1

Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
-3 -2 -3 -6
1 1×10 3.5274×10 2.20462×10 1×10 1.10231×10-6
1×103 1 3.5274×10 2.20462 1×10-3 1.10231×10-3
2.83495×10 2.8349×10-2 1 6.25×10-2 2.83495×10-5 3.12494×10-5
4.53592×102 4.53592×10-1 1.6×10 1 4.53592×10-4 5×10-4
1×106 1×103 3.5274×104 2.20462×103 1 1.10231
5 2 4 3 -1
9.07185×10 9.07185×10 3.2×10 2×10 9.07185×10 1

Pressure
Pa kPa MPa kgf/cm2 lbf/in2, psi
1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4
1×103 1 1×10-3 1.01972×10-2 1.45038×10-1
1×106 1×103 1 1.01972×10 1.45038×102
9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10
3 -3 -2
6.89476×10 6.89476 6.89476×10 7.03072×10 1

3 WA04-2091E
 Foreword

Work, energy
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
in-lbf
1 1×10-2 1.01972×10-1 1.01972×10-3 7.37562×10-3 8.85074×10-2
1×102 1 1.01972×10 1.01972×10-1 7.37562×10-1 8.85074
-2 -2 -2
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10-1
9.80665×102 9.80665 1×102 1 7.23301 8.67961×10
2 -1
1.355818×10 1.355818 1.38255×10 1.38255×10 1 1.2×10
-1 -2 -2
1.12985×10 1.12985×10 1.152513 1.15213×10 8.33333×10 1

Centigrade-Fahrenheit
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78
-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33
o
Conversion equation: t°C=5(T F-32)/9, T°F=(9×t°C+160)/5

Force
N kgf lbf
-1
1 1.01972×10 2.24809×10-1
9.80665 1 2.20462
-1
4.44822 4.53592×10 1

4 WA04-2091E
 GROUP INDEX

B Hydraulic Power Generating System

C Outrigger System

D Swing System

E Boom Elevating System

F Winch System

G Boom Telescoping System

H Safety System

K Cab

L Control System

S Steering System

T Brake System

U Suspension System

Y Data, Adjustment and Checks

Z System Diagrams
5 WA04-2091E
 Foreword

5. Contents
Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

General

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

A

Hydraulic Power Generating System

Hydraulic Power Generating System B-1

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

Hydraulic Valve (Emergency Steering) B-5

Flow Control Valve B-6

Pressure Reducing Valve (Pilot Pressure) B-7

Solenoid Control Valve (Outrigger) B-8

B
Rotary Joint B-9

Hydraulic Pilot Control Valve

B-10
(Elevating, Telescoping, Winch)

Sequence Valve (Pilot Pressure) B-11

Solenoid Valve (Pilot Pressure) B-12

Solenoid Control Valve (Jib Set) B-13

Pilot Check Valve (Jib Set) B-14

Solenoid Valve (Oil Cooler) B-15

Hydraulic Motor (Oil Cooler) B-16

6 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

Hydraulic Power Generating System

Jib Lock pin B-17

Jib Offset Cylinder B-18

B
Check valve (Gauge Isolator) B-19

Outrigger System

Outrigger System C-1

Jack Cylinder C-2

Pilot Check Valve

C-3
(Jack Cylinder Retracting Prevention)

Extension Cylinder C-4

C (UCHIDA) C-5

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

(NACHI) C-7

Check Valve
C-8
(Outrigger Extending Prevention)

Outrigger Operation Box C-9

Swing System

Swing System D-1

Swing Assembly D-2

D
Hydraulic Pilot Control Valve (Swing) D-3

Hydraulic Motor (Swing) D-4

7 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

D Swing Speed Reducer D-5

Boom Elevating System

Elevating System E-1

Elevating Cylinder E-2

E
Counterbalance Valve (Elevating) E-3

Winch system

Winch System F-1

Winch F-2

F Hydraulic Motor (Winch) F-3

Counterbalance Valve (Winch) F-4

Hydraulic Valve (Winch Brake Release) F-5

Boom Telescoping system

Telescoping System G-1

Boom (Five-Section Boom) G-2

Jib G-3

G Telescoping Cylinder G-4

Counterbalance Valve (Telescoping) G-5

Hose Reel G-6

Hydraulic Valve G-7

8 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

Safety System

Safety System H-1

Overload prevention Device (AML) Refer to separate manual W301-0215E

H Boom Length and Angle Detector H-2

Outrigger Extension Length Detector H-3

Solenoid Valve (Auto Stop) H-4

Cab

Crane Cab Glass K-1

Air Conditioner (Option) K-2

Hydraulic Motor
K-3
K (Air conditioner, Option)
Solenoid Valve
K-4
(Air conditioner, Option) (--#546165)
Solenoid Valve
K-5
(Air conditioner, Option) (#546166--)

Control System

Control System L-1

Remote Control Valve (Lever) L-2

Remote Control Valve (Pedal) L-3

Shuttle Valve (Lever, Pedal) L-4

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

Solenoid Valve (Air) L-7

9 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

Electrical System

N Multiplex Data Transmitter (MDT) Refer to separate manual W303-0257E

Driving Power Transmission System

Torque Converter and Transmission Refer to separate manual W561-0101E

R
Driving Axle Refer to separate manual W563-0053E

Steering System

Steering System S-1

Priority Valve S-2

Orbitrol S-3
S
Steering Cylinder S-4

Solenoid Valve (Steering Mode) S-5

Pilot Check Valve

S-6
(Rear Steering Cylinder Lock)

Brake System

Brake System T-1

Brake (Service Brake) T-2

Brake Valve T-3

Booster (Brake) T-4

T
Air Dryer T-5

Brake (Parking Brake) T-6

Brake Chamber T-7

Solenoid Valve (Air) T-8

10 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

Suspension System

Suspension System U-1

Suspension Lock Cylinder U-2

U
Pilot Check Valve
U-3
(Suspension Lock Cylinder)
Solenoid Valve
U-4
(Suspension Lock Check Release)

Data, Adjustment and Checks

Hydraulic Pressure Setting Table Y-1

Air Pressure Setting Table Y-2

Air Bleeding Procedure Y-3

Electric Switch Adjustment Y-4

Adjustment and Checks Y-5

Check (Crane Operation) Y-6

Y
Check (Driving Operation) Y-7

Oils and Grease Table Y-8

Mass Table Y-9

Specifications Y-10

Boom Connecting Pin and Thread Size

Y-11
Table

11 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

System Diagrams

Hydraulic Circuit Z-1

Torque Converter Circuit Z-2

Brake Circuit (Pneumatic Circuit) Z-3

Electric Circuit (AML, Crane) Z-4

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

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

Location of Installation

Location of Hydraulic Parts (Upper) Z-7

Location of Hydraulic Parts (Lower) Z-8

Location of Air Parts Z-9

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

Location of Electrical Parts

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

Location of Electric Parts (AML) Z-13

Location of Electric Parts (Lower) Z-14

Location of Electric Parts

Z-15
(Box Assembly/Lower)

Harness Diagrams

Harness (Connector No. Table) Z-16

Harness (Inside Cab) Z-17

Harness (Swing Table, Left) Z-18

12 WA04-2091E
 Foreword

Spec. No.
Chapter Section GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)

Harness (Swing Table, Right) Z-19

Harness (Boom) Z-20

Harness (AML, Upper) Z-21

Harness (Overwind) Z-22

Z Harness (Lower, Main) Z-23

Harness (Lower, Sub) Z-24

Harness (Lower, Electronic Governor) Z-25

Outdoor Air (Minus 25°C or less) System Z-26

Anemometer System Z-27

13 WA04-2091E
 B B

Hydraulic Power Generating System

Contents

B-1 Hydraulic Power Generating System B-6 Flow Control Valve.........................20

.................................................. 1
1. Structure .................................................. 20
1. General ...................................................... 1

B-7 Pressure Reducing Valve (Pilot

B-2 Hydraulic Pump (Double Variable Pressure) ................................21
Displacement Pump) ............... 5
1. Structure .................................................. 21
1. Structure .................................................... 5

2. Theory of operating of regulator section .. 11 B-8 Solenoid Control Valve

(Outrigger) ..............................22
3. Air bleeding procedure............................. 13
1. Structure .................................................. 22

B-3 Hydraulic Pump (Double Gear Pump)

................................................ 14 B-9 Rotary Joint ....................................27

1. Structure .................................................. 14 1. Structure .................................................. 27

2. Air bleeding procedure............................. 16 2. Potentiometer .......................................... 34

2.1 Adjustment ................................................34
2.2 Soldering ...................................................34
B-4 Hydraulic Pump (Gear Pump,
Emergency Steering)............. 17
B-10 Hydraulic Pilot Control Valve
1. Structure .................................................. 17 (Elevating, Telescoping, Winch)
.................................................35

B-5 Hydraulic Valve (Emergency 1. Structure .................................................. 35

Steering) (Option) .................. 18

1. Structure .................................................. 18

i
B-11 Sequence Valve (Pilot Pressure) .. 47

1. Structure .................................................. 47

B-12 Solenoid Valve (Pilot Pressure) .... 50

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

B-13 Solenoid Control Valve (Jib Set)... 52

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

B-14 Pilot Check Valve (Jib Set) ............ 58

1. Structure .................................................. 58

B-15 Solenoid Valve (Oil Cooler) ........... 59

1. Structure .................................................. 59

B-16 Hydraulic Motor (Oil Cooler) ......... 61

1. Structure .................................................. 61

2. Air bleeding procedure............................. 61

B-17 Jib Lock Pin.................................... 62

1. Structure .................................................. 62

B-18 Jib Offset Cylinder ......................... 63

1. Structure .................................................. 63

B-19 Check Valve (Gauge lsolator) ....... 64

1. Structure .................................................. 64

ii
B-1 B-1
Hydraulic Power Generating System

B-1 Hydraulic Power Generating System

1. General

Hydraulic Circuit for Carrier (for Europe)

winch, and auxiliary winch. This double variable

[NOTICE]
displacement pump is driven only when the PTO
Emergency steering and steering pump low
switch is turned on.
pressure warning are standard equipment for
Europe.
3. The double gear pump supplies oil to the circuits
of outrigger,steering, swing, pilot pressure, jibset,
1. The hydraulic power for this crane is generated by
air conditioner (option), and oil cooler.
the double variable displacement pump, double
gear pump, and gear pump for the emergency 4. The gear pump and the hydraulic valve in the
steering circuit. emergency steering circuit are standard. They are
provided for the case when the double gear pump
2. The double variable displacement pump supplies
malfunctions.
oil to the circuits of elevating, telescoping, main

1 WB02-0280E
B-1 B-1
Hydraulic Power Generating System

Hydraulic Circuit for Carrier (for General Export)

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

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

2. The double variable displacement pump supplies

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

2 WB02-0280E
B-1 B-1
Hydraulic Power Generating System

Hydraulic Circuit for Crane Applicable serial No. △

1 ：545520 ~

auxiliary winch). When the PTO switch is turned

[NOTICE]
on, the solenoid valve for automatic stop is shifted,
If the machine is not equipped with the optional air
making the condition of this circuit onloaded.
conditioner, two points "B" are directly joined.

Circuits for elevating, telescoping, main and auxiliary 2. The pressurized oil delivered through the P1 port
winches of the rotary joint is supplied to the circuits for the
main winch and the auxiliary winch.
1. The hydraulic oil provided from the pumps is The pressurized oil delivered through the P2 port
controlled (onloaded/unloaded) by the solenoid is provided to the circuits for elevating and
valve for automatic stop. This solenoid valve for telescoping. This oil, however, is supplied to the
automatic stop is switched by the AML output to circuits for the main winch and the auxiliary winch
control the vent ports of the relief valve (elevating, while neither elevating nor telescoping operation
telescoping) and the relief valve (main winch, is done.

3 WB02-0280E
B-1. B-1.
Hydraulic Power Generating System

Circuit for pilot pressure, jibset, air conditioner(option),

and oil cooler

1. The pressurized oil delivered through the P6 port

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

2. The pilot pressure is supplied to the swing brake

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

3. The pressurized oil delivered through the

sequence valve is supplied to the circuits for the
jibset, air conditioner(option), and oil cooler.

4 WB02-0280E
B-2 B-2
Hydraulic Pump (Double Variable Displacement Pump)

B-2 Hydraulic Pump (Double Variable Displacement Pump)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
This pump is a variable displacement piston pump.
The angle of the swash plate is controlled by the regulator.

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

Main body

Apply adhesive (No. 1305N of Threebond make)

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

886

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

774
111

824
261

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

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

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

Thread size and tightening torque

Tightening torque Tightening torque

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

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

Enlarged view of the main body (the left side)

Apply (Shealub L101)

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

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

953

886

717

406

774
111

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

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

Enlarged view of the main body (the right side)

901 954 719 124 151 152 113 406 710

466 114 885 313 141 467 271 401 262

725 728
Valve plate for clockwise rotation
IW101-0270E03

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

Regulator

962

412

801 924 627 701 624 651 652 621 496 887

728 625 402 629 724

IW101-012004

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

413 496 897 601

755

614

708

611

View Z IW101-012006

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

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

Thread size and tightening torque

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

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

2. Theory of operating of regulator section

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

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

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

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

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

366-540-20000 △
0

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

B-3 Hydraulic Pump (Double Gear Pump)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

1 2 3

IW101-013001

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

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

Gear pump assy-1

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

6,10

12

3 14 2 15
IW101-013002

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

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

Connecting section-2
2 1 4

IW101-013004

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

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

Gear pump assy-3

13 16 2 8,9 1 7 3

6,10

12

3 14 2 15
IW101-013003

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

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

2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

366-533-00000 △
0

366-519-00000 △
0

366-531-70000 △
0

16 W101-0131E
B-4. B-4.
Hydraulic Power Generating System

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

25 3 21 12 5 11 22 2

A B

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

IW101-014001

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

Thread size and tightening torque

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

D G1/4 24 - 29 17 - 22

31 M10 48 - 51 35 - 38

366-535-20000 △
2

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

B-5 Hydraulic Valve (Emergency Steering) (Option)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
T

B
P2 P3

P1
A
IW123-016001

P1

P3 T

P2
X X

Y
IW123-0260E01

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P3 G1 196 145

P2, T G3/4 167 123

18 W123-0261E
B-5. B-5.
Hydraulic Valve (Emergency Steering) (Option)

Cross section along the line X-X, Y-Y

14 13 5 9 6 2 A 1

12

3 11

8 C

X-X
7 10 B 11
Y-Y
IW123-0260E02

1.Body 5.Cover 9.O-ring 13.Spring washer

2.Check valve 6.Spring 10.Plug 14.Hexagon socket head bolt
3.Spool 7.Spring 11.Plug
4.Check valve 8.Spring 12.Plug

366-406-60000 △
0

19 W123-0261E
B-6. B-6.
Flow Control Valve

B-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

4
T
1
PA IW114-0130E02
2

PA

T 5
PB

6
IW114-0130E01 IW114-0130E03

1.Valve body 3.Spring 5.Plug 7.Relief valve assy

2.Spool 4.Plug 6.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
PA G3/4 167 123

T, PB G1/2 98 72

366-104-20000 △
0

20 W114-0132E
B-7. B-7.
Pressure Reducing Valve (Pilot Pressure)

B-7 Pressure Reducing Valve (Pilot Pressure)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
P

A1

DR A2
IW120-0120E01

(*1)

A1

DR A2

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

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

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

2.Spool 5.Filter 8.O-ring
3.O-ring 6.O-ring 9.Spring

Thread size and tightening torque

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

366-054-90000 △
1

21 W120-0121E
B-8 B-8
Solenoid Control Valve (Outrigger)

B-8 Solenoid Control Valve (Outrigger)

[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
A B

T
Sol. a1
Connector
R1

+-
(+): Red
P L
(-): Blue
G

IW121-0542E01
Sol. b1
IW112-015001

Sol. a1

R1

P T L

21 L
B
22

23

Sol. b1
10 1 15 IW112-015002

1.Body assy 15.T cover assy 22.Nut

10.P cover assy 21.Stud bolt 23.Spring washer

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T, L G1 196 145
A, B G3/4 167 123
G G1/4 29.4 22

22 W112-0152E
B-8 B-8
Solenoid Control Valve (Outrigger)

P cover assy
(illustrated as 10 on page 21)

1.Cover 7
2.O-ring
3.O-ring
R1
4.Shim
5.Plug
6.Plug assy
7.Relief valve assy
2

P
5 3

2
1

G
6
IW112-015003

23 W112-0152E
B-8 B-8
Solenoid Control Valve (Outrigger)

P cover assy (2/2)

Relief valve (illustrated as 7 on page 23)

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

T
IW112-011004

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

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

24 W112-0152E
B-8 B-8
Solenoid Control Valve (Outrigger)

Body assy (1/2)

(illustrated as 1 on page 21)

1.Body 10
2.Spool
3.Plug
4.Plunger Sol. a1
5.Spring
6.O-ring
7.O-ring
8.O-ring
7
9.Shim
9
10.Pilot cover assy

6 A
8 1
3

5 2

7 B

Sol. b1

IW112-015004

25 W112-0152E
B-8. B-8.
Solenoid Control Valve (Outrigger)

Body assy (2/2)

Pilot cover assy (illustrated as 10 on page 21)

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

7 9 5 3 4 2
IW112-015005

366-460-20000 △
0

26 W112-0152E
B-9 B-9
Rotary Joint

B-9 Rotary Joint

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
[NOTICE]
The parts marked with (*1) - (*10) require special attention for disassembling and assembling. The required
attention is described in the "Attention" on page 37.

27 W181-0440E
B-9 B-9
Rotary Joint

Upper (view A)

Lower (view B)

28 W181-0440E
B-9 B-9
Rotary Joint

1.Slip ring assy 10.Support 19.Plug 28.Fitting

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

Thread size and tightening torque

Thread Tightening torque

Sign / port
size N-m ft-lbf
16 *1 M12 74 - 82 55 - 61
17 *1 (to secure the plate [18]) M8 11.8 – 13.7 9 - 10
21 *1 (to secure the slip ring ass’y [1]) M6 4.4 – 5.4 3.5 - 4
25 *1 M8 23.5 – 27.5 17 - 20
29 - 16 - 24 12 - 17
*1: Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections.

Hydraulic section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper
Winch G1 196 145
Lower
P1
Upper - - -
Outriggers pilot
Lower G1/4 29.4 22
Upper G1/4 29.4 22
P1’ Gauge
Lower - - -
Upper
P2 Boom elevating, Boom telescoping G1 196 145
Lower
Upper G1/4 29.4 22
P2’ Gauge
Lower - - -
Upper G3/4 167 123
P3 Swing, Steering
Lower G1 196 145
Upper
P4 Steering (left) G1/2 98 72
Lower
Upper
P5 Steering (right) G1/2 98 72
Lower
Upper
P6 Option G1/2 98 72
Lower
Upper
T1 Tank - - -
Lower
Upper G3/4 167 123
T2 Tank
Lower - - -
Upper
DR Drain G1/2 98 72
Lower

29 W181-0440E
B-9 B-9
Rotary Joint

Pneumatic section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper Rc3/8 49 - 69 36 - 51
A1 Air supply
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
A2 Service brake (primary)
Lower G1/4 29.4 22
Upper Rc3/8 49 - 69 36 - 51
A3 Service brake (secondary)
Lower G1/4 29.4 22

L.L.C. section
Tightening torque
Sign / port Thread size
N-m ft-lbf
Upper
W1 Heater (IN) Rc3/8 49 - 69 36 - 51
Lower
Upper
W2 Heater (OUT) Rc3/8 49 - 69 36 - 51
Lower

Attention (*9): The "･" marks must be directed as shown in the

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

(*3): Apply thread locking agent equivalent to

THREE BOND 1401 to lock the threads.

(*4): Apply grease (EP2) when attaching.

(*5): Do not use an organic solvent.

(*6): Do not remove the shaft (8) from the core (7). It
is press-fit within the core.

(*7): To prevent rust, apply grease (EP2) when

assembling.

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

applicable thread size is M10.

30 W181-0440E
B-9 B-9
Rotary Joint

Slip ring Assy

21 22 20 31 28
31
C C
15

23
B
D D
24 19
A A 7 30
3 25
E E

2 T1
B
IW181-0260E03

27 26 13

11
12
F F

10
B-B
IW181-0260E04
4
12
8
29 6
16,17
3
9 18

7 1
P
A-A IW181-0290E03

P IW181-0260E05

31 W181-0440E
B-9 B-9
Rotary Joint

36 14

E-E
IW181-0260E09

C-C
IW181-0260E07

25

24

23
F-F
32,33 IW181-0260E10

D-D
IW181-0260E08

1.Shaft 10.BH+CB 19.O-ring 28.Hose band

2.Ring set plate 11.Spacer 20.Potentiometer 29.Hexagon socket set screw
3.Bearing 12.Spacer 21.Cover 30.Machine screw
4.Ring 13.BH+CB 22.Packing 31.Bolt
5.Ring 14.Support 23.Lever 32.Bolt
6.Ring set plate 15.Base 24.Pin 33.Spring washer
7.U nut 16.Dry lock nut 25.Guide 36.Hexagon socket head bolt
8.Support 17.Coned disc spring 26.Air breather
9.Stud bolt 18.Guide 27.Hose joint

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
16*1, T1*1 M6 4.9 3.6
31, 32, 36 M4 1.5 1.1
30 M3 0.63 0.5
*1：Apply LOCTITE 496 (strong quick-drying glue) to threaded sections.

32 W181-0440E
B-9 B-9
Rotary Joint

Wiring diagram

LOWER (Slip ring) UPPER (Brush holder)

G
3
W 2 3 2 1
R
1
3
2 B 6 6 5 4
Pot2 1 5
B
3 4
2
Pot1 1
Y Y
626 1 26 26 1 626
Y
2 1
3 2 23 Y 23 2 3 1 2

Y Y
627 12 27 27 12 627
Y 30 Y
628 11 28 28 11 628
Y 29 Y
629 10 29 29 10 629
Y 28 Y
630 9 30 30 9 630
Y 27 Y
20 8 20 20 8 20
1 2 3 4
Y 26 Y
4 3 2 1
5 6 7 8 21 7 21 21 7 21 8 7 6 5
Y 25 Y 12 11 10 9
9 10 11 12
22 6 22 22 6 22
Y 24 Y
4 5 24 24 5 4
Y 23 Y
615 4 15 15 4 615
Y 22 Y
16 3 16 16 3 16
Y 21 Y
618 2 18 18 2 618
Y 20 Y
19 1 19 19 1 19
19
Y 18 Y
12 6 12 12 6 12
Y 17 Y
13 5 13 13 5 13
1 2 3 Y 16 Y 3 2 1
614 4 14 14 4 614
4 5 6 Y 15 Y 6 5 4
8 3 8 8 3 8
Y 14 Y
9 2 9 9 2 9
Y 13 Y
10 1 10 10 1 10
12
Y Y
Y 11 Y
907 3 7 7 3 907
Y 10 Y
1 2 3 9111 2 11 11 2 911 3 2 1
Y 9 Y
5 1 25 25 1 5
8
Y 7 Y
2 1 17 3 17 17 1 17 3
W W
6 1 6 6 2 6
3 W 6 W 1 2
2 2 5 5 3 2
5
W 4 W
1CC 4 3 3 4 1CC
W 3 W 1 2
2 1 1DD 3 4 4 3 1DD
W 2 W
1AA 2 1 1 2 1AA 3 4
4 3 W 1 W
1BB 1 2 2 1 1BB

Connector Ring No.

Connector terminal No. ： Silver-plating ring

Mark No. IW181-0290E04

33 W181-0440E
B-9. B-9.
Rotary Joint

2. Potentiometer 3. Turn the potentiometer shaft using a slotted

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

Terminal 3
Terminal 2
Terminal 1
Potentiometer

Slotted screwdriver
Upper terminals 1, 2 and 3

Bolt (Tighten lightly.) Lever

IW181-0260E12

2. While keeping the stamp mark on the guide

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

2.2 Soldering

1. After finishing the potentiometer adjustment,

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

2. To insulate the terminals (6 pieces) from one

another, coat the terminal section with epoxy
Stamp mark Guide adhesive (equivalent to 3M DP-420).
IW181-0260E13

346-305-71000 △
7

34 W181-0440E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

B-10 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

35 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

C1 C2

Vent

Vent

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

b3,b4
b1 b2
b3 b4

B1 B2 T2 B3 B4

T1 P2 C3

A1 A2 A3 A4

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

P1
IW134-0270E02

36 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Thread size and tightening torque

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

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

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

37 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Cross section of whole body

B A

Aux. winch

Main winch

Telescoping

Elevating

B A
14 13
IW134-011012

38 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

1
12
・
8

C C
Aux. winch

D D
Main winch
12
・
9
E E
2

F F
Telescoping
3

G G
Elevating

4 7 16
A-A IW134-0270E03

39 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Aux. winch

Main winch

Telescoping

Elevating

5 15 6
B-B
IW134-011004

1.Winch selector valve 5.O-ring 9.Main relief valve 15.Plug

2.Telescoping selector valve 6.O-ring 12.Hex. socket head bolt 16.Eye bol
3.Elevating selector valve 7.Hex. socket head bolt 13.Plug
4.End cover 8.Main relief valve 14.O-ring

Thread size and tightening torque

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

40 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Winch selector valve

6 2 4 20 19 21 22 1
Overload relief valve

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

7
11 10
30
29

18 17 15 28 27 26 28 14 16,17

C-C (Aux. winch) , D-D (Main winch) IW134-0270E04

1 Main relief valve

18 17 15 28 27 26 5 28 16,17

E-E IW134-0110E07

41 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
M27×1.5 78 - 88 58 - 65
(Main winch), (Aux. winch)
11*1 - 18 - 20 13 - 14
2
14* M6 5-6 3.5 - 4.5
1
30* M8 12 - 14 8.5 - 10
16 M33 98 - 118 72 - 87
18 - 98 - 118 72 - 87
21 - 78.5 - 88.3 58 - 65
23 M8 27.5 - 29.4 20 - 22
26 G 3/8 39.2 - 49
29 - 36
28 - 10 - 12 7-9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

42 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Telescoping selector valve

5 4 29 30 2 3 22 21 23 24 1
Overload relief valve

11 10

27,26,25,13 7 8 9 12,25,26,27

6 19,20 18 17 28 14 16 15 19,20

F-F (Telescoping) IW134-0270E03

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve (Telescoping) M27×1.5 77 - 88 58 - 65
1
5* M8 12 - 14 8.5 - 10
1
11* - 18 - 20 13 - 14
1
15* - 18 - 20 13 - 14
17*2 M6 5-6 3.5 - 4.5
19 M33 98 - 118 72 - 87
23 - 78.5 - 88.3 58 - 65
25 M8 27.5 - 29.4 20 - 22
28 - 10 - 12 7-9
29 G3/4 78.5 – 88.3 58 - 65
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

43 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Elevating selector valve

Overload relief valve

5 4 18 19 18 19 2 1

11 10

22,21,20,13 7 8 9 12,20,21,22

6 16,17 15 14 23 3 16,17

G-G (Elevating) IW134-0110E09

1.Elevating selector valve body 7.Spring seat 13.Pilot cover 19.O-ring

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
Overload relief valve
M27×1.5 78 - 88 58 - 65
（Elevating）
5*1 M8 12 - 14 8.5 - 10
1
11* - 18 - 20 13 - 14
2
14* M6 5-6 3.5 - 4.5
16 M33 98 - 118 72 - 87
18 G3/4 78.5 - 88.3 58 - 65
20 M8 27.5 - 29.4 20 - 22
23 - 10 - 12 7-9
*1: Apply LOCTITE 242 (thread locking agent) to threaded sections.
*2: Apply LOCTITE 270 (thread locking agent) to threaded sections.

44 W134-0271E
B-10 B-10
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Main relief valve

(Main winch, Aux. winch), (Elevating, Telescoping)

20 19 14 13 12 11 10 9 8 7 6 3 2 1 5 4

15
16
17
18

IW134-011010

1.Socket 6.O-ring 11.Adjust screw 16.Valve

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

Thread size and tightening torque

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

45 W134-0271E
B-10. B-10.
Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)

Overload relief valve

(Main winch), (Aux. winch), (Elevating), (Telescoping)

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

16 15 T
IW134-011011

1.Socket 5.Valve seat 9.Valve 13.Nut

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

Thread size and tightening torque

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

366-405-40000 △
0

46 W134-0271E
B-11 B-11
Sequence Valve (Pilot Pressure)

B-11 Sequence Valve (Pilot Pressure)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

Thread size and tightening torque

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

47 W122-0113E
B-11 B-11
Sequence Valve (Pilot Pressure)

Cross section along the line A-A

(back pressure regulating valve, pressure reducing valve)
6

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
3 G1/2 9.81 - 11.8 7.2 - 8.7
6 M6 9.81 - 10.8 7.2 - 8

Back pressure regulating valve

(illustrated as 4 in the cross section along the line A-A)

1 2 6 7 3 4 8 5
1.Spring cover
2.Stopper
3.Piston
4.Valve
5.Socket
6.Spring
7.O-ring
8.O-ring
IW122-011004

Thread size and tightening torque

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

48 W122-0113E
B-11. B-11.
Sequence Valve (Pilot Pressure)

Pressure reducing valve

(illustrated as 5 in the cross section along the line A-A)

7 9 1

11 10 8 6 3 5 12 2 13 4
IW122-011005

1.Body 5.Spring seat 9.O-ring 13.O-ring

2.Spool 6.Spring 10.Nut
3.O-ring 7.Adjust screw 11.Cap nut
4.Plug 8.Body 12.O-ring

366-038-80000 △
0

366-060-30000 △
0

49 W122-0113E
B-12 B-12
Solenoid Valve (Pilot Pressure)

B-12 Solenoid Valve (Pilot Pressure)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

A2 A1

T
P
IW121-067001

701

Connector

IW121-0671E01

171

T
A2 A1

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

101 T1 IW121-067002

Thread size and tightening torque

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

50 W121-0672E
B-12. B-12.
Solenoid Valve (Pilot Pressure)

Solenoid valve assy

31 1 326 324

P A T
312 361 362 363 861 801 802
IW121-067003

311.Spool 326.Retaining ring 363.O-ring 861. O-ring

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

Thread size and tightening torque

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

367-401-00000 △
0

51 W121-0672E
B-13 B-13
Solenoid Control Valve (Jib Set)

B-13 Solenoid Control Valve (Jib Set)

[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
CO

A2
B2

P P A1
B1

G P T
IW112-0220E01

Connector

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

IW121-0542E01

52 W112-0222E
B-13 B-13
Solenoid Control Valve (Jib Set)

A B
33
C
18 32
D
33
B2 B1

31

OUT
T
21
C･O
P

IN

OUT
A2 A1
C 33
D

33
A P.P B

27,38

29

P.P

33
IW112-0220E02

18.Name plate 27.Plug 31.Nut 33.Ball

21.Tigh rod 29.Hexagon socket head bolt 32.Ribbet screw 38.O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P, T G1/2 98 72
A1, B1, A2, B2 G3/8 49 36
C•O G1/2 98 72
P•P G1/4 29.4 22

53 W112-0222E
B-13 B-13
Solenoid Control Valve (Jib Set)

6.Collar 16 28 34 19 38 23 27 33
7.Spring folder
8.Plug
9.Spring 8
16.Solenoid 7
19.Body
20.Spring 22
22.Spring 25
6
23.Filter 44
25.Spool end 35
35
27.Plug
33
28.Hexagon socket head bolt
33.Ball
34.O-ring
35.O-ring
37.O-ring
38.O-ring
44.O-ring

35 33

35
28
37
8
9

33

16 34 19 38 27 23 20
A-A
IW112-0220E03

54 W112-0222E
B-13 B-13
Solenoid Control Valve (Jib Set)

14.Spol
15.Housing
17.Housing plunger 14
24.Housing 14
35
35.O-ring
43.O-ring
24

17
43

15

35

B-B IW112-0220E04

55 W112-0222E
B-13 B-13
Solenoid Control Valve (Jib Set)

C-C
IW112-0220E05

CO

D-D IW112-0220E06

56 W112-0222E
B-13. B-13.
Solenoid Control Valve (Jib Set)

Relief valve

39 11 13 5 36 42 12 2 41 1 40 10 4 30 3

IW112-0220E07

1.Spring 5.Spring 13.Poppet 40.O-ring

2.Needle valve 10.Housing 30.Screw 41.O-ring
3.Nut 11.Sleeve 36.O-ring 42.O-ring
4.Gasket 12.Sleeve 39.O-ring

366-489-20000 △
0

57 W112-0222E
B-14. B-14.
Pilot Check Valve (Jib Set)

B-14 Pilot Check Valve (Jib Set)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

B A

D C
IW115-027001

7 6 5 3 4
B A

D C
8 1 9 2 10 11
X-X IW115-027002

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

2.Sleeve 5.Piston 8.O-ring 11.Plug
3.Poppet 6.O-ring 9.O-ring 12.Plug

Thread size and tightening torque

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

366-241-40000 △
1

58 W115-0271E
B-15 B-15
Solenoid Valve (Oil Cooler)

B-15 Solenoid Valve (Oil Cooler)

[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
4
b f
3

2
a

b f
1

P A
a T B
e T1

P
B
A
T

IW121-025001 IW121-025002

1.Solenoid valve assy 2.Body 3.Valve 4.Plug

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7-8 5-6

59 W121-0253E
B-15. B-15.
Solenoid Valve (Oil Cooler)

Solenoid valve assy

Connector

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

IW121-0542E01

T1 3

A P B
T T

T2 12 9 1 15 8 7 11 2

IW121-025003

1.Body 7.Spring seat 11.Spring

2.Plug 8.Square ring 12.Solenoid (DC24V)
3.Spool 9.O-ring 15.Hexagon socket head bolt

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
2 - 44 - 49 32 - 36
15 M5 7 5
T1 - 39 - 49 29 - 36
T2 - 4.4 – 5.4 3-4

366-457-50000 △
1

60 W121-0253E
B-16. B-16.
Solenoid Valve (Oil Cooler)

B-16 Hydraulic Motor (Oil Cooler)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
25 14 2 4 7 5 32 8 10 1 33 34 13

A,B

27 12 21 17 19 20 16 22 23 3
IW102-012001

1.Front case 8.Spherical pin 17.Needle bearing 23.Retaining ring

2.Rear case 10.Collar 19.Thrust roller bearing 25.Hexagon socket head bolt
3.Shaft 12.Spring 20.Thrust plate 27.O-ring
4.Cylinder block 13.Straight key 21.Hexagon socket head but 32.Piston assy
5.Piston retainer 14.Plain washer bolt 33.Seal plate
7.Spherical retainer 16.Oil seal 22.Ball bearing 34.Flat head machine screw

Thread size and tightening torque

Tightening torque
Sign /port Thread size
N-m ft-lbf
A, B G3/8 64 47
D G1/4 40 30
21 M5 4-6 2.9 - 4.3
25 M8 34 - 39 25 - 29
34 M5 2-3 1.4 - 2.2

2. Air bleeding procedure 366-632-60000 △

0

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

0

366-631-20000 △
0

61 W102-0122E
B-17. B-17.
Jib Lock Pin

B-17 Jib Lock Pin

[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.Spring pin 5.O-ring 9.Rod cover 13.Packing

2.plate 6.Piston 10.Plain bearing 14.Backup ring
3.Plain bearing 7.Cylinder 11.O-ring 15.Dust seal
4.Ring seal 8.Rod 12.Damper ring

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

*2 : Apply sealant equivalent to three bond 1104.
Thread size and tightening torque

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

360-531-60000 △
0

62 W180-0021E
B-18. B-18.
Jib Offset Cylinder

B-18 Jib Offset 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 5.Plain bearing 9.O-ring 13.Plate

2.Split pin 6.O-ring 10.Damper ring 14.Dust seal
3.Nut 7.Rod 11.packing 15.---
4.Piston 8.Rod cover 12.Backup ring 16.Plain bearing

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

Thread size and tightening torque

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

360-520-90000 △
0

63 W180-0031E
B-19. B-19.
Check Valve (Gauge Isolator)

B-19 Check Valve (Gauge lsolator)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

Hydraulic symbols
P' S

P1 P2 P3 IW116-012001

7 8 1 2 5 4 3 6

IW116-012002
P1 P2 P3

Thread size and tightening torque

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

G 3/8 49.0 36
S
M18×1.5 127 - 147 93 - 108 TT-300XL-1 only

Mounting bolt M8 13 - 15 9.6 - 11.0

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

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

366-244-50000 △
1

366-251-20000 △
0

64 W116-0123E
 C C
Outrigger System

Contents

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

(NACHI)...................................10
1. General ...................................................... 1
1. Structure .................................................. 10

C-2 Jack Cylinder.................................... 5

C-8 Check Valve (Outrigger Extending
1. Structure .................................................... 5 Prevention) .............................11

1. Structure ...................................................11
C-3 Pilot check Valve (Jack Cylinder
Retracting Prevention) ............ 6
C-9 Outrigger Operation Box ...............12
1. Structure .................................................... 6
1. Structure .................................................. 12

C-4 Extension Cylinder .......................... 7 2. Connector diagram .................................. 13

1. Structure .................................................... 7 3. Specifications........................................... 13

3.1 General .....................................................13
3.2 Bipolar toggle switch .................................13
C-5 Solenoid Valve (Slide/Jack) 3.3 Monopolar toggle switch ...........................13
(UCHIDA) .................................. 8 3.4 Push switch...............................................13
3.5 Diode.........................................................13
1. Structure .................................................... 8 3.6 Lamp assembly.........................................13

C-6 Solenoid Valve (Slide / Jack)

(TOKIMEC) ............................... 9

1. Structure .................................................... 9

i
C-1 C-1
Outrigger System

C-1 Outrigger System

1. General
Hydraulic Circuit

valve retracts.
1. The outrigger controls use the solenoid control
valve to select between extension or retraction for 5. The maximum puressure in the outrigger hydraulic
each cylinder. The solenoid valve selects between circuit is regulated by the relief valve.
operation of the extension cylinder and the jack
cylinder.

2. During outrigger extension, the pressure oil from

the pump passes through the solenoid control
valve and solenoid valve to enter the cylinders.

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

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

4. During outrigger retraction, the pressure oil

passes through the solenoid control valve and
pilot check valve, and operates on the retraction
side of the extension and jack cylinders. Only the
circuit of the cylinder selected by the solenoid

1 WC02-0290E
C-1 C-1
Outrigger System

Electric Circuit (Relay RF3, Solenoid Valve)

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

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

2 WC02-0290E
C-1 C-1
Outrigger System

Electric Circuit For Europe

〔 249A〕R D52
〔 249B〕LR D53

〔 249B〕LR Gr

〔 46〕WL R

〔 141B〕RL P
〔 236B〕LY O

〔 62〕Y Sb
〔 43〕WB L Outrigger operation box
(Left side)
〔 45〕PB G

〔 44B〕RL Y

〔 42〕WR Br

〔 41B〕RW W

〔 0〕B B

〔 41〕 W 5
〔 44〕 WY 8
〔 46〕 WL 14 Relay
〔 0〕 B 13
〔 44B〕 RL 12 RD5
〔 41B〕 RW 9

〔 141B〕 RL
〔 249〕RL
〔 236A〕 RY
〔 0〕 B
Relay
D50 〔 236A〕RY
〔 236〕YB D51 〔 236B〕LY 〔 561〕 R RB8

Relay 4 〔 106〕YW
〔 45〕PB 9 RF3 8 〔 107〕YB
〔 44〕WY 10 3 〔 108〕YO
1 5 2 6 3748
〔
〔
42〕WR
41〕W
11
12
+14 7
2
〔 109〕YG
〔 110〕RW
Solenoid valve
〔 46〕WL 14
9
-13
10 11 12
6 〔 111〕RB (slide/jack)
〔 43〕WB 〔 0〕B 13 1 〔 112〕RL
〔 62〕Y 5 〔 113〕RG

〔560〕RY
〔 141〕RB Power supply
〔 560〕RY
〔 0〕B
Relay
Multiplex data transmitter 〔 561〕R RB6
(Lower)
〔 43〕WB Solenoid valve
〔 62〕Y
(extending/retracting)

〔 561〕R
〔 236B〕LY
〔 0〕B
Relay
〔 141A〕BR RB7

〔 42〕WR 5
〔 45〕PB 8
〔 46〕WL 14 Relay
〔 0〕B 13
〔 45A〕LB 12 RD4
〔 42A〕WL 9

〔 249A〕R Gr
〔 46〕WL R

〔 141A〕BR P
〔 236A〕RY O

〔 62〕Y Sb
〔 43〕WB L
Outrigger operation box
〔 41〕W G (Right side)
〔 42A〕WL Y

〔 44〕WY Br
〔 45A〕LB W

〔 0〕B B

IWC02-0290E01

3 WC02-0290E
C-1. C-1.
Outrigger System

[In case of for Europe only, the control outside the cab
is applied.]

1. The controls are located at the both sides of the

carreir.

2. You can extend or retract only the sliders in the

same side of the crane as the controls operated.

Relay RD5: Selector relay for left side [SLIDE]

RD5
a-contact selected operation
relay coil
operates any
energized close jack
jacks
operates
de-energized open slide
left slide only

Relay RD4: Selector relay for right side [SLIDE]

RD4
a-contact selected operation
relay coil
operates any
energized close jack
jacks
operates
de-energized open slide
right slide only

3. If the right and left controls are opetated

simultaneously, the switch pressed first becomes
activated.
Relay RB7: Power supply selector relay
(This contact [CLOSES] when right side ext./ret.
switch’s selection is selected before the left side
one)
Relay RB8: Power supply selector relay
(This contact [CLOSES] when left side ext./ret.
switch’s selection is selected before the right side
one)

4. The Lower outrigger controls cannot be used

while the upper outrigger controls are in use.

Relay RB6: Power supply control relay for both lower outrigger operation box.
outrigger ext./ret. operating
RB6 relay coil b-contact priority
switch selection timing

lower is before upper de-energized close lower outrigger operation

upper is before lower energized open upper outrigger operation

4 WC02-0290E
C-2. C-2.
Jack Cylinder

C-2 Jack Cylinder

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

1.Cylinder 6.Stopper 11.O-ring 17.Backup ring

2.Rod 7.Spring pin 12.Backup ring 18.Dust seal
3.Bolt 8.Piston 13.O-ring 19.Damper ring
4.Spring washer 9.Packing 15.Rod cover assy 21.Backup ring
5.Bolt 10.Backup ring 16.Packing 22.Plain bearing

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
3,5 M10 22 - 25 16 - 18

T1 M24 588 - 666 434 - 492

360-302-90000 △
8

5 W151-0112E
C-3. C-3.
Pilot Check Valve (Jack Cylinder Retracting Prevention)

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
9
A B
C D

C D
IW115-023001

5 4 6 7,8

A B
IW115-0490E01

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

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

Thread size and tightening torque

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

B G1/4 29.4 22
Mounting
M10 43 - 49 32 - 36
bolt
366-200-00000 △
1

6 W115-0491E
C-4. C-4.
Extension Cylinder

C-4 Extension Cylinder

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

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

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

Thread size and tightening torque

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

D, E G1/4 29.4 22

2 M20 176 - 196 130 - 145

360-424-20000 △
1

7 W153-0012E
C-5. C-5.
Solenoid Valve (Slide/Jack) (UCHIDA)

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Connector

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

PT
IW121-026001 IW121-0542E01

T2

A P B
T T

11 9 7 3 8 15 1
IW121-026003

1.Body 7.Spring seat 9.O-ring 12.Solenoid (DC24V)

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

Thread size and tightening torque

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

T1 - 3.9 - 4.9 2.9 - 3.6

T2 - 38.3 - 41.2 28.3 - 30.4

366-478-90000 △
1

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

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Connector

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

PT
IW121-026001 IW121-0542E01

12

T P T

A B

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

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

1.Nut 4.Solenoid coil (DC24V) 7.Body 10.Centering washer

2.O-ring 5.Packing 8.O-ring 11.Spring
3.Solenoid core (DC24V) 6.O-ring 9.Spool 12.Spring pin

Thread size and tightening torque

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

3 - 18 - 22 13.3 - 16.2

Mounting bolt M5 6.9 - 7.8 5-6

366-465-40000 △
1

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

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Connector

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

PT
IW121-026001 IW121-0542E01

10 16

T T

A B

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

1.Body 6.Spring 10.Solenoid coil (DC24V) 16.O-ring

2.Spool 7.Nut 13.O-ring
3.Retainer 8.Rod 14.O-ring
4.Retainer 9.Solenoid guide (DC24V) 15.O-ring

Thread size and tightening torque

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

Mounting bolt M5 6-8 4.4 - 5.9

366-457-31000 △
1

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

C-8 Check Valve (Outrigger Extending Prevention)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

P1

C B

P2
IW116-011001

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

P1

B C

P2
IW116-011002

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

2.Cover 5.Stopper 8.Spring 11.Hexagon socket head bolt
3.Valve 6.Stop ring 9.Stopper 12.Spring washe
Thread size and tightening torque

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

P2 G1/2 98 72

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

C-9 Outrigger Operation Box

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
[NOTICE]
The illustration below shows the left side of the vehicle.
For the controls on the right side, the arrangement of the switches are different.

3 4 5

trol
Outrigger con
RR
1 12 RF
Extension
6

Retraction
11
2
ON
10 Slide

OFF
LR
Jack LF

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

View from end of connector

IW326-0180E01

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

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

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

2. Connector diagram

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

3. Specifications 3.4 Push switch

Current capacity: Resistance load 10 A

3.1 General
lnducatance load 4 A
Power voltage: DC20V ~ 30V
Service temp. range: -25° ~ +70°C 3.5 Diode

12-diode sect.: Average rectified current: 3A

3.2 Bipolar toggle switch
Peak inverse voltage: 600V
Current capacity: Resistance load 20 A
1-diode sect. : Average rectified current: 1A
lnducatance load 10 A
Peak inverse voltage: 600V
Contact connection resistance:
10mΩ or less (initial) 3.6 Lamp assembly

Rating: 24V, 3W
3.3 Monopolar toggle switch

Current capacity: Lamp load 2 A

[NOTICE]
Contact connection resistance: Coat the full surface of all diodes (13 total) with
10mΩ or less (initial) ThreeBond #2901 or equivalent product.

347-314-21000 △
1

347-314-22000 △
1

13 W326-0180E
 D
Swing System D

Contents

D-1 Swing System................................... 1

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

D-2 Swing Assmbly ................................ 3

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

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

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

D-3 Hydraulic Pilot Control Valve

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

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

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

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

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

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

i
D-1 D-1
Swing System

D-1 Swing System

1. General
Hydraulic Circuit for Swing

Remote Control Pressure Vent, Swing Free, Swing Brake Release

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

1 WD02-0211E
D-1. D-1.
Swing System

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

4. Circuit for swing automatic stop

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

2 WD02-0211E
D-2 D-2
Swing Assembly

D-2 Swing Assembly

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

1.Bolt
2.Plain washer

[NOTICE]
Apply torque control agent to the threaded sections of the bolts.

Thread size and tightening torque

Tightening torque
Sign/port Thread size
N-m ft-lbf
1 M18 294 - 343 217 - 253

3 W514-0161E
D-2 D-2
Swing Assembly

2. Swing bearing mounting bolt

2.1 Bearing Inner ring bolts

6 7 8 9 7,10 1,3 1,3

1,2
View A A
"S" mark

4,5
Front

1.Pain washer 1,3

2.Bolt (L=185mm) 1,3 11
3.Bolt (L=155mm)
4.Plain washer 4,5
5.Bolt
6.Support
7.Nut 1,3 1,2
8.Bolt
9.End
10.Spring washer
11.Pin

IW514-0140E01

[NOTICE]
Thread size and tightening torque
Install the bearing inner ring with the "S" mark
facing the rear of the carrier.
Apply torque control agent to the threaded sections Thread Tightening torque
Sign/port
of the bolts. size N-m ft-lbf
Install the plain washer, orienting its chamfer on the 2
internal periphery as shown below. (44 points)
M30 1620 - 1810 1195 - 1335
3
(4 points)

5 M12 69 - 82 51 - 60

4 W514-0161E
D-2. D-2.
Swing Assembly

2.2 Bearing outer ring bolts Applicable serial No. △

2 ：545543 --

△
2 168
1.Bolt (L=160mm)
2.Bolt (L=190mm)
3.Plain washer (50points)
4.Nut (5points) D
5.Reamer bolt (L=185mm)
6.Plain washer (2points)
D 1
C
3
A
C
B 5
B 6

D
3
D B 4
A
4
3
FRONT
Swing table
3
C 2

3
D

IW514-0140E02

[NOTICE]
Thread size and tightening torque
Apply torque control agent to the threaded sections
of the bolts.
Install the plain washer, orienting its chamfer on the Thread Tightening torque
Sign / port
internal periphery as shown below. size N-m ft-lbf
1
(42 points)
2
M27 1177 - 1275 868 - 940
(3 points)
5
(2 points)

343-007-20000 △
1
347-621-32000 △
0

342-310-40000 △
2

5 W514-0161E
D-3 D-3
Hydraulic Pilot Control Valve (Swing)

D-3 Hydraulic Pilot Control Valve (Swing)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

(+):Red
(-):Blue

BM AM Sol.2
Sol.3
Sol.1 Dr

RV
Sol.4
P

G Pi1
Pb
Pa Pi2

Pa Pi2 Pi1 Pb

Pa' Pb'
IW134-0122E01

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

Thread size and tightening torque

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

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

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

Dr G1/4 34 - 38 25 - 28

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

Cross section

706 702 703

A B
Sol.3 BM AM Sol.2
Sol.1 Dr

RV
Sol.4

352
G Pi1 Pb
Pa Pi2

353

253 351
263
RB RA
B
152 701 701 151
A
IW134-012003

Enlarged view (Sol.1, Sol.4, RV)

BM AM

Sol.1 Dr

RV
Sol.4

G
IW134-012007

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

Cross section along the line A-A C

Dr

C1

C2

R
C
152

414 413 401 450 412 411 415 151

A-A
IW134-012004

Cross section along the line B-B AM

152
644
643
642 CA2
641
661
RA

B-B
IW134-012005

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

Cross section along the line C-C

261 561 511 521 551 101 152 201 243 242 222 261

Sol.3 Sol.2

231 211 212 234 235

C1

BM P AM

Pa Pb
Pi2 Pi1

CB1 CA1

221 252 251 241 552 562 522 512 R 251 252
C-C
IW134-012006

Enlarged view (Sol.2, Sol.3)

Sol.3 Sol.2

Pa Pb
Pi2 Pi1

IW134-012008

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

101.Casing 242.O-ring 401.Plug 552.Plug

151.Plug 243.O-ring 411.Plunger 561.O-ring
152.Plug 251.Orifice 412.Spring 562.O-ring
201.Spool 252.Plug 413.O-ring 641.Spring seat
211.Spacer bolt 253.Plug 414.Steel ball 642.Spring
212.Stopper 261.Solenoid 415.Stopper 643.Steel ball
221.Cover inverse-proportional 450.Air bleeder screw 644.Seat
222.Cover reducing valve 511.Poppet 661.O-ring
231.Spring seat 263.O-ring 512.Poppet 701.Relief valve
234.Spring 351.Hex. socket head bolt 521.Spring 702.Solenoid relief valve
235.Spring 352.Hex. socket head bolt 522.Spring 703.Relief valve
241.O-ring 353.Hex. socket head bolt 551.Cap 706.Solenoid valve (DC24V)

Thread size and tightening torque

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

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

211 *1 M8 16 - 18 12 - 13

251 *1 M5 3.5 - 4.5 2.5 - 3.5

253 G1/4 34 - 38 25 - 28

261 M22 39 - 49 29 - 36

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

401 M24 58 - 70 43 - 51

450 M10 14.5 - 17.5 10.5 - 12.5

551 M33 190 - 210 140 - 155

552 M24 120 - 140 88 - 103

641 G1/8 8 - 10 6-7

701 M30 110 - 130 81 - 96

702 M22 39 - 49 29 - 36

703 M27 69 - 79 51 - 58

706 M22 39 - 49 29 - 36

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

366-461-30000 △
1

366-489-70000 △
0

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

D-4 Hydraulic Motor (Swing)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

DR PB

A B
IW102-050001

464 485

A- A

443 106 432 117 121 118 114 706 702 707 712 472 106 438 303 401

471 A(B) A
A
304

433

444 DR
101 DR

491

437
PB PB
301 113 124 122 123 116 111 742 743 131 451 IW102-050002

12 W102-0501E
D-4. D-4.
Hydraulic Motor (Swing)

101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring

106.Spacer 123.Guide plate 437.Iocking ring 491.Oil seal
111.Cylinder 124.Shoe plate 438.Iocking ring 702.Brake piston
113.Spherical bush 131.Valve plate 443.Roller bearing 706.O-ring
114.Cylinder spring 301.Casing 444.Roller bearing 707.O-ring
116.Push rod 303.Valve cover 451.Spring pin 712.Brake plate
117.Spacer 304.Font cover 464.Plug 742.Friction plate
118.Spacer 401.Hex. socket head bolt 471.O-ring 743.Separator plate
121.Piston 432.Stop ring 472.O-ring

Thread size and tightening torque

Tightening torque
Sing / port Thread size
N-m ft-lbf
PB G1/4 36 26.6

A, B G3/4 167 123

DR G1/2 108 80

464 G1/4 36 26.6

401 M20 430 317

366-635-90000 △
0

13 W102-0501E
D-5 D-5
Swing Speed Reducer

D-5 Swing Speed Reducer

[NOTICE]
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
7

30,31

20,21

19 22
18 23
16,17
15
24
14
13 25
12
26
11
27
10
9 28
8
7 26

6 29

IW511-024001

14 W511-0241E
D-5. D-5.
Swing Speed Reducer

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

1.Spur gear 9.Carrier 17.Spring washer 25.Needle bearing

2.Retainer 10.Bearing washer 18.Sun gear 26.Bearing washer
3.Roller bearing 11.Needle bearing 19.Bracket 27.King pin
4 Casing 12.Planetary gear 20.Bolt 28.Sun gear
5.Oil seal 13.Spacer 21.Spring washer 29.Snap ring
6.Ball bearing 14.Carrier 22.Snap ring 30.Bolt
7.Plug 15.Bearing washer 23.Coupling 31.Seal washer
8.King pin 16.Bolt 24.Planetary gear

Thread size and tightening torque

Tightening torque
Sing / port Thread size
N-m ft-lbf
20 M16 206 152

Mounting bolt (*1) M18 294 - 343 217 - 253

*1: Apply torque control agent to threaded sections.

360-816-51000 △
0

15 W511-0241E
 E
Boom Elevating System
E

Contents

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

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

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

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

E-3 Counterbalance Valve (Elevating) .. 5

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

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

i
E-1 E- 1
Elevating System

E-1 Elevating System

1. General
Hydraulic Circuit for Boom Elevating

Remote Control Pressure Vent

1 WE02-0200E
E-1. E-1.
Elevating System

[NOTICE] 3. Circuit for boom elevating slow stop

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

2 WE02-0200E
E-2 E- 2
Elevating Cylinder

E-2 Elevating Cylinder

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

3 W155-0232E
E-2. E-2.
Elevating Cylinder

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

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

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

*2:Apply Three-bond 1401 or equivalent.
*3:Apply Three-bond 1104 or equivalent.
*4:Apply KONISHI car body sealer or equivalent (waterproof), however it is not possible to paint on the rubber
side of dust seal.

Thread size and tightening torque

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

B G1/2 54 - 64 40 - 47

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

30 M8 24 - 27 17 - 20

360-267-50000 △
0

4 W155-0232E
E-3 E- 3
Counterbalance Valve (Elevating)

E-3 Counterbalance Valve (Elevating)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
B

P.P

A
IW119-021001

7 6 5 4 2-6 2-5 2-3 2-4 2-9 1 2-10 2-2 2-1 2-16 2-15

P.P B

2-8 2-7
2-11 2-12 2-13 2-14

3-7
3-8 3-5
3-6 3-4
3-1 3-2 A 3-3
IW119-021002

1.Valve block 2-8.Backup ring 2-16.O-ring 3-8.O-ring

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

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

Thread size and tightening torque

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

P.P G3/8 49 36

2-1 - 177 - 196 130 - 145

2-15 - 127 - 147 94 - 108

3-1 - 108 - 127 80 - 94

3-7 - 59 - 78 43 - 58

Mounting bolt M8 24 - 27 17 - 20

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

2. Function
a

P.P B

b
A
IW119-021003

This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the main spool to move the main
2.1 When control valve is at the neutral position spool.

The actuator holding pressure is sealed by seat 2. Consequently, the holding hydraulic pressure in
“a” of the main spool and seat “b” of the check port B is vented to port A.
valve.
3. At this time, the main spool motion is smoothened
2.2 While actuator is being pushed up by orifices.

1. The pressurized oil entering through port A of the

control valve enters chamber C, flows out through
port B by opening the check valve, and enters the
holding side of the actuator.

2. At this time, since port PP is connected to the tank

circuit, the main spool is kept forced to the valve
body by the spring, and remains inactive.

366-051-70000 △
2

7 W119-0212E
 F
Winch System

FF
Contents

F-1 Winch System .................................. 1 F-5 Hydraulic Valve

(Winch Brake Release) ..........12
1. General ...................................................... 1
1. Structure .................................................. 12

F-2 Winch ................................................ 4

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

F-3 Hydraulic Motor (Winch) ................. 6

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

2. Air bleeding procedure............................... 8

F-4 Counterbalance Valve (Winch) ....... 9

1. Structure .................................................... 9

2. Function ................................................... 10
2.1 Balancing and holding functions............... 10
2.2 Overload relief function ............................ 10

3. Principle of operation ............................... 11

3.1 When control valve is in neutral ............... 11
3.2 Hoisting up................................................ 11
3.3 Hoisting down ........................................... 11

i
F-1 F-1
Winch System

F-1 Winch System (*1): Application

1. General Europe Option

General Export ―
Hydraulic Circuit for Winch

1 WF02-0270E
F-1 F-1
Winch System

Boom Telescoping/Auxiliary Hoist (~#545522)

Boom Telescoping / Auxiliary Hoist (#545523~)

Remote Control Pressure Vent

2 WF02-0270E
F-1. F-1.
Winch System

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

3 WF02-0270E
F-2 F-2
Winch

F-2 Winch

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

1 17 18 19 20
12,13
3,4
21
29

22 24,25,26
5 9,10

31
7
32
8
9,10

11
12,13
14
15
28 27 30
16
12,13 23 41
A- A
IW526-012002

4 W526-0122E
F-2. F-2.
Winch

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

1.Bracket 13.Spring washer 23.Oil seal 33.Bolt

3.Bolt 14.Drum gear 24.Bolt 34.Spring washer
4.Spring washer 15.Collar 25.Spring washer 35.Plug
5.Oil seal 16.Ball bearing 26.Lock plate 36.Elbow joint
7.Bearing retainer 17.Ball bearing 27.Drum boss 37.Gear case cover
8.Ball bearing 18.Gear case 28.Pin 38.Plug
9.Nut 19.Spur gear 29.Drum 41.Sleeve
10.Washer 20.Ball bearing 30.Drum shaft
11.Collar 21.Bearing retainer 31.Ball bearing
12.Bolt 22.Bearing retainer 32.Bearing stand

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
3 *1 M14 177 - 190 130 - 140

12 M12 69 - 82 51 - 61

24 M20 353 - 392 260 - 289

33 M8 32 - 34 24 - 25

35 *2 R3/4 106 - 132 78 - 98

38 *3 R3/8 44 - 62 33 - 46

Mounting bolt M20 431 - 471 318 - 347

*1: Apply THREE-BOND 1305 to threaded sections.
*2: Oil filler port.
*3: Oil level port on the top and drain port on the bottom.

360-730-30000 △
0

360-731-80000 △
0

5 W526-0122E
F-3 F-3
Hydraulic Motor (Winch)

F-3 Hydraulic Motor (Winch)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
DR G3/4 167 123
PR G1/4 36 27
DA1 M10x1.25 16 12
DA2 M10x1.25 16 12
T1 M12 69 51
Mounting bolt M20 431 - 470 318 - 347

6 W102-0132E
F-3 F-3
Hydraulic Motor (Winch)

Cross section of the hydraulic motor

491 471 123 114 464 131 451 401 762

304 122 121 485 111 697 303 761

476
473
701
705
432

463
A

702

403 106 113 301 402 703 741 720 707

101 443 431 124 444 472 710 742 706 404
IW102-013003

(720) 773 771 772

A
IW102-013004

7 W102-0132E
F-3. F-3.
Hydraulic Motor (Winch)

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

122.Shoe 304.Front cover 472.O-ring 710.Brake shim
111.Cylinder 401.Hex. socket head bolt 473.O-ring 720.Brake casing
131.Valve plate 402.Hex. socket head bolt 476.O-ring 741.Separater plate
303.Valve cover 403.Bolt 485.O-ring 742.Friction plate
451.Pin 404.Hex. socket head bolt 491.Oil seal 761.Plug
101.Drive shaft 431.Stop ring 697.O-ring 762.O-ring
106.Spacer 432.Stop ring 701.Brake cover 771.Air breeder screw seat
113.Spherical bush 443.Self-aligning roller bearing 702.Brake piston 772.Air breeder screw
114.Cylinder spring 444.Needle bearing 703.Coupling 773.O-ring
123.Set plate 463.Plug 705.Brake spring
124.Shoe plate 464.Plug 706.O-ring
Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
401 M18 333 246

402 M18 333 246

403 M10 57 42

404 M12 98 72

463 R3/8 44 33

464 G3/4 167 123

761 G1/4 36 27

771 G1/4 36 27

772 M10 16 12

2. Air bleeding procedure

Refer to “Air Bleeding Procedure” in chapter Y.

366-628-20000 △
0

366-635-50000 △
0

8 W102-0132E
F-4 F-4
Counterbalance Valve (Winch)

F-4 Counterbalance Valve (Winch)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
B1 A1

b
a1
φ0.7

a
Dr
B A
IW119-0500E01

165 152
162 302 361 362 301 101 312 355 322 354 351 204 203 321 272 271
b a
202 Dr
262
253

B A
273
274 161 161 201 261 252 256
B1

A1

600

562 563 551 521 51 1 514

164 151
171 B A
172
a1

Dr

B1 A1
163
IW119-0500E02

9 W119-0501E
F-4 F-4
Counterbalance Valve (Winch)

101.Casing 201.Cover 272.Square spring washer 355.Orifice

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
151, 152 G3/8 69 - 79 51 - 58

171 M12 64 - 74 47 - 54

252 G1/4 34 - 38 25 - 28

253 G1/4 34 - 38 25 - 28

256 M10 14 - 18 10 - 13

271, 273 M12 88 - 108 65 - 80

551 M33 181 - 211 134 - 156

600 M33 166 - 186 123 - 137

2. Function 2.2 Overload relief function

When the circuit pressure rises above the preset

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

2. When the inlet pressure is below a certain level,

this valve closes the return passage to hold the
load at a desired position.

10 W119-0501E
F-4. F-4.
Counterbalance Valve (Winch)

3. Principle of operation

c b d

B A

B1 a
A1

Overload relief valve

IW119-0500E03

3.1 When control valve is in neutral 3. This pressure flows through choke b in the spool,
enters into chamber c, where it pushes the
The holding pressure of the hydraulic motor is plunger to the right by overcoming the spring force,
locked by the seat area a of the check valve, the and opens land d.
land area d of the spool and the overload relief
valve. 4. As a result, the return oil from the motor is
discharged to the control valve via land d to drive
3.2 Hoisting up the motor.

1. When the control valve sends oil to port A, the oil 5. When the load tends to pull the motor faster than
pushes open the check valve and flows to port A1 the speed corresponding to the flow rate to port B,
connected to the motor. the pressure in chamber c drops.

2. On the other hand, the return oil from the motor 6. Maintaining balance with the spring force to
port enters through port B1, and then, is automatically adjust the oil passage area in land d
discharged through port B to the control valve. to prevent the load from falling at speeds faster
than the motor drive speed.
3.3 Hoisting down

1. As oil is sent to port B by the control valve, it flows

to the motor via port B1.

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

to raise the pressure at port B.
366-058-20000 △
0

11 W119-0501E
F-5. F-5.
Hydraulic Valve (Winch Brake Release)

F-5 Hydraulic Valve (Winch Brake Release)

[NOTICE]
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
T3
B1

P1

Dr

B1 P2
AC
P1

B2 T B2
T P2
9 4 10 2 6 7 1 5 2 3 8
Dr AC T2 T1
IW123-020001 IW123-020002

1.Valve body 4.Side cover 7.Plug 10.Spring seat

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

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
AC, B1, B2, Dr
G1/4 29.4 22
T, P1, P2
T1, T2 M8 23 - 27 17 - 20

T3 M10 23 - 27 17 - 20

366-452-90000 △
0

12 W123-0281E
 G
Boom Telescoping System

Contents G
G-1 Telescoping System ........................ 1 4.4 Installing slide plates onto sides of
rear end...............................................16
1. General ...................................................... 1
5. Adjustment............................................... 16
2. Description of telescoping system (Refer to 5.1 Adjusting clearance for the boom.................16
the circuit diagram in Chapter Z.) ... 4 5.2 Adjusting boom telescoping wire rope .........16
2.1 Extension circuit ......................................... 4
2.2 Retraction circuit......................................... 4 6. Test ..................................................... 17
6.1 Operation test ...........................................17
3. Boom telescoping mechanism................... 5 6.2 Boom lateral warp test ..............................17
3.1 Extension.................................................... 5 6.3 Other functional test..................................17
3.2 Retraction ................................................... 6

G-3 Jib .................................................18

G-2 Boom (Five-Section Boom) ............. 8
1. Structure .................................................. 18
1. Structure .................................................... 8 1.1 Location of Jib...........................................18
1.2 Jib main body............................................20
2. Disassembly ............................................ 11
2.1 Removing the 2nd boom section.............. 11 2. Adjustment............................................... 22
2.2 Removing the 3rd boom section............... 12 2.1 Adjusting jib 1-2 connecting spring pin .....22
2.3 Removing the 4th boom section............... 13 2.2 Adjusting jib inclination..............................22
2.4 Removing the top boom section............... 13 2.3 Adjusting inclination of jib 2.......................23

3. Check ..................................................... 15
3.1 Boom ........................................................ 15 G-4 Telescoping Cylinder.....................24
3.2 Slide plate................................................. 15
3.3 Sheave ..................................................... 15 1. Structure .................................................. 24
3.4 Boom telescoping wire rope ..................... 15

4. Reassembly ............................................. 15
4.1 Greasing ................................................... 15
4.2 Install anti-buckling bolts for
telescoping cylinder............................ 15
4.3 Installing lower slide plates....................... 16

i
G-5 Counterbalance Valve
(Telescoping) ......................... 26

1. Structure .................................................. 26

2. Function ................................................... 27
2.1 When control valve is at the
neutral position ................................... 27
2.2 While actuator is being pushed up ........... 27
2.3 While actuator descends .......................... 27

G-6 Hose Reel ....................................... 28

1. Structure .................................................. 28

2. Dismounting............................................. 29

3. Mounting .................................................. 29

4. Disassembly ............................................ 29

5. Reassembly ............................................. 29

G-7 Hydraulic Valve .............................. 31

1. Structure ..................................................... 31

ii
G-1 G-1
Telescoping System

G-1 Telescoping System

1. General

Hydraulic Circuit for Boom Telescoping (2M2D)

Boom Telescoping/Auxiliary Hoist (--#545522)

1 WG02-0351E
G-1 G-1
Telescoping System

Boom Telescoping/Auxiliary Hoist (#545523--)

Remote Control Pressure Vent

Top Cylinder Select

2 WG02-0351E
G-1 G-1
Telescoping System

[NOTICE]
The solenoid valve and the hydraulic pilot control
valve are connected at the two points having the
same symbols such as "a4" and "b4".

1. The telescoping operation is controlled by the

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

2. The maximum pressure in the boom telescoping

hydraulic circuits is regulated by the relief valve
(elevating, telescoping).

3. Circuit for boom telescoping/auxiliary hoist

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

4. Circuit for remote control pressure vent

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

5. Circuit for top cylinder select

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

3 WG02-0351E
G-1 G-1
Telescoping System

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

Fold at the rear end the 3rd boom section.

Adjuster and sheave on the head of the 2nd boom section Sheave at the rear end of
the 3rd boom section
Sheave at the head of the 4th boom section Top boom section retraction wire
Sheave at the head of the telescoping cylinder
Fix at the head of
the 2nd boom section. Sheave at the rear end of Sheave at the rear end of
the top boom section. the 3rd boom section.

Top boom section extension/

4th boom section retraction wire Fix at the rear end of the 2nd boom section.
4th boom section extension wire Fix at the rear end of the 4th boom section.
Fix at the head of the 4th boom section. Fix at the rear end of the top boom section.
IWG02-0260E01

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

4 WG02-0351E
G-1 G-1
Telescoping System

3. Boom telescoping mechanism

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

3. 4th boom section Top boom

Extended by the wire rope mechanism that
WT
synchronizes with the extension of No.2 cylinder. 4th boom

F3
2nd boom
3rd boom
3rd boom
W4 W4

2nd boom
E4
4th 4th . IWG02-0420E02
boom boom
E5 : top boom section travel
W4 E3=L2
3rd E4 : 4th boom section travel
boom F4 : 4th boom section fotce
No.2 cylinder WT : Top boom section weight
2nd boom
2nd boom
IWG02-0420E01
WT
Balance of force : F4 = 3 ×
2
E4 : 4th boom section travel
Equation of workload : WT × E5 = F4 ×E4
E3 : 3rd boom section travel
(=L2: No.2 cylinder stroke) E4
∴E 5 = F4 ×
F3 : 3rd boom section force WT
(=No.2 cylinder force) WT E 4
= 3× ×
W4 : 4th boom section weight 2 WT
3
= E
Balance of force : F3 = 2W4 2 4
From equation (a)
Equation of workload : W4 × E4 = F3 × E3
3
E3 E5 = × 2L 2 = 3L 2
∴E 4 = F3 × 2
W4
E3
= 2W 4 × Top boom section travel (E5) = 3L2
W4

= 2E3 = 2L2 - - - (a)

4th boom section travel (E4) = 2L2

5 WG02-0351E
G-1 G-1
Telescoping System

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

2. 4th boom section

Retracted by the wire rope machanism that
synchronizes with the retraction of top boom
2nd section.
boom
2nd boom
4th
boom
3rd boom

2nd boom
R5

4th boom
WT WT
2 2 F5
Top boom R5
Top boom

Top
Top
boom
boom
IWG02-0420E03
F5 R4
2 F5
F5
R5 : Top boom section travel 2 2
R3 : 3rd boom section travel
4th boom
(=L2: No.2 cylinder stroke)
W4
F3 : 3rd boom section force
IWG02-0420E04
(=No.2 cylinder force)
WT : Top boom section weight
R4 : 4th boom section travel
R5 : Top boom section travel
F5 : Top boom section force
W4 : 4th boom section weight

6 WG02-0351E
G-1. G-1.
Telescoping System

F5
Balance of force : 3× = W4
2
2W4
∴F5 =
3

Equation of workload : W4 × R4 = F5 × R5
R5
∴R 4 = F5 ×
W4
2W4 R5
= ×
3 W4
2
= R
3 5

From equation (b)

2
R4 = × 3L 2
3
= 2L2

4th boom section travel (R4) = 2L2

3. 3rd boom section

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

4. 2nd boom section

Retraction by No.1 cylinder
2nd boom section travel (R2) = L1

7 WG02-0351E
G-2 G-2 G-2
Boom (Five-Section Boom) Applicable serial No. △
7 ：545611 - -

G-2 Boom (Five-Section Boom)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures,
make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

8 W536-0762E 8
G-2 G-2 G-2
Boom (Five-Section Boom) Applicable serial No. △
6 ：545561 - -

9 W536-0762E 9
G-2 G-2
Boom (Five-Section Boom)
Applicable serial No. △
6 ：545561 - - △
7 ：545611 - -

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

32.Nut 78.Shim 124.Retainer assy (R) 170.Bolt

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

42.Slide plate 88.Support 134.Spring washer 180.Pin

43.Grease nipple 89.Guide 135.Spacer 181.Split pin
44.Nut 90.Pin 136.Pin △
6 182.Retainer(R)

45.Bolt 91.Bolt 137.Guide △

6 183.Retainer(L)

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

9

10 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

Telescoping cylinder
2. Disassembly
The procedure to remove the 2nd boom section and
further sections as an assembly is described below.

2.1 Removing the 2nd boom section

1. Retract the boom fully and set the crane level.

2. Remove the hook block and the rope socket. High-pressure hose
Wind up the wire rope on the drum.

3. Swing the boom to place where there is enough

Hose reel
clearance, then lower the boom to 0° and stop the
engine. IW536-0620E04

4. Remove the wiring connector, loosen the wiring

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

Connecting pin

Bolt

Wiring clip Cable Cable guide (a)

IW536-0620E03 Nut

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

the hose leading to the hose reel from the
telescoping cylinder.
[NOTICE] IW536-0620E05

To prevent the hose reel from spinning, attach a

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

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

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

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

crane, and place it on a level platform.

11 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

2.2 Removing the 3rd boom section Top boom section

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

[NOTICE]
Before loosening the nut, measure the length of the
wire rope protrusion (L1) as a guide for reassembly.
Pin 2 Bolt 2 Wire rope (for top boom section retraction)
IW536-0620E08
Wire rope Nut L1

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

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

Hexagon socket head bolt Support assy

IW536-0620E06

2. Remove the wire rope for top boom section

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

Before loosening the nut, measure the length of the

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

L2 Wire rope (for top boom section retraction)

IW536-0620E07

4. Remove the supports (on both sides of the rear

end of the 3rd boom section) by loosening the bolt
1, and remove the pin and sheave assy by
loosening the nut.

5. Remove the pin from the rear end of the top boom 8. Remove the nut for the wire rope (for 4th boom
section by loosening the bolt 2 and remove the section extension) located on the rear end of the
wire ropes for top boom section retraction (2 2nd boom section, then loosen the bolt and
pieces). remove the support.

12 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

2. Lift up the rear end of the telescoping cylinder

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

3rd boom section No.2 telescoping cylinder

L3

2nd boom section

IW536-0620E11

9. After removing the retainer on the top of the 2nd

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

Hexagon
socket head bolt
Support L4 Support
Wire rope (for 4th boom section extension) Nut
IW536-0620E12

13 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

Guide Bolt 1

Support

Bolt 2

Pin

Wire rope
(for top boom section extension / 4th boom section retraction)
IW536-0620E14

3. To prevent damage to the wire rope, secure it to

the head of the top boom section using a jig.

Jig Top boom section

Wire rope
(for top boom section extension / 4th boom section retraction)
IW536-0620E15

4. After removing the retainer on the top of the 4th

boom section head and removing the slide plate,
pull out the top boom section by approx. 1 m.

5. While lifting up the top boom section slightly,

remove the retainer from the bottom of the 4th
boom section head.

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

crane.

7. Remove the wire rope for top boom section

extension/4th boom section retraction from the
rear end of the top boom section.

14 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

3. Check 4. Reassembly

3.1 Boom 4.1 Greasing

Check the boom for twist, deformation, wrap, and • When installing unplated pins, apply grease
cracks. beforehand.

3.2 Slide plate • Apply TNR-2 Grease sufficiently to the sliding

surfaces of the slide plates, the booms and
Check the slide plates for cracks and wear, and telescoping cylinders.
replace when these conditions are excessive.
4.2 Install anti-buckling bolts for telescoping
3.3 Sheave cylinder
Check the sheaves for damage, deformation and Base and 2nd boom section
wear, and replace them when these conditions are Boom side
A B
excessive. Cylinder side E
D
3.4 Boom telescoping wire rope

Wire rope in the condition described below must not

S
be used.
C
IW536-0680E12
• Deformation or corrosion
3rd boom section
• Kinking

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

one lay of the wire rope

• diameter reduction exceeding 7% of the nominal

diameter.

• Evidence of any heat damage from any cause.

1. Connect the boom and telescoping cylinder using

the pins A and B.
2. Adjust the bolt C locked with nuts D and E so that
it can be turned by hand and the clearance (S) is
0.5mm (0.02in) or less.(Apply thread locking
agent.)

[NITICE]
Refer to normal insert directions of bolt•C shown on
[2.Disassembly]

15 W536-0762E
G-2 G-2
Boom (Five-Section Boom)

4.3 Installing lower slide plates 5. Adjustment

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

3. Lateral clearance at boom head

Place shims so that the total clearance is 0.5 mm

when the boom is 1 m longer than that of full
retraction.

4. Adjusting the bolt on the bottom of each boom

section head

After retracting each boom section fully, lock the

bolt with a nut while it is lightly pressed against
the A surface. Apply thread locking agent.

Bolt
Surface
A
(7)

Reference
value Nut

IW536-0630E15

5.2 Adjusting boom telescoping wire rope

See the "Adjusting boom telescoping wire ropes"

section in the Y chapter.

16 W536-0762E
G-2. G-2.
Boom (Five-Section Boom)

6. Test
[NOTICE]
◆Bleed the telescoping cylinders completely and
apply grease to the boom sliding surfaces before
starting the tests.

6.1 Operation test

Telescope the boom several times, and make sure

that the telescoping operation is in order.

6.2 Boom lateral warp test

[Conditions]
･Crane levelness : ± 6' max.
･Boom length : Full extension
･Boom elevation : Maximum
･Boom direction : Over-front, Over-rear,
Over-right, Over-left
･Other conditions: Free from solar heat and wind 6.3 Other functional test

Check all the electric and electric parts (boom

1. The hook displacement (A in sketch) under the
length & angle detector, etc.) that are influenced
above test conditions under no load must be
by boom dismounting, for function and accuracy.
brought within 200mm (7.9 in) in all boom
directions by shim adjustment.

2. After shim adjustment, the hook displacement (A

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

17 W536-0762E
G-3 G-3 G-3
Jib Applicable serial No. △
1 ：545419,545430~,475327~ △
4 ：545419,545457~,475330~

△
2 ：545410~,475326~ △
5 ：545511~,475349~,437366~

G-3 Jib △
3 ：545419,545430~,475330~

1. Structure
1.1 Location of Jib

18 W537-0103E 18
G-3 G-3
Jib

1.Support assy 13.Support 25.End 37.Stopper

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

342-215-40500 △
5

19 W537-0103E
G-3 G-3 G-3
Jib Applicable serial No. △
1 ：545410~,475326~ △
4 ：545419,545457~,475330~

△
2 ：545410~,475326~ △
5 ：545511~,475349~,437353~

1.2 Jib main body △

3 ：545410~,475326~

20 W537-0103E 20
G-3 G-3
Jib

1.Jib 2 15.Pin assy 29.Roller assy 43.Spacer

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

342-215-42000 △
5

21 W537-0103E
G-3 G-3
Jib

2. Adjustment

2.1 Adjusting jib 1-2 connecting spring pin

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

Jib 2
X

Spring pin
Jib 1

Jib 1-2 connecting spring pin

IW537-0100E07

22 W537-0103E
G-3. G-3.
Jib

2.3 Adjusting inclination of jib 2

Slide plate
Shim (t 0.6)
Adjust the inclination to facilitate inserting and
removing the jib 1-2 connecting pin.

1) If the rear end of the jib 2 is too low for the pin to
be inserted and removed easily, apply shims (t0.6
mm (t0.02 in)) to the slide plate on the support on
the boom rear end.

2) If the rear end of the jib 2 is too high for the pin to Support on boom rear end
be inserted and removed easily, remove a shim IW537-0100E05

(t0.6 mm (t0.02 in)) one by one from the slide

plate on the support on the boom rear end until
the pin can be inserted and removed easily.

3) Add or remove shims (t0.6 mm (t0.02 in)) on the

support on the boom rear end and shims (t3 mm
(t0.12 in)) on the center support of the jib 2 to
facilitate the jib 1-2 connecting pin.

[NOTICE]
Boom rear end support: The rear end of the jib 2 is
raised when shims are added; lowered when shims
are removed.
Center support on jib 2: The rear end of the jib 2 is
lowered when shims are added; raised when shims
are removed.

23 W537-0103E
G-4 G-4
Telescoping Cylinder

G-4 Telescoping Cylinder

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1. No.1 cylinder
2. No.2 cylinder
3. Hose
4. Hexagon socket head bolt
5. Bolt

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A1, B G3/4 108 - 123 80 - 90

A2 G1/2 54 - 64 40 - 47

4 M12 68.6 - 82.4 50.6 - 60.7

5 M10 43 - 49 32 - 36

24 W157-0402E
G-4. G-4.
Telescoping Cylinder

*1

1 2 3 4 5,6 7 8 9 10 11 12 31 13 14 15 16 17 18

IW157-0390E03

1.Plug 6.Packing 11.O-ring 16.Backup ring

2.Spring pin 7.Plain bearing 12.Rod cover assy 17.Plain bearing
3.Nut 8.O-ring 13.Support 18.Dust seal
4.Piston 9.Cylinder 14.Damper ring 31.O-ring
5.Backup ring 10.Rod 15.Packing

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

360-171-10000 △
1
360-171-20000 △
2

360-169-10000 △
1
360-169-20000 △
2

25 W157-0402E
G-5 G-5
Counterbalance Valve (Telescoping)

G-5 Counterbalance Valve (Telescoping)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure
B

A
IW119-022001

6 12 11 3 2 5 4 10 9 1 8 20 14 13 15 16 17 19 18

B A M
IW119-022002

1.Body 6.Cap 11.Cap 16.Spring

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

Thread size and tightening torque

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

26 W119-0222E
G-5. G-5.
Counterbalance Valve (Telescoping)

2. Function

b a

P.P B C A
IW119-022003

This counterbalance valve prevents the actuator 2.3 While actuator descends
from being driven by the load and its own weight
faster than the speed corresponding to the oil 1. The hydraulic oil directly flowing from the control
supply rate. valve to the actuator also enters through port PP
to exert force to the main spool to move the main
2.1 When control valve is at the neutral position spool.

The actuator holding pressure is sealed by seat 2. Consequently, the holding hydraulic pressure in
“a” of the main spool and seat “b” of the check port B is vented to port A.
valve.
3. At this time, the main spool motion is smoothened
2.2 While actuator is being pushed up by orifices.

1. The pressurized oil entering through port A of the

control valve enters chamber C, flows out through
port B by opening the check valve, and enters the
holding side of the actuator.

2. At this time, since port PP is connected to the tank

circuit, the main spool is kept forced to the valve
body by the spring, and remains inactive.

366-054-80000 △
0

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

G-6 Hose Reel

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

1.Drum plate 8.Spring washer 15.Pin 22. --------

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

28 W183-0132E
G-6 G-6
Hose Reel

2. Dismounting 1) Remove the protection plate from the case 4

[NOTICE] and secure the case 4 in a sufficiently wide
When the circuit is suspected to retain high space.
pressure oil, be sure to vent pressure before
dismounting the hose reel. 2) Tie one end of a wire of a sufficient length to
Since the spring force for extra winding turns is the inner end of the spring 5 and pull the other
applied to the hose, hold the drum when end of the wire by hand to take out the spring 5.
disconnecting the hose.

5. Reassembly
3. Mounting
1. Install seal rings and backup rings on pin, apply
[NOTICE] grease thinly on these rings and their surrounding
After installation and bleeding the circuit and the areas,and install the pin in spring case.
device, test the operation check and check any
abnormality. 2. To reinstall spring in case proceed as follows:

1. After making sure that the whole hose is reeled in, [NOTICE]
turn the reel further (for 4.5 - 5.5 turns). If the spring recoils, it may hurt personnel. Be sure
to clamp it securely with vice pliers.
2. Draw out the hose and install it. Clamp with vice pliers, paying attention to the
installation orientation of the spring.

4. Disassembly 1) With spring clamped by vice pliers, remove

the spring holder constricting the spring.
[NOTICE]
This process is very dangerous. Take extreme
caution in executing it to secure safety.

1. Unscrew hexagon socket set screws, and remove

support from spring case .

2. Unscrew nuts, and remove drum plates from

spring case.

3. After attaching protection plates as shown,

utilizing the case mounting holes, to prevent
spring from hurtling out, unscrew special bolt on
the pin side, and extract pin.

4. To replace spring, remove it from spring case as

follows:

29 W183-0132E
G-6. G-6.
Hose Reel

2) With the lower side coated with grease,

place spring in case clamped in a vise, and
install the protection plates.

3) Fasten spring and pin with special bolt

coated with screw locking compound.

4) Remove the vise pliers on the outer end side

of spring and attach auxiliary spring.

5) Fasten the spring to spring case with special

bolt coated with screw locking compound.

6) After installation, apply water repellent

compound to nut.

7) Remove the remaining vice pliers.

3. Temporarily install drum plate, to spring case,

install support to pin, and fasten with set screws.

4. Remove the protection plates, install seat packing,

coated with adhesive on both sides, aligning with
the bolt holes to spring case.

5. Install drum plates to the spring case with nuts.

6. Apply water repellent compound to the mating

surfaces of drum plates.

366-716-50000 △
0

30 W183-0132E
G-7 G-7
Hydraulic Valve

G-7 Hydraulic Valve

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

PP

P C T Dr
IW123-017001

PP

Dr
C P T

IW123-017002

Thread size and tightening torque

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

PP, Dr G1/4 29.4 22

31 W123-0172E
G-7 G-7
Hydraulic Valve

19 6

17

15
C P T Dr

15 3 10 1 2 7 10
IW123-017003

1.Body 3.Cover 7.Spring 15.Hex. socket head bolt

2.Spool 6.Solenoid valve 10.O-ring 17.Plug
19.Orifice

Thread size and tightening torque

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

32 W123-0172E
G-7. G-7.
Hydraulic Valve

Solenoid valve assy

Connector

(+): Red

+- (-): Blue

IW121-0542E01

T1 3

A P B
T T

T2 12 9 1 15 8 7 11 2
IW121-025003

1.Body 7.Spring seat 11.Spring

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

Thread size and tightening torque

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

366-497-50000 △
1

366-463-10000 △
1

33 W123-0172E
 H
Safety System

Contents

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

Detector ....................................8
1. General ...................................................... 1
1.1 Pressure sensor ......................................... 1 1. Structure and function................................ 8
1.2 Boom length and angle detector ................ 1
1.3 Outrigger extension width detector............. 1 2. Disassembly .............................................. 9
1.4 Other detectors and switches..................... 1
1.5 AML (Load moment indicator) main body .. 1 3. Reassembly............................................. 10
1.6 Overwind cutout (Anti-twoblock) device ..... 1
1.7 Solenoid valve ............................................ 1
H-4 Solenoid Valve (Auto Stop) ...........12
2. Description of system ................................ 1
1. Structure .................................................. 12

H-2 Boom Length and Angle Detector .. 2

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

2. Disassembly and reassembly .................... 4

2.1 Removing the cord ..................................... 4
2.2 Installing the cord ....................................... 4
2.3 Replacing spiral spring ............................... 6
2.4 Disassembling the potentiometer
(for boom length detector).................... 6
2.5 Reassembling potentiometer...................... 7
2.6 Replacing the boom angle detector ........... 7

3. Adjustment................................................. 7

i
H-1. H-1.
Safety System

H-1 Safety System 1.6 Overwind cutout (Anti-twoblock) device

1. General The anti-twoblock device prevents damage to the
crane that would be caused by pulling the hook
1.1 Pressure sensor
block into the boom head. When the hook block
1. A retraction pressure sensor and an extension approaches the boom head, single top or jib, the
pressure sensor are incorporated in the elevating overwind cutout device sends a signal to AML,
cylinders. which then stops any further crane action toward
the critical condition.
2. They convert the elevation pressure into the
electric signal and transmit it to AML (Load 1.7 Solenoid valve
moment indicator) main body, making the limiter
calculate the total moment created by the lifted 1. If AML malfunctions or if the actual moment
load and the mass of the boom. reaches 100% of the rated moment or the hook
block is over-hoisted, an electric signal (auto.
1.2 Boom length and angle detector stop) is sent from AML main body to this valve.

The Boom length and angle detector is installed 2. When the solenoid valve is deenergizied, this
on the boom side, and uses the potentiometer solenoid valve contents the vent line of the relief
inside the detector to convert the extended boom valve mounted on the hydraulic pilot control valve
length and the angle of the boom relative to the to the tank. The solenoid valve by allowing the
ground into an electric signal that is transmitted to pressurized oil from the pump to escape through
AML main body. the relief valve to the tank, therefore the crane
operation stops.
1.3 Outrigger extension width detector

It is installed on the rear end of the outrigger outer

2. Description of system
case. The potentiometer in the detector converts
Refer to the repair manual of AML-L.
the outrigger extension width into the electric
signal and transmits it to AML main body.

1.4 Other detectors and switches

The outer detectors and switches convert the

crane operation modes and working conditions
into an electric signal that is transmitted to AML
main body.

1.5 AML (Load moment indicator) main body

1. AML main body calculates the moment being

generated on the crane based on signals from the
pressure sensor and the Boom length and angle
detector.

2. The calculation result is compared with the rated

moment and,when it reaches 90% and 100% of
the rating, AML sends alarm and auto. stop
signals, respectively, to prevent the crane from
being overloaded.

1 WH02-0080E
H-2 H-2
Boom Length and Angle Detector

H-2 Boom Length and Angle Detector

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1.Structure and function

rotation is reduced by the reduction gear,which in
1. The boom length and angle detector consists of a
turn rotates the shaft of the potentiometer.
recoil spring, cord, reduction gear, potentiometer
(for boom length detection), and boom angle 3. The electric resistance of the potentiometer shaft
detector. varies proportional to the reduction of the shaft
rotation,and the change in electric resistance is
2. The cord wound on the drum is unwound and
transmitted to the AML main body to detect the
rewound by the recoil spring after the extension
boom length.
and retraction of the boom.The resultant drum

2 W305-0452E
H-2 H-2
Boom Length and Angle Detector

1.Plate 16.Spring 31.Pin terminal 46.Cable

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

Potentiometer Resistance : 5000 ± 750Ω

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

Electric Symbol

[NOTICE]
About the connector applicable to serial No. up to 437648. 437648 (GT-550E-1)
437572 (GT-600-1)
475370 (GT-700E-1, GT-800-1)
545760 (GR-600-1, GR-700E-1, GR-800-1)

3 W305-0452E
H-2 H-2
Boom Length and Angle Detector

Drum assy
2. Disassembly and reassembly

2.1 Removing the cord

1. Remove the connector and the cord lock from the

end of the cord. Wind up the cord on the drum Plate
slowly until no tension of the spiral spring is
applied on the cord.

2. Loosen the clamp and remove the cover (2 place).

3. Disconnect the cable, potentiometer and angle

detector from the terminal, and remove the cover Nut IW305-0230E04

and the cable together.

4. Loosen the set screw and remove the gear. Then 7. Remove the slip ring assy from the drum assy.
remove the screw and detach the speed reducer. Then remove the solder that bonds the slip ring
and the cord.
[NOTICE]
Remove the speed reducer straight upward. Do not Slip ring assy
twist it while removing. Slip ring assy

5. Remove the retaining ring and bolt, and separate Core wire
the case from the drum assembly. Cord

[NOTICE]
Shield wire
Put match marks on the case and the plate to
identify the direction for removing the sub-cord. IW305-0230E05

Retaining ring
Case 8. Detach the whole old cord from the drum assy.

2.2 Installing the cord

1. Wind a yellow tape around the new cord as a

Bolt
0-marker.

Sub-cord

Plate

Match marks
IW305-0230E03

6. Remove the nut and separate the drum assy from

2. Pass the new cord through the hole of the drum
the plate.
assy. Solder it on the slip ring assy.

[NOTICE]
Attach the cord core wire to the inner slip ring.
Attach the shield wire to the outer slip ring.
Completely insulate the soldered section.

4 W305-0452E
H-2 H-2
Boom Length and Angle Detector

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

Cord
finger and released. If it is not returned, loosen the
bolt and adjust the position of the bracket.
Shield wire

[NOTICE]
Drum assy
Vinyl tube If the potentiometer is faulty, replace it referring to
IW305-0230E07 the "Replacing the potentiometer (boom length
detector)" described later.

3. Install the slip ring assy so that the cord is not 10. Fix the gear in the notched section of the speed
slackened. reducer shaft using a set screw. Apply thread
locking agent to the set screw.
4. Wind the new cord around the drum assy while
taking up slack in the cord. When the 0-marker on Tightening torque : 1.18 N-m {0.87ft-lbf}
the 8.83 m (29.0ft) point of the cord shows on the
drum, wind the cord 13 turns more and fix it with 11.Take out the new cord from the guide hole of the
gummed tape to prevent slackening. cord reel and draw it out completely. Then wind it
again the drum. When the 0-marker comes to the
[NOTICE] edge of the cord guide, fix the cord there as
Wind the cord around the drum assy clockwise as shown in the figure.
seen from the slip ring.
0-marker

Slip ring

Gummed tape
IW305-0230E09
Gummed tape
IW305-0230E08
12. Applied voltage DC 5V to the potentiometer (for
boom length detector) as shown in the figure and
5. Insert the shaft of the drum assy into the boss
turn the gear using a screwdriver until the output
hole of the plate and fix it with a nut.
voltage between the red and white terminals is 0.5
6. Put the case over the drum assy, leading the ± 0.06 V. Then fix the gear using a set screw.
sub-cord outside through the hole of the case and Apply thread-locking agent to the set screw.
the cord end outside through the opening of the
Tightening torque : 1.18N-m {0.87ft-lbf }
cord guide.
Screwdriver
7. Secure the case and the plate with a bolt and Gear B
Gear A Set screw
attach the retaining ring.
Bracket
8. Apply sealant agent thinly on the bottom of the Spring
speed reducer. Then install the speed reducer on
the case. White
Red +
- Tester
9. Inset the gear on the shaft of the speed reducer. Black
- Applied
Loosen the set screw on the potentiometer side to + voltage
allow both gears to idle. IW305-0230E10
Check that the gear is spring-returned to the

5 W305-0452E
H-2 H-2
Boom Length and Angle Detector

13. Draw out the cord slightly from the drum and 2.4 Disassembling the potentiometer
make sure that the resistance between the red (for boom length detector)
and white terminals increases smoothly. [NOTICE]
14. Connect the cable to the terminals for the If both the cord and spiral spring are faulty, remove
the detector assy from the boom.
potentiometer and angle detector.
If only the potentiometer is faulty, it is not necessary
15. Attach the cover. to remove the detector.

16. Pull the cable to eliminate slack, and tighten the 1. Loosen the 2 clamps and remove the bolt and
clamp. (2 places) cover.

17. Install the cord lock on the cord end and install 2. Disconnect the lead wire terminals (3 pieces) and
the lead wires and the connector close to the cord cable terminal from the potentiometer, and
end. Completely insulate the soldered remove the potentiometer together with the
connections. bracket.

8.5 m (27.9ft) [NOTICE]

0.08 m
ft) (0.26ft) Before replacement, disconnect the wiring to the
(0.8
m boom angle detector from the pin terminal section to
0.25
disconnect the lead wires (red and black) from the
Cord lock boom angle detector.
0-marker
Wind HI-BOND tape for
Connector waterproofing and then Gear
wind insulating tape.

70 Spring
7 Yellow 10

Cord Bracket
7 50 10
White Lead wire
IW305-0230E11
Lead wire

18. Check for conduction and shortcircuit between Potentiometer Black

the terminals of the sub-cord connector and the Red

cord connector. To boom angle detector

Pin terminal
IW305-0230E13

Sub-cord Cord

3. Remove the gear and the spring, and detach the

IW305-0230E12
potentiometer from the bracket.

4. Remove the connector and the cord lock from the

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

6 W305-0452E
H-2. H-2.
Boom Length and Angle Detector

2.5 Reassembling potentiometer 2.6 Replacing the boom angle detector

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

Bracket

0-marker Cord lock

Potentiometer Insulating sealant IW305-0230E16
IW305-0230E14

2. Adjust the boom length display of the AML.

2. Loosen the set screws on the reducer side and (Refer to the repair manual of the AML.)
potentiometer side to allow both gears to idle.
Check that the gear on the potentiometer side is
spring-returned to the original position after it is
rotated a quarter turn by finger and released. If it
is not returned, loosen the bolt and adjust the
position of the bracket.

Gear B

Gear A Bracket

Spring

Bolt

IW305-0230E15

3. Fix the gear in the notched section of the speed

reducer shaft using a set screw. Apply thread
locking agent to the set screw.
Tightening torque : 1.18N-m {0.87ft-lbf}

4. Follow the same procedure as described in the

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

7 W305-0452E
H-3 H-3
Outrigger Extension Length Detector

H-3 Outrigger Extension Length Detector

[NOTICE] 3. The consequent rotation of the drum drives the
There is a case that the appearance and so on potentiometer shaft through gears which reduce
differ from the parts for this machine. Although there the speed to 5/6.
is not so much difference in functions and
disassembly procedures, make sure of the serial 4. The rotation of the shaft causes a proportional
number of this machine and the part sales unit
described in the parts catalog before starting change in the electrical resistance of the
disassembling operations. potentiometer. This change is supplied by the
multiplex data transmission (MDT) system to the
1. Structure and function AML (Load Moment Indicator) unit for detection of
the outrigger extension length.
1. The detector consists of the following major
components: a spiral spring, wire, and 5. When the wire is reeled out, the gears,
potentiometer. potentiometer, and potentiometer brush either
rotate or move.
2. The wire wound around the drum is unwound or
rewound by the action of the spiral spring as the
cylinder extends or retracts.

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

Use silicon sealant to seal

the part that is shaded.

1 2 3 4 5 6 7 8 15 16

10

17

19
18 0V (Black)

11 12 13 14 Power supply (Red)

IW305-0251E02
Output (White)

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

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

2. Drum assy 7. Potentiometer 12. Set screw 17. Clamp
3. Case 8. Cover 13. Screw 18. Connector
4. Packing 9. Shaft 14. Gear•B 19. Cable
5. Gear•A 10. Bolt 15. Bracket

Specification 4. Remove screw to remove case .

Item Specifications Case

Gear ratio 6/5

Resistance: 2kΩ ± 5%
Potentiometer Mechanical rotating Screw

angle: 360°

IW305-0250E05

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

2. Remove screw and loosen clamp to remove

cover.

Cover

Screw Clamp Cable

IW305-0250E03

3. Remove screw and remove potentiometer and

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

Gear

Bracket

Screw

IW305-0250E04

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

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

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

wire.

Zero marker (yellow tape)

Aux. string
Drum side Scrwe

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

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

Gear side

Gummed tape

IW305-0251E11

3. Mount base plate on drum assy with bolt.

IW305-0250E09

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

10 W305-0251E
H-3. H-3.
Boom Length and Angle Detector

When replacing the potentiometer with a new one,

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

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

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

verify that the resistance between B and W
decreases smoothly.

9. Mount cover, while positioning clamp on the

opposite side of the potentiometer.

Cover

Screw Clamp Cable

IW305-0250E03

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

clamp.

361-318-00000 △
0

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

H-4 Solenoid Valve (Auto Stop)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure
1.Body
2.Distance piece
3.Filter element
4.Plug
5.Plug
6.O-ring
7.O-ring
8.Solenoid valve assy

T1

8 1 5 6 3 2 7 4 IW121-0540E03

Thread size and tightening torque

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

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

Solenoid valve assy

1.Body
2.Plug Connector
4.Spool

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

2
T2 T1

A P B
T T

12 11 9 7 4 8 1
IW121-0540E04

Thread size and tightening torque

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

366-460-80000 △
1

13 W121-0543E
 K
Cab

Contents

K-1 Crane Cab Glass .............................. 1 7. Condenser Assy ...................................... 18

1. Glass replacement procedure.................... 1 8. Electric..................................................... 19

8.1 Electric circuit............................................19
2. Bonding the joint between windshield glass 8.2 Main harness A .........................................20
and roof glass................................. 2 8.3 Main harness B .........................................21 K
9. Important points for assembly (Layout) ... 22
K-2 Air Conditioner................................. 3 9.1 Evacuation ................................................22
9.2 Charging with refrigerant...........................22
1. Component parts ....................................... 3 9.3 Check for gas leakage and amount of
refrigerant charge ...............................23
2. Introduction to air conditioning................... 4 9.4 Heated water circuit ..................................23
2.1 Principle of air conditioning ........................ 4 9.5 Run-in operation .......................................23
9.6 Bolt size and tightening torque .................23
3. Basic refrigeration cycle............................. 5
3.1 Structure ..................................................... 5 10. How to charge air conditioner gas ........... 24
3.2 Conditions for air conditioning equipment .. 6 10.1 Charging gas in automatic operation .........24
3.3 Refrigerant.................................................. 7 10.2 How to charge air conditioner gas .............26
3.4 Refrigeration cycle of a car air conditioner. 8 10.3 How to check air conditioner......................28
3.5 Comparison with a household air conditioner
............................................................. 8 11 Diagnosis table .......................................... 29
3.6 Receiver functions...................................... 9 11.1 Car air conditioner system diagnosis table I
3.7 Reheat method ......................................... 10 (Refrigeration circuit) ..........................29
3.8 Components ............................................. 11 11.2 Car air conditioner system diagnosis table II
(External causes other than insufficient
4. Layout ..................................................... 13 cooling and abnormal pressure) .........32
4.1 Overall layout............................................ 13 11.3 Car air conditioner system diagnosis table III
4.2 Overall layout............................................ 14 (Electrical system) ..............................34
4.3 Evaporator section ................................... 15 11.4 Car air conditioner system diagnosis table IV
(Electronic thermo system) .................36
5. Compressor Assy........................................ 16

6. Evaporator Assy....................................... 17

i
12. Compressor ............................................. 38
12.1 Compressor abnormal sound diagnosis chart
........................................................... 38
12.2 Compressor diagnosis chart..................... 39

13.Troubleshooting ......................................... 41

14.Control table .............................................. 47

K-3 Hydraulic Motor (Air Conditioner)

(Option) .................................. 48

1. Structure .................................................. 48

K-4 Solenoid Valve (Air Conditioner)

(Option) (--#546165)............... 50

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

K-5 Solenoid Valve (Air Conditioner)

(Option) (#546166--)............... 52

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

ii
K-1 K-1
Crane Cab Glass

K-1 Crane Cab Glass 6. Let the primer C coated surfaces dry for more
1. Glass replacement procedure than 15 minutes.

Follow the procedure described below to replace 7. Clean and degrease the bonding surfaces of the
the fixed windshield window glass, roof glass, new glass with a gauze soaked with white
front right window glass (quarter window glass) gasoline or acetone.
and rear right window glass of the crane cab. Leave it more than 1 minute to dry.

1. Remove the glass to replace and the adhesive [NOTICE]

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

4. Clean and degrease the glass bonding surfaces of

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

to let them dry.

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

1 W587-0011E
K-1. K-1.
Crane Cab Glass

while aligning the marks (masking tape pieces put

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

11. Fit the molding on the circumference of the new

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

2. Bonding the joint between windshield

glass and roof glass

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

Apply the adhesive so that its cross sectional form tape to places 1 to 2 mm (0.039 to 0.078 in) away
is as shown in the figure by shaping it with a from the edges of windshield glass and roof glass.
spatula.
For a portion where there is a clearance between 2. Remove the rubber dam backing paper.
the glass and rubber dam, apply the adhesive to a
bead height of more than 5 mm (0.2 in). 3. Install and press the new glass while aligning the
◆Install the glass in less than 30 minutes after marks with those on the cab body.
application of the adhesive.
4. Secure the windshield glass and roof glass on the
12. After installing the trim on the glass bonding cab body with an adhesive tape.
portion frame of the cab body, apply the adhesive
5. Fill the space between the windshield glass and
to the glass bonding surfaces.
roof glass with the adhesive (cemedine’s S-511A
• Adhesive:
or S-511F-1) and reshape it with a spatula so that
S-511A [Black paste to use when room
it will be flush with the glass.
temperature is higher than 15°C (59°F)]
S-511F-1 [Black paste to use when room [NOTICE]
temperature is lower than 15°C (59°F)] After the glass has been bonded, allow a curing
Cemedine Co., Ltd. period of more than two hours. Don’t move the
glass.
After the glass has been bonded, secure the glass
on the cab body with a rubber tape or elastic cord,
or by other suitable means.

6. Remove the masking tapes and wipe away

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

13. Remove the rubber dam backing paper.

(Refer to the figure.)

[NOTICE]
◆When the glass installed, press it only once. Do not
press it repeatedly (This can form air bubbles).
Excess adhesive must be wiped away with a
spatula and white gasoline.
Unit : mm (1mm = 0.039 in)
14. Set and press the new glass against the cab

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

K-2 Air Conditioner

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Component parts

1. Air conditioner assy 11. Compressor assy 17. Washer 24. Bush
2. Box assy 12. Harness 18. Nut 25. Bush
3. Air distributor 13. Pulley 19. V-belt 904. Pump assy
4. Harness 14. Bolt and washer 21. Suction hose 905. Control panel assy
5. Drain hose 15. Washer 22. Discharge hose 906. Condenser assy
6. Outlet grill 16. Bolt and washer 23. Liquid hose

3 W701-0221E
K-2 K-2
Air Conditioner

(Absorbing heat from surroundings.)

2. Introduction to air conditioning Vaporization

[NOTICE]
Liquid Vapor
This section explains the fundamentals of the car
air conditioner. Difficult concepts and special
mechanisms have been omitted where possible, Condensation
(Radiating heat of vapor outward.)
and only contents which focus on the basic
functions have been included. IS701-0010E0

2.1 Principle of air conditioning

5. A compressor is needed to compress the vapor,
1. When alcohol is applied to your skin, it feels cool, and a condenser is needed to absorb heat from it.
and when your garden is watered in the
summertime, you also feel cooler air. This is
because when alcohol or water vaporizes, it
absorbs heat (known as latent heat) from its
surroundings. As a liquid (such as alcohol and
water) changes into a vapor (such as alcohol
vapor and water vapor), it requires heat
(evaporation heat). The substance surrounding
the liquid is cooled as heat is absorbed from it.

2. This natural phenomenon explains in brief the

principle of the air conditioning that is used when
we need to lower the temperature in the cab.

3. However, if the vaporized liquid used for cooling is

simply disposed of into the air, it must be
constantly replenished with more liquid. As this is
not practical, in the actual cooling system the
vapor is cooled and returned to liquid form
(condensed).

4. To condense the vapor, it is necessary to absorb

heat from it. At this time if the vapor is
compressed to higher pressure, condensation will
take place relatively easily.

4 W701-0221E
K-2 K-2
Air Conditioner

3. Basic refrigeration cycle

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

5 W701-0221E
K-2 K-2
Air Conditioner

3.2 Conditions for air conditioning equipment

The conditions required for a high-performance air conditioner are the following.
Refrigerant vaporizes at the lowest temperature possible.
Refrigerant liquefies easily.
The largest possible quantity of refrigerant vaporizes in the evaporator.

1. When we look at the conditions of the refrigerant 5. If the amount of refrigerant is insufficient, it
within the refrigeration cycle, we find that the completely evaporates in the middle as it passes
refrigerant which was compressed by the through the evaporator. This results in degraded
compressor becomes a high-temperature performance of the evaporator.
high-pressure gas.
6. On the other hand, if there is too much refrigerant,
2. The refrigerant next enters the condenser, where it cannot vaporize in the evaporator, and some
it is cooled and changed from gas to liquid form as remains in liquid form when it enters the
it passes through. All of the refrigerant must be compressor. If this occurs, there is the possibility
changed to liquid form when it reaches the that compressing liquid instead of vapor will
condenser outlet. If the condenser cooling is damage the compressor.
insufficient, some refrigerant remains in gas form,
7. For these reasons, the amount of refrigerant must
and will result in degraded cooling performance.
be adjusted according to meet a variety of
3. When the liquid refrigerant passes through the conditions.
expansion valve, it is atomized.
8. The purpose of the air conditioner is to provide a
The expansion valve is also known as a throttle
comfortable environment not only by lowering the
valve. It sprays the high-pressure liquid through a
cab temperature, but also by reducing the
small nozzle to create a refrigerant mist. This
humidity. This is accomplished by cooling the hot
allows the refrigerant to vaporize easily.
air in the cab, and condensing the moisture in it
4. In the evaporator, the refrigerant mist absorbs when it passes the evaporator.
heat from the cab and vaporizes rapidly. By the
9. In this way, the moisture in the air is removed,
time it reaches the evaporator outlet, the
reducing the humidity. The water droplets that
refrigerant has been completely transformed to a
adhere to the fins are led to the outside of the
vapor.
vehicle through a hose.

6 W701-0221E
K-2 K-2
Air Conditioner

3.3 Refrigerant
2. As shown in the figure below, the refrigerant
1. The substance that circulates through the HFC134a remains in liquid form at relatively high
refrigeration cycle, and functions to transmit heat, temperatures when it is strongly compressed.
is known as the refrigerant. In our air conditioning However, at low pressures it vaporizes at
system, HFC134a is used. It is a freon-based temperatures as low as 0°C (32°F) or
refrigerant, but does not contain chlorine. -10°C (14°F).

3. This means, for example, that if the refrigerant 6. If 60°C (140°F) is possible, HFC134a will become
vaporizes at 0°C (32°F), then the evaporator is a liquid at 60°C (140°F) if the pressure is
also at 0°C (32°F). The air that passes through approximately 1.7 MPa (246.5 psi) or above.
this evaporator should be cooled. When the gaseous refrigerant is compressed to
1.7 MPa (246.5 psi) (by the compressor), the gas
4. If the pressure is reduced so that the refrigerant
temperature rises to approximately 80°C (176°F).
evaporates at -5°C (23°F), the evaporator is also
maintained at -5°C (23°F). This results in the 7. Therefore, the temperature of the gas as it enters
formation of frost, which inhibits the flow of air the condenser is 80°C (176°F). The curve above
through the evaporator and prevents cooling. shows that when the refrigerant gas is cooled by
20°C (68°F), it becomes a liquid at approximately
5. The vaporized refrigerant must then be liquefied.
60°C (140°F) by the time it reaches the condenser
However, it is impossible to obtain a temperature
outlet.
as low as 40°C (104°F) in a hot summer
environment.

7 W701-0221E
K-2 K-2
Air Conditioner

3.4 Refrigeration cycle of a car air conditioner 2. Compared with the basic refrigeration cycle
described earlier, this cycle has an expansion
1. The refrigeration cycle of a car air conditioner
valve with a different construction, and adds a
comprises a compressor, condenser, receiver,
receiver.
expansion valve, and evaporator. The refrigerant
circulates within this cycle, with the heat in the cab 3. To increase the cooling capacity of an air
being absorbed by the evaporator and radiated conditioner, the largest possible amount of
outside the vehicle by the condenser, cooling the refrigerant must be vaporized inside the
cab. evaporator. The refrigerant must also be
completely vaporized when it reaches the
evaporator outlet.

3.5 Comparison with a household air conditioner

1. Larger temperature variation

The temperature in the cab is greatly influenced
by the outside air temperature. The cab
temperature is very high, especially when the
vehicle is parked under the burning sun.
This means:
The required amount of refrigerant within the cycle
varies greatly.

8 W701-0221E
K-2 K-2
Air Conditioner

2. Large variations in compressor speed

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

Desiccant

Strainer

IW701-0110E08

In addition to temporarily storing the refrigerant,

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

3.6 Receiver functions

1. The receiver is installed between the condenser

and the expansion valve. It temporarily stores the Gas refrigerant
refrigerant after it has been liquefied by the Liquid refrigerant
condenser, so that the refrigerant can be supplied
as needed to the evaporator according to the
cooling load.

2. Inside the receiver is a strainer and a desiccant, IW701-0110E09

which remove dust and moisture from the cooling

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

9 W701-0221E
K-2 K-2
Air Conditioner

3.7 Reheat method

1. The air which cools (or heats) the cab is taken in

from outside (or inside) by a blower motor, and
then passes through the cooler unit and heater
unit before being blown out from each of the ducts.
The temperature control type at this time is the
reheat method.

Reheating type

Evaporator Heater core

IW701-0110E10

10 W701-0221E
K-2 K-2
Air Conditioner

3.8 Components

6 7 3

R/ F 1
HOT
D E F COOL
A/ C
MODE
O N
OFF

4
5

LCD panel Air circulation inside cab

8
13 COOL HOT Outside-cab air supply

12 11 10 Min. Max.
Cool Hot
Face Face and foot Foot
The current volume
The current temperature
IW701-0160E14

Switches Sign on the LCD panel

1.Power switch 8.Sign of air supply selection
2.Air conditioner switch 9.Sign of air conditioner operation (Snow-shaped sign)
3.Inside/outside air selector switch 10.Sign of air flow volume
4.Air flow switches 11.Sign of air temperature
5.Temperature control switches 12.Sign of air blowing direction
6.Air outlet changeover switch 13.Sign of the defroster switch
7.Defroster switch

11 W701-0221E
K-2 K-2
Air Conditioner

WARNING Air outlet changeover switch

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

Air conditioner switch

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

Inside/outside air selector switch

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

Air flow switches

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

Temperature control switches

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

12 W701-0221E
K-2 K-2 K-2
Air Conditioner

4. Layout
4.1 Overall layout

13 W701-0221E 345-107-61000 △
7 13
K-2 K-2 K-2
Air Conditioner

4.2 Overall layout

345-107-63000 △
5

345-110-73000 △
2

14 W701-0221E 14
K-2 K-2 K-2
Air Conditioner

4.3 Evaporator section

345-107-02000 △
5

15 W701-0221E 15
K-2 K-2
Air Conditioner

5. Compressor Assy

16 W701-0221E
K-2 K-2 K-2
Air Conditioner

6. Evaporator Assy

17 W701-0221E 17
K-2 K-2 K-2
Air Conditioner

7. Condenser Assy

18 W701-0221E 18
K-2 K-2 K-2
Air Conditioner

8. Electric
8.1 Electric circuit

363-205-60030 △
0

19 W701-0221E 19
K-2 K-2 K-2
Air Conditioner

8.2 Main harness A

20 W701-0221E 20
K-2 K-2 K-2
Air Conditioner

8.3 Main harness B

21 W701-0221E 21
K-2 K-2
Air Conditioner

9. Important points for assembly

(Layout)

9.1 Evacuation

[NOTICE]
If moisture and air are not fully eliminated from the
cycle, they will cause problems such as cooling
trouble and clogs in the cycle.

1. Evacuate by applying vacuum to the high- and

low-pressure service valves. Continue applying
vacuum for at least 10 minutes after the pressure
reaches 101 kPa (14.6 psi).

2. Airleakage check
After evacuation is completed, leave for 5 minutes
or longer, and then check that there are no
abnormal gauge readings (pressure increases).

9.2 Charging with refrigerant

CAUTION
Never inject refrigerant from the high-pressure
side while the cycle is operating. This is
extremely dangerous; the refrigerant will flow in
reverse, and the gas can or hose may rupture.

[NOTICE]
Never inject liquid refrigerant from the low-pressure
side, regardless of whether the cycle is operating or
not. This will harm the compressor.

1. Injecting liquid
Be sure to inject from the high-pressure side,
without operating the cycle.
(1100 g or 2.42 lb)

2. Injecting gas (additional charge)

Inject gas from the low-pressure side while
operating the cycle.

22 W701-0221E
K-2 K-2
Air Conditioner

9.3 Check for gas leakage and amount of 9.5 Run-in operation
refrigerant charge
Operate the A/C for 5 minutes or more under the
[NOTICE] conditions below to perform the initial run-in
Never check using a halide-torch type leak detector. operation.
Engine speed :Idle
1. Insert refrigerant in gas form until the gauge
(High-speed starting is especially prohibited.)
pressure reads 98.1 kPa (14.2 psi). Then use a
Temp. control :Max. cool
leak tester and check for leaks.
Blower :Hi
[NOTICE]
9.6 Bolt size and tightening torque
An excess or insufficient amount of refrigerant can
result in the following trouble.
Excess amount: Cooling trouble resulting from Tightening torque
Bolt
operation of the pressure switch
N•m ft•lbf
Insufficient amount: Cooling trouble or malfunction
resulting from compressor lubrication failure Compressor installation 24.5 - 29.4 18.1 – 21.7
Idle pulley center bolt 31.4 - 47.1 23.2 – 34.7
2. When the sight glass bubbles disappear, control
the refrigerant to +100 - 200 g.
(Conditions)
Doors : Open
Blower : Hi
Engine speed : Idle Proper amount of refrigerant
A/C switch : ON
Temp. control : Max. cool

9.4 Heated water circuit Refrigerant lack

(Bubbles are visible)
1. When connecting the heated water piping, be
Sight glass
careful not to incorrectly assemble the IN and IW701-0160E12

OUT piping.

2. In order to prevent damage resulting from freezing

of the water inside the heated water circuit, in the
wintertime use antifreeze in a concentration
appropriate for the outside temperature.

3. The pressure which is applied to the heated water

circuit heater core is 196 kPa (28.4 psi) or less
when the circuit is in use. However the usual
pressure is 98 kPa (14.2 psi) or less.

23 W701-0221E
K-2 K-2
Air Conditioner

10. How to charge air conditioner gas

10.1 Charging gas in automatic operation

Gas charging unit (Reference)

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

54453 Attach all freon cans. (6 cans) Be careful that gas

Tighten as it is though the gas leaks a little when attaching. liquor does not splash
4 Turn ON the automatic gas sweep switch. (to increase degree of
vacuum)
(If the gas is insufficient, turning OFF is allowed.)
5 Set the time switch to "20 minutes".
(Set to longer period if there is a time.)
6 Turn the power switch to the automatic side. (starts vacuum)
7 Vacuum operation is finished when the buzzer sounds 15-20
minutes later. Starts gas charging.
8 Engine start is allowed when buzzer sound stops. (Turn ON the air Make sure to check
conditioner switch.) surroundings
(Keep idling for at least 10 minutes --- specified by DENSO.)
9 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
10 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 rpm
The blowing temperature must be in the graphic chart value.
(Refer to the graphic chart.)
(Near the outside air temperature scale in the gauge is a standard
pressure.)
11 Stop the engine Pull out the key
12 Wait for two minutes until pressure falls, and detach the Be careful to the
high-pressure side and low-pressure side quick couplers. scaffold
13 Test gas leakage. (for all hose connections) Be careful to the Gas
(Check the gas leakage from the lower side because the freon is scaffold leak
heavier than air.) tester
Compressor: 2 places
Compressor charge coupler: 2 places
Receiver: 2 places
Condenser Assy: 2 places
Main body of air conditioner: 2 places
Pressure switch hose connections : 1 place
11 places in total
14 Detach the empty gas can, and purge pressure in the hose.
1) Set the timer knob to the vacuum side.
2) Set the power switch to the automatic or manual.
3) Turn OFF the power switch when the high/low-pressure gauge
indicates approx. "0" pressure-value after a few seconds.
15 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.

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10.2 How to charge air conditioner gas

Flow Jigs and
Procedure Safety point
No. tools
1 Plug the power supply cord of the main unit.
2 Connect the coupler of the high-pressure side (red hose) and the Be careful to the
low-pressure side with the compressor main body sequentially. scaffold
Purge residual pressure before connecting because the
connection of coupler becomes firm if there is residual pressure in
the unit.
(Usually it has been performed at work end. Refer to Flow No.16.)

3 Attach one freon can. Be careful that gas

(Put the blind caps to the couplers which gas-can has not been liquor does not splash
attached.)
Tighten as it is though the gas leaks a little when attaching.
4 Set the time switch to the position of gas replenishment.
5 Turns the power switch to the manual side. (with 3 seconds
automatic air purge)
6 Start the engine. Make sure to check
- Engine speed: Idling surroundings
- Temperature control: Maximum cool
- Blower: Lo-Hi
7 Check the condition of bubble in the sight glass. (Check whether Make sure to check
the bubble disappears.) surroundings
8 Turn OFF the power switch when the gas disappears from the Be careful to the
remainder gas sight glass of the main unit. scaffold
9 Detach the empty gas can, and attach another gas can. Be careful that gas
liquor does not splash
10 Turns the power switch to the manual side. (with 3 seconds
automatic air purge)
- Repeat Flow No.7 until the bubble disappears.
(The charging amount should be 200g±50g after the bubble
disappears.)
11 Turn OFF the power switch when the gas disappears from the
remainder gas sight glass of the main unit.
12 Check the air-conditioning capability
Temperature control: : Maximum cool
Blower: : Hi
Engine speed : Approx. 2000 rpm
The blowing temperature must be in the graphic chart value.
(Refer to the graphic chart.)
(Near the outside air temperature scale in the gauge is a standard
pressure.)
13 Stop the engine Pull out the key

14 Wait for two minutes until pressure falls, and detach the Be careful to the
high-pressure side and low-pressure side quick couplers. scaffold
15 Test gas leakage. (for all hose connections) Be careful to the Gas
(Check the gas leakage from the lower side because the freon is scaffold leak
heavier than air.) tester
Compressor: 2 places
Compressor charge coupler: 2 places
Receiver: 2 places
Condenser Assy: 2 places
Main body of air conditioner: 2 places
Pressure switch hose connections : 1 place
11 places in total

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Flow Jigs and

Procedure Safety point
No. tools
16 Detach the empty gas can, and purge pressure in the hose.
1) Set the timer knob to the vacuum side.
2) Set the power switch to the automatic or manual.
3) Turn OFF the power switch when the high/low-pressure gauge
indicates approx. "0" pressure-value after a few seconds.
17 Finish the work.
Unplug the power supply cord, and put away the gas charge unit.

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10.3 How to check air conditioner

Jigs
Flow
Procedure Check point and
No.
tools
1 Illumination lamp check (for control panel)
1) The lamp lights with the working lamp switch ON. (Two lamps
Lights both 2 lamps.
on upper and lower of center in the panel.)
2) The lamp turns off with the working lamp switch OFF.
2 Cooler temperature control switch. (Check with blower "HI".)
1) The cooler operates by setting to "COOL". (With maximum Must be a cold blow
cooling.)
(The cooler will be hard to operate if the ambient temperature is
low. The checking becomes easy when raising the cabin
temperature to about 25°C.)
2) The cooler stops by setting to "OFF". Must be a natural blow.
3 Heater temperature control switch (Check with blower "HI" and
engine speed maximum.)
1) Warm blow must come with maximum. Must be a warm blow
2) The heater stops by setting to "OFF". Must be a natural blow.
4
1) The blower stops by setting to "OFF".
There must be a change in
2) LO: Low, ME: Medium, and HI: High
three levels
5 Mode selector switch
1) Left position: Blows down from the duct.
2) Right position: Blows down from the windshield.
6 Electric fan for condenser
1) Must synchronize with the compressor.
7
Cooler performance check
Refer to the graphic chart in the instruction manual which is for
charging an air conditioner gas.
- Blower switch is HI.
- Temperature control is maximum COOL.
- Engine speed is MAX.
- All doors are opened. (All closes in winter.)
- Tmperature of air inhalation vent must be 25-35 °C.
(The standard of temperatures fluctuate is about 10-17°C.)
* Raise the cabin temperature with the heater as much as
Check with your hand in the
possible in the winter.
winter.
(Check with your hand that the cold blow is
Avoid performing in the low
output.---Compressor must be operating.)
ambient temperature period
as much as possible.

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11 Diagnosis table
11.1 Car air conditioner system diagnosis table I (Refrigeration circuit)
A/C system Status explanation Measures (specific
Phenomenon explanation to Diagnosis result (phenomenon of
trouble of A/C system Possible cause part name and
consider other factors principal cause)
phenomenon pressure repair method)
Bubble does not appear easily to
sight glass when dripping water on
Discharge
Sight glass is transparent with liquid condenser.
Refrigerant overcharge refrigerant up to
refrigerant. Liquid level in sight glass does not proper amount.
fall even if about two seconds have
passed since A/C OFF.
Install packing or
Hot air of condenser outlet
Pressure at high When idling, pressure at high There is a spot where hot air rubber sheet to a
Insufficient air and radiator outlet air
pressure side is pressure side is high. enters in front of condenser. part where hot air
cooling. flows in front of condenser.
high hits.
Deflate from circuit
Much air contaminates in and fill refrigerant.
----------------------------- --------------------------------
refrigeration circuit. Replace receiver
drier (R/D).
Dirt or blocking in condenser fin. ------------------------------ Wash condenser.
Ventilation to condenser is bad. Replace
Air volume of condenser fan is few. Condenser fan failure.
condenser fan.
Pressure at high pressure side Blocking in high-pressure Remove blocked
rises immediately after A/C ON. circuit between COMP. and foreign object, or
High pressure is
Bubbles appear in sight glass. R/D. replace part.
No cooling high, and low --------------------------------
(High pressure side is uncertain for
pressure is low.
vehicle with charge valve following
R/D.)
Both pressures at Gas leakage from piping Check joint
high pressure side Oil blots to the piping and parts. joint and parts. looseness and
Bubbles appear in sight glass.
and low pressure Gas detector detects. re-tighten, or
Insufficient side are low. replace part.
cooling. TXV adjustment failure TXV readjustment
Bubbles appear in sight glass, then (reduced too much), or gas or replace.
------------------------------
it changes transparently. leakage in therms sensor
tube.

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A/C system Status explanation Measures (specific

Phenomenon explanation to Diagnosis result (phenomenon of
trouble of A/C system Possible cause part name and
consider other factors principal cause)
phenomenon pressure repair method)
Remove blocked
foreign object, or
------------------------------ TXV failure (blocking)
replace TXV and
R/D.
Will not get cold when driving
Replace R/D.
continuously, and repeats getting Freezing of TXV by
Deflate from circuit
Both high Bubble appears in sight glass, then cold after a while. Blow air volume contamination of water.
Insufficient and fill refrigerant.
pressure and low it changes transparently. does not change.
cooling.
pressure low. Evaporator dirt and
Wash or replace.
blocking.
Seal the joint with
Air leakage between cooling
No air blow or air volume is few. repair tape or
unit and heater unit.
packing agent.
Blower electric circuit or Check and repair
blower motor failure. circuit, or replace.
High pressure is High-pressure side and
Compressor discharge Repair or replace
No cooling. low, and low low-pressure side will be balanced ------------------------------
failure. compressor.
pressure is high. after stopping compressor.
Improve contact of
therms sensor
TXV therms sensor tube part. Correct heat
Low-pressure piping is abnormally ------------------------------ contacts to piping, or heat insulation.
Insufficient Low pressure is
cold and frosting. (refrigerant insulation failure. Replace therms
cooling. high.
returning) sensor tube
fixation clip.
TXV adjustment failure Readjust or
-------------------------------
(raise too much) replace TXV.

Insufficient
cooling. (Normal Blowing air volume changes Evaporator is frosting. Thermistor Check thermistor,
cooling at gradually. When A/C is OFF, and is not cold. If louver blowing Turning OFF temperature of thermo amp., and
--------------------
beginning, and blower is ON, much water is temperature gets cold enough, thermostat has lowered. mechanical
gradually reduce drained from drain hose. compressor will be OFF tentatively. thermo.
cooling later.)

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A/C system Status explanation Measures (specific

Phenomenon explanation to Diagnosis result (phenomenon of
trouble of A/C system Possible cause part name and
consider other factors principal cause)
phenomenon pressure repair method)
Check that thermo
Evaporator is frosting. Thermistor Installation position failure of therms sensor is in
is not cold. If louver blowing thermo therms sensor proper position.
---------------- Blowing air volume changes temperature gets cold enough, (thermistor and mechanical Move it to proper
gradually. When A/C is OFF, and compressor will be OFF tentatively. thermo capillary). position in case of
blower is ON, much water is NG.
Insufficient drained from drain hose. Evaporator is frosting. Thermistor
Check thermo
cooling. (Normal is cold. If louver blowing Thermistor or thermo amp.
---------------- system wiring, or
cooling at temperature gets cold enough, failure (will not turn OFF).
replace parts.
beginning, and compressor will not be OFF.
gradually reduce Seal with repair
cooling later.) Gas leakage from
---------------- tape or packing
evaporator case.
Air volume is small from the agent.
Evaporator frost formation.
beginning. Gas leakage from joint of
Affix packing
---------------- heater unit and evaporator
again.
unit.
Deflate from circuit
---------------- Air volume does not decrease. Freezing of TXV Water intrusion in circuit.
and fill refrigerant.
Outside air intrusions to Adjust inside and
------------------------------------ inside, though inside outside air switch
circulation. dumper.
Warmed with heater. (Water
Check and adjust
valve adjustment failure or
Blowing temperature is high and it ------------------------------------- water valve and air
leakage, and air mix dumper
does not get cold (refrigeration mix dumper.
does not close completely.)
circuit is normal).
Check thermostat.
Insufficient (Check mechanical
Normal Thermostat operating
cooling. ------------------------------------- thermo, thermistor,
temperature failure.
thermo amp., and
thermo VR.)
Air volume is few and does not get Wash or replace
------------------------------------- Blocking of evaporator fin.
cold, though blowing temperature is evaporator.
cold. Blower motor revolution is Check and replace
slow. blower motor.
-------------------------------------
Blocking of blower
Check and repair.
inhalation vent.

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11.2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure)
Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Water leak is Cooling unit Leaks at normal operation. Water leak from cooling Drain hose for blocking, bend, or Install drain hose, grommets,
found. case. coming off failure. and heat insulators
Delivery valve blocking, bend, appropriately, or replace case
coming off, or opening at end. and failed components.
Blocking in outlet under case.
Crack under case.
Noise sounds. Inside cabin. Gas leakage sound is ------------------------------- Gas leakage between Seal with packing or packing
heard. evaporator unit and blower material.
motor heater unit.
Something is heard from ------------------------------- Abnormal sound from motor or Replace the one with large
blower motor fan relation. bearing. sound.
------------------------------- Foreign object intrusion in fan Remove foreign object.
case.
Refrigerant gas sound ------------------------------- Gas vibration sound (flow sound Remove interference between
(sound 'Goooo!') is heard. or pulse sound) refrigeration piping and vehicle
frame or hood, if there is.
Something is heard from Whistle sound. ------------------------------- Replace parts for the one with
TXV relation (whistle sound large whistle sound.
or gas flow sound). Gas flow sound Gas flow sound may be Check refrigerant level, and
generated at insufficient charge refrigerant.
refrigerant or at air/refrigerant
mixed condition.
------------------------------- Gas flow sound is generated
somewhat, and check sound
level, then replace if it is noisy.
Engine room side Sound is generated when ------------------------------- Clutch bearing or idle pulley Replace bearing and idle
compressor and bearing is failure. pulley. Longevity will be
electromagnetic clutch are shortened if belt is
OFF. over-tensioned.
------------------------------- Loosening of idle pulley Re-tighten screw.
mounting nut.
Sound is generated when ------------------------------- Compressor noise failure. Repair or replace in case of
compressor starts. failure.

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Trouble
Diagnosis result
phenomena Phenomenon explanation to Measures (specific part name
Disorder section (phenomenon of principal Possible cause
other than A/C consider other factors and repair method)
cause)
system
Noise sounds. Engine room side Sound is generated when -------------------------------- Vibration or slip by belt Tension belt, replace, or
compressor starts. looseness (continuous sound re-tighten screw.
'Quuuu!'). Screw looseness
failure.
Sound is generated from -------------------------------- Motor-fan shaft shaking, bearing Repair or replace.
radiator fan and condenser breakdown, fan damage, or
fan. fan/shroud come in contact.
Sound is generated from -------------------------------- Dropout of fixed bolt, looseness, Tighten appropriately, or
parts installation section or damage of brackets. replace brackets.
(shaking when touching).
Vehicle Condenser unit Condenser is set in front of Blocking in condenser fin. -------------------------------- Wash condenser fin.
overheats radiator. Revolution of condenser fan Condenser fan failure. Replace condenser fan motor.
easily. is slow.
High-pressure is high. (High Same cause as refrigeration Same measures as
pressure is high at idling.) circuit system-I. (Hot air flows in refrigeration circuit system-I
condenser.)
Vehicle Vehicle side Trouble around radiator. Blocking in radiator fin. Wash or replace radiator fin.
overheats -------------------------------- Dirt inside radiator. Check and replace.
easily. Radiator filler cap failure.
Water pump failure.
Blocking in water thermo.
Radiator coolant is -------------------------------- Check leakage and replenish,
shortage. or replace radiator.
Fan belt and water pump -------------------------------- Adjust belt tension or replace
belt are slippage. belts.
Revolution of radiator Radiator fan failure. Replace
cooling fan is slow, or
slippage.
Engine Vehicle side Engine revolution adjusting -------------------------------- Raising idling speed too much or Adjust idling speed to a
(revolutions) is device overheat. regulated value, and adjust
overrun. engine. Take measures for
overheat.
Smells Cooling unit -------------------------------- -------------------------------- Smoke of Tabaco, dust, and Wash evaporator.
unpleasant. mold, etc. are adhered or
deposited to the evaporator fin.

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11.3 Car air conditioner system diagnosis table III (Electrical system)
Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
1) Neither Check of fuse -------------------------------- No fuse blowing -------------------------------- Measures from diagnosis
compressor clutch blowing. (normal). of 2) and 4).
nor blower motor -------------------------------- Fuse blowing. Short-circuit of compressor clutch Repair
operate. or blower motor system wiring.
2) Only Connect battery Clutch does not suck. ---------------------------- Clutch failure. Replace
compressor clutch directly to clutch Clutch does suck. Clutch does suck. Either of thermo amp., pressure Check and replace parts.
does not suck. terminal. Short-circuit both ends SW, or thermistor is failure.
(Others are of thermo amp. bypass Clutch does not suck. 0 (zero) V Check parts, and repair or
operating.) connector, pressure SW, Check voltage of Either of clutch relay signal replace parts.
and thermistor. clutch relay connector. circuit or vehicle side electronic
control amplifier is failure.
Clutch does not suck. Approx. 12V Check parts, and repair or
Check voltage of Either of clutch relay or clutch replace parts.
clutch relay connector. power circuit (disconnection) is
failure.
3) Compressor Remove thermistor Clutch does not suck. ---------------------------- Thermistor failure. Replace
clutch suction does from thermo amp. Clutch does suck. Clutch does not suck. Thermo amp. failure. Replace
not stop. Remove thermo amp. Clutch does suck. Clutch relay contact failure. Replace
power supply connector.
4) Only blower Connect battery Blower motor does not ---------------------------- Blower motor failure. Replace
motor does not directly to "+" work.
work. terminal of blower Blower motor works. Blower motor works. Blower switch failure. Replace
motor. Connect L.M.H of blower Blower motor does not Blower system cords Repair
switch directly to battery work. disconnection.
terminal. Rresistor failure. Replace
5) Condenser fan Connect battery Fan motor does not work. ---------------------------- Fan motor failure. Replace
motor does not directly to "+" Fan motor works. 0 (zero) V Signal circuit is open, and thermo Check parts, and repair or
work. terminal of fan Check voltage of amp. failure. replace parts.
motor. condenser fan relay Approx. 12V Condenser fan relay contact Check parts, and repair or
connector. failure or fan motor power circuit replace parts.
open.
6) Compressor Check air gap. -------------------------------- ----------------------------- Air gap is large. Adjust air gap.
clutch slips.

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Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part
phenomenon of check and and confirmation (phenomenon of name and repair method)
functional parts confirmation principal cause)
6) Compressor Measure clutch -------------------------------- ---------------------------- Clutch suction voltage is low (7V Repair or replace parts.
clutch slips. suction voltage. or less).
Try to turn -------------------------------- ---------------------------- Compressor shaft does not turn Repair or replce parts.
compressor shaft smoothly.
manually.

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11.4 Car air conditioner system diagnosis table IV (Electronic thermo system)
Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Compressor Check thermistor. Measure resistance of Resistance is small. Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. (Abnormal if resistance is
ON. about 7kΩ or less.)
Resistance is about 2kΩ Thermistor is normal. ----------------------------
(25℃).
Check thermo Turn OFF thermo volume. Compressor clutch is turned Thermo volume is Replace thermo volume.
volume. OFF. short-circuited.
Check relay Remove connector of Compressor clutch cannot be Relay contact joining. Replace relay or thermo amp.
contact and thermistor. turned OFF. (Stayed ON) Thermo amp. failure.
thermo amp.
Compressor Check thermistor. Measure resistance of Resistance is about 7kΩ or Thermistor failure. Replace thermistor.
clutch stayed thermistor connector. more.
OFF. Check thermo Measure resistance of thermo Resistance is ∞ (infinity). Thermo volume is Replace thermo volume.
volume. volume terminal. disconnected.
Check relay Detach connector of thermistor, Compressor clutch cannot be Relay contact joining. Replace relay or thermo amp.
contact and and short-circuit thermo amp. turned ON. Thermo amp. failure.
thermo amp. side connector.
Compressor Check thermo Check conduction in thermo Tester indicator changes if Contact failure in thermo Replace thermo switch.
clutch does switch. volume terminal. applying shock to thermo switch.
chattering. volume.
Tester indicator does not Thermo switch is normal. ----------------------------
change even if applying
shock to thermo volume.
Check thermo Remove thermistor, and When applying shock to Soldering failure (or, Replace thermo amp.
amp. short-circuit thermo amp. side thermo amp., compressor caulking failure) in thermo
connector. clutch does chattering. amp.
Check contact Twist connectors. Compressor clutch does Connector failure. Repair connector.
condition in wiring chattering.
connector.
Insufficient Replaces Gets cold normally. Thermistor failure. Deterioration of thermistor. Replace thermistor.
cooling. (Clutch thermistor with
works ON and new one.
OFF.)

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Operation Measures
Guessing of Diagnosis result
trouble Check and confirmation of (Thermistor amplifier
trouble functional (Refer to temperature Possible cause
phenomenon of operational parts replacement, and connector
parts characteristic for thermistor.)
functional parts repair.)
Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp. internal Replace thermo amp.
cooling. (Clutch thermistor with not change. failure.
works ON and new one.
OFF.) Check installation Positioned correctly. -------------------------------- Thermistor failure. Replace thermistor.
condition of Incorrect position or comes off. -------------------------------- -------------------------------- Install thermistor in correct
thermistor. position.
Insufficient Refer to other -------------------------------- -------------------------------- -------------------------------- --------------------------------
cooling. (Clutch diagnosis tables.
stayed ON) (Excluding the
cause of
electronic thermo
system.)

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12. Compressor
12.1 Compressor abnormal sound diagnosis chart

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12.2 Compressor diagnosis chart (1/2)

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Compressor diagnosis chart (2/2)

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13.Troubleshooting

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14.Control table

Input Output
Input from Panel LCD display on panel
ON/OFF Blowout mode In/outside A/C switch In/outside air
M/A Blowout mode Air blow mode Relay

Air blow DOWN switch

change switch mode

Temp. control display

Temp. DOWN switch
Switch air switch

Air blow UP switch

DEF mode switch
INPUT/OUTPUT

Temp. UP switch

For blowout mode

Eva sensor

outside air mode

For water pump

For compressor
A/C sign
For inside and

Circulated air
　 Circulated air
FOOT
VENT

For air mix

OFF

OFF
B/L
ON

ON

Fresh air
FOOT
FACE

clutch
　　 Fresh air

DEF
B/L
Lo M1 M2 Hi

　　

　　

　　
　　

　　
　　
CONTROL

ＣＯＯＬ FACE Circulated COOL MAX

Initial settings (first power ON) - ON - - - - - - - - - - - - - ON OFF OFF OFF ON OFF ON OFF OFF OFF ON ー OFF
ＭＡＸ position ait position (display one bar)
Operates Bar increases
COOL→WARM OFF ON OFF - - - - - - - - - - - - - - - - - - - - - - - - - -
to WARM from left
Air mix M/A control
Operates Bar decreases
WARM→COOL OFF OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - -
to COOL from right
FACE mode OFF - - ON OFF ← ← - - - - - - - - FACE pos. - ON OFF ← ← - - - - - - - - - -
Blowout mode M/A B/L mode OFF - - OFF ON OFF ← - - - - - - - - Ｂ／Ｌ pos. - OFF ON OFF ← - - - - - - - - - -
control FOOT mode OFF - - OFF ← ON OFF - - - - - - - - ＦＯＯＴ pos. - OFF ← ON OFF - - - - - - - - - -
Status before turning OFF is held.

DEF mode OFF - - OFF ← ← ON - - - - - - - - ＤＥＦ pos. - OFF ← ← ON - - - - - - - - - -

Inside and outside Circulated air mode OFF - - - - - - - - ON OFF - - - - - Circ. air - - - - ON OFF - - - - - - - -
air M/A control Fresh air mode OFF - - - - - - - - OFF ON - - - - - Fresh air - - - - OFF ON - - - - - - - -
Lo OFF - - - - - - - - - - - - - - - - - - - - ON OFF ← ← - - - -
M1 Opera Opera
Blower amplifier OFF - - - - - - - - - - - - - - - - - - - - OFF ON OFF ← - - - -
-tes to -tes to
control M2 OFF - - - - - - - - - - - - - - - - - - - - OFF ← ON OFF - - - -
ＨＩ ＬＯ
Hi OFF - - - - - - - - - - - - - - - - - - - - OFF ← ← ON - - - -
Thermo operation OFF - - - - - - - - - - ＯＮ ＯＦＦ Note1 - - - - - - - - - - - - - ON - Note1 -
Compressor clutch
Frost formation detection OFF - - - - - - - - - - ＯＮ ＯＦＦ Note2 - - - - - - - - - - - - - ON - Note2 -
control
Fretting prevention OFF - - - - - - - - - - - - - - - - - - - - - - OFF OFF ON ON - - Note3 -
Bars displayed on LCD Water pump relay Eight bars
OFF - - - - - - - - - - - - - - - - - - - - - - - - - - - - ON
Water pump relay are eight. ON display
control Bars displayed on LCD Water pump relay Seven or less
OFF - - - - - - - - - - - - - - - - - - - - - - - - - - - - OFF
are seven or less. OFF bars display
A/C ON signal
Signal output at A/C ON OFF - - - - - - - - - - ＯＮ ＯＦＦ - - - - - - - - - - - - - - ON - ON -
output
Blinking of HOT
Air mix M/A OFF ON - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - - - - - -
sign
Abnormality
Open circuit Blowout mode Blinking of human
of M/A and its OFF ON - - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - -
detection M/A character sign
I/O circuit
In/outside air Blinking
OFF ON - - - - - - - - - - - - - - - ＯＦＦ - - - - - - - - - - - -
Abnormal detection mode M/A in/outside air
and subsequent Abnormality
Open or Blinking
control of sensors
short-circuit Eva sensor OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - - of A/C - OFF -
and their
detection sign
input circuits
Between
Abnormality of operation panel Blinking of bar
OFF ON - - - - - - - - - - - - - OFF OFF OFF - - - - - - - - - - - OFF OFF
communication and control display "Frame"
amplifier

　　Note 1. OFF temperature: 4-6℃(39.2-42.8°F), ON temperature: 5.5-8.5℃(41.9-47.3°F)

　　Note 2. Timer set temperature:6-10℃(42.8-50°F), Timer cancellation temperature:6-12℃(42.8-53.6°F), Count up time: 10±1 minutes, Timer reset temperature: 7-13℃(44.6-55.4°F)
　　Note 3. When compressor clutch is never turned ON after power ON of vehicle main key, also when compressor clutch is turned ON only once when air blow M2 or higher continues for five minutes. This control is cleared by main key power OFF in the vehicle,
and starts the control again by turning it ON. Compressor clutch ON time: 1±0.6 seconds

47 W701-0221E 47
K-3 K-3
Hydraulic Motor (Air Conditioner) (Option)

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

2 16 12 1 8 11 A 10 4 B 3

24 19

A B

9 13 15 IW102-037001

48 W102-0371E
K-3. K-3.
Hydraulic Motor (Air Conditioner) (Option)

5 7 6 14 25 20 21 22
A B
Dr
23

24

19

IW102-037002 IW102-037003

1.Casing 8.Tapered roller bearing 15.Spring washer 22.Spring

2.Drive shaft 9.Tapered roller bearing 16.Key (7×7×30) 23.Spring retainer
3.Pintle 10.Timing pin 17…. 24.O-ring
4.Cylinder block 11.Timing ring 18…. 25.O-ring
5.Piston 12.Oil seal 19.Plug
6.Piston ring 13.O-ring 20.Seat
7.Pistonring retainer 14.Hex. socket head bolt 21.Steel ball 5/16

366-634-40003 △
0
366-634-40002 △
0

366-634-40001 △
0

49 W102-0371E
K-4 K-4
Solenoid Valve (Air Conditioner) (Option) (--#546165)

K-4 Solenoid Valve (Air Conditioner) (Option) (--#546165)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

b f

b f 1

P A
T1
a T B
e

P
B
A
T
IW121-076001 IW121-076002

1.Solenoid valve assy 2.Body

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7-8 5-6

50 W121-0762E
K-4. K-4.
Solenoid Valve (Air Conditioner) (Option) (--#546165)

Solenoid valve assy

Connector

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

IW121-0542E01

T1 9 21 9

A P B
T T

T2 159 157 156 1 15 113 60 71 4

IW121-076003

1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V)

4.Plug 21.Spool 113.Square ring 159.O-ring
9.O-ring 60.Spring seat 156.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
4 - 23 - 28 17 - 21
15 M5 7-8 5-6
T1 - 38 - 41 28 - 30
T2 - 4–5 3-4

367-401-70000 △
0

51 W121-0762E
K-5 K-5
Solenoid Valve (Air Conditioner) (Option) (#546166--)

K-5 Solenoid Valve (Air Conditioner) (Option) (#546166--)

[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. Solenoid valve assy 2. Body 3. Orifice

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
a, b, e, f G1/2 98 72
T1 M5 7-8 5-6

52 W121-0950E
K-5. K-5.
Solenoid Valve (Air Conditioner) (Option) (#546166--)

Solenoid valve assy

Connector

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

IW121-0542E01

T1 9 21 9

A P B
T T

T2 159 157 156 1 15 113 60 71 4

IW121-076003

1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V)

4.Plug 21.Spool 113.Square ring 159.O-ring
9.O-ring 60.Spring seat 156.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
4 - 23 - 28 17 - 21
15 M5 7-8 5-6
T1 - 38 - 41 28 - 30
T2 - 4–5 3-4

367-415-00000 △
0

53 W121-0950E
 L
Control System

Contents

L-1 Control System ................................ 1 L-7 Solenoid Valve (Air) .......................14

1. General of hydraulic pilot system............... 1 1. Structure .................................................. 14

2. General of pneumatic control devices ....... 2

L-2 Remote Control Valve (Lever)......... 3 L

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

L-3 Remote Control Valve (Pedal)......... 6

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

L-4 Shuttle Valve (Lever / Pedal) ........... 9

1. Structure .................................................... 9

L-5 Solenoid Valve (Boom Telescoping

/ Aux. Hoist) ........................... 10

1. Structure .................................................. 10

L-6 Solenoid Control Relief Valve

(Elevating Slow Stop)............ 12

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

i
L-1 L-1
Control System

L-1 Control System

1. General of hydraulic pilot system

Hydraulic Pilot Circuit

(*1) : application
Europe Option
Greneral Export ―

1 WL02-0100E
L-1. L-1.
Control System

2. General of pneumatic control devices

Pneumatic Circuit

2 WL02-0100E
L-2 L-2
Remote Control Valve (Lever)

L-2 Remote Control Valve (Lever)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
TP

1 2 3 4
IW135-013001

A A

455

247
T

P
171
172

101

PORTS 1＆ 2 PORTS 3＆ 4

A 123 A
103
IW135-0130E02

3 W135-0132E
L-2 L-2
Remote Control Valve (Lever)

Cross section along the line A-A

501
402

445
454
453
452
481 411
212

401
211
213
214

T 215

216
217 161
241
131 P
221
201

PORTS 1•3 PORTS 2•4 122

125
111
A-A
IW135-0130E03

101.Casing 171.Bolt 216.Spring seat 445.Hexagon socket head bolt

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

4 W135-0132E
L-2. L-2.
Remote Control Valve (Lever)

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P, T G1/4 34 - 38 25 - 28

PORTS 1, 2, 3, 4 G1/4 34 - 38 25 - 28

125 M8 27 - 31 20 - 23

161 R1/4 20 - 24 14 - 17

172 M8 16 - 18 12 - 13

411 M12 27 - 31 20 - 23

445 M8 27 - 31 20 - 23

454 *1 M8 16 - 18 12 - 13

481 M6 11 - 13 8 - 9.4

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

366-349-20000 △
0

5 W135-0132E
L-3 L-3
Remote Control Valve (Pedal)

L-3 Remote Control Valve (Pedal)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
T P
[NOTICE]
This structure shows the
triple-bank valve.
The structure of the double-bank
valve is similar to the triple-bank
valve.
1 2 3 4 5 6
IW135-015001

323

315

A 431

414

262

263
T
115
P

272 273

1,2 3,4 5,6 102

101 103 A IW135-015002

6 W135-0152E
L-3 L-3
Remote Control Valve (Pedal)

Section A-A

501 413 472 473 420

471

214

210

271
202
201
212
311
324
T
335
217
P
313
251
261
301 2,4,6
1,3,5 IW135-015003

101

101.Casing 214.Push rod 273.Nut 413.Cam shaft

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

7 W135-0152E
L-3. L-3.
Remote Control Valve (Pedal)

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
272 M8 19.1 - 22.1 14.1 - 16.3
271 M6 8.7 - 8.9 6.4 - 6.6
251 G1/4 27.4 - 31.4 20.2 - 23.2
315 M12 56.3 - 61.3 41.5 - 45.2
5.9 - 7.9 4.4 - 5.8
472 M6
Apply LOCTITE 241
473 M8 15.2 - 18.2 11.2 - 13.4
P, T G1/4 27.4 - 31.4 20.2 - 23.2
Port 1,2,3,4,5,6 G1/4 27.4 - 31.4 20.2 - 23.2

366-380-60000 △
0

366-377-50000 △
2

8 W135-0152E
L-4. L-4.
Shuttle Valve (Lever/Pedal)

L-4 Shuttle Valve (Lever / Pedal)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
c d

e f

a b
IW128-011001

c d d(c)
2

f(e)
1

a b b(a)
IW128-011002

1.Body 2.Joint 3.O-ring 4.Steel ball

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
a, b, e, f G1/4 29.4 22

c, d G1/4 24 - 29 18 - 22

2 G3/8 49 36

366-236-90000 △
1

9 W128-0112E
L-5 L-5
Solenoid Valve (Boom Telescoping/Aux. Winch)

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

H F G D B C

E T A
IW121-031001

Connector

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

IW121-0542E01

10 W121-0313E
L-5. L-5.
Solenoid Valve (Boom Telescoping/Aux. Winch)

Cross section along the line X-X

3 1 14 16
B (F) D (H)

C (G)
11
T T
8

A (E)

4 16 7 15

X-X
IW121-031003

Note: Apply LOCTITE 262 (thread locking agent) to the threaded section of the seat (1).

1.Seat 5.Solenoid (DC24V) 11.Plain washer 16.Plug

2.Spring 7.Sleeve 13.Steel ball
3.Body 8.Stopper 14.Steel ball
4.Spool 10.Hexagon socket head bolt 15.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, B, C, D G1/4 29.4 22

E, F, G, H G1/4 29.4 22

T G1/4 29.4 22

366-481-30000 △
1

11 W121-0313E
L-6 L-6
Solenoid Control Relief Valve (Elevating Slow Stop)

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

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
601

171

151

A2 A1

101.Casing P2 P1
151.Plug
171.Hexagon socket head bolt
601.Proportional reducing valve

101 T1 IW136-0250E01

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
P1, P2, T, A1, A2 G1/4 34 - 38 25 - 28
151 R1/16 6-8 4-6
171 M5 6-8 4-6
T1 M8 26 - 32 20 - 24

12 W136-0251E
L-6. L-6.
Solenoid Control Relief Valve (Elevating Slow Stop)

Proportional Reducing Valve

351 311 326 324 331

P A T
312 361 362 363 861 325 801 802
IW136-0250E02

311.Spool 326.Retaining ring 362.O-ring 861.O-ring

312.Sleeve 331.Spring seat 363.O-ring
324.Spring 351.Orifice 801.Proportional reducing valve
325.C-ring 361.O-ring 802.Seal nut

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
351 M3 0.5 - 0.7 0.37 - 0.52
802 M6 6.9 - 7.9 5.1 – 5.8

367-301-50000 △
0

13 W136-0251E
L-7 L-7
Solenoid Valve (Air)

L-7 Solenoid Valve (Air)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

Connector

+-
IW210-0151E01

14 W210-0170E
L-7. L-7.
Solenoid Valve (Air)

1 2 3 4 5 6 7

8
9
10 21

11 22

12 27
13
18
IN
14
17
15
19 EXH
OUT 16
OUT
IN EXH IN

A-A B-B
IW210-0170E03 IW210-0170E04

1.Packing holder 8.Plunger 15.Valve 22.Valve seat

2.Packing 9.Rod 16.Spring 23.Bolt
3.Coil assy (DC24V) 10.O-ring 17.O-ring 24.Bolt
4.Core 11.Coil cover 18.Body 25.Spring washer
5.Spring 12.O-ring 19.Body 26.Filter
6.O-ring 13.Valve seat 20.Housing 27.Spring
7.Case 14.O-ring 21.Spring 28.Plug

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22

23 - 2-3 1.5 - 2.0

T1 M8x1.25 8 - 12 6-9

366-474-50000 △
3

15 W210-0170E
 S
Steering System

Contents

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

Cylinder Lock)........................12
1. General ...................................................... 1
1. Structure .................................................. 12

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

1. Structure .................................................... 2

2. Function ..................................................... 2

3. Principle of operation ................................. 3

3.1 Neutral state ............................................... 3
3.2 Right steering ............................................. 3
3.3 Right steering to the end ............................ 3

S-3 Orbitrol.............................................. 4

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

2. Function ..................................................... 7 S

S-4 Steering Cylinder ............................. 8

1. Structure .................................................... 8

S-5 Solenoid Valve (Steering Mode) ..... 9

1. Structure .................................................... 9

i
S-1. S-1.
Steering System

S-1 Steering System

1. General
Hydraulic Circuit for Steering

Layout of Steering Cylinders

1. The steering wheel is coupled with the orbitrol.
(Right steering)
2. The orbitrol, together with the priority valve,
supplies the steering cylinders with oil at the rate
corresponding to the rotational speed of the
steering wheel. Surplus oil is supplied to the
swing circuit.

3. The solenoid valve (steering mode) is switched

according to the outputs from the multiplex data
transmitter (lower).

4. The maximum pressure in the steering hydraulic

circuit is regulated by the relief valve in the priority
valve. The emergency steering can be provided to
the steering system as an option. (Refer to the
"Hydraulic Circuit for Carrier" in the "Hydraulic
[NOTICE] Power Generating System" for detailed
Two "*R"s and two "*L"s of the two front steering information.)
cylinders represent the right steering port and the
left steering port respectively.

1 WS02-0070E
S-2 S- 2
Priority Valve

S-2 Priority Valve

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
LS CF EF

P IW126-003001

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

LS

16 15
17 16 EF CF IW126-003002

1.Housing 7.Ring 11.Boll 15.Plug

2.Spool 8.Screen 12.O-ring 16.O-ring
3.Spring 9.Screw 13.Guide 17.Plug
6.Body 10.Spring 14.Boll Holder

Thread size and tightening torque 2. Function

Sign/ Tightening torque This valve serves to allow the hydraulic oil to flow
Thread size to the Orbitrol only in the flow rate required by the
port N-m ft-lbf
T, LS 7/16 - 20UNF - 2B 20 - 24 15 - 18 steering operation, and all the excess oil to flow to
P, EF 1•1/16 -12UN - 2B 78 - 88 58 - 65 other actuators.
CF 3/4 - 16UNF - 2B 54 - 66 40 - 48

2 W126-0051E
S-2. S-2.
Priority Valve

3. Principle of operation

NEUTRAL RIGHT STEERING

The above figure is for illustrating the principle. The construction of the actual machine may differ from the figure.

3.1 Neutral state 3.2 Right steering

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

366-103-80000 △
1

3 W126-0051E
S-3 S- 3
Orbitrol

S-3 Orbitrol
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
P, T, L, R 3/4-16UNF-2B 54 - 66 40 - 48
LS 7/16-20UNF 20 - 24 15 - 18
T1 3/8-16UNC 43 - 49 32 - 36

4 W184-0012E
S-3 S- 3
Orbitrol

Cross section

Star

13

A NG OK
IW184-001003 IW184-001006 IW184-0010E05

26 25 4 2
T P
18

21

22

14 5

20

19

16 17 13 10 11 12 8 24 7 23 3 1

A- A
IW184-001004

5 W184-0012E
S-3 S- 3
Orbitrol

[NOTICE]
Orient the star of the rotor set (4), drive (8) and pin (13) as shown in the "OK" figure.

1.Screw 8.Drive 16.Race bearing 22.Seal gland bushing

2.Retainer screw assy 10.Housing 17.Thrust needle 23.O-ring
3.End cap 11.Sleeve 18.O-ring 24.O-ring
4.Rotor set 12.Spool 19.Oil seal 25.Adapter screw
5.Spacer 13.Pin 20.Dust seal 26.Ball
7.Spacer plate 14.Centering spring 21.Retaining ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
1, 2 - 24 17

6 W184-0012E
S-3. S-3.
Orbitrol

2. Function
Spool
The machine is equipped with a load-sensing type Housing B Sleeve Drive
orbitrol consisting of the following main C
D
components:

1. Housing
The housing has five piping ports: P, T, R, L and
LS.

2. Spool and sleeve

Spool is splined to the steering wheel, and serves
to switch over hydraulic circuits by its relative
position to sleeve.
Spool and sleeve are mechanically connected at
two positions, as shown in section B-B and C Rotor set D
Spring
section C-C. B
Pin
In section B-B, spring is installed in the recess
grooves in spool and sleeve, so that while the IW184-001007

steering wheel is stationary, spool and sleeve are

kept in the neutral position relative to each other
as shown in section B-B by the force of spring. In
the area around section C-C, spool, sleeve and
drive are connected by pin. Here, sleeve and drive
are connected by pin without clearance, but spool
has oval holes in which pin can move through
small angles.

3. Drive
The drive serves to transmit the motion of the star
of rotor set to sleeve through pin.

4. Rotor set
This consists of a ring possessing seven internal
teeth and a star internally in mesh with the ring,
possessing six teeth.

366-316-40000 △
1

366-352-70001 △
1

7 W184-0012E
S-4. S-4.
Steering Cylinder

S-4 Steering Cylinder

[NOTICE]
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

A1,A2
B

C D

16 17 18

15 1 2 3 19 5 6 7 8 20 9 10,11 13 15

IW160-0020E01

1.Cylinder 7.Rod cover 13.Dust seal 19.Plain bearing

2.Spring pin 8.O-ring 15.Plain bearing 20.Plain bearing
3.Piston 9.Damper ring 16.Clip
5.O-ring 10.Packing 17.Boot
6.Rod 11.Backup ring 18.Clip

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A1, A2, B G3/8 49 36
C, D Rc1/8 9 - 12 6.5 - 9

360-603-50000 △
6

8 W160-0021E
S-5 S- 5
Solenoid Valve (Steering Mode)

S-5 Solenoid Valve (Steering Mode)

[NOTICE]
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
A1 B1

SOL2 SOL1

Pp

B2
Dr

Connector
SOL4 SOL3

A2
+- (+): Red
(-): Blue
IW121-0542E01
P T IW121-039001

301 403 104 502

3-d
B
SOL2 Pp
SOL1

B1 A1

Dr
A

A2 B2
A
SOL4
SOL3
P T B
501 502 IW121-039002

104.Spool 501.Plug
301.Hexagn socket head bolt 502.Plug
403.O-ring

9 W121-0392E
S-5 S- 5
Solenoid Valve (Steering Mode)

Section A-A

T1
T2
601
102 402 403 101 103 105 401 201

T3
A2 B2 Dr

Pp T
302 501 102
IW121-039003

Section B-B
Pp

101.Casing
102.Cover
103.Spool
105.Spring seat
201.Spring
302.Hexagon socket head
bolt
401.O-ring
402.O-ring
403.O-ring
601.Solenoid valve assy

P T
IW121-039004

10 W121-0392E
S-5. S-5.
Solenoid Valve (Steering Mode)

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
d(mounting bolt) M8 29.5 ± 3 22 ± 2.2
T1 - 2 or less 1.5 or less
T2 - 5.4 ± 0.5 4 ± 0.4
T3 - 44 ± 5 32.5 ± 3.7
302 - 11.8 ± 1.5 9 ± 1.1
501 - 6.9 ± 1 5 ± 0.7
502 - 9.8 ± 1.5 7 ± 1.1
P, A1, A2, B1, B2, T G 1/2 98 72
Pp, Dr G 1/4 29.4 22

366-438-60002 △
0

11 W121-0392E
S-6. S-6.
Pilot Check Valve (Rear Steering Cylinder Lock)

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

[NOTICE]
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
A B

C D
IW115-003001

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

A B

C D IW115-041001

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

2.Piston 5.Spring 8.O-ring 11.Valve
3.Sleeve 6.Plug 9.O-ring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
A, B, C, D G 1/2 98 72
Mounting bolt M8 14 ± 1 10 ± 0.7

366-254-50000 △
0

12 W115-0411E
 T
Brake System

Contents

T-1 Brake System ................................... 1 2.4 Operation under piping rupture................. 11

1. General ...................................................... 1 3. Dismouting and remounting......................11

4. Disassembly .............................................11
T-2 Brake (Service Brake)...................... 2 4.1 Disassembly of the mount plate................12
4.2 Disassembly of the body...........................12
1. Structure and function................................ 2
1.1 Principle of operation.................................. 3 5. Cleaning and checking ............................ 13
5.1. Cleaning ....................................................13
2. Checking the pad assy............................... 3 5.2 Checking ...................................................14

3. Checking the disc plate.............................. 3 6. Reassembly............................................. 14

6.1 Reassembly of the secondary side...........14
4. Replacing the pad assy.............................. 4 6.2 Reassembly of the primary side ...............14
6.3 Reassembly of the mount plate ................16
5. Disassembly .............................................. 5
7. Test ..................................................... 16
6. Washing and checking............................... 5 7.1 Air leakage through supply valve and
6.1 Washing...................................................... 5 exhaust valve ......................................16
6.2 Checking..................................................... 5 7.2 Air leakage in other parts ..........................16
7.3 Operation test ...........................................16
7. Reassembly ............................................... 6 7.4 Performance test.......................................16
T
8. Maintenance standards.............................. 6 8. Maintenance standards ........................... 17
8.1 600-hour check .........................................17
8.2 2000-hour or 1-year check........................17
T-3 Brake Valve ...................................... 7

1. Structure and function................................ 7 T-4 Booster (Brake) ..............................18

2. Description of operation............................. 9 1. Structure .................................................. 18

2.1 Generation of air pressure.......................... 9
2.2 Stabilization of air pressure ........................ 9 2. Function................................................... 21
2.3 Release of air pressure ............................ 10

i
3. Principles of operation ............................. 22 T-7 Brake Chamber...............................44
3.1 Relay valve ............................................... 22
3.2 Cylinder .................................................... 24 1. Structure .................................................. 44

2. Function................................................... 45
T-5 Air Dryer ......................................... 25
3. Disassembly ............................................ 45
1. Structure .................................................. 25
4. Cleaning and checking ............................ 46
2. Function ................................................... 29 4.1 Cleaning ....................................................46
2.1 Dehumidification ....................................... 29 4.2 Checking ...................................................46
2.2 Regeneration ............................................ 30
2.3 Intake position .......................................... 31 5. Reassembly............................................. 47
2.4 Release position....................................... 31
6. Test ..................................................... 47
3. Precautions for handling .......................... 32 6.1 Air leak test ...............................................47

4. Maintenance and inspections .................. 32 7. Maintenance standards ........................... 47

4.1 Daily inspection ........................................ 33 7.1 2000-hr or 1-year check............................47
4.2 Inspection and part replacement every 1 year
or 100,000 km (62140mi) of driving ... 33
T-8 Solenoid Valve (Air) .......................48
5. Disassembly ............................................ 33
5.1 Removing DU-3 ........................................ 33 1. Structure .................................................. 48
5.2 Disassembly of cartridge .......................... 33

6. Reassembly ............................................. 35
6.1 Cartridge (lower)....................................... 35
6.2 Tapping ..................................................... 36
6.3 Cartridge (upper) ...................................... 36

7. Troubleshooting ....................................... 37

T-6 Brake (Parking Brake) ................... 40

1. Structure and function.............................. 40

2. Replacing pad .......................................... 41

3. Remounting ............................................. 42
3.1 Connecting parking brake to spring chamber
........................................................... 42
3.2 Adjusting parking brake clearance ........... 42

4. Check ..................................................... 43

ii
T-1. T-1.
Brake System

T-1 Brake System

1. General

Brake Circuit (air over hydraulic brake)

1 WT02-0120E
T-2 T-2
Brake (Service Brake)

T-2 Brake (Service Brake)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure and function

The clearance between the pad assy and the disc
The brake system employs an opposed piston plate are maintained constant by means of the
type disc brake, using one each pad assy on both piston seals.
sides of each disc plate to pinch it between them,
Although 4-piston type and 6-piston type brakes
as shown here.
are used in the crane, the service procedures and
The disc plate turns together with the wheel, and
the maintenance standards for the two types are
pads are incorporated in a torque plate which is
identical. In the following explanation, the 4-piston
fixed to the knuckle.
type is mainly explained.
The torque plate incorporates pistons to force the
pad assy onto the disc plate to brake its motion.

1. Torque plate 6. Torque pin (smaller) 11. Piston plug 16. Backup ring
2. Bleeder valve 7. Pad assy 12. Cap seal 17. Bolt
3. Bolt 8. Pad assy 13. Piston 18. Cap bolt
4. Torque pin (larger) 9. Cap bolt 14. Scraper ring 19. Cap
5. O-ring 10. Cover plate 15. Piston seal 21. Backup ring

2 W577-0152E
T-2 T-2
Brake (Service Brake)

1.1 Principle of operation The simple check method of pad assy is shown as
follows:
1. When hydraulic pressure is applied Check the pad thickness by inserting a check gauge
as shown below in the check holes in the torque
The pistons exert force to the pad assy by plate.
deforming the piston seals. (Fig. 2)

5.5
2
0.
R

C
60±0.2

0.
5
90 IW577-017201

(Unit: mm) (1mm=0.039inch)

[NOTICE]
When one of the pad assy is found to have worn to
the use limit, all the other ones are also worn to the
same limit in most cases.
Replace the pad assy for the right and the left
2. When hydraulic pressure is removed wheels or even for all the four wheels
simultaneously.
The seals recover the original shape to push the Thickness of the brake lining of the Pad assy
pistons back, creating clearance between the disc Thickness of the brake lining
plate and the pad assy. (Fig. 3 ) New parts 14 mm (0.56in)
Use limit 4 mm (0.16in)
The regular check is necessary to prevent from
deteriorating brake function and from the brake
damage since the thickness of the brake lining
exceeding the limit results in serious damage.

Check gauge

3. When pad assy wears

The piston displacement distance increases

beyond the seal deformation limit, and the pistons Replace the pad assy when this
distance becomes zero.
slip relative to the seals, but when the hydraulic Piston
Back plate
pressure is removed, the pistons are pulled back Pad assy
Brake lining
by the seals through the same distance as before Disc plate IW577-0190E02

the occurance of wear, giving the same

clearances.

3. Checking the disc plate

2. Checking the pad assy
Check the disc plate for the thickness and
[NOTICE] damage. If it is excessively damaged or the
The brake caliper must be disassembled to check thickness is below 17.5 mm (0.689 in), replace the
the remained pad thickness. However, the check disc plate. (Thickness of new disc plate: 20 mm
gauge may use to check.
(0.787 in))

3 W577-0152E
T-2 T-2
Brake (Service Brake)

4. Replacing the pad assy

7. Push in torque pin 4 in its hole after applying
When the thickness of the brake lining has grease to both. At this time, adjust the clearance
reduced to 4 mm (0.16 in) , replace the pad assy. between the disc plate and torque pin 4 to 1.5 - 3
mm (0.06 - 0.12 in).
1. Set the outriggers, and remove the tire. (To Check that the torque pin on the brake mounting
remove the brake assy as a unit, unscrew the 4 side is not protruding adove the mounting surface.
mounting bolts. When remounting it, tighten the
mounting bolts to 480 - 578N-m (355 - 427ft - lbf)).

2. Apply an 11mm box wrench on bleeder valve 2,

connect a transparent vinyl tube (Inside diameter :
7 - 7.5 mm (0.276 - 0.295 in)) to the bleeder valve,
and open the bleeder valve by turning the wrench.

3. Insert a piston return lever as shown below

between pad assy 7, 8 and the disc plate, and
push all pistons 13 fully home. Then, close
bleeder valve 2.
[NOTICE]
When tightening bolts 3 and 17, make sure the bolt
end is fully in the groove in torque pin.

8. Clamp torque pin 4 with bolt 3 (or 17).

Tightening torque of bolts 3 and 17: 49 - 54 N-m

(36.2 - 39.8 ft-lbf)

(Unit : mm) (1mm = 0.039inch)

4. Unscrew bolts 3 and 17 on the side of larger

torque pin 4 approx. 4 turns, and extract torque
pin 4 .

5. Remove pad assy 7, 8, and install new pad assy

in their places.
9. Bleed the brake circuits as explained in “Air
6. Check O-ring 5 of torque pin 4, and replace it if Bleeding Procedure” in Chapter Y.
damaged or defective otherwise.
10.Mount the tires.

Hub nut torque:

490 - 588 N-m (362 - 434 ft-lbf)

4 W577-0152E
T-2 T-2
Brake (Service Brake)

5. Disassembly 6. Washing and checking

6.1 Washing

CAUTION
Never use mineral oil.

Wash the metal parts in trichloroethylene or brake

fluid. After washing, blow air into the holes and
grooves in the torque plate and wipe off all
residual liquid with clean cloth.

6.2 Checking

1. Torque plate
Check the torque plate, and if it is damaged in the
areas indicated below, correct the surface with No.
180 sandpaper.
If the damage is beyond repair, replace the torque
plate.

1. Loosen bolts 3 and 17, extract torque pins 4 and

6, and remove pad assy 7 and 8.

2. Remove cover plate 10, push out piston plugs 11

and pistons 13 on the cover plate side. Pull out
pistons 13 on the opposite side.

3. Remove scraper rings 14. Remove piston seals 2. Pad assy

15 and backup rings 16 with a hooked wire. Replace the pad assy when its wear lining has
been worn to 4 mm (0.16 in) or less.

3. Piston
When the sliding surface is damaged, dented or
the plated layer has been worn, replace the
piston.

4. Torque pin
Replace the pin if the portion in contact with the
back plate of the pad assy is excessively worn.

5. Seal kit (Sealing parts)

Replace the seal kit (cap seal, scraper ring, piston
seal, and backup ring) once a year or once in
1000 hours.
In addition, be sure to replace them whenever
they are disassembled.

5 W577-0152E
T-2. T-2.
Brake (Service Brake)

7. Reassembly
[NOTICE]
1. Apply the rust preventive lubricant found in the For the installing procedure, see
“ Replacing the pad assy ” .
seal kit to piston seal 15, backup rings 16, pistons
13 and to the cylinder bores.
5. Install torque pins 4, 6, pad assy 7, 8, and bolts 3,
17.

[NOTICE] 6. After mounting the brake assy on the axle,

Take care to install the piston seal in the correct readjust the clearance between the torque pins
orientation. (See Fig.1) and the disc plate to 1.5 - 3.0 mm (0.06 - 0.12 in).
Be sure to install the pistons from the inner side of
the torque plate.
8. Maintenance standards
2. Install backup ring 16, piston seal 15 and scraper
ring 14 in this order in the grooves in the bore of
Item Maintenance standards
torque plate 1. Then push in piston 13.
6 month Check the worn thickness of the pads,
check and replace them if worn beyond the
use limit (thickness of wear material:
4 mm (0.16 in)).
When the liquid level in the reservoir
sinks to a warning level, through
leakage, pad wear, etc., the brake lamp
lights during traveling. Check for
leakage and pad wear immediately.
1000 hour Disassemble and check all the parts.
or Replace the sealing parts with a seal kit.
1 year
check

3. Apply the rust preventive lubricant to backup ring

21 and cap seal 12, and install them in the
grooves in piston plug 11. Then install piston plug
11 in torque plate 1 with the cap seal on the piston
side.

4. Thoroughly clean the mating surfaces of torque

plate 1 and cover plate 10, and install the cover
plate on the torque plate with bolts 9 (18) with the
stamped part number of the cover plate out.

Torque for bolts 9:

197 - 217 N-m (146 - 160 ft-lbf)
Torque for bolts 18:
291 - 320 N-m (215.2 - 236.8 ft-lbf)

6 W577-0152E
T-3 T-3
Brake Valve

T-3 Brake Valve

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure and function It delivers air at pressures determined by the

position of the brake pedal to two systems, Even
This brake valve is a dual circuit rubber spring
when one of the systems fails, the other system
type brake valve for air brake systems.
remains operational to brake the vehicle.

46 45 16 26 T1
25
24
43 T2

42
23 19 T3
27 21
Primary side
22 20

3 15
Supply port Delivery port

18
17
1 4

9 5

10 40 14
Supply port 11 Secondary side

7
6
13
Delivery port
8
2
28,41 T4
12
Exhaust pot
36 34 37,38 T5 39 29 35 33 32 31 30
IW202-0010E01

7 W202-0013E
T-3 T-3
Brake Valve

1. Upper body 13.O-ring 25.Spring washer 37.Exhaust cover

2. Upper valve 14.O-ring 26.Nut 38.Screw and washer
3. Valve retainer 15.Return spring 27.O-ring 39.Exhaust check
4. Valve spring 16.Stem 28.Lower body 40.O-ring
5. Retainer 17.Inner spring 29.Lower valve 41.Bolt and washer
6. O-ring 18.Outer spring 30.Valve retainer 42.Mount plate
7. Special washer 19.Sleeve 31.Valve spring 43.Bolt and washer
8. Retaining ring 20.Stem washer 32.Retainer 44.－
9. O-ring 21.Piston 33.O-ring 45.Plunger boot
10. Retaining ring 22.Rubber spring 34.Special washer 46.Plunger
11. Spring 23.Spring seat 35.Retaining ring
12. Relay piston 24.Special washer 36.O-ring

Thread size and tightening torque

tightening torque
Sign / Port Thread size
N-m ft-lbf
T1 ― 3.9 - 6.9 2.9 - 5.1

T2 ― 8.8 - 13.7 6.5 - 10.1

T3 ― 3.9 - 6.9 2.9 - 5.1

T4 ― 3.9 - 6.9 2.9 - 5.1

T5 ― 1.3 - 2.5 1 - 1.8

Pipe port Rc 3/8 29.4 - 39.2 21.7 - 28.9

8 W202-0013E
T-3 T-3
Brake Valve

2. Description of operation 7. The lower valve moves further down, opening the
air inlet valve seat on the lower body. This allows
2.1 Generation of air pressure pressurized air from the secondary supply port to
flow through the delivery port into the brake
1. When the pedal is depressed, the depressing
chamber of the secondary system.
force is transmitted through the plunger, spring
seat, and rubber spring to the piston. The piston
moves down, compressing the return spring.

2. The discharge valve seat at the bottom of the

piston makes contact with the upper valve, closing
the discharge passage at the center.
Upper body
3.As the piston further compresses the return spring, Inlet valve sheet
it moves the upper valve, opening the air inlet
valve seat on the upper body. Relay piston

4. The pressurized air supplied from the primary

supply port flows through the delivery port to the
Discharge valve sheet
brake in the primary system.
Discharge air passage
Lower valve
Return spring Plunger IW202-0010E03

Spring sheet

Rubber spring 2.2 Stabilization of air pressure

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

2. As the pedal is depressed, the discharge valve

closes and the inlet valve opens to deliver air to
Discharge valve sheet
the system.
Upper body
3. This air also exerts upward pressure on the
Upper valve
underside of piston.

4. With the pedal maintained at a certain depressed

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

9 W202-0013E
T-3 T-3
Brake Valve

Rubber spring

Piston

Discharge valve sheet

Relay piston

Inlet valve sheet

Upper body

Upper valve Discharge valve sheet

Inlet valve sheet

Lower body Lower valve
IW202-0010E05
IW202-0010E04

7. In the secondary air system, relay piston lowers in 2.3 Release of air pressure
proportion to the air pressure in the primary
1. As the pedal is released, the plunger and piston
system to generate air pressure in the secondary
are pushed up by the return spring and by the
system. The generated pressure is also applied to
primary air pressure.
the underside of relay piston.
2. The discharge air seat at the bottom of the piston
8. As this pressure on the underside of relay piston
disengages from the upper valve, opening the
becomes balanced with the primary system
discharge passage at the center. This allows the
pressure applied on the top of the relay piston, it
primary system air pressure to be discharged from
is no more pushed down, but moves up while
the discharge port.
keeping contact with lower valve.
3. On the other hand, as the pressure in the primary
9. As lower valve comes into contact with the inlet
system drops, relay piston is pushed up by the
valve seat of lower body, the air supply through
secondary system air pressure and springs, and
the supply port is stopped.
the discharge valve seat at the bottom of relay
10. In this state, since the discharge valve seat is in piston disengages from lower valve to open the
contact with lower valve, the air pressure central discharge passage.
stabilizes.
4. Thus the secondary system pressure discharges
11. Thus, the pressure in the secondary system is into the discharge port.
kept stable at a level equal to that of the primary
system. Spring serves to minimize the pressure
difference between the two systems.

10 W202-0013E
T-3 T-3
Brake Valve

Return spring Plunger

Spring seat 2. Operation with only secondary system
Rubber spring When the primary brake system is damaged, no
Piston
air pressure is generated in the primary system,
so that no primary air pressure is available to work
on the relay piston for actuation of the secondary
Discharge valve seat system. However, in this case, depressing the
pedal further down brings the lower end of piston
Upper body
in contact with the top of relay piston, causing the
discharge valve seat of relay piston to directly
Spring
push lower valve to cause the secondary system
Relay piston
to operate in the same way as the primary system
Upper valve
in the normal state, generating air pressure,
stabilizing, and releasing it.
Discharge valve seat

Lower valve
IW202-0010E06

2.4 Operation under piping rupture

1. Operation with only primary system

Piston
When the secondary brake system is broken, the
primary system remains operational, because
relay piston separates it from the secondary
system. Relay piston

Lower valve
IW202-0010E08

3. Dismouting and remounting

1. Dismount the valve after immobilizing the vehicle
and discharging the compressed air from the
reservoir by opening the drain cock.
Relay piston
2. Tighten the pipe fitting: 29 - 39 N-m (21.4 - 28.8 ft-lbf)

4. Disassembly
[NOTICE]
IW202-0010E07 When disassembling, remove mud, dust, water etc.
from the outside surface to avoid their entry into the
interior.
Prior to disassembly, mark the joints to facilitate
correct reassembly.

11 W202-0013E
T-3 T-3
Brake Valve

Place the disassembled parts in neat order to Upper body Stem

facilitate reassembly.

4.1 Disassembly of the mount plate

1. Remove three bolts and washers, and remove

mount plate, plunger, and plunger boot.

Plunger Plunger boot

Bolt and washer

Mount plate Relay piston

IW202-0010E11

3. Unscrew nut at the top of piston, and remove

piston, return spring, relay piston, spring, and
stem.
IW202-0010E09

[NOTICE]
At this time, hold the piston to prevent it from being
4.2 Disassembly of the body popped out by the return spring.

1. Clamp the body in a vise, with lower body up; Nut

unscrew four bolts, and remove the lower body
Piston
assembly from upper body.

Lower body
Return spring
Bolt

Upper body
IW202-0010E10

2. Clamp a screwdriver in a vise, pass it through the

discharge passage of relay piston and place the
blade in the alit in the stem.

Relay piston

Stem

IW202-0010E12

12 W202-0013E
T-3 T-3
Brake Valve

4. Remove the O-ring from between the upper body

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

Lower valve assy Upper valve

Lower body

Upper valve assy

IW202-0010E15

Retaining ring

Special washer
O-ring
IW202-0010E13
O-ring

Retainer
6. Remove retaining ring from the groove inside
upper body, and take out the upper valve assy. Valve spring

Upper body Retaining ring

Valve retainer

Lower valve

Upper valve assy Lower valve assy

IW202-0010E16

Sleeve Stem washer

Spring Stem

Stem assy
IW202-0010E17
IW202-0010E14

5. Cleaning and checking

7. Disassemble the upper valve assy lower valve
assy and the stem assy.
5.1 Cleaning

1. Cleaning the rubber parts by wiping with a cloth

dampened with alcohol.

2. Wash all metal parts, except the mount plate, with

trichloroethylene or other suitable cleaning
agents.

13 W202-0013E
T-3 T-3
Brake Valve

3.The mount plate incorporates an oilless alloy bush. 2. Build the lower valve assy into lower body.
Wash it with kerosene and dry it with compressed
3. Install exhaust cover, and secure with screw and
air.
washers. Pack grease in the groove in the surface
5.2 Checking of lower body which mates with upper body; install
O-ring coated with grease.
1. Check the parts for cracks, deformation, etc., and
check the sliding surfaces for dents; replace any Screw

faulty parts.
Exhaust cover
2. Examine the springs for corrosion, and replace if
faulty.
Lower valve assy

Lower body
6. Reassembly
[NOTICE]
Apply lithium base grease (Idemitsu Daphne
Coronex Grease EP2, or equivalent) to the valve
sliding surface, body sliding surface, and the relay
piston sliding surface. O-ring
IW202-0010E18
When inserting O-rings, be sure to apply lithium
base grease to them, (Idemitsu Daphne Coronex
Grease EP2) and fill the O-ring groove with grease
in advance. 6.2 Reassembly of the primary side
Apply lithium base grease containing MoS2 (bearing
1. Place the upper valve on the work bench with the
grease No.3 by Nippon Molybdenum, or equivalent)
to the sliding surfaces of the plunger, and to the valve seat side down.
roller and fulcrums.
2. Install the valve retainer, valve spring, retainer
with 2 O-rings, and special washer in sequence.
6.1 Reassembly of the secondary side
Secure these parts with the retaining ring.
1. Place lower valve on the work bench with the
valve seal side down; install valve retainer, valve [NOTICE]
spring, retainer with O-rings, and special washer, Apply grease to the O-ring.
and secure with retaining ring.
Retaining ring Retaining ring

Special washer Special washer

O-ring O-ring

Retainer Retainer

Valve spring Valve spring

Valve retainer Valve retainer

Lower valve Upper valve

Lower valve assy

IW202-0010E16
Upper valve assy

IW202-0010E15

14 W202-0013E
T-3 T-3
Brake Valve

3. Insert the upper valve assy in upper body, and

secure with retaining ring.
Stem assy

Upper body Retaining ring

Relay piston

Upper valve assy

O-ring

Spring

IW202-0010E19

IW202-0010E20
4. Put the springs, stem washer, and sleeve onto the
stem, and tighten the sleeve.
6. Holding relay piston by hand to prevent it from
[NOTICE] being pushed loose by spring, apply the
Apply grease to the springs. screwdriver slit of stem to the blade of a
screwdriver clamped in a vise.
Sleeve Stem washer
Spring Stem Stem
Upper body

Stem assy
IW202-0010E17

5. Install O-rings and on relay piston; insert spring,

relay piston and the stem assy in this sequence
into upper valve previously placed in upper body.
Spring Relay piston
[NOTICE]
Be sure to apply grease amply to the O-ring and to
their sliding surfaces. IW202-0010E21

7. Install return spring, piston, rubber spring, spring

seat, special washer, and spring washer in this
sequence, and clamp them with nut.

15 W202-0013E
T-3 T-3
Brake Valve

Nut 7.1 Air leakage through supply valve and

Spring washer
exhaust valve

Special washer In the fully released state, the air leakage to the
Spring seat delivery port and the exhaust port combined
Spring seat should be less than 100 cm3/min {6.1in3/min}.
In the fully depressed state, the leakage to the
Piston exhaust port should also be less than 100
cm3/min {6.1in3/min}.
Return spring

7.2 Air leakage in other parts

Stem In the fully depressed state, there should be no
IW202-0010E22 leakage from the body, valve cap, and their joints.

7.3 Operation test

8. Clamp the upper body assy in a vise, put the
lower body assy on it, and clamp them with bolts Thrust the plunger speedily into the fully
and washers. depressed position, and then release speedily; the
delivery pressure should rise and fall smoothly.
Lower body
7.4 Performance test
Bolt
Depress the pedal slowly from the free state to the
fully depressed position, checking that the delivery
pressure changes smoothly, roughly tracing the
performance curve shown below.

Also check that when the upper delivery port

Upper body pressure is at 98.1 kPa {14.2psi}, the lower
IW202-0010E23
delivery port pressure is over 78.5 kPa {11.4psi}. If
these criteria are not met, the cause may be lack
of grease on sliding parts or weakened springs.
6.3 Reassembly of the mount plate
Performance curve
1. With the plunger boot on, install plunger in mount (Psi) (kPa) Max. travel 11.8mm (0.46in)
1015 690
plate, and clamp them to upper body with three
590
Delivery pressure

bolts and washers.

725 490
390
435 290
7. Test 200
145 98
[NOTICE] 0 0
1 2 3 4 5 6 7 8 9 10 11 12 (mm)
Test the brake valve for leaks and performance,
0 0.1 0.2 0.3 0.4 0.48 (in)
with a pressure gauge measuring up to 981 kPa
{142psi} or so connected to the delivery side, and Plunger travel
with the supply pressure adjust to 684 kPa {100psi}. IW202-0012E01

First, in the fully released state, make sure that the

delivery pressure is zero for both upper lower sides.
Then, check the following items for both upper and
lower sides.

16 W202-0013E
T-3. T-3.
Brake Valve

8. Maintenance standards

8.1 600-hour check

Disassemble the parts above the mount plate,

wash and check them. Replace defective parts,
and apply grease to the sliding surfaces.

8.2 2000-hour or 1-year check

Disassemble the valve, and clean all the parts.

Replace all rubber parts. Replace metal parts that
are scratched, worn, or otherwise damaged.
Execute all the tests specified.

366-010-00001 △
1
366-045-10000 △
0

17 W202-0013E
T-4 T-4
Booster (Brake)

T-4 Booster (Brake)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
28 7 10 9 11 8 1 2 37 13 27 3 4 5 6

33-16
Signal (from brake valve)
33-17
29
23
33-13
From oil reservoir
33-12 22
21 34
33-15
33-14 20

Supply Delivery
18
33-2
36
33-3
33-6 33-11

33-10 33-4
Exhaust
33-5 17 16 14-2 14-3 15 14-1 19 Output
33-9 33-19 hydraulic
33-1 33-7 pressure

33-8 26 25
Relay valve (air pressure) Air cylinder Oil cylinder

IW404-0010E01

33-11 7

Delivery

27 12

Joint section of relay valve and air cylinder

IW404-0010E02

35
28
30
28

31
Relay valve side of exhaust pipe (28) Air cylinder side of exhaust pipe (28)
IW404-0010E04 IW404-0010E03

18 W404-0012E
T-4 T-4
Booster (Brake)

Enlarged view of relay valve

28 7 10 9 11 8

33-16
Signal (from brake valve)
33-17
29
33-13
33-12
33-15
33-14

Supply Delivery

33-2
33-3
33-6 33-11

33-10 33-4
Exhaust
33-9 33-19 33-5

33-1 33-7
33-8 IW404-0010E05

Enlarged view of oil cylinder

1 2 37 13 27 3 4 5 6

23
From oil reservoir
22
21 34

20

18

36

Output
hydraulic
pressure

26 25 17 16 14-2 14-3 15 14-1 19 IW404-0010E06

19 W404-0012E
T-4 T-4
Booster (Brake)

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

1.Casing 14-3.Piston cup 30.Seal rubber 33-14.Air piston

2.Seal cup 15.Valve 31.O-ring 33-15.O-ring
3.Backup ring 16.Piston pin 33-1.Body 33-16.Cover
4.Seal cup 17.Pin holder 33-2.Valve retainer 33-17.Bolt
5.Support ring 18.End cap 33-3.Valve spring 33-19.Valve
6.C-ring 19.Oil cylinder 33-4.Valve holder 34.Lock nut
7.Air cylinder 20.Oil cylinder o-ring 33-5.Valve spacer 35.Bolt
8.Air piston assy 21.Pipe connector 33-6.Valve holder plate 36.Nipple
9.Air piston ring 22.Air bleeder screw 33-7.Dust seal rubber 37.Bolt
10.Air piston seal 23.Cap 33-8.C-ring
11.Return spring 25.Plug 33-9.O-ring
12.Spring washer 26.Lock washer 33-10.Valve holder o-ring
13.Cylinder seal 27.Nut 33-11.O-ring
14-1.Oil piston 28.Exhaust pipe 33-12.O-ring
14-2.Backup ring 29.Pipe holder 33-13.Return spring

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
18 - 118 - 147 87 - 108

21 - 20 - 39 14 - 29

22 - 12 - 20 9 - 14

25 - 20 - 29 14 - 22

27, 37 M10 25 - 29 18 - 22

33-17 M8 10 - 20 7 - 14

34 M50 118- 147 87- 108

35 M4 1.5 – 2.5 1–2

36 - 20 - 39 14 - 29

20 W404-0012E
T-4 T-4
Booster (Brake)

2. Function
This booster receives pressurized air from the
relay valve into the air cylinder, and outputs
hydraulic pressure in proportion to the pneumatic
pressure to the wheel cylinders and other
members of the brake system. It comprises the
following three major components.

1. Air cylinder
The air cylinder incorporates air piston assy 8,
return spring 11. The return spring side is always
open to the atmosphere, and the opposite side is
subject to the output pressure of the relay valve.

2. Oil cylinder
Oil piston 14-1 is connected to air piston assy 8 by
piston pin 16, via valve 15, and pin holder 17
prevents the pin from coming off. The pressurized
oil in the oil cylinder is sealed by a tight fit
between the valve in valve 15 and oil piston 14-1.

3. Relay valve
This valve serves to make the brake applied and
released quickly.

21 W404-0012E
T-4 T-4
Booster (Brake)

3. Principles of operation

3.1 Relay valve

1. Booster not in operation 2. Booster in operation for assisting braking

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

Booster in operation

22 W404-0012E
T-4 T-4
Booster (Brake)

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

When brakes are released

When the signal pressure becomes higher, the

above sequence is repeated, increasing the outlet
pressure proportionately with the increase in
signal pressure. In this manner, the pressure in
chamber A is constantly balanced with that in
chamber B during operation.

4. Brakes completely released

When the brake pedal is released completely, the

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

23 W404-0012E
T-4. T-4.
Booster (Brake)

3.2 Cylinder

3. Brakes are released

When the compressed air in the air cylinder

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

2. Booster in operation

When the compressed air flows from the relay

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

360-614-20000 △
0

360-614-30000 △
0

24 W404-0012E
T-5 T-5
Air Dryer

T-5 Air Dryer

[NOTICE] Air circuit diagram

There is a case that the appearance and so on
differ from the parts for this machine. Although there Purge chamber
is not so much difference in functions and Drying tube
disassembly procedures, make sure of the serial
number of this machine and the part sales unit
IN
described in the parts catalog before starting
disassembling operations. OUT
Drain valve
1. Structure
Governor

IW232-0030E01

48
Purge chamber
47
46 49
45
44
42
43
Desiccant
40
57
Oil separator filter 51
42
52 A
41
56
53
55
50
54
Check valve 34
35
OUT IN

37
6
38
5
36
9 4
14 3
8 7 Drain valve
1 11
10
12 13 12 15 16

IW232-0030E02
Drain

25 W232-0032E
T-5 T-5
Air Dryer

View A

58

39

B B

59 Heater
2

C
A
IW232-0030E03

26 W232-0032E
T-5 T-5
Air Dryer

Section B-B IN
33
32
30
31
28
29
25
27 26
23
17
19
22
18
24 21
20
2

OUT IW232-0030E04

IN
View C

61

60 Thermostat

63

62
39 OUT

C IW232-0030E05

27 W232-0032E
T-5 T-5
Air Dryer

1. Body 17. Piston 33. Cap nut 49. Screw and washer
2. Steel ball 18. O-ring 34. Check valve 50. Cover
3. Valve body 19. Special washer 35. Check valve spring 51. Oil separator filter
4. Valve spring 20. Governor valve 36. Check valve stopper 52. O-ring
5. Piston 21. Valve spring 37. O-ring 53. Hexagon socket head bolt
6. O-ring 22. O-ring 38. Retaining ring and washer
7. Valve 23. Exhaust stem spring 39. Plug 54. Gasket ring
8. Bolt and washer 24. Exhaust stem 40. Case 55. Gasket ring
9. O-ring 25. Adjusting screw 41. Filter plate 56. O-ring
10. Silencer case 26. Spring seat 42. Filter 57. Purge chamber
11. Silencer 27. Spring 43. Absorbent 58. Bolt and washer
12. Silencer plate 28. Spring seat 44. Filter plate 59. Heater
13. Retaining ring 29. Nut 45. Set spring 60. Thermostat
14. O-ring 30. Retaining ring 46. O-ring 61.Screw
15. Exhaust cover 31. Seat 47. Case cover 62. Cord clamp plate
16. Retaining ring 32. Plate 48. Check valve 63. Screw

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft - lbf
IN, OUT Rc 1/2 44 - 59 32.5 - 43.5

8 － 4-7 3-5

29 － 7-8 5-6

33 － 5-6 3.5 - 4.5

39 － 15 - 25 11 - 18

49 － 2-4 1.5 - 3

53 － 2-4 1.5 - 3

58 － 18 - 27 13 - 20.5

59 － 20 - 29 14.5 - 21.5

61 － 0.5 - 1 0.4 - 0.7

63 － 1 - 1.5 0.7 - 1.1

Mounting bolt M10 × 1.25 15 - 23 11 - 16.5

28 W232-0032E
T-5 T-5
Air Dryer

2. Function
2. The air flows through a filter which includes an oil
1. When the air pressure at the air dryer outlet port mist separator, which removes minute oil droplets
(air tank air pressure) reaches the specified and dust before the air enters the drying tube.
release pressure, this governor sends that
3. In the drying tube, the moisture in the air is
pressurized air to the control port, opening the air
removed by a desiccant that has a strong affinity
dryer drain valve.
for water.
2. When the air pressure at the air dryer outlet port
4. As the air proceeds from the bottom of the drying
has dropped to the specified intake pressure, the
tube to the top, it contacts a stronger desiccant,
pressurized air at the control port is released to
which further reduces the moisture. When the air
the atmosphere, closing the drain valve.
reaches the top of the drying tube, it is dry air.

2.1 Dehumidification 5. This dry air passes through the check valve and
purge chamber at the top of the drying tube, and
1. During the compressor load cycle, the air from the
is supplied to the governor chamber and main
compressor enters the air dryer inlet port. The
tank via the outlet port check valve.
compressed air is cooled down as it flows along
the body walls. This results in moisture and oil
accumulating at the bottom of the body.

Check valve
Purge chamber
Desiccant

Oil filter

Main tank

Outlet Inlet Compressor

Governor IW232-0030E06

29 W232-0032E
T-5 T-5
Air Dryer

2.2 Regeneration
4. In addition, because there is no feedback
1. When the air pressure in the system reaches the command to the compressor, the compressor
upper limit pressure of the governor, the governor continues to supply pressure. For this reason, this
control pressure passes through the control line pressure is also ejected from the dryer into the
and opens the drain valve atmosphere by the opening of the drain valve.

2. At this time, the air in the drying tube is released 5. When the load cycle begins again, a command
into the atmosphere. Because it is released from the governor closes the drain valve, and the
suddenly, the pressure in the drying tube cleans dehumidifying process starts.
the oil filter and ejects the oil and water
condensate into the atmosphere.

3. After the sudden decrease in pressure, the dry air

in the purge chamber passes through the orifice,
decompressing and expanding. It becomes
super-dry air, which flows backwards through the
drying tube, absorbing moisture from the
desiccant carrying it out into the atmosphere,
completing the regeneration of the desiccant.

Oriffice Check valve

Desiccant

Purge
chamber

Main tank

Outlet Inlet
Compressor

Silencer

Governor IW232-0030E07

30 W232-0032E
T-5 T-5
Air Dryer

2.3 Intake position 2.4 Release position

1. The pressurized air from the air dryer outlet port 1. When the outlet port air pressure (air tank air
(air tank pressurized air) travels through the pressure) increases, and the force acting on the
passage and acts on the bottom of the governor bottom of the governor piston becomes stronger
piston. than the force of the spring, the governor piston
moves toward the spring side.
2. When the air pressure is at or below the specified
pressure, the governor piston is kept pressed 2. The exhaust stem is closed by the governor valve,
down by the spring. and the control port air is cut off from the
atmosphere.
3. Under these conditions, the pressurized air in the
control port passes through the exhaust stem and 3. When the outlet port pressure increases further,
is released into the atmosphere. and reaches the release pressure, the governor
piston moves farther to the spring side, and the
governor valve is opened by the exhaust stem.

4. The pressurized air from the outlet port passes

through the governor valve, and is delivered from
Spring the control port to the top of the air dryer drain
Exhaust port valve, pressing the drain valve open.

Control port

Governor piston
Control port
Exhaust stem

From outlet port

IW232-0030E08
Governor valve

Direction of governor
piston movement
IW232-0030E09

5. The outlet port air pressure (air tank air pressure)

gradually decreases. When it drops to the intake
pressure, the governor piston is pressed back by
the spring.

6. This closes the governor valve. The exhaust stem

is disconnected from the governor valve, and the
control port pressurized air passes through the
exhaust stem to be released into the atmosphere.
This closes the drain valve.

31 W232-0032E
T-5 T-5
Air Dryer

3. Precautions for handling 4. Maintenance and inspections

WARNING WARNING
Never touch the desiccant with wet hands, or When performing inspections, use caution to
put the desiccant in your mouth. Doing so will prevent dirt from entering the eyes.
cause heating of the desiccant, and can result in
burns.
4.1 Daily inspection
[NOTICE]
1. Check for air leakage around the body, at pipe
Be certain to use the desiccant specified by
NABCO (part No. 41213640010), and replace it with openings, and other locations.
an amount that is within the specified range.
2. To check that the air dryer is operating normally,
Use of a desiccant other than that specified, or in
amounts less than those specified, will not only open the drain cock on the air tank, and check
reduce the moisture-absorption capability of the that there is no drainage.
dryer, but can lead to degradation and loss of the (A small amount of drainage may accumulate if
desiccant and can greatly increase the likelihood of the temperature around the air tank has
vehicle malfunctions.
decreased by more than 17°C (62.6°F)).
Be aware that the desiccant used in DU-3 is of a
different type than the desiccant used in DR-41, 3. In cases other than the above (drainage resulting
DR-42, and DU-4.
from temperature change), if a small amount of
Be sure to perform tapping when inserting the
drainage occurs, check the precautions for
desiccant.
handling again.
1. If the vehicle has been parked for several hours in
[NOTICE]
a cold location (-10°C (14°F) or below), wait at
If the desiccant becomes seeped in oil or other
least 10 minutes before driving after starting the
substance, its ability to absorb moisture is
engine. (It takes time for the temperature to rise decreased. Because this greatly affects dryer
after the heater turns ON.) function, be sure to replace the desiccant if this
occurs.
2. Make sure that the unload time is 50 seconds or It is recommended that you replace the filter at the
longer. same time as the desiccant.
(If the regeneration process is not performed, the
moisture-removal capability of the desiccant is 4. If no abnormalities are found, disassemble the air
decreased, and the dryer function is lost.) dryer and check whether or not the desiccant is
seeped in oil or other impurities. If 1/5 or more of
3. During unloading, air is continuously discharged the total desiccant is seeped in such substances,
from the air dryer exhaust port. replace the desiccant.
This is normal, and is not a problem of air
leakage. [NOTICE]
◆Oil (liquid oil and carbonized oil) is contained in the
4. Replace the desiccant every 1 year or 100,000 km compressed air that enters the air dryer. This will
(62140mi) of travel, whichever occurs sooner. accumulate in the compressor and dryer piping, and
inside the dryer itself. Because this oil may burn, be
5. If drainage occurs from the air tank, disassemble sure to perform cleaning periodically.
the dryer, and replace the desiccant if 1/5 or more
5. Pay attention to the drainage from the air dryer
of the total desiccant is seeped in oil.
exhaust port. If an abnormal amount of oil is
(If the desiccant becomes seeped in oil, its ability
drained, inspect the compressor and take steps to
to absorb moisture is decreased. Because this
prevent increases in the amount of oil.
greatly affects dryer function, be sure to replace
the desiccant if this occurs.)

32 W232-0032E
T-5 T-5
Air Dryer

6. Use the on-board air pressure gauge to check that 5. Disassembly

the pressure governor is operating at the specified
pressure. Also check that there is no decrease in 5.1 Removing DU-3
pressure when the brakes are not in use.
1. Block the wheels without using the pneumatic
Governor switching pressure: circuit.

Load → Unload: 861 - 910 kPa {129.4 - 132.2psi} 2. Open the drain cock on the air tank. Discharge the
Unload → Load: 740 - 780 kPa {106.7 -113.8psi} air from the brake piping.

3. Disconnect the thermostat wiring.

4.2 Inspection and part replacement every 1
year or 100,000 km (62140mi) of 4. Disconnect all the wires (IN, OUT, CONTROL)
driving
from the air dryer.
1. Disassemble the air dryer. Replace the desiccant,
5. Loosen the three bolts to remove the UD-3.
oil filter, filter, and all rubber parts, regardless of
whether or not scratches or wear is visible on 5.2 Disassembly of cartridge
these parts.
1. Anchor the DU-3 body-1 in a vise. Unscrew the
2. Check that there are no abnormalities in the bolts and washers that fasten the purge chamber
piping and wiring. to the body, and remove the purge chamber.

[NOTICE] Case cover

Corrosion of metal parts can result in air leakage Purge chamber
when the corrosion falls off and becomes caught in Set spring Screws
the valves. and
These inspections and maintenance are to be washers
performed when either the travel distance or
installation time is reached, whichever occurs first. Purge chamber

Absorbent
3. Check all metal parts for corrosion. Repair or Bolts
replace them as necessary. and
washers

Body

IW232-0030E10

2. When the purge chamber is removed, cartridge

assy through containing the desiccant is exposed.
Directly remove the cartridge assy upward by
hand.

33 W232-0032E
T-5 T-5
Air Dryer

Case cover
CAUTION Purge chamber
Keep pressing on the case cover with your Set spring Screw
hand until all screws and washers have been and
Washer
removed.
The case cover can be extremely dangerous if
the set spring inside causes the cover to jump Purge chamber
up and strike a person in the face or other body Desiccant
part.

Bolt
and
3. Use your hand and press from above on the case Washer
cover attached to the desiccant case. At the same
time, use a Phillips screwdriver to unscrew and
remove the 4 screws and washers.

4. Remove set spring, filter plate B, filter, desiccant,

filter and filter plate A from above the case. Body

Purge chamber
Set IW232-0011E12
spring

6. Press the cover with your hand, and lift the case
Filter
Filter up to remove it. Remove the oil separator filter
plate B Absorbent that is inside.
Filter
Filter
plate A

IW232-0030E11

5. Use a 4 mm hex wrench to unscrew and remove

the 4 hexagon socket head bolts and washers.

34 W232-0032E
T-5 T-5
Air Dryer

6. Reassembly 3. Insert filter plate A and the filter into the case.
Insert the filter so that the soft surface is on top.
[NOTICE]
With the exception of rubber parts and the
Purge chamber
desiccant, wash all disassembled parts well with
clean oil and wipe off all adhering substances.

WARNING
Filter
Be certain to use the specified NABCO Filter
desiccant (41213640010). plate B Case
Absorbent
Use of a desiccant other than that specified is Desiccant
Filter
extremely dangerous. It can result in the
Filter
desiccant deteriorating and being lost, with plate A
pieces blocking the brake piping and preventing
normal brake operation.
The desiccant used is different than that used
for NABCO DR-41, DR-42, and DU-4. Be careful
not to use the wrong type.

6.1 Cartridge (lower)

1. Install the oil separator filter in the center of the

cover, and install the O-ring into the groove.
IW232-0030E13

Purge chamber
4. Insert the specified amount of desiccant.
The specified amount is 590 - 619 cm3 (36 -
37.8in3) [480g (1.06lb)]. Insert the entire bag of
Case desiccant that was purchased for use with the
Oil separator Absorbent repair kit.
filter

O-ring Hexagon soket

head bolts

Cover
DANGER
If less than the specified amount of desiccant
is used, the desiccant may deteriorate and be
lost, with pieces blocking the brake piping and
preventing normal brake operation. Be sure to
insert the specified amount.

5. Next insert the second filter, this time with the soft
surface on the bottom. Then place filter plate B in
IW232-0030E12 position and perform tapping.

2. Place the case in position, and use a 4 mm hex

wrench to tighten the hexagon socket head bolts
and washers.
Tightening torque: 2.0 - 3.9 N-m
(1.5 - 2.9 ft-lbf)

35 W232-0032E
T-5 T-5
Air Dryer

6.2 Tapping 6.3 Cartridge (upper)

[NOTICE]
DANGER Applying grease to the raised part of the check
valve will allow it to be inserted more easily.
When tapping is not performed, the desiccant
may deteriorate and be lost, with pieces blocking Use NABCO grease (grease pack 45499030090,
the brake piping and preventing normal brake grease weight: approximately 10 g (0.022lb).
operation.
Be sure to follow the procedure below when 1. Fit the check valve into the case cover by
performing tapping.
pressing on the center bulge with your thumb.

2. Install the O-ring onto the case, then insert the set
[NOTICE]
spring. Tighten the screws and washers while
When tapping, place 2, 3 sheets of shopcloth or
other soft cloth on top of one another at the tapping pressing down on the case cover with your hand.
location to prevent the cover from being scratched. Tightening torque: 2.0 - 3.9 N-m
(1.5 - 2.9 ft-lbf)
Check valve Case cover
purge chamber
Set spring Screws
and
washers
O-ring
Case

Filter plate Absorbent

Cover

IW232-0030E14

1. While pressing on filter plate B with both hands,

lift the entire case up approximately 10 cm (4in).

2. Next, gently tap the raised case against the

workbench. At this time, do not let go, and lower
your hands with the case.

3. Repeat steps 1 and 2 approximately 30 times.

Check that the position of filter plate B is 4 - 6 mm
(1.5 – 2.4in) below where it was initially. When this
is verified, the work is complete.

36 W232-0032E
T-5 T-5
Air Dryer

7. Troubleshooting
[NOTICE]
Be sure to perform daily inspections and periodic
maintenance, as described in 4. Maintenance and
Inspections.
If any of the below symptoms or malfunctions occur,
follow the remedy procedures listed below to
inspect and correct the problem

Symptom Probable cause Remedy

Condensate The amount of oil increase in the Replace the desiccant.

flows out from compressor is abnormally large. 1/5 or Also take steps to prevent the increase of oil.
the air tank. more of the desiccant is seeped in oil and
its ability to absorb moisture has
decreased.

Because the amount of desiccant is too Insert the specified amount of desiccant.
little, its ability to absorb moisture is (Specified amount: 590 - 610 cm3 (36 - 37.2in3))
insufficient.

Because the type of desiccant is wrong, Insert the specified type of desiccant.
its ability to absorb moisture is insufficient. (Be aware that the type is different than that used
with DR-41, DR-42, and DU-4.)

The amount of air consumed is too large, Reduce the amount of air consumed in 1
and has exceeded the moisture-absorbing loading/unloading cycle.
capability range of the desiccant. {The maximum amount of air that can be
processed for moisture-removal is 93 L
[25gal(us)] /cycle.}

The drain valve is not opening, and Check the governor discharge pressure. If it
regeneration of the desiccant is not being differs from the specified value, adjust or replace
performed. the governor.
• Disassemble and inspect the valve operation
parts. Remove any foreign substances that are
found.
• If the drain valve is frozen, check for a open
circuit in the heater, thermostat failure, missing
wire, or other problem. Replace parts or
connect wires securely.

If the dryer inlet temperature is higher Make arrangement to reduce the inlet
than 60°C (140°F), moisture absorption temperature to less than 60 °C (140°F).
will be insufficient.

If the desiccant has not been replaced for Replace the desiccant every 1 year or 100,000
a long time, and 1/5 or more is seeped in km (62140mi) of travel, whichever occurs sooner.
oil, its ability to absorb moisture will
decrease.

37 W232-0032E
T-5 T-5
Air Dryer

Symptom Probable cause Remedy

Condensate If the purge time is too short, the Inspect the check valve and O-ring.
flows out from desiccant regeneration capability will be (Purge time should be approximately 35 seconds
the air tank. reduced. from 890 kPa (129psi) to 0 kPa (0psi).)

If the pressure in the purge chamber is Check the governor discharge pressure. If it is
too low, the desiccant regeneration different from the specified value, adjust or
capability will be reduced. replace the governor.

No condensate The drain valve is frozen and will not If there is an open circuit in the heater, replace
is discharged open. the heater.
from the (Check the continuity with a tester.)
exhaust port.
• If there is a thermostat failure, replace the
thermostat.
(Leave at 0°C (32°F) or less, then check the
continuity with a tester.)

• Check that no wires have been disconnected.

• If left for a long time in a cold environment, time

will be required for the temperature to rise
after the heater is turned ON.
(Approximately 15 - 20 minutes to rise -20°C -
0°C (-4°F - 32°F.)

If the governor discharge pressure is 490 Check the governor discharge pressure. If it
kPa (71psi) or less, the drain valve will not differs from the specified value, adjust or replace
open. the governor.

A foreign substance (carbonized oil) has Disassemble and inspect the valve operation
entered during the valve operation, parts. Remove any foreign substances that are
preventing valve operation. found.

Air leaks from The drain valve is frozen and will not If there is an open circuit in the heater, replace
the exhaust close. the heater.
port.
• If there is a thermostat failure, replace the
thermostat.

• Check that no wires have been disconnected.

• If left for a long time in a cold environment, time

will be required for the temperature to rise
after the heater is turned ON.

A foreign substance has been caught in Disassemble and inspect the valve, and remove
the valve, preventing it from sealing. any foreign substances. If the valve seal surface
is scratched, replace the valve component or
valve body.

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

Symptom Probable cause Remedy

Main tank If the air dryer outlet check valve fails to Disassemble and inspect the air dryer outlet
pressure drops function, the air in the main tank flows check valve. If necessary, replace the check
abnormally backwards and out through the air dryer. valve.
when the
compressor is
unloaded.

368-703-70000 △
3

368-703-60000 △
3

39 W232-0032E
T-6 T-6
Brake (Parking Brake)

T-6 Brake (Parking Brake)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure and function

The clearance of pad assy 6 and 7 is
Inner pad carrier 1 and outer pad carrier 2 are automatically adjusted by means of the
mounted to the mounting bracket by means of elastic-plastic property of retraction plates 4,
respective pad carrier bolts 3, and pad assy 6 and which must be replaced when the pads are
7 are mounted to the respective pad carriers with replaced.
special bolts integral with the pads and nuts 8.
Lever assy 10 is connected to inner pad carrier 1
with pivot seat 14, and lever assy 10 incorporates
trunnion 12 and spring support pin 19. Hand brake
bolt 11 is screwed into self lock nut 13 to serve as
an element in the actuating train for pad assy 6
and 7. Return spring 17 between inner pad carrier
1 and lever assy 10 serves to return lever assy
10.

1. Inner pad carrier 6. Pad assy 11. Hand brake bolt 16. Cotter pin
2. Outer pad carrier 7. Pad assy 12. Trunnion 17. Return spring
3. Pad carrier bolt 8. Nut 13. Self lock nut 18. Spring anchor
4. Retraction plate 9. Toothed lock washer 14. Pivot seat 19. Spring support pin
5. Tab washer 10. Lever assy 15. Pin

40 W577-0141E
T-6 T-6
Brake (Parking Brake)

2. Replacing pad
[NOTICE]
At this time, if the clearance between the pad and
WARNING the disc plate is too narrow to adjust, loosen the
hand brake bolt.
Be sure to immobilize the vehicle before starting
to work.
7. Set pad carrier 1 and 2 with new pads to the
mounting bracket, and install pad carrier bolts 3
CAUTION
together with new retraction plates 4 and tab
Make sure that the run out of the disk plate is
washers 5.
less than 0.15 mm (0.006 in) at the center of the
pad sliding surface.
8. Fold one tab of tab washers 5 to lock pad carrier
bolts 3.
[NOTICE]
The pads should preferably be replaced in a set of
two. If only fully worn one is replaced, the other one
would require replacement soon, and in this way,
the checking and changing intervals would become
short.

1. With the parking brake lever in the release

position and the brake chamber in the extension
sided stroke end, disconnect lever assy 10 from
the brake chamber push rod.

2. Move the parking brake lever to the braking

position to return the brake chamber push rod.

3. Loosen hand brake bolt 11 to free retraction plate

4.

4. Unfold the tab of tab washer 5, unscrew pad

carrier bolts 3 with a wrench, and remove them
together with retraction plate 4.

5. Remove one of the pad carriers from the

mounting bracket and replace the pad with a new
pad. To replace the pad, first, unscrew hexagon
nut 8 with a wrench and remove together with
toothed lock washer 9, and then, withdraw the
worn pad along the fixed bolt hole. Install a new
pad by reversing the procedure. Replace also the
toothed lock washer 9 and hexagon nut 8.

6. Replace the other pad similarly.

41 W577-0141E
T-6 T-6
Brake (Parking Brake)

3. Remounting

3.1 Connecting parking brake to spring chamber 3.2 Adjusting parking brake clearance

1. Adjust the clearance between the pad and the 1. Move the parking brake lever to the release
disc plate to approximately 0.15 mm (0.006 in) per position to bring the brake chamber into the
side with the hand brake bolt. extension side stroke end.

2. Move the lever to release the parking brake and 2. Screw the hand brake bolt in accordance with the
bring the brake chamber to the extension stroke pad wear, until the clearance between the pad
end, and connect the link to the lever by adjusting and the disc plate becomes approx. 0.15 mm
its position. Then, check the clearance between (0.006 in) per side.
the pad and the disc plate. It must be approx. 0.15 when it becomes impossible to adjust the
mm (0.006 in) per side. If the clearance is correct clearance by the hand brake bolt, readjust the
lock it with the jam nut. brake in accordance with the preceding paragraph,
“ 3.1 Connecting parking brake to spring
chamber ”

42 W577-0141E
T-6. T-6.
Brake (Parking Brake)

4. Check

WARNING
When the brake has been used as
emergency brake, adjust the pad clearance as
soon as the use is terminated.
When the clearance between the pad and
the disk plate is set to 0.15 mm (0.006 in)
per side before starting to use, the brake can
be used without adjusting the hand brake
bolt, until the pad wears approx. 2.0 mm
(0.079 in).
When the brake wears more, the trunnion
fouls the pivot seat to make the brake
ineffective, and at the same time, undue force
is applied to the pivot seat to break it. Adjust
the clearance in time.

1. The pad assy consists of a backing plate and

wear material, and they are 3.2 mm (0.126 in) and
10.5 mm (0.413 in) respectively in thickness when
new (total: 13.7 mm (0.539 in)).
Since change in thickness by wear changes the
stroke, adjust the hand brake bolt according to the
pad wear from time to time.

CAUTION
If the wearing condition is not regularly
checked, the inner and outer pad carriers
may foul the disk plate to damage it, making
its replacement necessary.

2. The use limit of the pad assy is considered to be

reached when the remaining thickness of the wear
material has become 3.8 mm (0.150 in), that is,
the total thickness has become 7 mm (0.276 in),
at any part.

43 W577-0141E
T-7 T-7
Brake Chamber

T-7 Brake Chamber

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure
Stroke
3 2 4 5

IW576-0020E01

7 1. Pressure plate
2. Non pressure plate
6 3. Diaphragm
4. Spring
5. Push rod
6. Clamp ring
A IW576-001002
7. Bolt
8. Nut
Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft - lbf
7, 8 － 9.8 - 14.7 7.2 - 10.8

44 W576-0022E
T-7 T-7
Brake Chamber

2. Function DANGER
Never attempt to disassemble without using the
1. When compressed air is introduced behind the special jig. Doing so is extremely dangerous.
diaphragm, it pushed the diaphragm, and the The spring is powerful. Be sure to use the
push rod to release the brake. special jig to pull the push rod out approximately
5 mm before disassembling.
2. When the compressed air is freed to the outside
air, the push rod is pushed back by a strong return
spring, puling the brake lever to effect the parking
brake. 3. Disassembly
[NOTICE]
Mark the clamp bolts, non-pressure plate, and
pressure plate with alignment marks before
disassembling, so that they can be aligned correctly
during reassembly.

Dimensions of special jig (sample) (Unit：mm) (1mm＝0.039in)

Rod
M12×1.25 M14×1.5
(0.77)
19.6

20 (0.8)
17 30 (1.2) 150 (5.9)
(0.67)
IW576-0021E01

Adapter
Thrust ball bearing
(1.97)
(0.94)
20
(0.8)

(1.1)
28

50
24
(0.59)
15

9
100 (3.94) (0.35)
IW576-0021E02

45 W576-0022E
T-7 T-7
Brake Chamber

Pressure plate Clamp ring Spring Nut

Adapter Push rod

Special jig

IW576-0020E03

4. Cleaning and checking

1. The diaphragm and clamp ring are pressed
against the pressure plate by a spring.
4.1 Cleaning
2. In order to neutralize this force, use the special jig
1. Wash all parts in kerosine thoroughly, and dry
to first pull out the push rod by approximately 5
them by blowing with compressed air.
mm (0.2in) and fix it in place.
2. Don’t wash the diaphragm, but wipe it with dry
3. Remove bolts by unscrewing two clamp ring nuts,
cloth, and then, blow with air.
and remove clamp ring by expanding.
4.2 Checking

1. Pressure plate
Check for deformation (dents, etc.) and damage,
Nut
and replace if excessive defects are found.

2. Diaphragm
Bolt
Replace it after using for one year.
Clamp ring When it has not been used one year, check it for
IW576-0020E04
cracks, breaks and excessive wear, and replace it
if these defects are found.

4. Gradually loosen the nut of the special jig to 3. Spring

unload the spring, and remove push rod and Replace, if broken or rusted substantially.
spring from non-pressure plate.
4. Other parts
Check all the parts for breaks and other defects,
and replace all defective parts.

46 W576-0022E
T-7. T-7.
Brake Chamber

5. Reassembly
5. Align diaphragm and pressure plate to
1. Set push rod vertically on a flat bench, with its end non-pressure plate, hook clamp ring on the edge
up. of the pressure plate by expanding the ring, and
align the marks.
2. Put spring and non-pressure plate over the push
rod. 6. Clamp clamp ring with clamp bolts and nuts just
sufficient to stop air leaking.
3. Tighten the nut of the special jig to compress Tightening torque：9.8 - 14.7 N-m
spring, and keep it compressed. (7.2 - 10.8 ft-lbf)
4. Hook clamp ring on the edge of non-pressure 7. Loosen the nut of the special jig, and remove the
plate by expanding the ring, and align the marks. rod, nut, and the adapter.

Pressure plate Clamp ring Spring Nut

Adapter Push rod

Special jig

IW576-0020E03

6. Test 7. Maintenance standards

6.1 Air leak test 7.1 2000-hour or 1-year check

1. Apply soapy water to the entire surface of the 1. Disassemble the spring chamber, and replace
pressure plate, and to the gaps between the damaged or cracked parts.
clamps, non-pressure plate, and push rod.
2. Replace the diaphragm. Conduct the air leak test,
2. Apply compressed air at 0.5 - 0.8 MPa (72.5 - as described above.
116psi) to the inlet port, and check for air leakage.

367-001-40000 △
1

367-001-80000 △
0

367-001-50000 △
1

367-000-10000 △
1

47 W576-0022E
T-8 T-8
Solenoid Valve (Air)

T-8 Solenoid Valve (Air)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure

OUT
Connector

＋ +-
ー
Diode
GP 15M IN
EXH
IW210-0120E01 IW210-0151E01

4 3 2 1 18,19

5
6
8
9
10
11
12
IN OUT
11
13 T1
14 15 16 17

IN
EXH

OUT
IW210-0123E01

48 W210-0123E
T-8. T-8.
Solenoid Valve (Air)

1.Core 6.Coil assy (DC24V) 12.Valve seat 17.Filter

2.O-ring 8.Rod 13.Valve 18.Packing
3.Case 9.Coil cover 14.Body 19.Packing holder
4.Spring 10.O-ring 15.Spring
5.Plunger 11.O-ring 16.Cover

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
IN, OUT Rc1/4 15 - 29 11 - 22

T1 M8x1.25 8 - 12 6-9

366-459-60000 △
5

49 W210-0123E
 U
Suspension System

Contents

U-1 Suspension System......................... 1

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

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

1. Structure .................................................... 2

U-3 Pilot Check Valve (Suspension Lock

Cylinder)................................... 3

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

U-4 Solenoid Valve (Suspension Lock

Check Release) ........................ 4

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

i
U-1. U-1.
Suspension System

U-1 Suspension System

1. General
Hydraulic Circuit for Suspension Lock

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

1 WU02-0190E
U-2. U-2.
Suspension Lock Cylinder

U-2 Suspension Lock Cylinder

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1 2 3 4 5 6 7 8 10 9 11 12

A
For air bleeding

B IW159-0020E01

1.Cylinder 4.Plain bearing 7.Rod 10.O-ring

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

Thread size and tightening torque

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

- - - -

360-501-10002 △
6

2 W159-0021E
U-3. U-3.
Pilot Check Valve (Suspension Lock Cylinder)

U-3 Pilot Check Valve (Suspension Lock Cylinder)

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

2.O-ring 6.Body 9.Spring
3.Plunter 7.Valve 10.Plug

Thread size and tightening torque

Tightening torque
Sign / port Thread size
N-m ft-lbf
T, P•P, A, B G1/4 29.4 22

1, 10 M34×1.5 93 - 103 68.7 – 75.9

366-205-30001 △
1

3 W115-0501E
U-4 U-4
Solenoid Valve (Spring Lock Check Release)

U-4 Solenoid Valve (Spring Lock Check Release)

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure

T
G A

P
IW121-0700E01

T P 5
2
A

3,4

1.Solenoid valve (DC24V)

2.Body
3.Plug
4.O-ring
5.Hexagon socket head bolt
G

T IW121-0700E02

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
A, P, T, G G1/4 34 - 38 25 - 28
5 M5 4.9 – 6.9 3.6 – 5.1
346-410-52500 △
0

4 W121-0702E
U-4. U-4.
Solenoid Valve (Spring Lock Check Release)

Solenoid valve assy

Connector

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

IW121-0542E01

11 17 13 12

IW121-044002

8 14 9 10 6 16 4 3 14 2 1 7

1.Body 6.Spring 10.Solenoid guide 14.O-ring

2.Spool 7.Detent spring 11.Solenoid coil 15.O-ring
3.Retainer 8.Nut 12.Name plate 16.O-ring
4.Retainer 9.Rod 13.Screw 17.O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m ft-lbf
8 - 5–7 3.6 – 5.1

366-498-90000 △
0

5 W121-0702E
 Y
Data, Adjusting and Checks

Contents

Y-1 Hydraulic Pressure Setting Table... 1 5. Jib lock pin and jib offset cylinder ....................14
1. Winch ............................................................. 1 6. Suspension lock cylinder .................................15
2. Telescoping and Elevating ................................ 2 7. Hydraulic pilot circuit........................................16
3. Steering ............................................................. 3 7.1 Swing ........................................................16
4. Swing ............................................................. 4 7.2 Elevating ...................................................16
5. Outrigger ........................................................... 5 7.3 Telescoping ...............................................16
6. Lower pilot pressure.......................................... 6 7.4 Winch (main and aux.) ..............................16
7. Pilot pressure .................................................... 7 8. Oil cooler motor ...............................................16
8. Flow control valve ............................................. 8 9. Air condition motor (option) .............................16
9. Torque converter oil pressure ........................... 8
10.Pressure reducing valve
[for Europe and Canada (option)]......... 9 Y-4 Electric Switch Adjustment ...........17
1. 3rd / top boom full retraction detection switch
(CN859) ..............................................17
Y-2 Air Pressure Setting Table ............ 10 2. 2nd boom full retraction detection switch
1. Air pressure setting table ................................ 10 (CN553).............................................17
3. Jib stowed detection proximity switch
(CN572) ..............................................17
4. Jib lock pin retraction detection switch
Y-3 Air Bleeding Procedure ................. 11
(CN573) ..............................................18
1. Starting pump .................................................. 11
5. Main winch drum rotation detection proximity
1.1 Before starting the engine ........................ 11
switch (CN591) (option) ......................18
1.2 Shakedown of the pump........................... 11 6. Aux. winch drum rotation detection proximity
1) Steering, winch brake pilot pressure pump switch (CN592) (option) ......................18
(double gear pumps) .......................... 11 7. Over-front detection proximity switch
2) Main pump..................................................... 11 (CN521).............................................18
3) Others ........................................................... 11 8. Control lever stand position detection switch
2. Service brake circuit........................................ 12 (Swing control and boom
3. Swing circuit .................................................... 12 telescoping/aux. hoist) (CN529) .........19
3.1 Swing motor.............................................. 12 9. Straight ahead detection proximity switch
3.2 Swing hydraulic pilot control valve ........... 12 (CN408) ..............................................19
4. Winch circuit (main and aux.).......................... 13 10.Counterweight equipped detection proximity
switch (CN994) ...................................19
4.1 Winch motor ............................................. 13
4.2 Winch counterbalance valve .................... 13
11. Over-rear detection proximity switch (CN518)
[for Europe only] .................................20
Y
4.3 Winch brake release circuit ...................... 13

i
Y-5 Adjustment and Checks ................ 21 7. Speed limiter (For Europe) ..............................36
1. Service brake adjustment ............................... 21 8. Reverse steering (For Europe) ........................36
1.1 Adjusting the brake pedal......................... 21
1.2 Tightening the cap of reserve tank of service
brake fluid........................................... 21 Y-8 Oil and Grease Table .....................37
2. Accelerator adjustment ................................... 21
2.1 Accelerator pedal ..................................... 21
3. Parking brake adjustment ............................... 22 Y-9 Mass Table......................................38
3.1 Adjusting the parking brake clearance
(between pad and disc plate) ............. 22
3.2 Connecting the parking brake and spring Y-10 Specifications.................................39
chamber ............................................. 22 1. Engine speed...................................................39
4. Tire steering angle adjustment........................ 22 1.1 Idling speed...............................................39
4.1 Tire air pressure ....................................... 22 1.2 MAX. speed (unload) ................................39
4.2 Adjusting the tire Steering angle .............. 22 1.3 Stall speed.................................................39
5. Engine speed (and governor setting).............. 23 2. Hydraulic pump (for crane) (Double Variable
6. Torque converter and transmission................. 23 Displacement Pump) ..........................39
6.1 Maximum allowable speed ....................... 23 2.1 Pump speed..............................................39
6.2 Adding oil to the torque converter and 2.2 Pump displacement ..................................39
transmission ....................................... 23 3. Hydraulic pump (for steering)
7. Braking force ................................................... 24 (Double Gear Pump)...........................39
7.1 Parking brake force .................................. 24 3.1 Pump speed..............................................39
7.2 Service brake force .................................. 24 3.2 Pump displacement ..................................39
8. Adjusting the headlight light axes ................... 24 4. Charging pump (for torque converter) .............39
9. Adjusting boom telescoping wire ropes .......... 25 4.1 Pump speed..............................................39
4.2 Pump displacement ..................................39
5. Emergency steering pump (option) .................39
Y-6 Check (Crane Operation)............... 29 5.1 Pump speed..............................................39
1. Outrigger status indicator ................................ 29 5.2 Pump displacement ..................................39
2. Hoisting ........................................................... 30 6. Winch motor.....................................................39
3. Backward stability control................................ 30 7. Swing driving unit ............................................39
4. Outrigger emergency setting........................... 30 7.1 Swing motor ..............................................39
5. Jib ........................................................... 30 7.2 Swing speed reducer ................................39
6. Boom Telescoping Control .............................. 31
7. Alarms ........................................................... 32
8. Outrigger slide plate adjustment ..................... 32 Y-11 Boom Connecting Pin and Thread
Size Table ...............................40

Y-7 Check (Driving Devices)................ 33

1 Exhaust brake (EXB)....................................... 33
2. Automatic transmission................................... 33
3. Steering mode change .................................... 34
4. Emergency switches ....................................... 34
5. Overshift prevention ........................................ 35
6. Warnings ......................................................... 35

ii
Y- 1 Y- 1
Hydraulic Pressure Setting Table

Y-1 Hydraulic Pressure Setting Table

1. Winch
[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Confirm set pressure on AML (load moment indicator) moment display
Shift the elevation slow stop cancel switch to OFF side
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
Main winch 1. Place the main winch brake in the hold state. *1
hoisting up 2. Turn the PTO switch ON.
(RV1) 3. Move the main winch control lever fully to the hoist
2150
27.5±0.5 3980±70 up position while the boom elevating control lever
(MAX.)
Aux. winch is fully moved to the boom lowering position. In this
hoisting up state, set the engine speed to 2150 min-1 and
(RV1) check the pressure.

1. Place the auxiliary winch brake in the hold state. *1

Aux. winch 2. Turn the PTO switch ON.
hoisting (IDL.) 3. Move the boom telescoping /auxiliary winch control
8.8±0.5 1280±70
down 670 lever fully to the hoist down position while the boom
(PR1) elevating control lever is fully moved to the boom
lowering position. In this state, check the pressure.

1. Place the main winch brake in the hold state. *1

Main winch 2. Turn the PTO switch ON.
hoisting (IDL.) 3. Move the main winch control lever fully to the hoist
8.8±0.5 1280±70
down 670 down position while the boom elevating control
(PR2) lever is fully moved to the boom lowering position.
In this state, check the pressure.

(*1): When the winch brake is in the hold state, the winch brake will not be released and winch drum will
not rotate by hoist up or hoist down operation. To have the winch brake placed in the hold state,
remove the pipes for the winch brake release to the hydraulic motor for winch. The pilot pressure for
the winch brake release will be produced during the hoist up or hoist down operation, therefore, fit on
the cap to avoid the oil leak. (After checking the pressure, return the pipes to the original position and
bleed the winch brake release circuit.)

1 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

2. Telescoping and Elevating

[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Confirm set pressure on AML (load moment indicator) moment display
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Turn the PTO switch ON.
2. Fully extend the boom.
Boom
2150 3. Move the boom telescoping control lever fully to the
extending 19.6±0.5 2840±70
(MAX.) boom extension position. In this state, set the
(PR4)
engine speed to 2150 min-1 and check the
pressure.
1. Turn the PTO switch ON.
Boom 2. Fully retract the boom.
2150
retracting 23.5±0.5 3410±70 3. Move the boom telescoping control lever fully to the
(MAX.)
(RV2) boom retraction position. In this state, set the engine
speed to 2150 min-1 and check the pressure.
1. Turn the PTO switch ON
2. Shift the elevation slow stop cancel switch to OFF
side.
Boom
2150 3. Fully extend the boom elevating cylinder.
raising 23.5±0.5 3410±70
(MAX.) 4. Move the boom elevating control lever fully to the
(RV2)
boom raising position.
In this state, set the engine speed to 2150 min-1
and check the pressure.
1. Turn the PTO switch ON.
2. Shift the elevation slow stop cancel switch to OFF
Boom side.
(IDL.)
lowering 2.9 420 3. Fully retract the boom elevating cylinder.
670
(PR3) 4. Move the boom elevating control lever fully to the
boom lowering position. In this state, check the
pressure.

2 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

3. Steering
[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Connect a pressure gauge to the pressure check
port.
2. Turn the PTO switch OFF.
3. With the outriggers stowed, turn the steering wheel
Steering 2600
13.7±1 1990±140 to the right to bring the steering cylinders to the
(RV5) (MAX.)
travel ends. (Do steering as to get lightly to travel
end.) In this state, set the engine speed to 2600
min-1 and check the pressure by the pressure
gauge. (Adjusting the relief pressure is impossible)

Pressure
check port (G1/4)

Steering cylinder

Front axle
Pressure check port IWY03-0210E01

Steering
(RV5)

Priority valve (Steering)

IWY03-0210E02

3 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

4. Swing
[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Confirm set pressure on AML (load moment indicator ) moment display
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)

*1
(21.1) (3060) -
(RV4)

Unable to be checked. (The pressure is preset by the

Swing
valve manufacturer.)
*2
(RA, (26.0) (3770) -
RB)

*1 : Relief valve
*2 : Overload relief valve (high pressure)

4 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

5. Outrigger
[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)

1. Connect a pressure gauge to the pressure

check port.
2. Turn the PTO switch OFF.
Outrigger 2600
20.6±0.5 2990±70 3. Extend all the jack cylinders fully. And again
(RV3) (MAX.)
press the outrigger collective control switch. In
this state, set the engine speed to 2600 min-1
and check the pressure by the pressure gauge.

Pressure check port

(for relief valve, G1/4) Relief valve (RV3)

Solenoid control valve (Outrigger)

IWY03-0210E03

5 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

6. Lower pilot pressure

[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Connect a pressure gauge to the pressure
check port.
2. Turn the PTO switch ON.
Lower Pilot 3. Select the jib set status on the AML.
(IDL.)
pressure 3.6±0.5 522±70 4. Retract the jib lock pin fully to stroke end.
670
(RDV2) 5. Since this valve is unable to adjust the pressure,
abnormal pressure valve indicates the valve is
defective. Renew the reducing valve if the
abnormal pressure is defected.

Pressure check port

Front Solenoid valve (for pressure reducing valve, G1/4)
(Suspension lock)

R View
Reducing valve Solenoid valve (Suspension lock)
(RDV2) IWY03-0210E04 IWY03-0210E05

6 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

7. Pilot pressure
[NOTICE]
Oil temperature: 50±5 (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Connect a pressure gauge to the pressure
check port.
2. Turn the PTO switch ON.
3. Remove the solenoid connector for the oil cooler
to prevent the oil cooler from operating.
4. Turn the power switch of the air conditioner
*1
2.5 or (IDL.) (option) OFF.
(RG 360 or over
over 670 5. Make sure that constant pressure is being
V1)
produced while engine is running. And check
the pressure by the pressure gauge. Since this
valve is unable to adjust the pressure,
Pilot abnormal pressure value indicates the valve is
pressure defective. Renew the valve if the abnormal
pressure is detected.

1. Connect a pressure gauge to the pressure

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

*1: Low pressure

*2: High pressure

7 WY02-0641E
Y- 1 Y- 1
Hydraulic Pressure Setting Table

8. Flow control valve

[NOTICE]
Oil temperature: 50±5°C (113 – 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Connect a pressure gauge to the pressure
Flow control
2150 check port (U).
valve 18.1±0.5 2630±70
(MAX) 2. Turn the PTO switch ON.
(RV6)
3. Retract the jib lock pin fully to stroke end.

Front

Pressure check port

(U)
RV6

T View

Flow control valve Flow control valve

IWY03-0220E02 IWY03-0210E07

9. Torque converter oil pressure

Set pressure Engine

Item speed Check procedure
MPa psi (min-1)
(IDL.)
1.7 or over 250 or over
Torque 670 1. Turn the PTO switch OFF.
converter oil 2. Check the pressure at the torque converter oil
pressure 2600 pressure gauge on the combination meter.
2.0 - 2.3 290 - 340
(MAX.)

8 WY02-0641E
Y- 1 . Y-1.
Hydraulic Pressure Setting Table

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

[NOTICE]
Oil temperature: 50±5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic oil LL)
Set pressure Engine
Item speed Check procedure
MPa psi (min-1)
1. Connect a pressure gauge to the pressure
check port.
2. Turn the PTO switch OFF.
Pressure
2600 3. Retract the jack fully to stroke end.
reducing valve 4.9 or less 711 or less
(MAX.) 4. Since this valve is unable to adjust the pressure,
(RDV3)
abnormal pressure valve indicates the valve is
defective. Renew the reducing valve if the
abnormal pressure is defected.

345-803-31500 △
0

347-320-30000 △
1

9 WY02-0641E
Y- 2 . Y-2.
Air Pressure Setting Table

Y-2 Air Pressure Setting Table

1. Air pressure setting table

Pressure
Item
KPa psi

Turning on pressure 745±20 108±3

Pressure regulator
Turning off pressure 833±20 121±3

Cracking pressure 853 124

Safety valve
Full opening pressure 951±20 138±3

Light-on pressure 539 78

Air low-pressure switch
(low air pressure warning)
Light-off pressure 539 78

Air pressure switch (stop lamp) Operating pressure 29 4.2

Air low-pressure switch (parking brake) Operating pressure 372±20 54±3

345-800-02000 △
0

10 WY03-0142E
Y- 3 Y- 3
Air Bleeding Procedure

Y-3 Air Bleeding Procedure 3) Others

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

1.2 Shakedown of the pump

1) Steering, winch brake pilot pressure pump

(double gear pumps)

1. Fill the oil tank with hydraulic oil.

2. With the engine stopped, loosen the air-bleed plug

on the suction flange of the main pump. After
bleeding air from the suction side, tighten the plug
again.

3. Start the engine (with PTO OFF) and run it at idle

(approx. 700 min-1) while bleeding the air from the
circuit for 1 minute.

4. Start the engine, and run-in the engine for 10

minutes at idle.

2) Main pump

1. Fill the oil tank with hydraulic oil. (If the suction
section was disassembled for repair or other
reasons, bleed air from the air-bleed plug on the
suction side, as described above.)

[NOTICE]
If the tank is to be pressurized, pressurize it at a
pressure of 15 kPa {2.2 psi} or less.

2. Bleed the air from the pump case. Remove the

drain plug or drain hose from the pump. Inject oil
into this location until it overflows, then reinsert
the plug.

3. Start the engine, with PTO ON, and run-in the

engine at idle for 5 minutes.

11 WY05-0582E
Y- 3 Y- 3
Air Bleeding Procedure

2. Service brake circuit 3. Swing circuit

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

(3) Set the swing brake switch to ON. Perform the

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

2. Bleed the calipers of the axles as the step 1 (TR-600,TT-600) (TR-800,TT-800,GR-700E)

above. IWY05-0580E06

Air bleeder screw 3.2 Swing hydraulic pilot control valve

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

Front wheel (right) IWY05-0580E05

12 WY05-0582E
Y- 3 Y- 3
Air Bleeding Procedure

4. Winch circuit (main and aux.)

[NOTICE]
Bleed the main and auxiliary winch circuits by following the procedures below. The procedures are common to
the both circuits.

4.1 Winch motor 4.3 Winch brake release circuit

Bleed the winch motor by following either (1) or (2). Repeat the slow hoist-up and slow hoist-down
operations with the engine idling until no more air
(1) Pour the hydraulic oil through the drain port into
bubbles come out of the air bleeder screw.
the casing until the oil flows out.

(2) Perform the slow hoist-up or hoist-down

operation for approx. 1 minute.

4.2 Winch counterbalance valve

Repeat the slow hoist-up and slow hoist-down

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

13 WY05-0582E
Y- 3 Y- 3
Air Bleeding Procedure

5. Jib lock pin and jib offset cylinder

[NOTICE]
Bleed the jib lock pin, jib offset cylinder as follows.

(1) Start the engine, turn the PTO switch ON, and
raise the engine speed to approx. 2,150 min-1.

(2) Attach a hose to the bleeder screw (A).and

loosen the bleeder screw. In this condition, repeat
the rapid jibset operation to the retract or the
extend until no more air bubbles come out of the
air bleeder screw.

Air bleeder plug

(A) (B)

Jib lock pin

Air bleeder plug

(C) (D)

Jib offset cylinder

IWY05-0580E02

[NOTICE]
Bleed in the order of bleeder plugs, (A), (B), (C) and
(D).

(3) After air-bleeding is over, fasten the bleeder plug

and remove the hose.

14 WY05-0582E
Y- 3 Y- 3
Air Bleeding Procedure

6. Suspension lock cylinder

(6) Turn off the starter switch and connect the on/off
[NOTICE] connector in the inside-cab relay box.
Bleed the suspension lock cylinder as follows.

(1) Set the crane in the traveling configuration on

level ground.

(2) Keep the starter switch to OFF, open the door of

the inside-cab relay box, and disconnect the on/off ON/OFF connector
connector.

IWY05-0580E03

(7) Turn on the starter switch. Turn the PTO switch

on. Make sure then the suspension lock indicator
ON/OFF connector lamp lights.

IWY05-0580E03

(3) Start the engine, turn the PTO switch on, and
raise the engine speed to approx. 2,150 min-1.

(4) Attach a hose to the bleeder screw (A).and

loosen the bleeder screw. In this condition, bleed
the axle for approx. one minute.

[NOTICE]
Bleed in the order of bleeder screws, (A), (B), (C)
and (D).

IWY05-0580E04

(5) After air-bleeding is over, fasten the bleeder

screw and remove the hose.

15 WY05-0582E
Y- 3 . Y-3.
Air Bleeding Procedure

7. Hydraulic pilot circuit 8. Oil cooler motor

7.1 Swing Pour the hydraulic oil through the drain port into the
casing until the oil flows out.
Set the hydraulic oil temperature to 50oC (122oF) or
higher, set the PTO switch and the swing brake
switch to ON, let the engine idle, and move the 9. Air condition motor (option)
swing control lever fully to the right-swing side. Keep
Pour the hydraulic oil through the drain port into the
the above conditions for 20 seconds or more for
casing until the oil flows out.
bleeding. Proceed the same steps by moving the
swing control lever to the left-swing side.

7.2 Elevating

Pull out the connector of the AML vent solenoid. Set

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

7.3 Telescoping

Pull out the connector of the AML vent solenoid. Set

the hydraulic oil temperature to 50oC (122oF) or
higher, set the PTO switch to ON, let the engine idle,
and move the boom telescoping control lever fully to
the retraction side. Keep the above conditions for 20
seconds or more for bleeding. Proceed the same
steps by moving the boom telescoping control lever
to the boom extension side.

7.4 Winch (main and aux.)

[NOTICE]
Bleed the main and auxiliary winch circuits by
following the procedures below. The procedures are
common to the both circuits.

Pull out the connector of the AML vent solenoid. Set

the hydraulic oil temperature to 50oC (122oF) or
higher, set the PTO switch to ON, let the engine idle,
and move the hoist control lever fully to the hoist-up
side. Keep the above conditions for 20 seconds or
more for bleeding. Proceed the same steps by
moving the hoist control lever to the hoist-down side.
345-800-92500 △
0
345-800-00500 △
0

16 WY05-0582E
Y- 4 Y- 4
Electric Switch Adjustment

Y-4 Electric Switch Adjustment Tightening torque :

3.7N-m (33in-lbf)
1. 3rd / top boom full retraction detection (*1)
switch (CN859)
Adjust the switch position so that its contact is
shifted (opened/closed) when the top boom section
is extended/retracted beyond the position where it is
5-8 mm (0.2-0.31 in) longer than its fully retracted
length.

Tightening torque :
4.9-5.9N-m (43-52in-lbf)
Base boom 2nd boom
IWY04-0430E02

Top boom 3. Jib stowed detection

proximity switch (CN572)
Adjust the switch position so that the dimension A
becomes 4 mm (0.16 in) with the jib stowed.

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

IWY04-0430E01

2. 2nd boom full retraction

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

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

17 WY04-0911E
Y- 4 Y- 4
Electric Switch Adjustment

4. Jib lock pin retraction

detection switch (CN573)
Adjust the switch position so that the dimension A
becomes 30.5 mm (1.2 in) with the switch in
free position.

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

Tightening torque :
4-6N-m (35-53in-lbf)
(*1)
A

6. Aux. winch drum rotation detection

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

7. Over-front detection proximity switch

D (CN521)
Fully retract the boom and swing it to the over-front.
Insert the swing lock pin and set the boom angle to
0°. Then, adjust the switch position so that the
dimension A becomes 3 mm (0.12 in).
(*1): Apply the screw locking agent (Three-Bond
1401 or the equivalent).
IWY04-0430E04

5. Main winch drum rotation detection

proximity switch (CN591) (option)
Adjust the switch position so that the dimension A
becomes 2.5±0.5 mm (0.1±0.02 in).

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

18 WY04-0911E
Y- 4 Y- 4
Electric Switch Adjustment

8. Control lever stand position detection 9. Straight ahead detection proximity

switch (Swing control and boom switch (CN408)
telescoping/aux. hoist) (CN529)
Set the rear wheels in a straight-forward position,
Before the adjustments below, tilt the lever stand by and adjust the switch position so that the dimension
the angle of 16°. Squeeze the switch upward and A becomes 3 mm (0.12 in).
secure it temporarily where its contact is shifted
(*1): Apply the screw locking agent (Three-Bond
(opened/closed). Then, lower the switch by 1 mm
1401 or the equivalent).
(0.039 in) from the temporary secured position and
secure it. (A rotation of the switch mounting nut
makes the switch move upward or downward by
approx. 1 mm (0.039 in) ).

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

10. Counterweight equipped detection

proximity switch (CN994)
Adjust the switch position so that the dimension A
becomes 5±1 mm (0.2±0.04 in)

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

19 WY04-0911E
Y- 4 . Y-4.
Electric Switch Adjustment

11. Over-rear detection proximity switch

(CN518) [for Europe only]
Fully retract the boom and swing it to the over-rear.
Set the boom angle to 0°. Then, adjust the switch
position so that the dimension A becomes 3 mm
(0.12 in).

(*1): Apply the screw locking agent (Three-Bond

1401 or the equivalent).

20 WY04-0911E
Y- 5 Y- 5
Adjustment and Checks

Y-5 Adjustment and Checks 2. Accelerator adjustment

1. Service brake adjustment 2.1 Accelerator pedal
1.1 Adjusting the brake pedal

With the pedal weight causing the roller to contact

the plunger, adjust the bolt until it contacts the Switch
(Idle volume)
stopper, then use the nut to lock it in place.
A
Bolt

Idling

Nut

Roller
MAX

Plunger
IWY05-0141E07

1. Adjust bolt F so that lever I is vertical, then lock

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

mark on tank as shown in Fig.2. [NOTICE]

The stopper might be broken when tightening the Be sure to check that the idle SW operates reliably.
cap too much.
2. Move the accelerator sensor lever so that it
contacts stopper C. Then adjust nut H until there
is no pedal play.

Apply grease

Stopper D
Lever

Stopper C
(Idle SW)

IWY05-0141E09

3. When at Max. position (accelerator sensor lever in

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

21 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

3. Parking brake adjustment 4. Tire steering angle adjustment

3.1 Adjusting the parking brake clearance 4.1 Tire air pressure
(between pad and disc plate)
unit: kPa {psi}
Adjust so that the clearance between pad and Tire size Traveling On-tire operation

disc plate becomes approx. 0.15 mm (0.006 in) 29.5 - 25 - 22PR 350 (50.75 ) 420±20 (60.9±2.9)

per side. 29.5 - 25 - 28PR 330 (47.85 ) 450±20 (65.25±2.9)

3.2 Connecting the parking brake and spring 4.2 Adjusting the tire Steering angle
chamber

(1) Move the spring chamber to the end of its stroke.

(Use air pressure to move it to the end of its
extension stroke.) Then adjust the position of Link,
connect the chamber and brake lever.

(2) After connecting, check so that the clearance

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

2. Before adjusting the tire turning angle, use a

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

3. If it is more than ± 5 mm (0.197 in), loosen the

bolts that fasten the left and right tie-rod ends.
Then rotate the tie-rod and adjust the toe-in..

4. Jack up the vehicle on a level road surface (so

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

5. Adjust the rear wheels as the procedures of the

front wheels.

22 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

5. Engine speed (and governor setting) 6. Torque converter and transmission

[NOTICE] 6.1 Maximum allowable speed
Before checking the engine speed, run the engine Units: MPH (km/h)
to warm it up. (Light weight grease should reach
Shift position Hi position Lo position
approximately 50°C (122°F).)
1 5.5 (8.9) 1.6 (2.5)
1. No-load Max. speed 2 11.6 (18.5) 3.2 (5.1)
• PTO - OFF : 2860 ± 40 min-1 D 22.5 (36.2) 6.2 (10.0)
• PTO - ON : 2150 min-1 R 3.9 (6.2) 1.6 (2.5)

2. Idling speed : 670 ± 25 min-1 (PTO - OFF) [NOTICE]

Engine speed: 2600 min-1
3. Stall speed
Gauge display
(1) Set the switches and levers as described below. Pay attention to the tachometer and do not overrun
the engine.
• PTO switch : OFF
(Max. 2900 min-1)
• Shift lever : 2nd gear
Drive-speed selection must be done with the
• Drive speed selector switch : 4WD Hi vehicle at a complete stop and with the brakes not
• Service brake : ON applied.
The mechanism does not allow 2WD selection in Lo
(2) Depress the accelerator pedal all the way. Check position.
the speed when the engine speed has stabilized.
Max. speed standard when stalled: 6.2 Adding oil to the torque converter and
Approx. 2160 min-1 transmission

[NOTICE]
When checking the oil level, turn PTO OFF. Check
at an oil temperature of 50°C, once the oil level has
stabilized after the engine is started.
Do not add too much or too little oil.
Do not allow dust or water to enter when adding oil.

1. With the engine stopped, add oil to the oil injection

port in the top of the T/C, to the prescribed level
on the T/M oil level gauge.

2. Put the T/M in neutral and start the engine. While

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

Total oil volume:

approx.46L (12.2gal)

23 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

7. Braking force 8. Adjusting the headlight light axes

7.1 Parking brake force (1) Turn the switch to the high beam side.

1. Must be 20% or more of the vehicle weight. Check (2) Use a tester and adjust as following.
that both the front and rear braking forces. Left-right direction: 0°
Braking force Up-down direction: 0°

GR-800-1 94.7 kN or more

{9663 kgf}
(21307 lbf)
GR-700E-1 95.0 kN or more
{9697 kgf}
(21382 lbf)
TR-600-1 84.2 kN or more
{8596 kgf}
(18954 lbf)
GR-550E-1 84.6 kN or more
{8630 kgf}
(19029 lbf)

7.2 Service brake force

1. Check that the difference in braking force between

the left and right wheels is 8% or less of axle load.
Braking force
GR-800-1 19.4 kN or less
GR-700E-1 {1976 kgf}
(4357 lbf)
TR-600-1 18.0 kN or more
GR-550E-1 {1840 kgf}
(4057 lbf)
Check that the difference in braking force between
the left and right wheels is 6.86kN {700 kgf}.

2. Check the braking force

• FRONT .... 75 kN{7700 kgf}(16980 lbf) or more
• REAR....... 45 kN{4600 kgf}(10140 lbf) or more

24 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

9. Adjusting boom telescoping wire ropes

1. With the boom fully retracted, tighten the nut-A until a tension is placed on the top boom section retraction
wire rope (to keep the boom fully retracted).

[NOTICE]
Loosen the sway stopper bolt
on the bottom of each boom
section until it is out of contact
with the support.

2. Tighten the four nut-B’s equally until the 4th boom section extends by 1-5 mm (0.04-0.2 in) from the 3rd
boom section.

3. Tighten the two nut-C’s equally until the top boom section extends by 1-5 mm (0.04-0.2 in) from the 4th
boom section.

25 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

4. Tighten the nut-A until the top and 4th boom sections are fully retracted.

5. Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control lever and then retract
it fully. Check the boom is fully retracted.
NG OK
END
6. Check the tension of the two 4th boom section extension wire ropes.

7. When the wire rope is slack: 8. When the wire rope is tense:

7.1 Tighten the two nut-B’s by approx. a third turn equally.

7.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping control
NG
lever and then retract it fully. Check the boom is fully retracted.
OK

END

26 WY05-1391E
Y- 5 Y- 5
Adjustment and Checks

8. When the wire rope is tense:

8.1 Tighten nut-A by approx. a third turn.

8.2 Extend the boom by 200-300 mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
NG OK

9. When only the 4th boom section is not fully retracted: END

9.1 Tighten two nut-C’s by approx. a third turn equally.

9.2 Extend the boom by 200-300mm (8-12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
OK

END

27 WY05-1391E
Y- 5 . Y-5.
Adjustment and Checks

10. Adjust the sway stopper bolt for the each boom section.

[NOTICE]
Refer to “Adjusting the bolt on the bottom of each boom section head” in chapter G.

345-803-33000 △
0

345-800-62500 △
1

28 WY05-1391E
Y- 6 Y- 6
Check (Crane Operation)

Y-6 Check (Crane Operation)

1. Outrigger status indicator

Main switch : ON
Shift lever : Not in N position

Operate the outrigger extension/retraction switch.

N Lamp lights.
O/R SW
IWY05-014019

Press all operation push-buttons.

Outriggers do not operate.

Main switch : ON
Shift lever : N position

Operate the outrigger extension/retraction switch.

N Lamp lights.
O/R SW
IWY05-014019

Press all operation push-buttons.

Outriggers operate.

29 WY05-1440E
Y- 6 Y- 6
Check (Crane Operation)

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

2. Make sure that the main winch moves slowly

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

4. Outrigger emergency setting

1. Turn the switch of the upper right panel in the cab

ON.

2. Make sure that the indicator lights up.

3. Check that the extension width can be changed

on AML manually regardless of current extension
width (360-degree same).

30 WY05-1440E
Y- 6 Y- 6
Check (Crane Operation)

6. Boom Telescoping Control Retraction

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

Telescoping possible only for Emergency telescoping

2nd boom section.

11.5m (37.7ft) boom (base)

Boom length: 19.47m (63.9ft)
Turn the AML override key to the
emergency side, and turn PTO swtch to
Switch S7 : OFF “OVER RIDE” side.

With switch S1 pressed, extend the 3rd, 4th, and top

boom sections by approximately 1m(3.3ft) each.
2nd boom section can be moved
to the stroke ends.
(AML function: 2nd boom section) With switch S2 pressed, fully extend the 2nd boom
section.
At this time, check that the error contents are as
follows until the boom length reaches 19.22m (63.0ft).
Switch S7: ON

With switch S2 pressed, retract the 2nd boom section

and reduce the boom length to 18.6m (61.0ft) or less.
Extension is possible of 3rd to top boom At this time, because the No. 2 cylinder is connected
sections. to the tank through the hydraulic valve orifice, the 3rd
(AML function changes to 3rd boom section to top boom sections may also retract.
when switch L7 turns OFF.)

With switch S1 pressed, retract the 3rd to top

boom sections.

31 WY05-1440E
Y- 6 . Y-6.
Check (Crane Operation)

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

• 2300Hz Sounds when either the outrigger extension/retraction or

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

8. Outrigger slide plate adjustment 9. Lower outrigger operation

1. Only the right (left) side sliders can be controlled
from the right (left) side of lower structure.
Both individual jack and all jacks controls must be
controlled from either right and left side.

2. When retracting the slider from the cab side, the

operation must not be affected even if extending
the jack from right or left of lower structure side.
(O/R accelerator switch OFF)

3. When retracting the slider from the right (left) of

lower structure side, the operation must not be
affected even if extending the jack from cab side.
(O/R accelerator switch OFF)

4. When retracting the slider from the right (left) of

lower structure side, the operation must not be
affected even if extending the jack from the left
1. With the outriggers fully retracted, install the slide (right) of lower structure side.
plate and the plate into the outrigger box. (O/R accelerator switch OFF)

2. Adjust the slide plate with the bolt X so that the 5. When retracting the slider from the right (left) of
slide plate is 2mm away from the upper surface of lower structure side with the accelerator switch
outrigger box bottom plate. ON, the operation must not be affected even if
controlling the jack (extend/retract selector switch
3. Tighten the nut Y to secure the bolt X in position.
OFF) from the left (right) of lower structure side
with the O/R accelerator switch ON.
345-803-34500 △
0

32 WY05-1440E
Y- 7 Y- 7
Check (Driving Devices)

Y-7 Check (Driving Devices) Manual shift

1 Exhaust brake (EXB)

1. Turn the EXB switch ON.
Engine speed is idling.
(The pilot lamp illuminates.)

2. Check pattern
[Low position]
[NOTICE]
Check whether or not EXB is operating from the [NOTICE]
engine noise and from the movement of the air
No automatic shift in Low position.
cylinder.

Seq. EXB
1 With the shift lever in the N position. OFF
Move the shift lever from the N
2 ON
position to the D position.
3 Depress the accelerator pedal. OFF
Release your foot from the accelerator
4 ON
pedal.
Use the service brake to reduce speed
5 OFF
to 1 km/h or less.
Release your foot from the service
6 brake pedal. ON

7 Move the shift lever to the N position. OFF

2. Automatic transmission
[NOTICE]
Numbers indicate speedometer readings
(units: km/h)
( ) Indicates lock-up ON and OFF values.

[High position]

33 WY05-1451E
Y- 7 Y- 7
Check (Driving Devices)

3. Steering mode change

2-wheel 4-wheel Crab Rear

Change the steering mode switch to 4-wheel, crab, or rear steering.

IWY05-0141E16

Turn the steering wheel, and check the steering.

Check that the lamp is ON, except when it is straight advancement

of the state of the rear tire.
R/CENTER
IWY05-014016

Match the rear tire in the state of straight advancement.

Check that the lamp is OFF.

R/CENTER
IWY05-014016

Change the steering mode switch to 2-wheel steering.

4. Emergency switches
1. Emergency gear shifting procedure
After turning the emergency transmission switch
to ON, make sure that gear shift lever position “D”,
“2” and ”1” are assigned to the 3rd gear, 2nd gear
and 1st gear respectively for traveling.

2. Emergency accelerator
Turn the emergency accelerator switch to ON, and
make sure the engine revolution rises to
maximum when the accelerator pedal is dipressed
even slightly.

3. Emergency engine stop

Make sure that the engine stops when the
emergency engine stop switch is pulled.

34 WY05-1451E
Y- 7 Y- 7
Check (Driving Devices)

5. Overshift prevention
4. Maintain a speed of 10 km/h. Move the shift lever
[NOTICE] to “1.” Check that transmission does not downshift
Jack up the vehicle and shift to 4WD Hi position. (display: 2).
Perform the operations below and check the shift
position with the combination meter. 5. Gradually decrease speed. Check that
transmission downshifts to 1st gear at 8 km/h
1. Move the shift lever to “D” and increase speed to
(display: 1).
18 km/h or more. Check that transmission shifts to
3rd gear (display: D). Combination meter
Meter speed
display
2. Gradually reduce speed. Maintain a speed of 20 a 18 D
km/h. Move the shift lever to “2.” Check that b 18 2
transmission does not downshift (display: D). c 10 2
d 8 1
3. Gradually reduce speed. Check that transmission
downshifts to 2nd gear when the speed is 18 km/h
(display: 2).

6. Warnings
Warning
Item Identification Check conditions
type
Buzzer does not sound when the following conditions are met.
It sounds at all other times.
Low air pressure Electronic • 2300 Hz 1.Air pressure is 540 kPa {5.5 kgf/cm2} or less. From parking
and parking buzzer • Continuous beep OFF, main switch is turned ON.
2.Parking and brake lock are ON, shift lever is in D position,
and speed is 1 km/h or less.
The mechanism sounds at engine speed of 3030 min-1. There
Electronic • 2300 Hz is not need to check it.
Engine overrun
buzzer • Intermittent beeping
Turns OFF at 2800 min-1.
Attach a step-up gear to the vehicle speed detection gear box.
Accelerating:
• 2300 Hz Speedometer reading 41 km/h: Intermittent sound
Electronic
Speed warning • Continuous and 43 km/h: Continuous sound
buzzer
intermittent sounds Decelerating:
Speedometer reading 40 km/h: Intermittent sound
36 km/h: OFF
Torque converter Electronic • 2300 Hz Buzzer sounds if the parking brake is OFF, and the torque
low pressure buzzer • Continuous beep converter pressure is 1.0 MPa (10.0 kgf/cm2) or less.
Sounds if vehicle speed exceeds 0.6MPH when 2-/4-wheel
Electronic • 2300 Hz
2WD/4WD select switch condition is differ from 2-/4-wheel indication in the meter
buzzer • Continuous beep panel.
Sounds if vehicle speed exceeds 0.6MPH when Hi/Lo selector
Electronic • 2300 Hz
Hi/Lo select switch condition is differ from Hi/Lo indication in the meter
buzzer • Continuous beep panel.
Check is unnecessary because structurally sounds when oil
Torque converter Electronic • 2300 Hz temperature exceeds 110℃ if vehicle speed exceeds 0.6MPH.
oil temperature buzzer • Continuous beep No sound when oil temperature is below 100℃ or vehicle is
stop.

35 WY05-1451E
Y- 7 . Y-7.
Check (Driving Devices)

7. Speed limiter (For Europe) 8. Reverse steering (For Europe)

[NOTICE] 1. Face the boom to the rear of the vehicle.
Check this together with “2. Automatic
transmission”. 2. Check that when the boom is within a range of
Jack up the vehicle and shift to 4WD Hi position. 18° ± 3° from the direct rear of the vehicle, and
Perform the operations below. the reverse steering switch is ON, the lamp
illuminates (boom direct rear area detection is
1. Keep the starter switch to OFF, open the door of ON).
the inside-cab relay box, and connect the on/off
Lamp
connector.

2. Check that T/M is not shifted up to 3rd at Hi range

ON
of “2. Automatic transmission”.
Reverse

3. After checking, remove the connector in the

IWY05-0141E14
condition of starter switch OFF.
After removing the connector, check that T/M is
restored to Hi range of “2. Automatic transmission” 3. Turn the steering wheel and check that the tires
(shift up to 3rd and locked). turn in the opposite direction from when the
vehicle is moving forwards.

4. With the boom outside the rear range (boom

direct rear area detection OFF), turn the reverse
steering switch ON and check that the lamp
flashes and the warning buzzer sounds
intermittently.

345-803-34000 △
1

36 WY05-1451E
Y- 8 . Y-8.
Oil and Grease Table

Y-8 Oil and Grease Table

Item Quantity :L (gaL) Remarks

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

(*1): Applicable to a machine equipped with an air conditioner

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

(*2): Canada Specification

345-803-31000 △
0

37 WY01-1160E
Y- 9 . Y-9.
Mass Table

Y-9 Mass Table

Spec. No.
Part Name GR-700E-1-00211 GR-700E-1-00212
2M2D 2M2D
(Europe) (General Export)
Boom assy (including telescoping
11470kg (25290lbf)
cylinder, jib-1 and jib-2)
Telescoping cylinder (No.1) 790kg (1740lbf)
Boom Telescoping cylinder (No.2) 880kg (1940lbf)

Jib-1 560kg (1230lbf)

Jib-2 280kg (620lbf)

Elevating cylinder 950kg (2090lbf)

Swing table assy
(excluding boom and elevating cylinder, swing 5150kg (11360lbf)
bearing, counter weight)
Swing bearing 630kg (1390lbf)

Swing speed reducer and swing motor 210kg (460lbf)

Rotary joint 180kg (400lbf)

Main winch assy
640kg (1410lbf)
(including winch motor)
Winch Auxiliary winch assy
640kg (1410lbf)
(including winch motor)
Winch motor (main/auxiliary) 150kg (330lbf)

Weight Counterweight 1 7900kg (17420lbf)

Outrigger inner case assy
(including jack cylinder and 800kg (1760lbf)
extension cylinder)
Outrigger
Jack cylinder 170kg (370lbf)

Extension cylinder 60kg (130lbf)

Front axle 1570kg (3460lbf)

Rear axle 1460kg (3220lbf)

Engine 630kg (1390lbf)

Torque converter 230kg (510lbf)

Transmission 450kg (990lbf)

Wheel assy (tires: 29.5×25-22PR) 790kg (1740lbf)

38 WY01-1180E
Y- 1 0 . Y-10.
Specifications

Y-10 Specifications Idling speed: 629±23min-1

1. Engine speed Max. speed: 2683±38min-1
3.2 Pump displacement
• Engine model : MITSUBISHI 6M60-TLA3B
• T/C model : RF80C-76F4 52.2 + 31.1cm3/rev (3.18 + 1.9in3/rev)

1.1 Idling speed 4. Charging pump

670±25min-1 (PTO: OFF) (for torque converter)

1.2 MAX. speed (unload) 4.1 Pump speed

Engine speed
2860±40min-1 (PTO: OFF) (Pump speed= )
1.066
2150 min-1 (PTO: ON)
Idling speed: 629±23min-1
1.3 Stall speed
Max. speed: 2683±38min-1
Approx. 2160min-1 (measured value for reference)
4.2 Pump displacement
Measuring conditions:
PTO switch: OFF 33.2cm3/rev (2.03in3/rev)
Gearshift position: 2nd
Drive mode select switch: H/4WD 5. Emergency steering pump
Service brake: Fully applied (option)
Accelerator pedal: Fully operation
5.1 Pump speed
2. Hydraulic pump (for crane)
Pump speed (min-1)
(Double Variable Displacement
Transmission output shaft revolution
Pump) =
1.439
2.1 Pump speed
5.2 Pump displacement
Engine speed
(Pump speed= )
0.918 14.56cm3/rev (0.89in3/rev)

Idling speed: 730±27min-1 6. Winch motor

Max. speed: 2342 min-1 Displacement: 533cm3/rev (32.5in3/rev)

2.2 Pump displacement

7. Swing driving unit
3 3
82 + 82cm /rev (5 + 5in /rev)
7.1 Swing motor
3. Hydraulic pump (for steering) Displacement: 169.4cm3/rev (10.33in3/rev)
(Double Gear Pump)
7.2 Swing speed reducer
3.1 Pump speed
Reduction ratio: 33.68
Engine speed
(Pump speed= )
1.066

39 WY01-1201E
Y- 1 1 . Y-11.
Boom Connecting Pin and Thread Size Table

Y-11 Boom Connecting Pin and Thread Size Table

(mm)
GR-450-1- , GT-250C-1- ,
Applicable spec. No.
GR-500-1- GT-350C-1-
Part Name Diameter Thread size Diameter Thread size

Rod end pin Φ100 M30×3.5 Φ100 M30×3.5

Elevating cylinder
Base pin Φ90 M30×3.5 Φ90 M30×3.5
M16×2.0 M18×2.5
Boom base pin Φ90 Φ100
(Qty:4) (Qty:4)

(mm)
GR-550E-1- , GT-550E-1- ,
GR-600-1- , GT-600-1- ,
Applicable spec. No GR-700E-1- , GT-700E-1- ,
GR-800-1- , GT-800-1- ,
GT-900-1-
Part Name Diameter Thread size

Rod end pin Φ120 M33×3.5

Elevating cylinder
Base pin Φ110 M30×3.5
M18×2.5
Boom base pin Φ100
(Qty:4)

(mm)
TR-300-4- ,
Applicable spec. No TL-300E-3-
GR-300E-1- ,
Part Name Diameter Thread size Diameter Thread size

Rod end pin Φ100 M30×3.5 Φ100 M30×3.5

Elevating cylinder
Base pin Φ110 M30×3.5 Φ100 M30×3.5

Boom base pin Φ100 M30×3.5 Φ100 M30×3.5

(mm)

Applicable spec. No TT-300-1- TR-150-4-

Part Name Diameter Thread size Diameter Thread size

Rod end pin Φ90 M30×3.5 Φ60 -

Elevating cylinder
Base pin Φ90 M30×3.5 Φ70 M24×3.0

Boom base pin Φ90 M30×3.5 Φ60 M10×1.5

40 WY01-0627E
 Z
System Diagrams

Contents

Z-1 Hydraulic Circuit .............................. 1 Z-8 Location of Hydraulic Parts

(Lower)....................................17
1. For Europe................................................. 1
1. Carrier ..................................................... 17
2. For general export ..................................... 3 1.1 Front..........................................................18
1.2 Center .......................................................19
1.3 Rear ..........................................................20
Z-2 Torque Converter Circuit ................ 5

Z-9 Location of Air Parts......................21

Z-3 Brake Circuit (Pneumatic Circuit)... 6
1. Cab and swing table ................................ 21

Z-4 Electric Circuit (AML, Crane) .......... 7 2. Carrier ..................................................... 22

Z-5 Electric Circuit Z-10 Location of Electric Parts

(MDT, Carrier/Upper) ............. 9 (Inside cab).............................24

Z-6 Electric Circuit Z-11 Location of Electric Parts

(MDT, Carrier/Lower) ............. 11 (Swing Table, Boom) .............25

Z-7 Location of Hydraulic Parts Z-12 Location of Electric Parts

(Upper).................................... 13 (Relay Assembly / Upper) .....26

1. Cab and swing table ................................ 13

Z-13 Location of Air Parts (AML)...........27
2. Boom ..................................................... 16

Z-14 Location of Electric Parts

(Lower)....................................28

Z
i
Z-15 Location of Electric Parts Z-27 Anemometer System .....................44
(Box Assembly / Lower)........ 29
1. Structure .................................................. 44

Z-16 Harness (Connector No. Table) .... 30 2. Harness ................................................... 45

3. Cord reel.................................................. 46
Z-17 Harness (Inside Cab) ..................... 33

Z-18 Harness (Swing Table, Left) .......... 34

Z-19 Harness (Swing Table Right) ........ 35

Z-20 Harness (Boom) ............................. 36

Z-21 Harness (AML, Upper) ................... 37

Z-22 Harness (Overwind) ....................... 38

Z-23 Harness (Lower, Main)................... 39

Z-24 Harness (Lower, Sub) .................... 40

Z-25 Harness (Lower,

Electronic Governor)............. 41

Z-26 Outdoor Air (Minus 25°C or less)

System.................................... 42

1. Structure .................................................. 42

2. Harness ................................................... 43

ii
Z-1 Z-1
Hydraulic Circuit

Z-1 Hydraulic Circuit Applicable serial No. △

1 ：545520 - -

1. For Europe

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

1 WZ01-1201E
Z-1 Z-1 Z-1
Hydraulic Circuit

For Europe [NOTICE]

When the optional air conditioner is not installed, two points "B" are directly joined.

344-019-70000 △
1

2 WZ01-1201E 2
Z-1 Z-1
Hydraulic Circuit

2. For general export

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

3 WZ01-1201E
Z-1. Z-1. Z-1.
Hydraulic Circuit
[NOTICE]
When the optional emergency steering is not installed, two points "A" are directly joined
For general export and three portions "*1" are plugged.
When the optional air conditioner is not installed, two points "B" are directly joined.

344-019-70000 △
1

4 WZ01-1201E 4
Z-2. Z-2. Z-2.
Torque Converter Circuit

Z-2 Torque Converter Circuit

Torque converter case Transmission case

G3/8 G3/8 Lubrication relief valve

G1 G1
Oil cooler
Hydraulic valve (2nd) Hydraulic valve (1st)
M16×1.5

Thermo sender
(T/C oil temp.)

F2 F1
SL44 SL43

G3/8 G3/8 Reverse F3

SL42 SL45

Lock up P.T.O G1
SL49 SL41 Hydraulic valve (3rd)
Line filter 20μ

Pressure sensor
Accumulator M14×1.5
Accumulator
Cold oil relief valve

G1
Clutch pressure
main relief valve

OUT PUT

Torque converter INPUT

F2 R

G3/4
Charging pump F3 F1
G1

G1
Rear Front
Low High

G1-1/4 Air cylinder Air cylinder

Drain (2/4 wheel drive shift) (High/Low shift)
G1-1/4 G1-1/4

Rc1/4 Rc1/4 347-411-60000 1

IWZ05-0331E01

5 WZ05-0331E 5
Z-3. Z-3. Z-3.
Brake Circuit (Pneumatic Circuit)

Z-3 Brake Circuit (Pneumatic Circuit)

347-411-50000 △
0

6 WZ06-0410E 6
Z-4 Z-4 Z-4
Electric Circuit (AML, Crane) Applicable serial No. △
1 ：546049 - -

Z-4 Electric Circuit (AML, Crane)

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

7 WZ03-3291E 7
Z-4. Z-4. Z-4.
Electric Circuit (AML, Crane) Applicable serial No. 1 :546049- -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Jib lock pin retracting
detection switch
Working lamp
(boom)
〔Notice〕 (1) This program includes options ; is based on the following conditions : (2) Wire specification codes are based on JIS D607. (4) The wiring numbers 900∼999 show 12-voltage system, the other show 24-voltage system. (6) Applicable model list Mark (-) is not applied. Mark (○) is applied. Mark (△) is option
2 2
(contact closes at
pin retracting)
70W
1.Crane : traveling condition (3) Wire gauges of inside cab are CAVS 0.5mm (0.0008in ) or (5) Following sign indicates the connection of the same number mutually.
2 2
2.PTO switch : OFF AVS 0.85mm - (0.0014in -). Receiving side of power supply : Supply side :
Outside cab Inside cab

CN853
Jib stowed detection
3.Boom : fully retracted, over-the-front Wire gauges of swing table and boom are AVS. Receiving side of signal and load : Supply side :
A proximity switch
(contact closes at stowing)
4.Hook blocks : overwound
2 2
(Size not shown are 0.5mm (0.0008in ) ). (It becomes it for the negative-type logic circuit contrary to the electric current direction of the load.)
TR-600-4 TR-800-4 GR-700E-1 GR-700E-1 GR-550E-1 GR-550E-1
North North 00211 00212 00211 00212
A

〔174〕1.25YR
〔 0〕1.25B
5.Starter switch : OFF America America Europe General Europe General

Output
Boom, top

R
Export Export

B
+
CN888 Boom, base

CN573
3 1 2
2 CN887 6.Control levers : neutral positions

Br
Rope run-out release - - △ - △ -

B
L
〔 35〕0.85Br 0.85Br〔 35〕 〔 35〕Br

CN572
1 5
1 2 3 GL〔785〕 〔785〕0.85GL 0.85GL〔785〕 〔785〕GL Rope run-out
GR〔781〕
8
4
〔781〕0.85GR 0.85GR〔781〕
7
6
〔781〕GR Main and Aux. rope run-out detection - - △ - △ -
1.25YR〔174〕
1.25Lg〔250〕
3
〔174〕1.25YR
〔250〕1.25Lg
1.25YR〔174〕
1.25Lg〔250〕
4
〔174〕1.25YR
〔250〕1.25Lg
Main and Aux. hoisting down detection - - △ - △ -
5 12
GW〔367〕
7
〔367〕0.85GW 0.85GW〔367〕
11
〔367〕GW External alarm（Buzzer 5） - - ○ - ○ -
1.25B〔 0〕 〔 0〕1.25B 1.25B〔 0〕 〔 0〕1.25B
3rd/top boom full ret. detection switch
6
0.85G〔304〕
9
2
〔304〕G Touch-type controller △ △ - - - -
0.85LgY〔301〕 〔301〕LgY
Overwind/two-blocking detection
(contact closes at full ret.)
0.75B 0.85R〔305〕
1
〔305〕R Touch-type SOL（Main/Aux.） △ △ - - - -
CN859 CN858 3 Drum indicator
B B
switch (boom)
(for right installation)
0.75W
2
W W 〔304〕0.85G
2 8 Left lever Visible type indicator - - △ △ △ △
0.85R 1.25LgB 1.25LgB Y Y 〔301〕0.85LgY
(contact opens at overwinding/ 2 1 1 10
two-blocking) 0.85B
1
1.25YB 1.25B
For separated transport of CN531 Main/Aux. winch drum rotation
Cord reel 〔324〕LW △ △ △ △ △ △
Connecting when boom and swing table 1 Boom length detector Boom angle detector detection proximity switch

〔0〕1.25B
(Boom length detector) Swing horn switch 〔470〕LgY
For left installation the boom operating 2
1.25Y
2
1.25YB
CN553
CN576
B G G
CN993
G
Reverse steering - - ○ - ○ -
1.25Y 2nd boom full retraction R CN506
1 1 1
detection switch B
2
〔 0〕1.25B
3rd/top boom
extending switch 1
〔 0〕B W
3
W W
3
W Indicator assy (outdoor air temperature indicator) - - △ - △ -
0.85R 0.85LgB 0.85LgB (contact opens at full ret.) 1 〔277〕LG R R R R
0.85B 1.25B 1.25B Connecting when the jib oerating
W
3
〔305〕0.85R Touch-type aux. winch drum
indicator solenoid (ISO array)
(ISO array) 2
G
4
B B
4
B Telescoping mode select - ○ - - - -
6 6
CN969 Shield Shield Shield
Connecting when Telescoping system select
(option)
R CN934
〔344〕RB
0.3A 〔470〕LgY
Shield
5 5 Counterweight removable type - ○ - - - -
the 2nd jib poerating Swing angle detector 2 Swing angle detector 1 2 2
Connecting when the single top operating Protection of NO.2 cylinder
1.25Y (option) retraction while mode Ⅱ
B 〔450〕BY (Pot1) (Pot2)
For separated transport of Counterweight fitted type ○ - ○ ○ ○ ○
0.85B Oil cooler Jib lock pin retracing Jib lock pin extending CN935 boom and swing table
select solenoid valve
0.85R 1.25Y solenoid valve Jib stowing Jib mounting solenoid valve solenoid valve (Energized:top cylinder select) R 〔311〕GR
Control lever stand position 2

〔250〕1.25Lg

〔250〕1.25Lg
(Energized: solenoid valve solenoid valve (Energized:pin (Energized:pin B 〔250〕1.25Lg
SL.238 detection switch 1 CN580

〔252〕LgW
cooler operating) (Energized:stowing)(Energized:mounting) retracting (free)) extending (lock))

〔301〕LgY
〔253〕LgB
Connecting when the single top operating W B R
(contact opens at stowing)

〔304〕G
C
Overwind detection switch (jib and single top) SL.281 SL.223 SL.222 SL.193 SL.192 3 4

〔 0〕B

〔 0〕B
G W
(contact opens at overwinding) CN529 3
W G
1
R B
6
Jib mounting/stowing operation box 1 2
3 1 4 2 3 1 4 2 Shield Shield
5 Relay
Right lever 2 CN665 AML connector 1
AML-LⅡ B/C

R36

R2
B

CN281

CN193

CN192
CN223

CN222

CN238
Jib mounting/stowing
operationality indicator lamp〔785〕GL 1 2 1 2 1 2 1 2 1 2 1 2
Connector
B
CN530
〔343〕GY R R W
CN581
R
1 DET1GND Make R1,2,4,8,13,22,23,26,
2
〔311〕GR Pressure sender
Output
B
1
B W
2 DET1SRC contact R29,33,36,47
1 - 2 3 ANAINA Boom length input 1pole

〔786〕LgR
CN999

〔787〕LgY
(main pressure)

〔321〕LW

〔292〕RG
〔792〕BG

〔791〕BR
〔 0〕B Touch-type main winch drum Overwind relay Boom full ret. detection relay R R G
3 3 ANAINB Boom angle input
CN968 + 4
Break
〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B
indicator solenoid (ISO array) (contact opens (contact closes at full ret.) W
(option) R CN932 〔342〕R
0.3A
〔470〕LgY at overwinding) AML Shield
5
6
ANAINC Swing angle 1 input
DET1SLD contact R9,11,53
CN488 B 〔440〕BR CN892 B
7 DET2GND
B
3
〔785〕GL CN933 G〔 22〕 〔 22〕G
6
R
8 DET2SRC C
contact R46
R 〔787〕LgY G〔 22〕 〔 22〕G G
1 CN936 5 9 ANAIND Swing angle 2 input
〔786〕LgR R 〔344〕RB 1.25Lg〔250〕 〔250〕Lg W
2 4 10 ANAINE Main pressure input
W B 〔450〕BY 1.25Lg〔250〕 〔250〕Lg
Jib mounting/stowing 3 11 ANAINF Input spare
Shield

D
GR〔371〕 〔371〕GR
2poles KR27
D
switch CN937 2 12 DET2SLD
CN995 Touch-type aux. winch drum 3rd/top boom CN507 LgB〔253〕
indicator solenoid (TDN array) extending switch
1 13 Di1 Overwind (two-blocking) detection
B 〔781〕GR 〔 0〕B R〔305〕
3 (option) (TDN array) 1 1 14 Di2 2nd boom full retraction detection
R 〔791〕BR 〔277〕LG LgW〔252〕
1 2 2 15 Di3 3rd/top boom full retraction detection
〔792〕BG
2
Swing table,right BL〔378〕
16 Di4 Swing free input 4poles ＊
W CN891 G〔22〕
Jib lock pin switch 17 MB
RG〔157〕 〔157〕RG G〔22〕
1 18 MB
BrW〔279〕 〔279〕BrW Lg〔250〕
YR〔259〕
BrY〔295〕
2
3
〔259〕YR
〔295〕BrY
LgB〔253〕 〔253〕LgB
6
R〔305〕 〔305〕R
Lg〔250〕
19
20
RB
RB Diode
AML (Load moment indicator) 4 5 21 TC
external indicator lamp 5
〔352〕LW LgW〔252〕 〔252〕LgW
4
GR〔371〕
22 ACC Swing stop cancel input
For 1A ＊
LgR〔165〕 〔165〕LgR BL〔378〕 〔378〕BL
(red)20W
6 3
WY〔384〕 〔384〕WY WY〔384〕
23 NC For 3A ＊
CN829 2
WR〔385〕 〔385〕WR
24 Di5 Overwind cutout (anti-twoblock) disable
〔0〕B 〔 0〕B CN889 WR〔385〕
1
YG〔349〕 〔349〕YG
25 Di6 AML override
Resistance
〔412〕GW GW〔412〕 〔412〕GW YG〔349〕
CN828 3 14
GW〔367〕 〔367〕GW
26 Di7 Elevating slow stop cancel input
〔0〕B 〔411〕GL GL〔411〕 〔411〕GL GW〔367〕
4 13
BW〔333〕 〔333〕BW
27 Di8 Jib stowed detection
BW〔333〕 〔333〕BW BW〔333〕
(yellow)20W 8 12 28 Di9 Over-front detection ＊
E E
〔275〕LgY LgW〔275〕 〔275〕LgW LgY〔275〕
6 11 29 Di10 input spare
〔250〕1.25Lg B〔011〕 〔0〕B B〔0〕
9 10 GND
Condenser
30

〔011〕1.25B
LgY〔470〕 〔470〕LgY B〔011〕 〔0〕B B〔0〕
17 9 31 GND
RY〔451〕 〔451〕RY B
10 8 32 MOGND/DET3GND
CN521 LY〔130〕
12
〔130〕LY
7
R
33 MOSRC/DET3SRC C2
Over-front detection B 〔333〕BW O〔441〕 〔441〕O W
proximity switch Output 1 13 CN886 34 MOINP/ANAING (Elevating cylinder raising pressure input)
L 〔 0〕B 10W GL〔785〕 〔785〕GL AML W
(contact closes at - 2 1 35 MOINN/ANAINH (Elevating cylinder lowering pressure input)
Br 〔156〕1.25RY GR〔781〕 〔781〕GR Shield
over-front) + 3 2 36 MOSLDSLD
1.25YR〔174〕 〔174〕1.25YR
Reverse steering 5 37 NC
CN518 1.25RY〔156〕 〔156〕1.25RY
7 38 NC
Over-rear detection B 〔165〕LgR LW〔321〕 〔321〕LW CN584 CN991
Output 1 1 11 39 SIF1GND 2A
proximity switch L 〔 0〕B BrR〔294〕 〔294〕BrR W W W W
- 2 2 14 Front controll panel Output 1 2 40 SIF1SRC
(contact closes at Br 〔157〕RG Y〔296〕 〔296〕Y B B B B
over-rear) + 3 3 15 Winch selector indicator lamp - 2 3 41 SIF1TXD+
YG〔298〕 〔298〕YG CN967 R R R R
16 CN966 + 3 1 42 SIF1TXD-
1.25B〔 0〕 〔  0〕1.25B 〔250〕1.25Lg 〔319〕YL Shield Shield
C/W removable type 18 4 43 SIF1RXD+
CN994 Pressure sender
For separated transport of 44 SIF1RXD-
Counterweight equipped B G 〔294〕BrR CN890 (elevating cyllinder boom raising)

F F
Output 1 1 boom and swing table 45 SIF1SLD
detection proximity switch L 〔 0〕B RG〔292〕 〔292〕RG
(contact closes when - 2 2 4 CN965
Br 〔156〕1.25RY
C/W equipped) + 3 3 3
6 〔318〕LY CN585 CN992
2 Winch selector switch 3
C/W fitted type (M・S⇔M select) 5 〔 0〕B W W W W
1 For emergency jib operation 4 Output 1 2
(connect when jib setting in AML failure) B B B B

〔156〕1.25RY

〔156〕1.25RY
Thermo switch (85℃/185°F) - 2 3
CN60 (contact closes at 85℃/185°F) CN918 CN919 R R R R
+ 3 1

〔470〕LgY

〔470〕LgY

〔470〕LgY

〔470〕LgY
〔412〕GW
Overwind cutout (anti-twoblock)

〔321〕LW
CN505

〔298〕YG

〔402〕YR

〔411〕GL
〔  0〕B 〔250〕1.25Lg Shield Shield

〔401〕O
SL.60 1 CN556 1 1 disable switch 4
SOL 〔130〕LY 〔296〕Y 〔781〕GR 6 〔384〕WY Pressure sender
Air horn 2 (contact closes at 3 For separated transport of
overwinding) 5
4
〔 0〕B (elevating cyllinder boom lowering)
boom and swing table
〔 0〕B
For air bleeding of suspension lock cylinder
CN949 3 1 4 2 3 1 4 2 3 1 4 2 (not connect with PTO-ON at air bleeding)
CN555

R29

R23

R22
B 〔 0〕B 〔298〕YG CN938 CN484
Buzzer 5(external alarm) 1 1
P 〔259〕YR 〔22 〕G 2 〔 35〕Br
2 2 1 2
〔 0〕B R R R 〔22A〕G 5 〔 0〕B
5
Swing brake switch 4 〔 0〕B
Rope run-out (option) Thermo switch (50℃/122°F) 4
Oil cooler relay (contact closes 〔352〕LW
CN595 (contact closes at 50℃/122°F) AML lamp assy relay 3
3
For reducing the main pressure at braking)
CN894

G G
1  295 (connect with PTO-OFF) 1 〔250〕1.25Lg
1
Main rope run-out R G 〔295〕BrY 〔295A〕BrY 〔295〕BrY CN583 CN820
2 2 2
detection switch (option) B 〔  0〕B 〔  0A〕B 〔  0〕B Pressure sender 〔156〕1.25RY
(contact opens when 1 1 1 CN852 (air pressure) - 1 1 1
W
3 3 1 0 Working lamp 〔174〕1.25YR
Output 2
〔228〕W
2 2
〔250〕1.25Lg CN486
rope run-out) For separated transport (RH,Swing table) 〔 0〕B 〔227〕R 〔 35〕Br
Ｃ/Ｗ ⇔
Swing table 70W + 3
Swing stop
2
5
4 4
〔 0〕B
1 1
CN596 CN821 cancel switch 1 〔 0〕B
(contact closes
3 3
Aux. rope run-out R G 〔279〕BrW 〔336〕P 〔371〕GR
2 2 Connect CN821 to valve when AML is failure AML vent 2 at release)
3
5 5
detection switch (option) B 〔  0〕B
(contact opens when 1 1 solenoid valve 1 〔 0〕B 4
2
〔250〕1.25Lg
2
W
rope run-out) 3 3 Swing brake
release Top cylinder selector
Swing free/lock Swing relief Swing proportional solenoid valve solenoid valve CN491

〔385〕WR

〔314〕YW
solenoid valve proportional control valve (energized : AML vent (energized : Elevating slow stop 2 〔 35〕Br
Drum indicator (option) cancel switch 4 4

〔 0〕B

〔 0〕B
(energized : free) control valve (left) (right) brake release) solenoid valve top cylinder select) 5 〔 0〕B
CN591 SL.161 SL.162 SL.121 SL.120 SL.160 SL.100 SL.230 (contact closes 1 1
1 〔 0〕B
at release) 3 3
A
Main winch drum rotation B 〔441〕O
Output 1 1 3 〔347〕YL
detection proximity L 〔 0〕B 5 5
switch (option) - 2 2 3 1 4 2 4 〔250〕1.25Lg
CN121

CN120

Br 〔470〕LgY 2 2

H H
1 2 1 2

R8
+ 3 3
〔271〕RW
〔281〕YW

〔270〕RB
〔280〕YB

〔250〕1.25Lg
CN592 R
CN161

CN160

CN100
CN162

CN230

Aux. winch drum rotation B 〔451〕RY

〔352〕LW

〔349〕YG
Output 1 1 1 2 1 2 1 2 1 2 1 2

〔347〕YL
CN818

〔353〕O
detection proximity L 〔 0〕B Swing talbe, left

〔 0〕B

〔 0〕B

〔 0〕B
switch (option) - 2 2 CN893 AML emergency switch relay W
〔348〕BW

〔256〕YG

H 1
〔303〕RL

Br
〔290〕LgR

〔470〕LgY
〔291〕LgY

3 (contact closes at AML override)

〔353〕O

+ 3 Buzzer 3 B 〔 0〕B
〔 02〕B
〔 0〕B

〔 0〕B

〔 0〕B
〔0〕1.25B

8 (AML alarm)
2
Boom lowering Boom raising R 〔259〕YR
10 L 3

R33
proportional

R9
proportional 3 1 4 2 3 1 4 2
control valve control valve 11 Stabilizing power 3A
SL.125 13 CN817
SL.124 Buzzer 4 (Overwind R 〔257〕YO supply circuit
14 (two-blockomg)
〔746〕RY B 〔 0〕B R R
6 alarm)
O〔353〕 〔353〕O
CN124
CN125

5 AML
1 2 1 2 YG〔256〕 〔256〕YG Swing brake relay Elevating slow stop CN896
1 (contact opens cancel relay
WR〔262〕 〔262〕WR
7 7
〔272〕RG
〔282〕YG
〔273〕RL

at braking) (contact closes

〔283〕YL

WY〔268〕 〔268〕WY
9 at relese) 9
BW〔348〕 〔348〕BW
SL.102 2 10
〔 01〕B RL〔303〕 〔303〕RL GR〔781〕 〔781〕GR

I I
Remote control pressure vent solenoid valve 1 12 6
(energized : remote control pressure on-load) 〔343〕GY GY〔343〕 〔343〕GY GW〔793〕 〔793〕GW
2 4 1
LgW〔337〕
3
〔337〕LgW RY〔746〕 〔746〕RY
3 CN666 AML connector 2
CN102 YG〔256〕 〔256〕YG YG〔256〕 Auto. stop 1 (AML vent) RLY1 3A
8 1
YR〔259〕 〔259〕YR Output spare RLY2
5 2 3A
Boom telescoping/aux. hoist control select YW〔260〕 〔260〕YW GR〔781〕 Jib setting RLY3
Swing talbe, left 4 3
CN143 CN894 YO〔257〕 〔257〕YO YR〔259〕 Buzzer output (AML alarm) RLY4
SL.143 2 4 3A
Boom telescoping/aux. hoist control 〔 03〕B RB〔270〕 〔270〕RB RB〔270〕 〔270〕RB YW〔260〕 Telesclping control output RLY5
1 10 18 5
selector solenoid valve 〔337〕LgW YB〔280〕 〔280〕YB YB〔280〕 〔280〕YB GW〔793〕 Telescoping system select RLY6
2 11 17 6
Buzzer output (Over wind alarm) 3A
(energized : telescoping operation) RW〔271〕 〔271〕RW RW〔271〕 〔271〕RW YO〔257〕 RLY7
12 16 7
CN144 YW〔281〕 〔281〕YW YW〔281〕 〔281〕YW RY〔746〕 Output spare RLY8
SL.144 13 15 8
〔 04〕B RG〔272〕 〔272〕RG RG〔272〕 〔272〕RG W〔261〕
Boom telescoping/aux. hoist control 1 14 14 9 Di11 Main winch hoisting up detection 3A
selector solenoid valve 〔337〕LgW YG〔282〕 〔282〕YG YG〔282〕 〔282〕YG WR〔262〕
2 15 13 10 Di12 Main winch hoisting down detection
(energized : telescoping operation) RL〔273〕 〔273〕RL RL〔273〕 〔273〕RL V〔267〕
16 12 11 Di13 Aux. winch hoisting up detection
YL〔283〕 〔283〕YL YL〔283〕 〔283〕YL WY〔268〕
17 11 12 Di14 Aux. winch hoisting down detection 2A
WG〔263〕 〔263〕WG RB〔270〕
3 13 (CNTL1P)Right swing proportional control valve output Current
1.25B〔 0〕 〔 0〕1.25B AML CN897 YB〔280〕 Supply
20 14 (CNTL1N)Right swing proportional control valve COM
RW〔271〕

J J
W〔261〕 〔261〕W W〔261〕 〔261〕W amplifier
1 5 15 (CNTL2P)Left swing proportional control valve output
V〔267〕 〔267〕V V〔267〕 〔267〕V YW〔281〕
2 3 16 (CNTL2N)Left swing proportional control valve COM
WB〔265〕 〔265〕WB WB〔265〕 〔265〕WB WG〔263〕
4 11 17 Di15 Boom extention
WL〔266〕 〔266〕WL WL〔266〕 〔266〕WL LY〔318〕
5 10 18 Di16 Aux. winch employed
GL〔286〕 〔286〕GL GL〔286〕 〔286〕GL WB〔265〕
6 9 19 Di17 Boom raising
AML override switch GR〔287〕 〔287〕GR GR〔287〕 〔287〕GR WL〔266〕
7 8 20 Di18 Boom lowering
(contact closes at overriding) LgR〔290〕 〔290〕LgR WR〔262〕 〔262〕WR GL〔286〕
18 4 21 Di19 Swing right
CN558 LgY〔291〕 〔291〕LgY WY〔268〕 〔268〕WY GR〔287〕
19 2 22 Di20 Swing left 2A
〔 22〕G G〔 22〕 〔 22〕G WG〔263〕 〔263〕WG RG〔272〕
2 8 1 23 (CNTL3P)Boom raising proportional control valve output Current
KEY

〔336〕P P〔336〕 〔336〕P LY〔318〕 〔318〕LY YG〔282〕 Supply

1 9 6 24 (CNTL3N)Boom raising proportional control valve COM
Right side control panel RL〔273〕 amplifier
7 25 (CNTL4P)Boom lowering proportional control valve output
YL〔283〕
12 26 (CNTL4N)Boom lowering proportional control valve COM
Rope run-out (option) CN574 27 (CNTLSLD)
CN546 2 〔 35〕Br
Main winch hoisting down 2 AML 28 SIF2GND 2A
G 〔 0〕B 5 〔 0〕B CN899
detection switch (option) 1 1 Oil cooler switch 5 29 SIF2SRC
〔262〕WR 4 〔 0〕B W〔196〕 〔196〕W W〔196〕
(contact opens at hoisting down) 2 2 (contact closes 4 1 30 SIF2TXD+
3 〔321〕LW G〔197〕 〔197〕G G〔197〕
at ON position) 3 2 31 SIF2TXD-

K K
CN547 1 〔156〕1.25RY R〔198〕 〔198〕R R〔198〕
1 5 32 SIF2RXD+
Aux. winch hoisting down G 〔 0〕B B〔199〕 〔199〕B B〔199〕
1 1 6 33 SIF2RXD-
detection switch (option) 〔268〕WY Shield
(contact opens at hoisting down) 2 2 3 34 SIF2SLD
CN503 4
CN534 1 〔 35〕Br CN667 AML connector 3
Boom extending 2 AML CN898
〔 0〕B 3rd/top boom emergency 5 〔 0〕B
detection switch 1 telescoping switch 6 5 1 TR1 External indicator(∼90%)
〔263〕WG 2 〔250〕1.25Lg O〔401〕 〔401〕O O〔401〕
(contact opens at extending) 2 (contact closes at 3 4 2 TR2 External indicator(90∼100%)
3 〔332〕V YR〔402〕 〔402〕YR YR〔402〕
emergency telescoping) 4 3 3 TR3 External indicator(100%∼)
CN532 4 〔 0〕B 〔178〕Sb Sb〔178〕
Main winch hoisting up 5 2 4 TR4 Output spare
〔 0〕B 〔794〕YB YB〔794〕
detection switch 1 1 5 TR5 Output spare
〔261〕W CN504 YL〔319〕 〔319〕YL YL〔319〕
(contact opens at hoisting up) 2 12 6 TR6 Aux. winch employed
1 〔 35〕Br
2nd boom emergency 2 11 7 TR7 Output spare
CN533 5 〔 0〕B
Aux. winch hoisting up telescoping switch 6 10 8 TR8 Output spare
〔 0〕B (contact closes at 2 〔250〕1.25Lg
detection switch 1 3 9 9 NC
〔267〕V emergency telescoping) 3 〔379〕Y BW〔748〕
(contact opens at hoisting up) 2 4 8 10 Di25 Emergency outrigger state control
4 〔 0〕B LB〔289〕
5 7 11 Di26 Rope run-out release
CN536 LW〔276〕

L L
Boom raising 6 12 Di27 Telescoping system select
〔 0〕B LG〔277〕
detection switch 1 Front control panel 13 Di28 Top boom extension
〔265〕WB AML CN964
(contact opens at raising) 2 14 NC
CN487 BW〔748〕 〔748〕BW
7 15 NC 2A
CN537 Swing free/lock 2 〔 35〕Br LB〔289〕 〔289〕LB LgR〔290〕
Boom lowering selector switch
2 6 16 (CNTL5P)Swing relief proportional control valve output Current
〔 0〕B 5 〔 0〕B LW〔276〕 〔276〕LW LgY〔291〕 supply
detection switch 1 (contact closes at 5 5 17 (CNTL5N)Swing relief proportional control valve COM
〔266〕WL 4 〔 0〕B LG〔277〕 〔277〕LG amplifier
(contact opens at lowering) 2 Boom telescoping/aux. swing free) 4 4 18 (CNTL6P)
3 〔348〕BW LgR〔290〕 〔290〕LgR
hoist control select 3 3 19 (CNTL6N)
CN540 1 〔250〕1.25Lg LgY〔291〕 〔291〕LgY
Swing right
1 18 20 CNTLSLD
〔 0〕B WL〔288〕 〔288〕WL WL〔288〕
detection switch 1 SWF 15 21 Di21 Jib state switch
〔286〕GL CN485 BrR〔294〕 〔294〕BrR BrR〔294〕
(contact opens at swing right) 2 14 22 Di22 Counterweight equipped detection
〔250〕1.25Lg BrY〔295〕 〔295〕BrY BrY〔295〕
Boom telescoping/aux. hoist 5 13 23 Di23 Main rope run-out detection
CN541 〔337〕LgW BrW〔279〕 〔279〕BrW BrW〔279〕
control selector switch 7 12 24 Di24 Aux. rope run-out detection
Swing left 〔 0〕B 〔729〕LgR
detection switch 1 1 20
〔287〕GR (Up:telescoping)
(contact opens at swing left) 2 6 19
8 17
〔0〕1.25B

2 16

M Indicator lamp
3
4
11
10
9
〔289〕LB
CN939

3
6
Rope run-out
release switch
M
〔 35〕Br 〔 0〕B 5 (contact closes
9 8 4
〔 0〕B at release)
10 SWF 2 Rope run-out
CN922 Jib removed indicator lamp 1 (option)
Indicator assy {outdoor air temperature indicator} (option) 〔337〕LgW
(when outdoor air temperature becomes minus 25°C (minus 13°F)
or less, crane operation is stopped) Boom telescoping operation CN923 CN904
indicator lamp 〔 0〕B 〔288〕WL 〔288〕WL
2 Jib state switch
Remote control pressure vent signal taking out 〔748〕BW 〔 0〕B KEY
1 (contact closes without jib)
Swing talbl,left 〔729〕LgR CN906
CN893 Aux. winch operation CN905
〔250〕1.25Lg 〔288〕WL
indicator lamp CN924
Gy 〔 0〕B
8 8
Gy CN909 CN907
10 10 CN908
Gy 〔250〕1.25Lg 〔748〕BW 〔748〕BW Emergency outrigger state
11 11 Telescoping system select 2
Gy 〔 0〕B KEY
register switch
13 13 1
Gy Telescoping mode Ⅰ/Ⅱ CN976 Emergency outrigger state (contact closes at emergency)
14 14
N Outdoor air
O〔353〕
YG〔256〕
5
6
Gy
Gy
Gy
5
6
〔746〕RY
〔353〕O
〔256〕YG
switch
(up : mode Ⅱ
down: mode Ⅰ)
2
5
1
4
1
〔 35〕Br
〔 0〕B
〔 0〕B
control indicator lamp
N
1 1 Emergency crane operation 3
temperature WR〔262〕 Gy 〔262〕WR CN917 3 〔274〕LB
7 7 switch in minus 25°C 5 Touch-type winch drum indicator controller (option)
sensor WY〔268〕 Gy 〔268〕WY 〔250〕1.25Lg 4 〔250〕1.25Lg
9 9 (minus 13°F) or less in 2 2 CN931
(TS5051)
To remote control
pressure vent
BW〔348〕
RL〔303〕
2
12
Gy
Gy
2
12
〔348〕BW
〔303〕RL
outdoor air temperature KEY
(contact closes at
emergency operation)
〔480〕BW
1 B Telescoping mode Ⅱ
indicator lamp CN978
〔285〕LR

〔 0〕B 〔 0〕B
LgY〔470〕
B〔 0〕
2 10
3 9 1A N.C.
+24V
GY〔343〕 〔343〕GY PTO power supply and 1 11 GND
(SL.102) 4 4 BR〔440〕
B
LgW〔337〕 Gy 〔337〕LgW CN916 〔440〕BR
5 7 Solenoid output M
〔156〕1.25RY

3 3 Controller(TR7430) earth signal taking out

〔250〕1.25Lg

Br Br 〔250〕1.25Lg 〔441〕O O〔441〕

1 N.C. Power supply 1 11 1 Lead switch input M1
〔470〕LgY

1
〔159〕YB

B B 〔480〕BW Telescoping mode Ⅰ 〔284〕L

10 2 Lead switch input M2
〔 22〕G

〔 22〕G

2 Sencor Output1 4 4 CN977

〔 0〕B

〔 0〕B

indeicator lamp 〔 0〕B

〔250〕1.25Lg

W W 9 3 Lead switch input M3

〔250〕1.25Lg

3 N.C. Output2 2 2
〔250〕1.25Lg

L L 〔 0〕B 〔450〕BY BY〔450〕

〔260〕YW

4 Sencor GND 3 3 4 8 Solenoid output S

〔260〕YW

〔260〕YW

〔348〕BW
〔276〕LW

〔292〕RG
〔784〕GB
〔782〕LG
〔285〕LR

〔782〕LG

RY〔451〕
〔783〕LY

〔285〕LR

〔303〕RL

〔303〕RL
〔332〕V

〔783〕LY

〔274〕LB

〔378〕BL

〔451〕RY
8 4 Lead switch input S1
〔 0〕B

〔379〕Y

〔332〕V
〔284〕L

R26

R1
〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

〔481〕G 3 1 4 2 3 1 4 2
7 5 Lead switch input S2
〔343〕GY 6 6 Lead switch input S3
R13

R53

O
KR27

O
3 1 4 2
R46

R11
〔480〕BW
〔343〕GY

5 11 6 1 4 3 2 10 9 8 7 2 1 4 6 3 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 R R
〔481〕G
〔 0〕B

GW
RG

R4
R13
YL

Br

W
G

R
Y

B
L

AML power AML power Visible type winch drum indicator (option)
R R R R R supply relay 2 supply relay 1 CN380

A
〔250〕1.25Lg

3 1 4 2 (contact closes (contact closes LgY〔470〕 B

Outside cab Inside cab R R
at P.T.O) at P.T.O) O〔441〕
1
KR27

2nd boom 3rd/top boom Swing free selector relay 2 LED1(Main)

〔 0〕B

1c emergency emergency (contact closes at swing free) RY〔451〕

R47 2c RESET SET 3
R telescoping telescoping W
Gy

Gy

Remote control pressure vent

R13

(contact opens at minus 25°C relay relay

(minus 13°F) or less) 3 1 4 2 Telescoping system select relay
〔174〕1.25YR

〔156〕1.25RY

LED2(Aux.)
〔158〕1.25L

〔165〕LgR
〔294〕BrR

〔793〕GW
〔188〕YW

〔314〕YW

〔333〕BW
〔157〕RG
〔324〕LW
〔195〕YO

〔298〕YG

〔784〕GB
〔159〕YB

R
〔130〕LY

〔22A〕G
〔 35〕Br
〔 0〕2B
〔336〕P

〔296〕Y
〔 22〕G

Washer tank

Washer motor
roof front
Power supply (PTO synchronization)

P P
GMDT Oil temperature 50℃ (122°F)

Residence (telescoping system select)

Power supply (AML relay board)

Upper MDT Electric Circuit

Diode (telescoping system select)
MDT Oil temperature 85℃ (185°F)

M M
Power supply (AML main bord)

Power supply (clearance lamp)

MDT Over-front area detection

MDT Over-rear area detection
CN849

CN850

MDT C/W equipped detection

MDT AML serial input/output

1 2 1 2
Power sypply wiper washer

MDT Air pressure input

Power supply (sensor)
〔158〕1.25L

〔158〕1.25L

60B
〔188〕YW

Washer relay (front)

〔195〕YO

Washer relay (roof)

Working lamp relay

IWZ03-3291E01
Diode, horn relay
Diode, horn relay

PTO switch
PTO switch

0.5μF
MDT PTO

C2
CN837 〔158〕1.25L
GND

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

8 WZ03-3291E 344-121-81000 1 8
Z-5 Z-5 Z-5
Electric Circuit (MDT, Carrier/Upper)

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

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

9 WZ03-3300E 9
Z-5. Z-5. Z-5.
Electric Circuit (MDT, Carrier/Upper)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Power supply (PTO synchronization)

AML emergency switch
AML emergency switch

Telescoping system select (AML)

Power supply (AML main bord)

Power supply (clearance lamp)

Thermo switch ( 50℃/122°F)

Electric Circuit

Telescoping system select (R46)

Over-front area detection proximity switch
Over-rear area detection proximity switch
Thermo switch (85℃/185°F)
Power supply (AML relay board)
Power supply (sensor)
Telescoping system

C/W equipped detection proximity switch

Conbination switch

Power supply (wiper washer)

Pressure sender (air)

Conbination meter

Washer motor (front)

ZD4
D31

D30

D54

Washer motor (roof)

RSj
Lever P

D2

R6
(AML, Crane)

Swing horn switch

1.5kΩ/1W
Switch (Horn)

150Ω/1W

Air horn solenoid

Lamp (boom)
〔793〕GW
RSj

〔324〕LW
〔193〕YG

〔784〕GB
〔182〕LG

〔572〕LR
〔130〕LY
R6

〔563〕G
〔 35〕Br

AML SIF2
〔614〕L
〔 0〕B
[NOTICE] 1.Number within [ ] indicate the circuit identification numbers (the numbers of the wiring terminals)

select
A A

GND

PTO
2 2 2 2
2.Wire gauges are CAVS 0.5mm (0.0008in ) and AVS 0.85mm - (0.0014in -)

CN863
22 LY

9 GW

6 RW
5 RW
14 W

3 GR
2 GB
12 O

8 GL
5 7 1 3 16 20 18 17 15 13 11 10 12 14 6 4 2 9 8 19

13 R

7 RL
15 B
11 L

21 L
1G

4B
Left side control panel
(the size not shown is 0.5mm2 (0.0008in2)

CN511

CN562

〔156〕1.25RY
Bubble level

〔158〕1.25L
〔174〕1.25YR
6 9 1 8 5 7 2 3 4 1 8 9 7 6 2 4 3 5

〔165〕LgR
〔793〕GW

〔294〕BrR

〔793〕GW
〔188〕YW

〔314〕YW

〔333〕BW
〔324〕LW

〔324〕LW

〔157〕RG
〔193〕YG

〔784〕GB

〔195〕YO

〔298〕YG

〔784〕GB
3.Wire specification codes are based on JASO D607.

〔182〕LG

〔159〕YB
(illumination)

〔572〕LR
〔130〕LY

〔130〕LY

〔22A〕G
〔563〕G
〔 35〕Br

〔 35〕Br
〔336〕P

〔 0〕2B

〔296〕Y
〔614〕L

〔 22〕G
CN805

〔 0〕B
〔155〕RW

〔155〕RW
〔193〕YG

〔 36〕BrR
〔 37〕BrY
〔182〕LG

〔176〕YB
〔563〕G

〔194〕YL

〔178〕Sb
〔 14〕GB
〔 13〕LB
1
First character is base color, and second character is trace color.

〔 9〕LR

〔 35〕Br
〔179〕L

14 Speed meter signal

〔 52〕Y
〔 0〕B

5 Tachometer signal
〔 0〕B
2

7 T/C OIL PRESS

3 WATER TEMP
11 Illumination(+)

2 T/C OIL TEMP

4.The wiring numbers 900∼999 show 12-voltage system, the other show 24-voltage system.

6 Serial signal
8 AIR PRESS
15 ING(12V)
16 ING(24V)
20 GND(E1)

18 GND(E3)
17 GND(E5)

13 GND(E4)
19 TURN(L)

4 TURN(R)
9 GND(E2)
Connector B

Connector A
10 GLOW
12 BEAM

1 FUEL
5."FL, "FR", "RL" and "RR" for the outrigger switches indicate the outrigger positions.

CN811

CN810
CN470

Front control panel

2
5
2
〔 35〕Br
〔 0〕B
5 6 7 8 9 1 2 3 4 6 7 8 9 10 11 1 2 3 4 5
6.Following sign indicates the connection of the same number mutually.
5
Working
4
4
〔 0〕B Receiving side of power supply : Supply side :

〔 0〕1.25B

〔908〕LgW
〔912〕LgY
〔155〕RW

〔211〕WR
3 〔167〕YG

〔915〕WY

〔169〕YG
CN494 3
Receiving side of signal and load : Supply side :

〔239〕BL

〔170〕YL
lamp

〔 24〕YB
〔 13〕LB

〔191〕W
〔 35〕Br

〔 9〕LR
〔010〕B

〔192〕B

〔143〕Y

〔171〕Y
〔 09〕B

〔 08〕B
E 〔 0〕B switch 1
1 〔152〕1.25LO
1
B T
TR
4
3
〔 35〕Br
〔180〕GB (It becomes it for the negative-type logic circuit contrary to the electric current direction of the load.) B
T
T
B
8
〔 6〕1.25O
〔202〕GR
7.Next circuits apply to the machine for Europe only.
Hazard switch L
9
B1
7
F
5 Front wiper motor CN812
B2
6
R
R
5
〔150〕1.25LR
Crane operation Emergency stop
2 6
M
3 Upper MDT
Y 〔185〕1.25GB CN621 AMP040mk Ⅱ Reverse steering
H
L

4 CN2
W 〔189〕1.25YB WR〔 3〕
2 1 TXD1 Upper-lower serial output

〔150〕1.25LR
L 〔190〕1.25YW LY〔 5〕
1 2 RXD1 Upper-lower serial input
R〔198〕
B〔199〕
3 TXD2 AML serial output(+) Toggle switch (the switch of lower electric circuit contains it.)
Wiring built in cab 4 TXD2 AML serial output(−)
Right upper control panel W〔196〕
5 RXD2 AML serial input(+)
G〔197〕 Up Middle Down Switch

〔181〕1.25BW
〔190〕1.25YW

〔181〕1.25BW
C5 CN835

〔185〕1.25GB
6 RXD2 AML serial input(−)

〔189〕1.25YB

〔150〕1.25LR

〔150〕1.25LR
CN495 W〔191〕

C C
①- 2 <①- 3> Power window

〔 0〕1.25B
7 TXD3 Conbination meter serial output

〔193〕YG
〔182〕LG
0.5μF B〔192〕 ①- 3 OFF *
1 8 GND

〔 6〕1.25O
B〔 02〕 ②- 3 OFF Outrigger operation box illumination
4

〔174〕1.25YR
9 GND

〔152〕1.25LO

〔152〕1.25LO
〔150〕1.25LR
2 〔 35〕Br ② -3,⑤- 6 OFF 1- ②,4-⑤ Lower outrigger operation jack /slide select

〔 0〕1.25B
2 10 Pi3 Aux. drum indicator input

〔179〕L

〔155〕RW

〔155〕RW
〔202〕GR

〔 0〕B
〔180〕GB

〔195〕YO

〔167〕YG

〔167〕YG
〔176〕YB

〔233〕YB
〔 0〕B <② -3,⑤- 6> <1- ②,4-⑤> Lower outrigger operation extending /retracting select

〔130〕LY

〔178〕Sb
Roof washer OFF

〔 13〕LB
5
5

〔 9〕LR
11 Pi4 Main drum indicator input

〔179〕L

〔179〕L
〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B
switch 3 〔186〕LB 2 1 4 6 3 2 1 4 6 3
3 12 DPOW Drum power supply(12V and 24V)
RC3

RC2
CN468 6 〔 0〕B Notice: ( ) shows the momentary switch.
6

CN814

1
〔 0〕B

4
2
1
6 CN629 AMP070mk1 CN9

RA26

RA14
RA6

RA5

RA1

RA2
2 〔173〕LY R R 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2
2 1 Tr1７ Output spare

B
E
L
Roof wiper
3
3
〔187〕V
2 Tr18 Output spare Locker switch (the switch of lower electric circuit contains it.)
4 〔158〕1.25L Front wiper Front wiper YG〔193〕
switch 1 3 Tr19 Front wiper operation output
〔 0〕B Hi relay ON relay R R R R R R V〔187〕
6
4 4 Tr20 Roof wiper operation output Up MIddle Down Switch
5 〔 35〕Br
5 5 Tr21 Drum indicator (LED1) 1-3 OFF Reverse steering, Working lamp, Emergency mission, Emergency accelerator
Turn signal relay Turn signal relay Flasher unit Washer relay Horn relay Working lamp Working lamp 6 Tr22 Drum indicator (LED2) 3-4 OFF *
Wiring built in cab (L)(contact closes (R)(contact closes (front) relay 1 relay 1 7 Tr23 Drum indicator (LED3) 1-3 OFF 1-2 Slider/Jack (O/R), Ext./Ret. (O/R), Drive select, Roof wiper
Working lamp at hazard) at hazard)
8 Tr24 Drum indicator (LED4) 2-3 1-2 *
70W CN(A) Y〔143〕
Roof wiper motor 9 Po4 Air pressure output <3-1> <3-2> *

D D
R 1.25L YB〔 24〕 〈B-U〉 *
5 10 Po5 T/C pressure output 〈E-U〉
〈L-B〉 OFF 〈L-E〉
R CN806 〈a-e〉 〈b-e〉 Power window
f-d,a-e 〈f-d〉
6 11 Tr25 MDT CPU output 〈b-d〉
M 〔158〕1.25L 1.25B〔 05〕 〈5-6〉 *
〈2-3〉
3 5 12 GND
Y 1.25LW 〔184〕1.25LW
H
L

4 6
W
2
1.25LG 〔183〕1.25LG
4 CN626 AMP040 Ⅱ CN７ Notice: ( ) shows the momentary switch.
L CN819 WY〔915〕
1 3 1 SPOW 12V IN
1.25YB 〔233〕YB 〔907〕P P〔907〕
1 1 2 Pi1 Tachometer sensor input
1.25B
7
〔 0〕1.25B Engine speed output 2 〔 0〕B LgW〔908〕
3 Po1 Tachometer sensor output
1.25O 〔 6〕1.25O WL〔911〕 Combination switch
2 3 4 Pi2 Main speed input
LgY〔912〕
Room lamp 2 5 Po2 Main speed output Light switch circuit Exhaust brake switch
CN833 〔158〕1.25L

(door side)
〔184〕1.25LW

1 6 Po3 Tachograph output

〔183〕1.25LG

YW〔 4〕 Wire OFF

〔158〕1.25L

〔158〕1.25L Wire
10W
〔 0〕1.25B

7 CHK System check

color A B C A B C A B C Connected to color OFF
ON
〔188〕YW
〔186〕LB

8 Ao1 Fuel gauge output

〔187〕V

〔 0〕B

B〔 05〕

〔251〕RY
〔572〕LR
Door switch 5RW POWER

〔05〕1.25B
21L

〔 30〕RL
9 GND
B〔 05〕

〔 0〕B
10 GND 6RW Head lamp 22LY
2 1 4 6 3 3 1 4 2 7RL Dimmer
AMP040mk Ⅱ CN8 ※ A:Push forward

E E
RC1

RA3

3 1 4 2 1 AVCC Spare 2 5V 8GL POWER B:Neutral

RA10
Wiring built in cab 9GW Tail, clerance C:Pull backward
9 Ai5 Spare 2 input
C1

R R
5 AGND Spare 2 GND
CN804 R 2 AVCC Spare 3 5V Wiper, Washer switch circuit
CN895
0.5μF

Room lamp 〔 6〕1.25O Roof wiper Washer relay (roof)

2 Crane operation 〔227〕R 〔227〕R 10 Ai6 Spare 3 input
Wire Turn signal switch
(relay box side) 〔 0〕B ON relay Emergency stop relay emergency stop 4 OFF INT LOW HIGH WASHER Connected to
10W 1 〔228〕W 〔228〕W 6 AGND Spare 3 GND
color
〔 0〕B 3 Wire Lever position
Front control panel 〔229〕B 〔229〕B 3 AVCC Spare 4 5V HORN Connected to
2 11L Washer motor color R N L
Shield BL BL 11 Ai7 Spare 4 input
Emergency stop switch 1 Motor (Low)
7 AGND Spare 4 GND 12O 1G Flasher unit
1a CN915 4 AVCC Spare 5 5V 13R Amp 2GB Turn signal lamp
Crane operation 2 1 0.85Lg 〔251〕RY
emergency stop 1 Accelerator pedal
12 Ai8 Spare 5 input
Turn signal lamp
0.85Lg 〔 22〕G 14W Motor (High) 3GR
2 8 AGND Spare 5 GND
15B Earth 4B Horn solenoid
CN548 CN627 AMP040mk Ⅱ
CN557 Accelerator switch 〔626〕WB R〔227〕
2 1 AVCC Air 5V
AC
0.85GB
1
〔 14〕GB (contact closes when 〔 0〕B
1
W〔228〕
9 Ai1 Air puressure input Starter switch
1.25GR 〔 17〕1.25LW pedal is released) B〔229〕

F F
B1 2 5 AGND Air GND
0.85LG 〔153〕LG BL BR B1 B2 R1 R2 AC C P Remarks
B2 3 13 SLD Shield GND
0.85LO CN586 R〔610〕 OFF
R2 4 R
6
〔610〕R 2 AVCC Accelerator 1 5V 2 3 1 − Antomatic return to 2
0.85RW 〔122〕RW W〔611〕
Starter switch C 5 Accelerator Y 〔611〕W 10 Ai2 Accelerator sensor 1 input 2 ACC
0.85YR sencor 1 5 B〔612〕 1 4
P 6 W 〔612〕B 6 AGND Accelerator 1 GND
4 Shield B OFF
7 L 〔620〕R 14 SLD Shield GND
0.85YL 〔 16〕1.25YL 3 R〔620〕 3 ON
BR 8 Accelerator G 〔621〕W 3 AVCC Accelerator 2 5V
0.85LO sencor 2 2 W〔621〕 4 START Antomatic return to 3
R1 9 B 〔622〕B 11 Ai3 Accelerator sensor 2 input
1 B〔622〕
7 AGND Accelerator 2 GND
1b CN509 CN587 Shield B
Front control panel 15 SLD Shield GND
2 1 0.85B 〔 22〕G
1 SLOW 1
〔632〕R R〔632〕
4 AVCC Idling adjustment 5V PTO switch
P.T.O switch 1a 4 Idling adjustment switch 2
〔633〕W W〔633〕
12 Ai4 Idling adjustment input
4 3 0.85B
2
〔314〕YW
FAST
〔634〕B
3
B〔634〕
8 AGND Idling adjustment GND 1 2 3 4 Remarks
0.85B
5
〔336〕P Shield B
16 SLD Shield GND
PTO ON
OFF
0.85B
3
〔154〕Y
1
〔 0〕B OFF AML override
CN631 AMP040 Ⅱ PTO ON
CN588 CN10
Y〔 52〕 AML override Automatic return to PTO ON position
1 Di33(+) Exhaust brake

G 2 1a
1b
1 0.85B
1
4
YG〔167〕
G〔22A〕
2
3
4
Di34(+)
Di35(+)
Di36(+)
Input spare
Working lamp
PTO
G
Parking brake 4 3 0.85B 〔 19〕WG WG〔 19〕
switch 2 5 Di3７(+) Parking brake release
0.85B 〔144〕LY Pull：ON：manual
5 Push：OFF：auto 6 Di38(+) Input spare
0.85B Use prohibition
3 7 Di39(+) Input spare Parking brake switch
Cigarette lighter CN510 8 Di40(+) Input spare
CN824 9 Di41(+) Input spare
〔151〕1.25LB 1 2 3 4 Remarks
10 Di42(+) Input spare
B〔 06〕 OFF

〔06〕1.25B
11 GND OFF PARK
B〔 06〕 PARK
12 GND
B〔 06〕
13 GND
B〔 06〕
14 GND
15 Di43(+) Input spare
CN925 16 Di44(+) Input spare
〔574〕LG LG〔574〕
1 1 17 Di45(+) Vehicle speed limit
〔157〕RG
18 Di46(+) Input spare

H Vehicle speed limit connector：not connecting

(25km/h or less at connecting)r
19
20
Di4７(+)
Di48(+)
Input spare
Input spare H
CN630 AMP040 Ⅱ
BW〔333〕 Relay
1 Di49(-) Over-front detection
YB〔176〕
2 Di50(−) Washer operation (front) Make
YG〔298〕
3 RA1-6,10,14,26
BrR〔294〕
Di51(−) Oil temperature 50℃ (122°F) contact
4 Di52(-) C/W equipped detection
5 Di53(-) Input spare Break
6 Di54(-) Input spare 1 pole RB5
contact
7 Di55(-) Input spare
YL〔194〕
8 Di56(-) Wiper intermittent operation (front) C
LgR〔165〕 RC1-3,7
9 Di5７(-) Over-rear detection
contact
Front control panel 10 Di58(-) Input spare
Y〔296〕
11 Di59(-) Oil temperature 85℃ (185°F)
CN473 12 Di60(-) Input spare 2 poles
〔 35〕Br Use prohibition

I I
2
2 13 Di61(-) Input spare
5 〔 0〕B Use prohibition
5 14 Di62(-) Input spare
4 〔177〕RB
Reverse steering switch 4 15 Di63(-) Input spare 4 poles RF1
3 〔 57〕PB LY〔173〕
3 16 Di64(-) Wiper intermittent operation (roof)
CN476 1 〔157〕RG
1
1 〔157〕RG CN624 AMP070mk1 CN5
6
2
2
〔 51〕YB L〔 29〕
1 Di20(+) 2 wheel steering Diode
High/low and 2/4 3 〔 50〕YL LR〔 48〕
3 2 Di21(+) 4 wheel steering For 1A ZD4
wheel drive select 4 〔157〕RG LB〔 47〕
1 3 Di22(+) Crab steering
switch 6 〔 0〕B BrW〔 53〕
4 4 Di23(+) Rear steering
5
5
〔 35〕Br PB〔 57〕
5 Di24(+) Reverse steering
For 3A D2,30,31,54
YB〔 51〕
6 Di25(+) High/Low select
YL〔 50〕
7 Di26(+) 2/4 drive select
8 Di2７(+) Input spare Resistence
9 Di28(+) Input spare
10 Di29(+) Input spare RSJ, R6
BrR〔 36〕
11 Di30(+) Head lamp (A)

J J
BrY〔 37〕
Br〔 35〕
12 Di31(+) Head lamp (B) Condenser
Buzzer 1 13 Di32(+) Clearance lamp
(air low pressure alarm) 〔04〕1.25B 1.25B〔 04〕
14 GND C1,3,5,6,7
CN815
R 〔155〕RW CN622 AMP040mk Ⅱ CN3
B 〔212〕V V〔212〕
1 Tr1 Alarm buzzer
CN816 BL〔239〕
2 Tr2 High beam lamp
WR〔211〕
3 Tr3 Glow lamp
V〔212〕
4 Tr4 T/C oil temperature alarm
Steering mode 10 〔 35〕Br
2 5 Tr5 Output spare
select switch 11
1
〔 0〕B
6 Tr6 Output spare
2 〔 29〕L
10 7 Tr７ Output spare
4 〔 48〕LR
8 8 Tr8 Output spare
6 〔 47〕LB B〔 03〕
6 9 GND
8 〔 53〕BrW B〔 03〕
4 10 GND
3 〔 73〕RW RW〔 73〕
9 11 Tr9 2 wheel steering
5 〔 74〕LG LG〔 74〕
7 12 Tr10 4 wheel steering

K 7
9
1
5
3
〔 75〕GL
〔 76〕G
〔157〕RG
GL〔 75〕
G〔 76〕
RB〔17７〕
13
14
Tr11
Tr12
Crab steering
Rear steering K
11 15 Tr13 Reverse sttering
CN514 16 Tr14 Output spare
17 Tr15 Output spare
YB〔559〕
18 Tr16 Engine is stopping
B〔 03〕 344-121-82000

Emergency switch 1 19 GND

NO
CN564 〔03〕1.25B B〔 03〕
(system check) 3 20 GND
COM 0.85R 〔 4〕YW
1
0.85B 〔157〕RG CN639 CN625 AMP040mk Ⅱ CN6
1 4
Emergency switch 0.85R 〔214〕Y LR〔800〕
3 2 2 1 TXD
(mission) 0.85B 〔 20〕YG LW〔801〕
6 5 2 RXD
0.85R 〔615〕GL LG〔802〕
3 1 3 Boot
0.85B 〔214〕Y LB〔803〕
Emergency switch 1 7 4 4 GND
Br〔804〕
(accelerator) 3 5 3 5 GND
Br〔804〕
6 6 GND
Br〔804〕

L L
7 GND
CN517 MDT Br〔804〕
(for maintenance) 8 GND
1 〔 17〕LW
1
3 〔614〕L 〔614〕L CN623 AMP070mk1 CN4
Engine emergency stop switch 2
2 B〔 04〕
3 1 GND
CN563 YG〔 20〕
2 Di1 (+) Emergency transmission
〔 31〕RY RY〔 31〕
1 7 3 Di2 (+) 1
〔 32〕RB RB〔 32〕
2 6 4 Di3 (+) 2
5 5 Di4 (+) Input spare
〔 33〕RW RW〔 33〕
Mission select switch D 4 6 Di5 (+) D
N 3
〔 30〕RL 〔 30〕RL RL〔 30〕
7 Di6 (+) N
(shift lever) 〔214〕Y R〔 40〕
R 2 8 Di７ (+) R
〔 40〕R Sb〔 72〕
1 9 Di8 (+) ALL
PB〔 45〕
10 Di9 (+) FL
〔 0〕B WY〔 44〕
2 11 Di10(+) FR
〔 35〕Br WR〔 42〕
1 12 Di11(+) RL
W〔 41〕
CN513 13 Di12(+) RR

M M
WB〔 43〕
14 Di13(+) Extending
Front control panel Y〔 62〕
15 Di14(+) Retracting
WL〔 46〕
CN498 16 Di15(+) Jack
GY〔 60〕
17 Di16(+) Slide
6 〔157〕RG
(ALL) 3 18 Di1７(+) Input spare
5 〔 72〕Sb
4 19 Di18(+) Input spare
20 Di19(+) Input spare
Outrigger individual
operation switch (FL) CN499
CN620 AMP070mk1 CN1
6 〔157〕RG WB〔213〕
3 1 MPOW Power supply 24V
5 〔 45〕PB WB〔213〕
(FR) CN500 4 2 MPOW Power supply 24V
〔169〕YG

〔 33〕RW

WB〔213〕
〔170〕YL

〔 31〕RY
〔 32〕RB
〔171〕Y

3 MPOW Power supply 24V

〔 40〕R

6 〔157〕RG CN865 DC-DC Converter 1.25B〔 01〕

3 4 GND
5 〔 44〕WY 5 Meter illumination 1.25B〔 01〕
4 3 5 GND
WB 〔 35〕Br 〔01〕1.25B 1.25B〔 01〕
1 6 GND
WL 〔226〕YG 1 Clearance lamp 7 4 9 3 8 2 6 1 5 RF1-1
(RL) CN501 2 7
WG 〔558〕RW Pulse transducer
GW

LgW

BrW
GR

LgR
LW

BrR

3
LR

N (RR) CN502
6
5
3
4
〔157〕RG
〔 42〕WR
Air conditioner
(option)
WR
RL
4
5
〔225〕1.25LR
〔238〕R
〔915〕WY

〔 14〕GB
2
6 Meter

2 Starter switch
1 5 2 6 3 7 4 8 14
Relay RF1
Emergency
(engine speed) CN998
24V 1
〔155〕RW N
6 6 transmission selector GND 2
〔157〕RG B 〔016〕2B Rotary joint
6
3 7 R Pi1 3
〔918〕PB
To Lower MDT electric circuit
〔0〕2B

5 〔 41〕W 4 Buzzer CN880 CN780

4 8 4 (3/4 GND 4
9 10 11 12 13 dividing) Po1 5 〔907〕P 〔 3〕WR
〔558〕RW

9 1 23 1 Lower MDT RXD1

〔234〕YR

〔234〕YR
〔559〕YB

CN497 3 Starter switch 〔626〕WB

CN802 5 Timer GND 6 2 26 2 ECU ACCEL,Emergency accelerator select RC5
(P terminal)
LgY

〔157〕RG
BrY

1
GY

6 Po2 7
LY

R
B

2 〔 62〕Y 〔 07〕B CN881 CN783

Outrigger switch 2 1 7 Unusable GND 8
3 〔 43〕WB 1 2 4 6 5 3 7 RF1-2 〔 5〕LY
(for ext./ret. select)
〔218〕1.25YG

3 3 25 3 Lower MDT TXD1

〔156〕1.25RY
〔152〕1.25LO

3 1 4 2
〔150〕1.25LR

〔225〕1.25LR

〔151〕1.25LB

〔 0〕2B 5 GND 〔918〕PB

〔158〕1.25L

〔157〕RG
〔629〕GR

4
RB5

1 1 1 7 1 Lower MDT tachometer output

〔 12〕YO

〔 20〕YG
〔 10〕GY

Outrigger switch
〔155〕RW

〔 8〕YR
〔213〕WB
〔157〕RG
〔226〕YG

〔160〕RB
〔234〕YR
〔153〕LG

〔159〕YB

〔911〕WL
〔472〕LR

〔 0〕B 4 12V output

〔144〕LY

〔 0〕B

6
4 2 11 2 Lower MDT main speed output
〔238〕R

2
〔214〕Y

〔154〕Y

(for jack/slide select) DC/DC

CN480 5 〔 35〕Br 〔 0〕B 3 GND Converter
5 R 3
1 〔157〕RG 2 Unusable CN884 CN784
6 4
〔 46〕WL 〔160〕RB 1 24V input 〔 8〕YR
CN871

CN870

CN876

CN875

2
2 Air conditioner 5 1 8 1 Emergency transmission select relay RF2(Engin water temperature sensor)
3 〔 60〕GY 5 4 3 2 1 7 6 4 3 2 5 1 5 4 3 2 1 7 6 4 3 2 5 1 〔 10〕GY
3 power supply cut relay CN864 3 10 3 Emergency transmission select relay RF2(fuel sender)
〔157〕RG 〔 12〕YO
1.25GW

1.25GW
1.25LW

1.25LW
1.25GR

1.25GR

O O
1.25GY

1.25GB

1.25GY

1.25GB

4
1.25LG

1.25LG

1
1.25LR

1.25LR

4 12 4 Emergency transmission select relay RF2(T/C oil temperature sensor)

1.25LY

(B) 1.25LB

1.25LY

1.25LB
1.25G

1.25G
1.25L

1.25L

6
4
〔 0〕B Fan switch CN926 〔614〕L
6 14 6 Starter interception relay RB12,Engine emergency stop relay RB4
5 〔 35〕Br LR 〔472〕LR 〔 9〕LR
5 2 9 2 Signal lamp (R)
LB 〔 13〕LB
(G)

(G)
(H)

(D)
(C)

(H)

(D)
(C)
(K)

(K)
(E)

(A)

(E)

(B)

(A)
(F)

(F)
(J)

(J)
(I)

(I)

5 13 5 Signal lamp (L)

(R) (L)
10A
10A
10A

10A

10A

10A
10A
10A

10A

10A
15A
15A

15A

15A

15A
15A

15A

15A

C6
5A

5A

5A

5A

〔122〕RW

R B
〔 21〕LG

0.5μF
〔 30〕RL

CN467 M CN885 CN785

〔 0〕B

f 〔 0〕1.25B Fan motor 〔 21〕LG

5 Fan 6 21 6 ECU(STARTER SW),Starter interception relay RB12,Lower MDT Engine start
1.25RW

1.25RW

〔 0〕1.25B 〔629〕GR
1.25YW

1.25YW
1.25RG

1.25RG
1.25YG

1.25YG
1.25RY

1.25RB

1.25RY

1.25RB
1.25YR

1.25YR
1.25YB

1.25YB
1.25RL

1.25RL

a
3 (option) 11 29 11 Emergency transmission select relay RF2
1.25R

1.25R
1.25Y

1.25Y

Power window switch 〔218〕1.25YG 〔 20〕YG

b
4 5 20 5 Emergency transmission select relay RF2(Emergency transmission select),Transmission power supply cut relay RB1
e
1
〔127〕1.25LO 3 1 4 2 〔 19〕WG
Parking brake SOL
4 19 4
CN873

CN872

CN878

CN877

RA4

d 〔128〕1.25LY 5 4 3 2 1 7 6 4 3 2 5 1 5 4 3 2 1 7 6 4 3 2 5 1
2 3 18 3 Spare
〔 4〕YW
8 24 8 Lower MDT CHK
R 〔615〕GL
1.25W
1.25W
1.25W
1.25W
1.25W

1.25W
1.25W
1.25W
1.25W
1.25W

1.25W

1.25W
1.25W
1.25W
1.25W
1.25W

1.25W
1.25W
1.25W
1.25W
1.25W

1.25W

CN461 1 15 1 Emergency accelerator relay RC5,6

B 〔 2〕1.25Y
Power window switch
1 10 28 10 Spare wiring (connector in fuse box)
R Neutral starter relay
(outside cab) 2 12 30 12 Spare wiring (connector in fuse box)
〔 22〕G
CN836 〔2〕1.25Y

〔539〕YB
3 7 22 7 ECU(PTO SW),PTO limitter relay RB3
W
9 27 9 Spare wiring (connector in fuse box)
〔218〕1.25YG

P P
〔 16〕1.25YL
Wiring built in cab 2 16 2 Electronic governor power supply relay RA22
〔128〕1.25LY

Power window motor UP Cab CN813 CN882 CN781

〔 2〕1.25Y

Door
C7 0.5μF

M 〔 2〕1.25Y
〔539〕YB

side side
1 1 5 1 Power supply (direct coupled battery)
〔 0〕B

R L 4 1.25R 〔127〕1.25LO 〔 6〕1.25O

3 2 6 2 Power supply (direct coupled battery)
G LB 1.25G 〔538〕1.25LB 〔 17〕1.25LW

IWZ03-3300E01
5 3 17 3 Power supply (direct coupled battery)
CN834

2
2
Door junction 2 1 4 6 3 CN883 CN782
4
RC7

〔 1〕8W 〔 1〕8W 〔 1〕2W

0.5μF

1 1 1 Power supply (Upper) (By way of battery relay)

C3

〔 1〕2W
2 2 2 Power supply (Upper) (By way of battery relay)
Power window relay R 〔 1〕2W
3 3 3 Power supply (Upper) (By way of battery relay)
〔 1〕2W
4 4 4 Power supply (Upper) (By way of battery relay)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

10 WZ03-3300E 344-121-82000 1 10
Z-6 Z-6 Z-6
Electric Circuit (MDT, Carrier/Lower)

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

CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page
Suspension lock selector solenoid valve 608 MDT (lower) CN7 L-3 773 Fuse box (R) J-22
02 Suspension lock J-6 609 MDT (lower) CN8 K-3 774 Fuse box (R) I-21
03 Suspension free J-7 610 MDT (lower) CN9 H-3 775 Fuse box (R) J-21
Outrigger ext./ret. selector solenoid valve 611 MDT (lower) CN10 I-3 778 Fuse (upper power supply) (75A) L-21
20 Retracting H-15 612 MDT (lower) CN11 J-3 779 Fuse (main) (75A) L-21
21 Extending H-15 619 MDT (for maintenance) G-4 780 Rotary joint N-3
22 Slide (for FL) J-18 685 ECU (A connector) D-14 781 Rotary joint P-3
23 Jack (for FL) J-18 686 ECU (B connector) B-14 782 Rotary joint P-3
24 Slide (for FR) J-17 687 ECU (C connector) B-14 783 Rotary joint N-3
25 Jack (for FR) J-17 688 ECU (D connector) A-14 784 Rotary joint O-3
26 Slide (for RL) J-17 689 ECU (E connector) A-14 785 Rotary joint O-3
27 Jack (for RL) J-18 690 Q-ADJ B-12 788 Sub. harness F-13
28 Slide (for RR) J-16 691 MUT-Ⅲ D-12 789 Sub. harness G-13
29 Jack (for RR) J-17 700 Head lamp (LH) N-15 790 Harness (electronic governor) B-12
Steering mode selector solenoid valve 701 Head lamp (LH) N-15 791 Harness (electronic governor) A-12
30 Crab, K-7 702 Head lamp (RH) N-16 792 Harness (engine) A-19
31 4 wheel, K-6 703 Head lamp (RH) N-16 793 Harness (engine) C-19
32 Reverse, K-6 704 Head lamp relay H-21 794 Harness (engine) D-19
33 Rear select K-6 705 Head lamp relay H-21 795 Harness (engine) D-19
Transmission selector solenoid valve 706 Head lamp relay H-22 797 MEMORY CLEAR F-11
42 R L-12 707 Head lamp relay H-22 880 Rotary joint N-2
43 F1 L-11 708 Head lamp relay H-22 881 Rotary joint N-2
44 F2 L-11 709 Combination lamp (RH) N-16 882 Rotary joint P-2
45 F3 L-11 710 Combination lamp (RH) N-16 883 Rotary joint P-2
41 PTO solenoid valve N-13 711 Combination lamp (LH) N-15 884 Rotary joint O-2
49 Lockup solenoid valve M-13 712 Combination lamp (LH) N-14 885 Rotary joint O-2
50 Air solenoid valve (parking brake) G-15 717 Rear combination lamp (L) P-14 940 Thermo switch (T/C oil 110°C/230°F) I-10
51 Air solenoid valve (2/4 wheel drive shift) F-15 718 Rear combination lamp (L) P-15 941 Hour meter (option) J-11
52 Air solenoid valve (High/Low select) F-15 719 Rear combination lamp (R) P-16 942 Lower outrigger operation box (L) (option) H-16 Next
Next Next page
54 Air solenoid valve (exhaust brake) F-15 720 Rear combination lamp (R) P-16 943 Bubble level (illumination) (L) (option) H-13
page page
408 Straight ahead detection proximity switch D-6 721 Backup lamp P-15 944 Low-pressure switch (steering pump low-pressure alarm) (option) D-6
409 Low pressure switch (Engine oil) E-19 723 License lamp (option) P-16 945 Side turn signal (LH) N-14
410 Air Low-pressure switch F-15 726 Bubble level (illumination) (R) (option) I-13 946 Side turn signal (RH) N-17
411 Air low-pressure switch (parking brake) F-15 730 DIAG switch F-11 957 Spare circuit M-21
413 Lead switch (4WD detection) C-4 731 ECU DIAG lamp-1 (red) F-11 959 Diode assy (lower outrigger operation) (option) J-13
414 Lead switch (reservoir assy) F-16 732 ECU DIAG lamp-1 (red) F-11 RA11 Backup lamp relay P-14
415 Lead switch (reservoir assy) F-16 733 ECU DIAG lamp-2 (umber) F-10 RA17 Steering power supply relay P-4
416 Water in fuel sensor E-6 734 ECU DIAG lamp-2 (umber) F-10 RA8 Clearance lamp relay P-13
419 Pressure sender (torque converter oil pressure) C-4 745 Air drier heater G-16 RA9 Battery power supply keeping relay K-21
420 Main speed sensor A-4 747 Starter relay (SW) L-19 RA21 ECU main power supply relay F-9
421 Pickup sensor (sub. speed) A-4 748 Alternator (R terminal, L terminal) L-20 RA22 Electronic governor power supply relay K-21
422 Outrigger length detector (FL) B-4 749 Alternator (B terminal) L-20 RA28 Glow relay F-10
423 Outrigger length detector (FR) B-4 750 Alternator (P terminal) L-20 RB1 Transmission power supply cut relay O-10
424 Outrigger length detector (RL) B-4 751 Back buzzer P-16 RB3 PTO limiter relay O-11
425 Outrigger length detector (RR) C-4 755 Fuse (Grid heater) (70A) M-21 RB4 Engine emergency stop relay F-10
426 Engine water temperature thermo sender M-11 758 Battery relay M-22 RB6 Lower outrigger power supply select relay M-15
427 Torque converter oil temp. thermo sender M-12 759 Battery relay M-22 RB7 Lower outrigger operation box relay M-14
428 Fuel sender G-16 760 Battery relay M-22 RB8 Lower outrigger operation box relay I-15
434 Lower outrigger operation box (R) L-16 761 Battery relay M-22 RB11 Starter continuous energizing prevention relay F-9
440 Lead switch (High/Low detection) C-4 762 Battery relay M-22 RB12 Starter interception relay F-9
568 Pressure switch (stop lamp) G-15 763 Battery relay M-22 RC5 Emergency accelerator relay 1 C-6
569 Pressure switch (stop lamp) G-15 765 Diode assy B-6 RC6 Emergency accelerator relay 2 C-7
600 MDT (lower) CN1-1 F-3 766 Diode (fuse box) J-21 RD4 Lower outrigger operation box relay M-14
601 MDT (lower) CN1-2 D-3 767 Fuse box (L) I-22 RD5 Lower outrigger operation box relay I-15
602 MDT (lower) CN2 G-3 768 Fuse box (L) I-22 RF2-1 Emergency transmission selector relay M-10
603 MDT (lower) CN3 M-3 769 Fuse box (L) H-21 RF2-2 Emergency transmission selector relay M-10
604 MDT (lower) CN4 A-3 770 Fuse box (L) I-21 RF3-1 Outrigger jack/slide select relay J-15
605 MDT (lower) CN5 G-3 771 Fuse box (R) I-22 RF3-2H Outrigger jack/slide select relay J-16
606 MDT (lower) CN6 B-3 772 Fuse box (R) J-22

11 WZ03-3310E 11
Z-6. Z-6. Z-6.
Electric Circuit (MDT, Carrier/Lower)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
[NOTICE]
Transmission
Lower MDT CN604 CN689 ECU 1.Number within [ ] indicate the circuit identification numbers
CN4 AMP040mk Ⅰ CN421 CN791 MF CN792
Sub-speed (+)
Input (-)
Pi3
Pi3
1
2
〔135〕W
〔129〕B
〔135〕W
〔129〕B
2
1
〔655〕BW
〔681〕WR
1
2
〔655〕BW
〔681〕WR
〔 06〕1.25B
〔 07〕1.25B
3
4 140
141 POWER GND-3
POWER GND-2 E Connector
COMMON-2
COMMON-2
143
142
1
2
〔670〕1.25YR
〔670〕1.25YR
〔671〕1.25GL
〔669〕1.25GR
4
5
TWV-1(Cylinder-#1)  (the numbers of the wiring terminals)
A 2.Wire gauge is AVS and wire gauge of ECU is CAVS. A
〔203〕W 〔0〕B 〔0〕B 〔617〕B 〔617〕B 〔676〕1.25YW 〔673〕1.25GB
Tachometer (+) Pi4 3 Pickup sensor 3 21 158 CAN-1(L) TWV-6(CYL#4) 139 5 2 TWV-3(Cylinder-#3)
Input (-) 〔609〕BY 〔609〕BY 〔674〕1.25YB 〔669〕1.25GR
Pi4 4 (sub. speed) 4 22 157 CAN-1(H) TWV-4(CYL#6) 138 6 3
2 2
Tachometer input (ECU)
Fuel sender input
Pi1
Ai11
5
15 〔 0〕B
CN420
2 W
〔 54〕LO
5
6
〔 54〕LO CN688
〔 04〕1.25B
6 102 POWER GND-1
TWV-2(CYL#5)
SCV POWER2
137
147
7
14
〔672〕1.25YL
〔654〕BrW
〔675〕1.25GW
〔669〕1.25GR
1
6
TWV-5(Cylinder-#2) (the size not shown is 0.5mm (0.0008in ))
Main speed
Main speed 12V
Main speed input
SPOW
Pi2
9
7
〔914〕WR
〔913〕WG
〔914〕WR
〔913〕WG
3 R
1 G
sensor
〔683〕L
〔638〕Br
7
8
〔683〕L
〔638〕Br
〔655〕BW
13
19
111
126
EXH.BRAKE M/V(1.1A 出力可)
SENSOR SOURCE-1(+5V)
SCV POWER1
SCV 2
146
145
15
16
〔652〕BrY
〔692〕BrR
〔672〕1.25YL
〔670〕1.25YR
8
9
TWV-2(Cylinder-#5) 3.Wire specification codes are based on JASO D607.
Main speed output
Tachometer output
Po2
Po1
8
6
〔911〕WL
〔918〕PB
〔637〕BrR
〔635〕LY
9
10
〔637〕BrR
〔635〕LY
〔681〕WR
〔617〕B
22
28
123
136
SENSOR SOURCE-3(+5V)
SENSOR GND-3
SCV 1
WATER TEMP(SIG)
144
155
17
24
〔690〕Br
〔643〕LgY
〔674〕1.25YB
〔670〕1.25YR
16
7
TWV-4(Cylinder-#6) First character is base color, and second character is trace color.
Accelerator sensor 1 output Ao1 12
〔616〕YR
11
〔617〕B
30 134 SENSOR GND-1 D Connector AIR TEMP(SIG) 154 25
〔677〕RG 〔676〕1.25YW
15 TWV-6(Cylinder-#4) 4.The wiring numbers 900∼999 show 12-voltage system,
〔617〕B CN687 〔678〕RL 〔670〕1.25YR
GND 16 12 FUEL TEMP(SIG) 163 30 10
〔623〕YL 〔 98〕WR 〔 98〕WR 〔 98〕WR 〔653〕YW 〔 98〕WR
Accelerator sensor 2 output
1/1 main speed
Ao2
Po3
13
11
〔910〕WB 〔679〕L
13
14
〔679〕L 〔609〕BY
1 76
2 75
M/V SURGE OUT-2
ECU MAIN RELAY-2
FUEL TEMP LEAK(SIG) 162 31
MF
〔657〕WG
14
13
EGR M/V-1  the other show 24-voltage system.
〔625〕YG 〔609〕BY 〔669〕1.25GR 〔 98〕WR
Idling adjustment output Ao3
GND
14
10
〔024〕B 〔 02〕1.25B
3 74
4 73
ECU MAIN RELAY-1
ANALOG GND-2
COMMON-1
COMMON-1
107
106
1
2
〔669〕1.25GR 〔658〕WL
12
11
EGR M/V-2 5."FL, "FR", "RL" and "RR" for the outrigger switches indicate the
〔 03〕1.25B C Connector 〔675〕1.25GW 〔 98〕WR
CN6 AMP040mk Ⅱ
CN606
CN422 RSd
Diode assy
RSc 〔681〕WR
CN765
Q-ADJ
〔 54〕LO
5 72
7 70
ANALOG GND-1
GLOW RELAY DRIVE RELAY
TWV-5(CYL#2)
TWV-3(CYL#3)
105
104
3
4
〔673〕1.25GB 〔659〕WB
22
21
EGR M/V-3  outrigger positions.
R R R 〔681〕WR 〔671〕1.25GL 〔695〕RB
FL O/R length 5V AVCC 1 3 1 9 85 EXH.BRAKE LAMP 5 20
6.The following circuit is applied only for Europe.
B
TWV-1(CYL#1) 103
FL O/R length input Ai1 11
W W
1 W Outrigger length detector (FL) 〔606〕LY
3
〔606〕LY 〔683〕L
10 84 GLOW LAMP EGR M/V-3 110 14
〔659〕WB 〔668〕LG
19 COMMONRAIL B

CN690
B B B 〔607〕GY 〔607〕GY 〔638〕Br 〔658〕WL 〔668〕LG
FL O/R length GND AGND 6 2 5 1 2 11 83 DIAGNOSIS LAMP2 EGR M/V-2 109 15 18 PRESS.SENSOR
Shield GND SLD 16
Shield B CN423
RSe 〔617〕B
7
〔617〕B 〔637〕BrR
12 82 DIAGNOSIS LAMP1 EGR M/V-1 108 16
〔657〕WG 〔698〕BL
17 Reverse steering Steering pump low-pressure alarm

〔642〕LgR
R R R 〔647〕BW 〔647〕BW 〔641〕LgW 〔678〕RL

〔647〕BW
FR O/R length 5V AVCC 2 3 4 14 80 EXH.BRAKE CUT SW BOOST SENSOR(SIG) 128 17 32 FUEL TEMP
W RSg 〔660〕Lg 〔660〕Lg 〔635〕LY 〔695〕RB 〔647〕BW
FR O/R length
FR O/R length
input Ai2
GND AGND
12
7
B
W
B
1
2
W
B
Outrigger length detector (FR) 2
6
17 77
32 97
MEMORY CLEAR SW
TRQUE CUT SW
SENSOR SOURCE-2(+5V)
COMMON PRESS.SENSOR(SIG1)
125
121
20
24
〔668〕LG 〔654〕BrW
31
25
SENSOR2
 Outrigger operation assy (option)
Shield B RSc:1kΩ CN686 〔666〕W 〔692〕BrR SCV
Shield GND SLD 17 CN424 8 G SENSOR(SIG) 120 25 23
RL O/R length 5V AVCC 3
R
W
R
W
3 R
W
RSd:2.2kΩ
RSe:680Ω
9
〔 98〕WR
〔601〕WY
7 35 M/V SURGE OUT-1 SENSOR GND-2 135 29
〔698〕BL
〔697〕RY
〔652〕BrY
〔690〕Br
26 7.Following sign indicates the connection of the same number mutually.
RL O/R length input Ai3 13 1 Outrigger length detector (RL) 10 CN790 8 53 COOLER SW G SENSOR(+5V) 133 31 24
RL O/R length GND AGND 8
B
Shield B
B
2 B RSg:270Ω
11
〔680〕RL
〔 52〕Y
1
〔680〕RL
〔 52〕Y
〔680〕RL
23 58 NEUTRAL SW COMMON PRESS.SENSOR(SIG2) 132 32
〔668〕LG
〔667〕BW
27 Receiving side of power supply : Supply side :
Shield GND SLD 18 CN425 12 2 10 51 IDLE UP CANCEL SW G SENSOR(GND) 131 33 28
RR O/R length 5V AVCC 4
R
W
R
W
3 R
W Outrigger length detector (RR)
〔 21〕LG
〔694〕YW
3
〔 21〕LG
〔694〕YW
〔 52〕Y
〔 21〕LG
12 49 EXH.BRAKE SW MF
〔651〕B
29 Receiving side of signal and load :     Supply side :
RR O/R length input Ai4 14 1 4 13 48 STARTER SW(S) NE SENSOR(GND) 41 1 30
RR O/R length GND AGND 9
B
Shield B
B
2 B
Transmission
〔626〕WB 〔626〕WB
5
〔601〕WY
〔694〕YW
15 46 STARTER SW(M)-1 NE SENSOR(SIG) 40 2
〔650〕W
〔 0〕B CN793
(It becomes it for the negative-type logic circuit contrary to
Shield GND SLD 19 6 18 43 STARTER SAFETY RELAY NE SENSOR(SHEILD) 39 3
T/C 5V AVCC 5
R〔220〕
W〔221〕
〔220〕R
〔221〕W
3 VC Pressure sender
〔601〕1.25WY
〔636〕LR
7
〔601〕WY
〔636〕LR
〔626〕WB
20 61 ACCEL SW SENSOR SOURCE-4(+5V) 57 24
〔693〕RW
〔699〕BY
〔653〕YW
〔699〕BY
1 FUEL TEMP  the electric current direction of the load.)
C C
T/C oil pressure sensor input Ai5 15 2 VOUT (torque converter 8 22 59 COLD START SW SENSOR GND-5 55 26 2 SENSOR1(LEAK)

〔626〕WB
〔607〕GY
B〔222〕

〔615〕GL

〔615〕GL
〔624〕YB
〔 22〕G 〔 22〕G

〔606〕LY

〔623〕YL
〔222〕B oil pressure) 〔601〕WY 〔647〕BW
T/C GND AGND 10 1 9 25 56 STARTER SW(M)-2 54 27 3

〔604〕Y

〔604〕Y

〔030〕B
GND SENSOR GND-4
Shield B 〔642〕LgR 〔642〕LgR 〔636〕LR
Shield GND SLD 20 CN419
〔602〕1.25RB
10
11
〔602〕1.25RB 〔 22〕G
29 68
31 66
DIAGNOSIS SW
PTO SW
B Connector 〔693〕RW
5
4
VC
AMP040mk Ⅱ 〔203〕W 〔203〕W 〔642〕LgR 〔641〕LgW BOOST Toggle switch (the switch of upper electric circuit contains it.)

RC5

RC6
12 35 62 Q-ADJUST(SIG) 6 P
SENSOR
CN413 Lead switch
3 5 6 4 1 2 3 5 6 4 1 2 〔910〕WB 〔910〕WB 〔647〕BW
Spare 1 5V AVCC 1 13 7 GND
〔 0〕B 〔644〕LgB 〔644〕LgB 〔602〕1.25RB 〔677〕RG

G
R

R
Y

B
L

L
Spare 1 input Ai6 11 1 (4WD detection) 14 1 7 +VB-3(ECU POWER) 10 AIR TEMP
〔 70〕GB
2 (contact closes 〔624〕YB 〔624〕YB 〔602〕1.25RB A Connector 〔699〕BY SENSOR Up Middle Down Switch
Spare 1 GND AGND 6 15 2 6 +VB-2(ECU POWER) 8

RC5

RC6
at 4WD) 2 1 4 6 3 2 1 4 6 3 〔616〕YR 〔616〕YR 〔602〕1.25RB ① -2 <① -3> Power window
Spare 2 5V AVCC 2 16 3 5 +VB-1(ECU POWER) 11
CN440 〔625〕YG 〔625〕YG 〔679〕L 8B GLOW PLUG ① -3 OFF ＊
Spare 2 input Ai7 12 Lead switch 17 14 11 PWM ACCEL OUT(SIG) 9
〔 0〕B 〔647〕BW 〔647〕BW 〔203〕W ② -3 OFF Outrigger operation box illumination
Spare 2 GND AGND 7 1 (Hight/Low detection) 18 16 9 NE OUT(SIG) 12
〔 71〕GL R R GLOW RELAY ②- 3,⑤-6 OFF 1- ②,4 -⑤ Lower outrigger operation jack /slide select
Spare 3 5V AVCC 3 2 (contact closes 19 17 8 TACHO OUT 13
〔910〕WB <②- 3,⑤-6> OFF <1- ②,4 -⑤> Lower outrigger operation extending /retracting select
Spare 3 input Ai8 13 at Low) 20 18 27 VEHICLE SPEED SENSOR(SIG) 14
Emergency Emergency 〔644〕LgB
Spare 3 input AGND 8 19 26 PTO MAX.REV.SET(SIG) 15
accelerator relay 1 accelerator relay 2 CN691 〔624〕YB
Spare 4 5V AVCC 4 Fuse box
MUT-Ⅲ
1 23 22 ACCEL SENSOR-2(SIG) 16 Notice:（ ） shows the momentary switch.
CN408 〔616〕YR
Spare 4 input Ai9 14 2 24 21 ACCEL SENSOR-1(SIG) CN795
〔123〕RG Br 〔645〕LW
Spare 4 GND AGND 9 3 Straight ahead detection 3 26 19 MUT-Ⅲ (K-LINE：KWP2000)

D D
〔 78〕Y B 〔 01〕B 8B 8B
Spare 5 5V AVCC 5 1 proximity switch 6 27 18 CASE GND 1
Spare 5 input Ai10 15
〔 0〕B L
2 (contact closes at straight) 8 28 34 EGR TEMP.SENSOR(SIG) Fuse box Locker switch (the switch of upper electric circuit contains it.)
〔625〕YG
Spare 5 GND AGND 10 9 32 30 IDLE VOLUME(SIG)
Shield GND SLD 16 CN944 10 CN685 Up MIddle Down Switch
〔123〕RG R Low-pressure switch (steering pump CN794
3 3 11 1-3 OFF Reverse steering, Working lamp, Emergency mission, Emergency accelerator
CN1 AMP040 Ⅱ CN601 〔161〕G G low-pressure alarm)(option) 〔651〕B
1 1 12 2 3-4 OFF ＊
〔 0〕B W (contact closes at low-pressure) 〔650〕W
Input spare (−)Di15 1 2 2 13 1 1-3 OFF 1-2 Slider/Jack (O/R), Ext./Ret. (O/R), Drive select, Roof wiper
〔 0〕B NE SENSOR
Input spare (−)Di16 2 14 3 2-3 1-2 ＊
〔683〕L 〔643〕LgY
Glow lamp (−)Di17 3 15 6 WATER TEMP <3-1> <3-2> ＊
〔684〕BG 〔684〕BG 〔645〕LW 〔699〕BY SENSOR
Water separator (−)Di18 4 2 WATER IN FUEL 7 5 〈E-U〉
〈L-B〉 OFF 〈B-U〉 ＊
〈L-E〉
〔 0〕B SENSOR 〔602〕RB 〔697〕RY
Input spare (−)Di19 5 1 16 7 +5V 〈b-d〉〈a-e〉 〈b-e〉 Power window
f-d,a-e 〈f-d〉
〔 05〕B 〔666〕W G SENSOR
Input spare (−)Di20 6 CN416 5 8 SIG 〈5-6〉 ＊
〈2-3〉
〔 05〕B 〔667〕BW
Input spare (−)Di21 7 4 4 GND
Input spare (−)Di22 8 CN409
Input spare (−)Di23 9
〔 85〕BR 〔 85〕BR Low-pressure switch Notice:（ ) shows the momentary switch.
〔 79〕Gy (engine oil)
Input spare (−)Di24 10
〔021〕B 〔600〕1.25R (contact closes at low-pressure)
GND 20

E GND
Input spare (+)Di32
19
18
〔021〕B 〔696〕WL
〔 98〕WR
〔649〕1.25BY
Fuse box
Relay E
Input spare (+)Di31 17
〔556〕RW
Input spare (+)Di30 16 Make
Input spare (+)Di29
RA8, 9, 11, 17, 21, 22, 28
15 contact

〔637〕BrR
〔 98〕WR

〔 98〕WR
Input spare (+)Di28 14

〔638〕Br
〔249〕RL
Outrigger acclerator (+)Di27 13
Break

〔601〕1.25WY
〔602〕1.25RB

〔649〕1.25BY

DIAG LAMP−2(UMBER)
〔236〕YB Unit 1 pole RB1, 3, 4, 6,7,8, 11, 12,

〔600〕1.25R
Outrigger switch neutral (+)Di26 12
contact

CN731
CN733
〔 21〕LG

DIAG LAMP−1(RED)
〔694〕YW
〔696〕WL

〔 98〕WR
Engine start (+)Di25 11

〔609〕BY

〔 21〕LG

〔 54〕LO
〔 79〕Gy

〔 98〕WR
〔600〕R

〔689〕R

〔689〕R

〔636〕LR
〔030〕B

〔030〕B

〔030〕B

〔635〕LY
Air low-pressure switch

〔614〕L

〔614〕L

〔679〕L
CN410

〔030〕B
(contact closes at Lead switch (resorvoir assy)
AMP040 Ⅱ CN600 〔175〕GW
(contact closes at lack) C
〔 78〕Y
low-pressure) RC5, 6

CN414

CN415
Straight ahead detection (−)Di6 6 CN411 contact
2 1 2 1

CN797

CN730
〔 83〕BL Low-pressure switch (parking brake)
Input spare (−)Di5 5 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 3 1 4 2 2 1 2 1

RA21

RB11

RB12

RA28
〔 0〕B (contact closes at low-pressure)

RB4
Input spare (−)Di4 4
RD4, 5

B
B

B
B
DIAG lamp 2 (−)Di14 14
〔638〕Br 〔 82〕BW 2 poles

CN734

CN732
〔637〕BrR 〔 0〕B
DIAG lamp 1 (−)Di13 13 R R R R R
〔575〕LR 〔 0〕B

F F
T/C oil temperature 110℃(230°F) (−)Di12 12 MEMORY DIAG CN51 SL.51
〔 85〕BR CLR SW SW 〔 50〕YL
Engine oil low-pressure (−)Di2 2 2 Air solenoid valve 4 poles RF2, 3
( )( )
〔 71〕GL ECU main Starter continuous Starter Engine Glow relay Memory is deleted DIAG mode when CN788 〔 0〕B
Low detection (−)Di11 11 power energiaing interception emergency stop 1 (2/4 wheel drive shifte)
〔161〕G when disconnected disconnected
Steering pump low-pressure (−)Di10 10 supply relay prevention relay relay relay then connected 6
〔244〕YO 〔 51〕YB 〔 51〕YB CN54
Fuel level detection (−)Di7 7 5 SL.54
Air low-pressure (−)Di9 9
〔175〕GW 〔 83〕BL
4
〔 83〕BL 〔 79〕Gy
2 Air solenoid valve Diode
〔 83〕BL 〔655〕BW 〔655〕BW 〔655〕BW Air drier heater
Air low-pressure (parking brake) (−)Di3 3 3 1 (exhaust brake)
Brake fluid level detection (−)Di1 1
〔 82〕BW 〔 79〕Gy
2
〔 79〕Gy For 1A
〔 70〕GB CN52
4WD detection (−)Di8 8 1 SL.52
〔021〕B 〔 51〕YB
GND 15
〔021〕B 〔021〕1.25B 〔 0〕B
2 Air solenoid valve For 3A D37, 44, 50~53
GND 16 CN789 1 (High/low select) CN745
〔556〕RW 〔556〕RW 〔556〕RW
12 2
CN602 〔 0〕B CN428
CN2 AMP070mk1 11 1
Power supply 24V MPOW 1
〔105〕W Fuse box 〔117〕GW
10
〔117〕GW 〔117〕GW
3 + - Resistence
〔105〕W 〔244〕YO 〔244〕YO 〔 0〕B Fuel sender
Power supply 24V MPOW 2 9 2
Power supply 24V MPOW 3
〔105〕W 〔 0〕1.25B
8
〔 0〕1.25B 〔244〕YO
1 (contact closes RSc, d, e,g, k, l
〔022〕1.25B 〔175〕GW 〔175〕GW CN50 when fuel is low)
GND 4 7 SL.50

G G
〔022〕B 〔 19〕WG 〔 19〕WG 〔 19〕WG
GND 5
〔022〕B
6
〔 0〕B
2 Air solenoid valve Condenser
GND 6 5 1 (parking brake)
〔 50〕YL
4 〔 50〕YL CN569 ＊
CN5 AMP040mk Ⅱ CN605 CN619 〔101〕WY 3 〔101〕WY 〔101〕WY Pressure switch(stop lamp)
〔800〕LR 〔124〕RY
TXD 1 2 2 〔124〕RY 〔124〕RY (contact closes at depressing brake pedal)
〔801〕LW 〔 82〕BW
RXD 2 5 1 〔 82〕BW CN568
BOOT 〔802〕LG MDT
3 1
GND 〔803〕LB (for maintenance)
4 4 Extending Retracting
GND 〔804〕Br Outrigger operation assy (option) Fuse box
5 3 SL.21 SL.20
GND 〔804〕Br
6 6 Lower outrigger operation box (L)
GND 〔804〕Br
7

CN21

CN20
GND 〔804〕Br 1 2 1 2 B 2 Head lamp relay
8

〔0〕B

〔0〕B
〔 43〕WB
CN610 〔146〕

〔 62〕Y
CN9 AMP070mk1 3
RY28 G Illumination 1.25BrB CN704 L2 15A S2 CN708 〔 36〕BrR
7 Outrigger Head lamp (traveling beam)
RY29 FL switch
8 ext./ret. 〔042〕B
RY30 Y S B CN707 〔125〕1.25RL
9 selector
H RY31
RY32
RPOW9
14
15
solenoid valve
〔 0〕B
CN942 Br
RL
FR
Head lamp (passing beam)
〔145〕
1.25BrW CN705 L1
15A
S1 CN706 〔 37〕BrY H
2 1 1
〔027〕B Outrigger operation assy (option) 〔 45〕PB W
GND 10 4 4 RR MDT RY49
〔027〕B 〔 44B〕RL
GND 11 5 5 MDT RY22
〔027〕B 〔 42〕WR
GND 12 6 6 ALL
〔027〕B CN943 〔 41B〕RW
GND 13 2 2
〔027〕1.25B 〔564〕GL 〔 46〕WL
GND 20 Bubble level 1 1 3 3 CN769
RY33 〔 0〕B 〔 43〕WB 5 0.85RB (A)
16 (illumination)(L) 2 2 7 7 1 5A
RY34 〔 62〕Y Sb 4 〔 96〕YL 0.85RW (B) CN768
17 10 10 Transmission power supply relay 4 5A
RY35 〔141B〕RL L 6 〔 87〕P 0.85LgB (C) 2Y 〔1D〕2W
18 11 11 Outrigger operation/MDT RPOW2 2 5A 1
RY36 CN726 〔249B〕LR P 2 〔 79〕Gy 0.85Gy (D) 2L 〔1D〕2W
19 8 8 Head lamp relay(traveling beam), Exhaust/MDT RPOW7, Glow relay, Exhaust SOL. 6 5A 2
RY25 〔660〕Lg 〔563〕G 〔236B〕LY O 1 Outrigger switch 〔 90〕GR 0.85GR (E)
4 Bubble level 1 1 9 9 Outrigger operation/MDT RPOW1 3 5A
RY26 Not use 〔 0〕B 5 3 (for ext./ret. 〔 88〕GY 0.85GY (F)
5 (illumination)(R) 2 2 12 12 Lockup, Transmission N/MDT RPOW13 7 5A
RY27 Not use R 4 selector)
6 5
RPOW8 〔644〕LgB 6 (L)
1 3 CN770
RY24 2 〔 95〕RL 0.85RL

I I
(G)
3 7 2/4 wheel drive・Hi/Lo drive shift, Hour meter /MDT RPOW6 1 5A
RSk,RSl:1.5kΩ/1W 1 Outrigger switch 〔 94〕G 0.85G (H) CN767
RSl 11 Steering power supply relay 3 5A
CN10 AMP070mk1 CN611 〔564〕GL 〔564〕GL 3 (for jack/slide select) 〔 93〕GW 0.85GW (I) 2R 〔1D〕2W
10

〔 41B〕RW

〔236A〕RY
〔141B〕RL
Head lamp relay (passing beam), Suspension lock/MDT RPOW15 4 5A 1

〔 44B〕RL
〔 44〕WY
RY23

〔 46〕WL
〔563〕G 〔563〕G 0.85GL (J) 2W 〔1D〕2W
9

〔561〕R
13

〔 41〕W

〔030〕B

〔030〕B
Gy
Accelerator 2 5A 2
RY22 〔 36〕BrR Head lamp relay (traveling beam) RSk 〔142〕BrW 〔142〕0.85BrW 〔 91〕GO 0.85GO (K)
12 8 switch Outrigger operation/MDT RPOW3 5 5A
RY21 〔 52〕Y D53 〔249B〕LR 〔249B〕LR
11 Thermo switch (T/C oil 110°C/230°F) 2 CN774
RPOW7 〔 79〕Gy CN940 D52 〔249A〕R 〔249A〕R 〔123〕RG 1.25RG (A)
3 1

RB8
(contact closes at T/C oil temperature 110℃) Steering low-pressure switch, Straight ahead detection switch 1

RD5
5A
RPOW5 〔575〕LR 〔249〕RL 〔249〕RL 1 4 2 5 6 3 7 3 1 4 2 〔125〕1.25RL 1.25RL (B) CN771
2 6 Slide Jack Slide Jack 4 15A

R
LW

B
RPOW6 〔 95〕RL 〔 0〕B 〔 0〕B D51 〔236B〕LY 〔236B〕LY

LY
1.25RY 3Y

BrW
Fuse box 〔124〕RY (C) 〔1B〕3W

BrR

BrY
1 Hour meter 5 SL.24 SL.25 SL.22 SL.23 Stop lamp, Backup lamp, Clearance lamp relay 2 10A 2
RY20 〔570〕RB 〔570〕RB D50 〔236A〕RY 〔236A〕RY 〔 98〕WR 1.25WR (D) 3L 〔1B〕5W
10 (option) 4 Starter continuous energizing prevention relay, DIAG lamp, MEMORY CLEAR 6 10A 1
RY19 〔236〕YB 〔236〕YB R (for FR) (for FL)

Relay RD5
CN941 〔141〕RB 1.25RB (E)

1
5
9
4
8
9 12

CN24

CN25

CN22

CN23
12
13
14
1 2 1 2 1 2 1 2 Lower outrigger operation power supply cut relay 3 10A
RY18 〔 51〕YB 〔556〕RW 1.25RW (F)
8 Diode assy CN959 Air drier 7 10A
RY17 〔 50〕YL Suspension lock selector Lower outrigger
R

〔110〕RW
(R)

〔113〕RG
7

〔111〕RB
5

〔112〕RL
Suspension Supension

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B
〔028〕1.25B operation box relay
GND 14 lock free Jack Slide Jack CN775
RY16 Slide 〔600〕1.25R 1.25R (G)
6 SL.02 SL.03 Lower outrigger SL.28 SL.29 SL.26 SL.27 ECU main power supply 1 15A CN772
RY15 〔 17〕1.25LW 1.25LW (H) 3R 〔100〕3R
5 operation box relay (Rotary joint) Starter switch, Eemergency stop 3 15A 2
RY14 (for RR) (for RL) 〔 6〕1.25O 1.25O (I) 3W 〔100〕3R
CN2

CN3

CN28

CN29

CN26

CN27
1 2 1 2 Upper power supply battery connecting directly 4 15A 1

J J
Outrigger operation assy (option) 1 2 1 2 1 2 1 2 〔 2〕1.25Y 1.25Y (J)
(Rotary joint) Power window 2 15A
CN612 〔105〕W 1.25W (K) 1.25G 〔1D〕W
〔567〕LG

CN11 AMP070mk1

〔106〕YW
〔566〕LY

〔108〕YO

〔109〕YG
MDT power supply/MDT MPOW 5 1

〔107〕YB
5A
〔 0〕B

〔 0〕B

RY13

〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B
17
RY12 Relay RF3 CN773
16
RY11 (jack/slide select) RF3-2H CN766
15
RY10 1 LR 4 〔112〕RL 〔696〕WL 〔696〕WL
14 9 Starter continuous energizing prevention relay RB11 6
RY9 RF3-1 5 LW 9 〔113〕RG 〔042〕B 〔 0〕B D44
13 5
RY1 〔 45〕PB 〔 45〕PB LY 2 GR 3 〔110〕RW 〔 16〕1.25YL 〔 16〕YL D37
5 1 10 (Rotary joint) Starter switch 1
RY2 〔 44〕WY 〔 44〕WY GY 6 GW 8 〔111〕RB 〔134〕1.25RL 〔134〕RL
6 2 2
RY3 〔 42〕WR 〔 42〕WR LgY 3 LgR 2 〔108〕YO
7 4 11 MDT CHG 3
RY4 〔 41〕W 〔 41〕W BrY 7 LgW 6 〔109〕YG Diode
8 6 4
RY7 〔 46〕WL 4 BrR 1 〔106〕YW
11 5 12 Engine emergency stop relay RB4
RY5 〔 43〕WB 〔 46〕WL R 8 BrW 5 〔107〕YB
9 7
RY6 〔 62〕Y 〔030〕B B 7 H type outrigger
10 3 14 13
RY8
12
〔560〕RY R

〔649〕1.25BY

〔134〕1.25RL
〔 17〕1.25LW

〔 17〕1.25LW
〔 16〕1.25YL
RPOW3 〔 91〕GO
1 Fuse box
RPOW2 〔 87〕P

〔 86〕BG
4 Fuse box
K K

〔042〕B

〔042〕B
RPOW1 〔 90〕GR Outrigger operation assy (option)
3 Fuse box Steering mode selector
RPOW4 Lower outrigger operation box (R)
2
GND 〔029〕1.25B

RA22
18 SL.32 SL.33 SL.31 SL.30

RA9
B 2 3 1 4 2 3 1 4 2
CN609
CN31
CN32

CN33

CN30

CN8 AMP070mk1
RPOW10 1 2 1 2 1 2 1 2
1 3
〔 0〕B

〔 0〕B

GND 〔026〕B G Illumination R R

〔 0〕B

〔 0〕B

6
〔 53〕BrW

〔 57〕PB
〔 48〕LR
〔 47〕LB

GND 〔026〕1.25B RR switch

12
MSOL2 RPOW14 〔 89〕GB Y Electronic Battery power
5
MSOL1 RPOW13 〔 88〕GY RL
4 Fuse box governor power supply keeping
RPOW12 CN434 Br supply relay relay
3 Engine body Fuse
RPOW11 〔 0〕B FR
2 1 1 (upper power supply)
RY37 〔 41〕W W
7 Transmission 4 4 FL 75A
RY38 〔 42A〕WL

CN778
8 5 5 CN747
RY39 SL. 43 44 45 42 〔 44〕WY 〔696〕WL - +
9 Transmission selector 6 6 SW 1
RY40
10 solenoid valve F1 F2 F3 R 〔 45A〕LB
2 2
ALL 〔 1A〕8W 〔1F〕8W
RY41 〔680〕RL 〔 46〕WL Rotary joint
L L
CN43

CN44

CN45

CN42

TH1 11 2 1 2 1 2 1 2 1 3 3 B
〔 43〕WB 5 CN749 〔 1E〕8W Fuse
7 7 S B
CN608 〔 62〕Y Sb 4 (Main)
〔 0〕B

〔 0〕B

〔 0〕B

〔 0〕B

CN7 AMP070mk1 10 10
RY42 〔 58〕LgY 〔141A〕BR L 6 Starter relay
3 11 11 CN748

〔100〕3R
75A

〔1D〕3W
〔1B〕5W
RY43 〔 31〕RY 〔 31〕RY 〔249A〕R P 2

CN779
TH3 4 8 8 〔 1B〕W
〔 32〕RB O R 1
TH2
RY44
5
〔 32〕RB 〔236A〕RY
9 9
1 Outrigger switch 〔 86〕BG - +
〔 33〕RW L 2
RY45 〔 33〕RW 5 3 (for ext./ret. 〔 1E〕8W 〔1C〕8W
6 12 12
RY46 R 4 select)
7 Fuse box P 1
RY47 6
8
RY48 〔 40〕R 〔 40〕R 2

CN761
CN758
CN760
CN763
5BW

CN759
9 CN750

5B
K RY49 〔 37〕BrY 1 8B
Head lamp relay (passing beam) Outrigger switch

〔141A〕BR
10 E

〔236B〕LY
〔42A〕WL
〔 42〕WR
LR

〔45A〕LB
K RY50 3

〔 46〕WL
〔566〕LY 〔117〕GW

〔141〕RB

〔560〕RY
1

〔 45〕PB
4 (for jack/slide select) S

〔561〕R
11

〔030〕B

〔030〕B
9

〔561〕R

〔030〕B
Alternator
K RY51 〔567〕LG RF2-1 5 LW 〔 40〕R B 60B 60B 60B 60B 60B
12 9 Accelerator
RY52 〔 10〕GY LY 2 GR Gy
13 1 10 3 switch

〔134〕1.25RL
RY53 〔 48〕LR 〔629〕GR GY 6 GW 〔 33〕RW 60B Fuse + - + -
14 2 8 Engine water temperature

RD4

RB7

RB6
RY54 〔 47〕LB 〔 8〕YR LgY LgR CN426 1 4 2 5 6 3 7 3 1 4 2 Battery
15 4 11
3
2
〔118〕GL
thermo sender 3 1 4 2 (Grid heater)
Starter motor

R
LW

B
RY55 〔 57〕PB 〔 12〕YO BrY 7 LgW 〔 32〕RB

LY

BrW
BrR
CN427 70A

BrY
16 6 6

M M
RY56 〔 53〕BrW 4 BrR 〔147〕GR 〔147〕GR Torque converter oil temp.
17 5 12 1 + -
RPOW16 〔248〕GL 〔 20〕YG R 8 BrW 〔 31〕RY thermo sender R R

Relay RD4
CN755 CN762

1
5
9
4
8
2 7 5

12
13
14
RPOW15 〔 93〕GW 〔030〕B B
1 Fuse box 3 14 13 7
GND
18
〔025〕1.25B
Relay RF2
R RF2-2 R Power supply
Outrigger operation assy (option)
Glow relay
8B 15B Battery relay

(Emergency select relay

CN3 AMP040mk Ⅱ CN603 transmission selector) Lower outrigger operation box relay
〔 5〕LY CN49
Upper/Lower unit serial ouptut TXD1 1
〔 3〕WR 〔 0〕B CN957
Upper/Lower unit serial intut RXD1 2 1
〔 58〕LgY SL.49 〔627〕GB
Spare serial output TXD2 3 2 Passing beam (55W) (Rotary joint) 1
Spare serial input RXD2 4 〔628〕GW Spare circuit
Lockup solenoid valve Traveling beam (50W+50W) (Rotary joint) 2
〔023〕B 〔630〕GO
GND 5 (Rotary joint) 3
〔 4〕YW Head lamp(LH) Head lamp (RH)
System check input CHK 6
〔 86〕BG CN41
Charging lamp input CHG 7 Fuse box

Traveling beam
Traveling beam
〔245〕YR 〔 0〕B

Passing beam
Passing beam
PTO Limiter Tr1 8 1
〔 35〕Br 〔246〕GY SL.41
Clearance lamp Tr2 9 2
Steering power supply Tr3 〔247〕GB
10 PTO solenoid valve Conbination lamp (LH) Conbination lamp (RH)
Output spare Tr4 11 Fuse box
N N
Side turn signal (LH) Side turn signal (RH)
〔023〕B

ce
GND 12 0.85B 0.85B

Cle
Torque converter

na
Tu

al
RW
ara

RW

ara
RB
RB

rth ign
Parking 4W GY

rn

CN701

CN703
CN702
nc

CN700

Cle

Ea rn s
sig rth
Clearance 10W G

e
Ea
na
Rotary joint

Tu
〔246〕GY

G
Turn 25W+25W GB
〔245〕YR

CN

0
G
〔 89〕GB

〔 20〕YG

l
〔 96〕YL

CN880 CN780

〔146〕1.25BrB

71
〔030〕B

〔146〕1.25BrB

GB
〔 22〕G

〔 22〕G

GB

GB

GB
〔0〕0.85B
〔0〕0.85B
71
〔 3〕WR

6
CN

CN
Upper MDT TXD1 1 23 1

94
9

B
CN
B

70
〔626〕WB

CN
94

〔145〕BrW
〔145〕BrW
Accelerator switch 2 26 2

CN
5

12

〔142〕0.85BrW
RB1

RB3

CN881 CN783 3 1 4 2 3 1 4 2

〔142〕0.85BrW
〔 13〕0.85LB

〔 5〕LY 〔 13〕0.85LB

〔 9〕0.85LR

〔 9〕0.85LR
〔 0〕0.85B

〔 0〕0.85B
Upper MDT RXD1 3 25 3
〔 0〕0.85B

〔 0〕0.85B

〔918〕PB 〔145〕1.25BrW
Pulse transducer(engine speed) Pi1 1 7 1
〔911〕WL R R
Upper MDT mainspeed input 2 11 2

CN884 CN784 Transmission power PTO limiter

〔 8〕YR supply cut relay relay
Emergency transmission selector relay RF1(Engine water temp. thermo sender) 1 8 1
〔 10〕GY
Emergency transmission selector relay RF1 (Fuel sender) 3 10 3 Head lamp
〔 12〕YO

O O
Emergency transmission selector relay RF1(T/C oil temp. thermo sender) 4 12 4 relay
〔614〕L
Engine emergency stop switch 6 14 6
〔 9〕0.85LR
Turn signale switch (right) 2 9 2
〔 13〕0.85LB
Turn signale switch (left) 5 13 5
〔142〕0.85BrW
CN885 CN785 〔 40〕R
〔 21〕LG
Key switch START and shift N 6 21 6
〔629〕GR
Emergency transmission selector relay RF1 11 29 11
〔 20〕YG
Emergency transmission selector relay RF1(Emergency transmission select) 5 20 5
〔 19〕WG
Parking brake switch 4 19 4
〔124〕RY
Spare 3 18 3 Fuse box
To upper MDT 〔 4〕YW 〔168〕0.85YL
CHK SW/Upper MDT CHK 8 24 8
electric circuit 〔615〕GL
Emergency acclerator switch 1 15 1
〔628〕GW
Spare 10 28 10 Fuse box

〔142〕0.85BrW
CN723
〔142〕0.85BrW

〔630〕GO
Spare 12 30 12 Fuse box
〔13〕0.85LB

〔9〕0.85LR
〔 22〕G
〔142〕0.85BrW
〔030〕1.25B

〔0〕0.85B
〔168〕0.85YL

PTO SW 7 22 7
〔101〕WY

〔101〕WY
CN721

〔627〕GB
CN751

Spare 9 27 9 Fuse box

〔124〕RY

P P
〔124〕RY

〔124〕RY

〔 16〕1.25YL
〔030〕B

Key switch ACC/ON/START 2 16 2 Fuse box Fuse box

〔 35〕Br

〔 40〕R

〔0〕B 〔0〕B

CN719
〔247〕GB

CN717

〔 0〕B
〔248〕GL

CN718

CN882 CN781

CN720
〔 94〕G

〔 94〕G

〔 2〕1.25Y 2 1 3 3 1 2
Power window 1 5 1 Fuse box
RA11

GW

GW
3 1 4 2 3 1 4 2
RA8

GY

〔 6〕1.25O
GL

GY

GL
Upper power supply battery connectiong directly 2 6 2 Fuse box Licence lamp

B
G

G
B

〔 17〕1.25LW Back buzzer

IWZ03-3310E01
(option) 12W
RA17

Key switch power supply 3 17 3 Fuse box

3 1 4 2 Backup lamp
R R (25W)
CN883 CN782
〔 1A〕2W 〔 1A〕8W
Upper power supply fuse 1 1 1 Fuse box Tail, stop lamp Turn signal Turn signal 25W GY
Turn signal Tail, stop lamp
〔 1A〕2W Steering power R Clearance lamp relay Backup lamp relay
Upper power supply fuse 2 2 2 Stop 25W GW
〔 1A〕2W supply relay
Upper power supply fuse 3 3 3 Rear conbination lamp (L) Tail 10W G Rear conbination lamp (R)
〔 1A〕2W
Upper power supply fuse 4 4 4 Parking 3W GL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

12 WZ03-3310E 347-510-40000 1 12
Z-7 Z-7
Location of Hydraulic Parts (Upper)

Z-7 Location of Hydraulic Parts (Upper)

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

13 WZ07-0951E
Z-7 Z-7
Location of Hydraulic Parts (Upper)

List of components illustrated in the “Cab and swing table” figure (in alphabetical order)
Compressor (air conditioner, option)
Condenser (air conditioner, option)
78.Hose real
38.Hydraulic motor (air conditioner, option)
34.Hydraulic motor (oil cooler)
33.Oil cooler
52.Orbitrol
48.Priority valve
61.Remote control valve (lever)
27.Rotary joint
47.Sequence valve (pilot pressure)
46.Solenoid control valve (jib set) (SL192, SL193, SL222, SL223)
89.Solenoid valve (air conditioner, option) (SL280)
36.Solenoid valve (oil cooler) (SL281)

14 WZ07-0951E
Z-7 Z-7
Location of Hydraulic Parts (Upper)

A section (behind cab)

List of components illustrated in the “A section” figure (in alphabetical order)

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

15 WZ07-0951E
Z-7. Z-7.
Location of Hydraulic Parts (Upper)

2. Boom

List of components illustrated in the “Boom” figure (in alpha betical ovder)
42.Jib lock pin
39.Jib offset cylinder
40.Pilot check valve (jib set)

16 WZ07-0951E
Z-8 Z-8
Location of Hydraulic Parts (Lower)

Z-8 Location of Hydraulic Parts (Lower)

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

17 WZ07-0961E
Z-8 Z-8
Location of Hydraulic Parts (Lower)

1.1 Front

List of components illustrated in the “Front” figure (in alphabetical order)

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

18 WZ07-0961E
Z-8 Z-8
Location of Hydraulic Parts (Lower)

1.2 Center

(*1): Application
Europe {
General Export ―

List of components illustrated in the “Center” figure (in alphabetical order)

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

19 WZ07-0961E
Z-8. Z-8.
Location of Hydraulic Parts (Lower)

1.3 Rear

List of components illustrated in the “Rear” figure (in alphabetical order)

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

20 WZ07-0961E
Z-9 Z-9
Location of Air Parts

Z-9 Location of Air Parts

1. Cab and swing table

List of components illustrated in the “Cab and swing table” figure (in alphabetical order)
Air pressure sender
Air solenoid valve (air horn) (SL60)
Air tank (10L)
Brake valve
Check valve 347-112-70000 △
0

347-219-30000 △
0

343-453-10000 △
0

21 WZ08-0300E
Z-9 Z-9
Location of Air Parts

2. Carrier

Enlarge view of A (center of the carrier’s right hand)

22 WZ08-0300E
Z-9. Z-9.
Location of Air Parts

List of components illustrated in the “Carrier” figure (in alphabetical order)

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

349-221-60000 △
1

349-221-70000 △
1

23 WZ08-0300E
Z-10. Z-10. Z-10.
Location of Electric Parts (Inside cab)
[NOTICE]
CN473, CN915 are applied only for Europe.
Z-10 Location of Electric Parts (Inside cab)
Bubble level Touch-type main winch drum indicator (TDN array) (option) CN932,933
CN805 Touch-type main winch drum indicator (ISO array) (option) CN932,933
Shift lever
Accelerator sensor CN563,513 Touch-type aux. winch drum indicator (TDN array) (option) CN936,937
CN586 3rd/top boom extending switch (TDN array) CN507
Accelerator switch Connect the waterproof cap with CN506 (ISO array) when you apply theTDN array
CN548
Front wiper motor
CN812
Condenser (front wiper motor noise supperssion
CN835

To condenser for washer motor

CN850,CN849,CN837
To conbination switch
CN511,562
Condenser (power window motor noise suppression)
CN834

To door junction Touch- type aux. winch drum indicator (ISO array) (option) CN934,935
CN813 3rd/top boom extending switch (ISO array) CN506
To power window
Horn switch
CN461 CN531
CN467,494,514,510,476,505 MDT
509,484,824,487,485,922 (Left) CN620～624
923,924,965 (Right) CN625～627,629～631
966,967,810,811 To harness with cab CN806
Visible type winch drum indicator (option) (CN976～978,486,491,915,473：not used) Room lamp (door side) Swing table harness (air)
CN380 Working lamp (LH) Roof wiper motor, CN895
Working lamp
CN495,468,470,574,907 Condenser (power window motor noise suppression)
908,909,504,503 CN836
904,905,906 Air conditoner control
(CN939：option) panel (option)
CN864,865

CN499,500,498,501
502,480,497 Condenser (Roof wiper motor noise suppression
CN833

① For MDT /maintenance ：CN639 Flasher unit

② For reducing the main pressure：CN820 CN814
③ For engine speed output：CN819
④ For vehicle speed limit :CN925(2 pieces) Do not connect Relay assy
⑤ For emergency jib operation：CN918,919
CN915 Relay：RA1～6,14,26
Idling adjustment switch ⑥ Fuse (for drum indicaor)：CN968,969
(Emergency stop) R1,2,4,8,9,11,13,22,23,26,29
CN587,588 For air conditoner (option) CN802 R33,36,RB5,RC1～3,7
CN473
(Reverse steering)
View Starter switch For fan (option) CN926 RF1(4c),R47(option)
CN557 (R10,46,53,KR27: not used)
(option)
Terminal assy：CN863
Room lamp Emergency switch (system check)：CN564
CN804 Engine emergency stop switch：CN517
Touch-type winch drum indicator (option):CN931
Pulse transducer Fuse (L)：CN875～878
CN998 Fuse (R)：CN870～873

To boom harness
Buzzer 3 (AML alarm) Buzzer 1 (air low pressure alarm) CN887
CN818 CN815,816
Buzzer 4 (overwind (two -blocking) alarm) Swing table (Left) CN893,894
Harness (AML)
CN817 Swing table (Right) CN889,890
Control lever stand position detection CN886,892,896～899,964
Detail Swing table sub. harness CN891
This side CN529, When there is AML trouble, Rotary joint CN880～885
Opponent CN530 use this wiring to force the
relief vent solenoid to function.
Normally these wires are kept
taped together.
CN821 IWZ02-3111E01

343-532-31000 △
1

343-536-61000 △
0

24 WZ08-3111E 24
Z-11. Z-11. Z-11.
[NOTICE]
Location of Electric Parts (Swing Table, Boom) The connection in frame ( ) in figure is applied only for Europe: CN546,547,595,596,CN518,CN949
(*1): CN238 is applied for GR-800XXL-1 and GR-550EX-1.
Z-11 Location of Electric Parts (Swing Table, Boom) (*2): CN994 is applied for GR-800XXL-1 and GR-700EXL-1.
(*3): CN894 is applied only for GR-550EX-1.

343-536-22000 △
3
343-536-82000 △
2

25 WZ02-2981E 25
Z-12. Z-12. Z-12.
Location of Electric Parts (Relay Assembly / Upper)

Z-12 Location of Electric Parts (Relay Assembly / Upper)

343-536-61500 △
0
343-632-33000 △
0
343-532-31000 △
1

26 WZ02-3120E 26
Z-13. Z-13. Z-13.
Location of Air Parts (AML)

Z-13 Location of Air Parts (AML)

343-632-81000 △
0

343-632-31000 △
0

27 WZ02-3000E 27
Z-14. Z-14. Z-14.
Location of Electric Parts (Lower)
[NOTICE]
Z-14 Location of Electric Parts (Lower) The connection in frame ( ) in figure is applied only for Europe.

349-310-00000 △
2

28 WZ02-3010E 28
Z-15. Z-15. Z-15.
Location of Electric Parts (Box Assembly / Lower)

Z-15 Location of Electric Parts (Box Assembly / Lower)

349-310-02000 △
0 349-310-01000 △
0

349-310-02300 △
1 349-310-01300 △
0

29 WZ02-3020E 29
Z-16 Z-16 Z-16
Harness (Connector No. Table)

Z-16 Harness (Connector No. Table)

CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page
Suspension lock selector solenoid valve 408 Straight ahead detection proximity switch B-11 514 Steering mode select switch J-2
39 33
02 Suspension lock J-4 409 Low pressure switch (Engine oil) B-12 517 Engine emergency stop switch G-6
39
03 Suspension release J-5 410 Air Low-pressure switch 518 Over-rear detection proximity switch
40 35
Outrigger ext./ret. selector solenoid valve 411 Air low-pressure switch (parking brake) 521 Over-front detection proximity switch
20 Retracting J-5 413 Lead switch (4WD detection) K-5 39 529 Control lever stand position detection switch J-8
21 Extending J-5 414 Lead switch (reservoir assy) 530 Connector I-8 33
40
22 Slide (for FL) F-3 415 Lead switch (reservoir assy) 531 Swing horn switch K-6
23 Jack (for FL) F-2 416 Water in fuel sensor D-6 532 Main winch hoisting up detection switch
24 Slide (for FR) I-3 419 Pressure sender (torque converter oil pressure) K-9 533 Aux. winch hoisting up detection switch
39
25 Jack (for FR) I-2 420 Main speed sensor K-7 534 Boom extending detection switch
26 Slide (for RL) B-14 421 Pickup sensor (sub. speed) C-10 536 Boom raising detection switch
27 Jack (for RL) B-15 422 Outrigger length detector (FL) G-2 537 Boom lowering detection switch 34
39
28 Slide (for RR) I-11 423 Outrigger length detector (FR) J-2 540 Swing right detection switch
29 Jack (for RR) I-11 424 Outrigger length detector (RL) B-14 541 Swing left detection switch
Steering mode selector solenoid valve 425 Outrigger length detector (RR) I-12 546 Main winch hoisting down detection switch (option)
30 Crab, I-4 426 Engine water temperature thermo sender G-10 547 Aux. winch hoisting down detection switch (option)
31 4 wheel, I-4 427 Torque converter oil temp. thermo sender K-3 548 Accelerator switch I-1 33
39
32 Reverse, I-4 428 Fuel sender 40 553 2nd boom full retraction detection switch 36
33 Rear select J-4 434 Lower outrigger operation box (R) B-7 555 Thermo switch (50°C/122°F)
39 35
Transmission selector solenoid valve 440 Lead switch (High/Low detection) K-9 556 Thermo switch (85°C/185°F)
42 R E-8 461 Power window switch (outside cab) K-8 557 Starter switch C-2 33
43 F1 E-9 467 Power window switch J-4 558 AML override switch 34
39
44 F2 E-9 468 Roof wiper switch A-2 562 Combination switch E-2
45 F3 E-9 470 Working lamp switch A-3 563 Mission select switch (shift lever) H-3 33
41 PTO solenoid valve K-5 473 Reverse steering switch K-4 564 Emergency switch (system check, mission, accelerator) F-7
39
49 Lockup solenoid valve K-4 476 High/low and 2/4wheel drive select switch J-2 33 568 Pressure switch (stop lamp)
40
50 Air solenoid valve (parking brake) 480 Outrigger switch (for jack/slide select) D-6 569 Pressure switch (stop lamp)
51 Air solenoid valve (2/4 wheel drive shift) 484 Swing brake switch C-3 572 Jib stowed detection proximity switch
40 36
52 Air solenoid valve (High/Low select) 485 Boom telescoping/aux. hoist control selector switch C-4 573 Jib lock pin retracting detection switch
54 Air solenoid valve (exhaust brake) 486 Swing stop cancel switch C-4 574 Oil cooler switch A-4 33
60 Air solenoid valve （air horn） 35 487 Swing free/lock selector switch E-4 576 Boom length and angle detector 36
100 AML (Load moment indicator) vent solenoid valve 488 Jib mounting / stowing switch 35 580 Swing angle detector
37
102 Remote control pressure vent solenoid valve 491 Elevating slow stop cancel switch C-5 581 Pressure sender (main pressure)
120 Swing right proportional control valve 494 Hazard switch J-5 583 Pressure sender (air pressure) 35
121 Swing left proportional control valve 495 Roof washer switch A-1 584 Pressure sender (elevating cylinder, boom raising)
37
124 Boom raising proportional control valve 497 Outrigger switch (for ext./ret. select) D-6 585 Pressure sender (elevating cylinder, boom lowering)
125 Boom lowering proportional control valve 34 498 Outrigger Individual operation switch (all) E-6 586 Accelerator sensor I-1
143 Boom telescoping/aux. hoist control selector solenoid valve 499 Outrigger Individual operation switch (FL) F-5 587 Idling adjustment switch D-3 33
144 Boom telescoping/aux. hoist control selector solenoid valve 500 Outrigger Individual operation switch (FR) F-6 588 Idling adjustment switch D-2
160 Swing brake release solenoid valve 501 Outrigger Individual operation switch (RL) E-6 591 Main winch drum rotation detection proximity switch
161 Swing free/lock solenoid valve 502 Outrigger Individual operation switch (RR) F-5 592 Aux. winch drum rotation detection proximity switch
33 35
162 Swing relief proportional control valve 503 3rd/top boom emergency telescoping switch B-6 595 Main rope run-out detection switch (option)
192 Jib lock pin extending solenoid valve 504 2nd boom emergency telescoping switch B-6 596 Aux. rope run-out detection switch (option)
193 Jib lock pin retracting solenoid valve 505 Overwind cutout (anti-twoblock) disable switch C-2 600 MDT (lower) CN1-1 H-4
35
222 Jib mounting solenoid valve 506 3rd/top boom extending switch (ISO array) J-6 601 MDT (lower) CN1-2 H-4
223 Jib stowing solenoid valve 507 3rd/top boom extending switch (TDN array) I-6 602 MDT (lower) CN2 G-5
230 Top cylinder selector solenoid valve 34 509 P.T.O switch C-3 603 MDT (lower) CN3 G-5 39
238 Protection of NO.2 cylinder retraction while mode Ⅱselect solenoid valve 510 Parking brake switch K-4 604 MDT (lower) CN4 G-5
35
281 Oil cooler solenoid valve 511 Combination switch D-2 605 MDT (lower) CN5 F-5
380 Visible type winch drum indicator (option) D-1 33 513 Mission select switch (shift lever) H-3 606 MDT (lower) CN6 F-4

30 WZ04-2261E 30
Z-16 Z-16 Z-16
Harness (Connector No. Table)

CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page
608 MDT (lower) CN7 H-6 734 ECU DIAG lamp-2 (umber) B-2 39 813 Door junction I-2
609 MDT (lower) CN8 G-6 745 Air drier heater 40 814 Flasher unit D-16
610 MDT (lower) CN9 G-7 747 Starter relay (SW) C-13 815 Buzzer 1 (air low pressure alarm) C-16
39
611 MDT (lower) CN10 F-6 748 Alternator (R terminal, L terminal) H-9 816 Buzzer 1 (air low pressure alarm) C-15
612 MDT (lower) CN11 F-6 749 Alternator (B terminal) H-9 817 Buzzer 4 (overwind (two-blocking) alarm) C-15
33
619 MDT (for maintenance) B-6 751 Back buzzer C-15 818 Buzzer 3 (AML alarm) C-14
620 MDT (upper) CN1 B-9 755 Fuse (Grid heater) (70A) E-14 819 Engine speed output E-8
621 MDT (upper) CN2 B-9 758 Battery relay F-15 820 For reducing the main pressure F-8
622 MDT (upper) CN3 B-10 759 Battery relay F-15 821 AML vent solenoid valve G-5
623 MDT (upper) CN4 C-9 760 Battery relay F-16 824 Cigarette lighter E-6
624 MDT (upper) CN5 C-9 761 Battery relay E-15 828 AML external indicator lamp (yellow)
35
625 MDT (upper) CN6 A-12 762 Battery relay E-15 829 AML external indicator lamp (red)
33
626 MDT (upper) CN7 A-12 763 Battery relay E-16 833 Condenser (C1) (roof wiper motor) A-9
627 MDT (upper) CN8 A-12 765 Diode assy D-3 834 Condenser (C3) (power window motor) G-2
629 MDT (upper) CN9 B-12 766 Diode (fuse box) F-14 835 Condenser (C5) (front wiper motor) H-1
630 MDT (upper) CN10-1 B-12 767 Fuse box (L) G-12 836 Condenser (C7) (power window motor) C-11 33
631 MDT (upper) CN10-2 C-12 768 Fuse box (L) G-12 837 Condenser (C2) (washer motor) H-1
639 MDT (upper) (for maintenance) E-7 769 Fuse box (L) H-12 39 849 Washer motor (roof) G-1
665 AML connector 1 770 Fuse box (L) H-12 850 Washer motor (front) G-2
666 AML connector 2 37 771 Fuse box (R) F-12 852 Working lamp 35
667 AML connector 3 772 Fuse box (R) F-12 853 Working lamp (boom)
36
685 ECU (A connector) 773 Fuse box (R) G-12 858 Cord reel (boom length detector)
686 ECU (B connector) 774 Fuse box (R) F-12 859 3rd/top boom full retraction detection switch 38
687 ECU (C connector) 41 775 Fuse box (R) G-12 863 Terminal assy F-10
688 ECU (D connector) 778 Fuse (upper power supply) (75A) F-14 864 DC-DC converter B-15
689 ECU (E connector) 779 Fuse (main) (75A) G-14 865 DC-DC converter B-16
690 Q-ADJ D-5 39 780 Rotary joint F-9 870 Fuse box (right) D-10
691 MUT-III 41 781 Rotary joint F-9 871 Fuse box (right) D-11
700 Head lamp (LH) K-1 782 Rotary joint G-9 872 Fuse box (right) D-9
701 Head lamp (LH) J-1 783 Rotary joint F-9 873 Fuse box (right) E-9
702 Head lamp (RH) F-1 784 Rotary joint F-9 875 Fuse box (left) E-9
703 Head lamp (RH) F-1 785 Rotary joint G-9 876 Fuse box (left) F-9
33
704 Head lamp relay H-14 Sub. harness B-8 877 Fuse box (left) F-9
788
705 Head lamp relay H-14 To main harness 40 878 Fuse box (left) F-8
706 Head lamp relay H-13 Sub. harness B-9 39 880 Rotary joint I-12
789
707 Head lamp relay H-13 To main harness 40 881 Rotary joint I-13
708 Head lamp relay H-13 Harness (electronic governor) E-4 39 882 Rotary joint I-13
790
709 Combination lamp (RH) E-1 To main harness 41 883 Rotary joint J-13
710 Combination lamp (RH) E-1 Harness (electronic governor) E-4 39 884 Rotary joint J-12
791
711 Combination lamp (LH) K-1 To main harness 885 Rotary joint J-12
39
712 Combination lamp (LH) K-2 792 Harness (engine) Harness (AML) I-9
41 886
717 Rear combination lamp (L) J-11 793 Harness (engine) To inside cab harness 37
718 Rear combination lamp (L) J-12 794 Harness (engine) Harness (boom, base)(for separated transport of boom and swing table) H-15 33
887
719 Rear combination lamp (R) B-15 795 Harness (engine) B-11 To inside cab harness
39 36
720 Rear combination lamp (R) B-15 797 MEMORY CLEAR B-6 888 Harness (boom, top)
721 Backup lamp A-16 802 Air conditioner (option) H-7 Harness (Swing table, right) J-15 33
889
723 License lamp (option) D-16 804 Room lamp H-7 To inside cab harness 35
726 Bubble level (illumination) (R) (option) E-7 805 Bubble level (illumination) H-6 Harness (Swing table, right) J-15 33
890
730 DIAG switch B-6 806 Harness with cab (room lamp, roof wiper motor, working lamp) A-8 33 To inside cab harness 35
731 ECU DIAG lamp-1 (red) B-1 810 Combination meter F-2 Harness (Swing table, right) J-15 33
891
732 ECU DIAG lamp-1 (red) B-1 811 Combination meter F-2 To inside cab harness 35
733 ECU DIAG lamp-2 (umber) B-2 812 Front wiper motor I-1

31 WZ04-2261E 31
 Z-16. Z-16. Z-16.
Harness (Connector No. Table) Applicable serial No. △
2 ：546049 - -

CN No. Usage Coordinates Page CN No. Usage Coordinates Page CN No. Usage Coordinates Page
Harness (AML) I-9 33 Harness (AML) K-9 33 RB11 Starter continuous energizing prevention relay C-4
892 964
To inside cab harness 37 To inside cab harness 37 RB12 Starter interception relay C-3
Harness (Swing table, left) I-15 33 965 Winch selector switch C-1 RB3 PTO limiter relay C-4
893
To inside cab harness 34 966 Winch selector indicator lamp C-2 RB4 Engine emergency stop relay C-4
Harness (Swing table, left) I-15 33 967 Winch selector indicator lamp C-1 RB5 Air conditioner power supply cut relay E-11 33
894
To inside cab harness 34 968 Fuse (for drum indicator) (main) D-8 RB6 Lower outrigger power supply select relay A-4
33
2 894 Harness (for separated transport of C/W and swing table) 35 969 Fuse (for drum indicator) (aux.) D-8 RB7 Lower outrigger operation box relay A-4 39
Swing table harness (air) A-14 33 976 Telescoping mode Ⅰ/Ⅱswitch K-2 RB8 Lower outrigger operation box relay A-3
895
To inside cab harness 35 977 Telescoping mode Ⅰindicator lamp K-3 RC1 Roof wiper ON relay G-12
Harness (AML) J-9 33 978 Telescoping mode Ⅱindicator lamp K-2 RC2 Front wiper ON relay G-13 33
896
To inside cab harness 37 991 For separated transport of boom and swing table RC3 Front wiper Hi relay G-15
37
Harness (AML) J-9 33 992 For separated transport of boom and swing table RC5 Emergency accelerator relay 1 D-2
897 39
To inside cab harness 37 For separated transport of To harness (AML) 36 RC6 Emergency accelerator relay 2 D-1
993
Harness (AML) K-9 33 boom and swing table To harness (boom) 37 RC7 Power window relay G-14 33
898
To inside cab harness 37 994 Counterweight equipped detection proximity switch RD4 Lower outrigger operation box relay C-2
35 39
Harness (AML) J-9 33 995 Jib lock pin switch RD5 Lower outrigger operation box relay C-3
899
To inside cab harness 37 998 Pulse transducer (engine speed) B-15 33 RF1-1 Emergency transmission selector relay F-9
33
904 Jib state switch A-7 999 Jib mounting / stowing operationality indicator lamp 35 RF1-2 Emergency transmission selector relay G-9
905 Jib removed indicator lamp A-6 R1 AML power supply relay 1 F-12 RF2-1 Emergency transmission selector relay D-2
906 Jib removed indicator lamp A-6 R11 2nd boom emergency telescoping relay E-10 RF2-2 Emergency transmission selector relay D-1
39
907 Emergency outrigger state register switch A-5 33 R13 3rd/top boom emergency telescoping relay D-14 RF3-1 Outrigger jack/slide select relay C-1
908 Emergency outrigger state control indicator lamp A-5 R2 Boom full ret. detection relay E-15 RF3-2H Outrigger jack/slide select relay C-1
909 Emergency outrigger state control indicator lamp A-5 R22 AML lamp assy relay E-12 KR27 Telescoping mode Ⅰ/Ⅱselector relay G-10 33
915 Crane operation emergency stop switch J-2 R23 AML lamp assy relay E-12
33
916 Controller (outdoor air temperature sensor) R26 AML power supply relay 2 F-12
43
917 Emergency crane operation switch R29 Oil cooler relay E-13
918 For emergency jib operation C-7 R33 Elevating slow stop cancel relay E-13
919 For emergency jib operation D-7 R36 Overwind (two-blocking) relay E-14
922 Boom telescoping/aux. hoist control indicator lamp D-4 R4 Swing free selector relay E-15
923 Boom telescoping operation indicator lamp D-3 R46 Telescoping mode Ⅰ/Ⅱselector (diode) relay G-13
924 Aux. winch operation indicator lamp D-4 R47 Remote control pressure vent relay 43
925 Vehicle speed limit E-9 R53 Telescoping mode Ⅰ/Ⅱselector relay E-11
926 Fan (switch, motor) (option) H-8 R8 AML emergency switch relay D-14
931 Touch-type winch drum indicator controller (option) D-13 R9 Swing brake relay E-10 33
33
932 Touch-type main winch drum indicator solenoid (ISO array)(option) J-6 RA1 Working lamp relay 1 D-12
933 Touch-type main winch drum indicator solenoid (ISO array)(option) J-6 RA10 Emergency stop relay F-14
934 Touch-type aux. winch drum indicator solenoid (ISO array)(option) J-7 RA11 Backup lamp relay A-4 39
935 Touch-type aux. winch drum indicator solenoid (ISO array)(option) J-7 RA14 Horn relay F-14 33
936 Touch-type aux. winch drum indicator solenoid (TDN array) (option) I-7 RA17 Steering power supply relay B-4 39
937 Touch-type aux. winch drum indicator solenoid (TDN array) (option) I-7 RA2 Working lamp relay 1 D-12 33
938 For air bleeding of suspension lock cylinder G-7 RA21 ECU main power supply relay B-4
39
939 Rope run-out release switch (option) A-6 RA22 Electronic governor power supply relay G-16
940 Thermo switch (T/C oil 110°C/230°F) C-12 RA26 Washer relay (front) F-15 33
941 Hour meter (option) D-14 RA28 Glow relay B-3 39
942 Lower outrigger operation box (L) (option) I-7 RA3 Washer relay (roof) D-13
943 Bubble level (illumination) (L) (option) I-6 39 RA4 Neutral starter relay D-13
33
944 Low-pressure switch (steering pump low-pressure alarm) (option) K-7 RA5 Turn signal relay (R) F-13
945 Side turn signal (LH) K-2 RA6 Turn signal relay (L) F-13
946 Side turn signal (RH) E-2 RA8 Clearance lamp relay A-4
949 Buzzer 5 (external alarm) 35 RA9 Battery power supply keeping relay H-15 39
959 Diode assy (lower outrigger operation) (option) A-3 39 RB1 Transmission power supply cut relay C-4

32 WZ04-2261E 32
Z -1 7 . Z-17. Z -1 7 .
Harness (Inside Cab)

Z-17 Harness 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
625 F CN6
ルーフウォッシャ ルーフワイパ 作業灯 オイルクーラ ワイヤ捨巻解除 ジブ有り無し ル−ムランプ 800 801 802 803
非常用 80
(Inside Cab)
LR LW LG LB
非常用O/R O/R状態設定 ジブ有り無し 切り替え 作業灯 J3５ 804 804
35
Br F 187
V
173
LY
158
1.25L
35
Br
F 152
1.25LO
35
Br
F 156
1.25RY
状態設定ランプ F F 切り替えランプ F 806 ル−フワイパモ−タ
Br Br
804
Br
804
Br

250 （908
908） 748 250

35
A 905）288
A
0 0 186 0 35 0 0 0 167 0 0 321 0 0 289 1.25Lg（905 0 626
B B LB B Br B B B YG B B LW
1.25Lg BW B
B LB WL B 6
1.250 YB
F
233
915 907 908
F
911
CN7
912
904 J34
80 WY P LgW WL LgY
495 468 470 574 748 907 939 288
0 184 158 183 4 0５ 0５

80

80

80

80

80

80

80
B 1.25LW 1.25L 1.25LG 158 コンデンサ YW B B DCーDCコンバータ

80

80
BW WL 1.25L (ワイパモータ用) 旋回台ハーネス

45
627 F CN8 0 915
610 620 632 612 622 634 F 895
（909
909） （906
906） （833
833） 80
227
R R R R
229
B B B B 50 229 228 227
2B WY

80
J103 BL
00 228 611 621 633 シールド シールド シールド B W R 160 0 14

100

100

100

100

100

100

100
1 W W W W
BL
B B B RB B GB
620 F CN1
J５7 J５6 J５５ J５3 J５2 J89 J90 J98 J５1 50 213 213 213 01 01 01 610 864 865

５0

５0
WB WB WB 1.25B 1.25B 1.25B 611 620 632

55
612
30 30 60 30 60 30 40 520 50 621
621
622
633
634
J30
621

40
CN2 629 F CN9

100
F
B B
150

0
13
3 5 198 199 196 197 193 187
J91 J５0 50 80

150
WR LY R B W G YG V
ウインチ位置選択スイッチ 過巻停止解除 P.T.O 旋回ブレーキ 旋回緩停止 起伏緩停止 191 192 02
J33 143 24 05
M6 50 W B B Y YB 1.25B エンジン回転パルス変換器
998
F F 314 F 22 35 F 250 250 F 0 250 F 0 80 F

40
02 01 622 630 155 918
YW G Br 1.25Lg 1.25Lg B 1.25Lg B
B 1.25B F CN3 F CN10 RW PB 50
0 318 0 384 336 154 0 0 352 371 35 0 347 35 0 212 239 211 212 03 03 333 176 298 294 194
907 07
503 504 Earth 50 V BL WR V B B BW YB YG BrR YL 130

65
B LY B WY P Y B B LW GR Br B YL Br B J49 P B
73 74 75 76 177 559 03 03 165 296 173
50 RW LG GL G RB YB B B LgR Y LY
965 505 509 484 486 491 35
F 35
F

80

80

80

80
エアー低圧警報（ブザー1）
80

80
Br Br 623 CN4 631 AML警報（ブザー3）

55
F
06 0５
F CN10 過巻警報（ブザー4）
0 0 332 250 0 0 379 250

80
J72 J71 J70 J69 J64 J6５ 04 20 31 32 33 30 40 72 52 167 22A 19
B B V 1.25Lg B B Y 1.25Lg 50 B YG RY RB RW RL R Sb 1.25B 1.25B Earth Y YG G WG F 0 257 212 155
918 J32

150
50 50 50 50 50 200 80 3段ブーム以降非常伸縮 2段ブーム非常伸縮 45 44 42 41 43 62 46 60 06 06 06 06 ５74
259 0 B YO V RW
50
C C
PB WY WR W WB Y WL GY M6 B B B B LG
557 YR B （817
817）
50

250 （966
966） スタータスイッチ 781

60
624
60

F CN5 触覚式ドラムインジケータ用 （818

818） （815
815）

100
13
1.25Lg 153 F 17 14
伸縮操作状態表示灯 O／ R（張出／ 格納）
GR
コンデンサ

0
LG 1.25LW GB J48 50
29
L
48
LR
47
LB
53
BrW
57
PB
51
YB
コントローラ（オプション） 80 80

80
30 (パワーウインド用) 440 450 470 0
50

（967
967）319 16 122 337 250 50 36 37 35 04
ウインチ位置 0 43 62 157 1.25Lg 50 100 80 BR BY LgY B
YL 1.25YL RW LgW B 80 WB Y RG
YL BrR BrY Br 1.25B 2 （816
816）
470 選択表示灯 アイドルボリューム J66 〔470〕LgY
Mドラムインジケータ
1.25Y J31 200 441 451 J1
（923
923） 485 157 35 0 非常用
Lg RG Br B 100 0.3A
（836
836） O RY
50 50
ジブ操作
80

80
0 337 968 931

100
441 150
O B LgW 497 919 870
Sドラムインジケータ 〔342〕R

30
451 視覚式ドラムインジケータ 588 50 0 35 250 O／ R（J／ S） 100 0.3A 472 M 234 225 Earth フラッシャ
B Br
100
RY （オプション） 1.25Lg
969 LR YR 1.25LR RA1 RA2 RA3 RA4 R8 R13 ユニット

100
380 60 46 157 Earth
150 0
922 159 226
D D
〔344〕RB 2B
632 J104 J7５
J67
80 GY WL RG 0 18 04 03 130 YB YG 167 152 167 152 158 188 30 122 314 385 332 250 0
R 587 729 157 35 0 1.25B 1.25B 1.25B M6 YG 1.25LO YG 1.25LO 1.25L YW RL RW YW WR V 1.25Lg M6 B
100 100

100
50

80
コンビネーションスイッチ RG Br B J47 0 174 0 233 186 0 0 21 0 0 0 260
511
634
B
633
W
LgR 1 1
1.25W 1.25W
1
1.25W
F B 1.25YR B YB LB B B LG B B B YW
6
1.25O
179
L
480

13
M 50 伸縮／サブウインチ切換 872

200
176 13 9 179 1 1 1 1 ヒューズ（右）

0
814
50

80

120

120

120

120

120

120
50
（924

50
YB LB LR L
729
924） 1.25W 1.25W 1.25W 1.25W
J8 J7 J6 J５ J4
0 182 194 193 LgR
シガライター M
871

240
50
B LG YL YG
J74 サブウインチ操作 200 925 1 1 F 153 M
214 35 35 35 35 35 65 J3 50
100

151 574
0 J68 1.25W 1.25W LG Y
100 状態表示灯 ビニール(φ4×φ5) 1.25LB エンジン回転取出し用 30 LG
37 36 F 155 178 B F 819

13
車速制限 873 1 1 1 155 150 158
R22 R23 R29 R33 R36 R2 R4

0
BrY BrB RW Sb （824
824）
旋回フリー／ロック 0 0 907 F 1.25W 1.25W 1.25W RW 1.25LR 1.25L
12

50
プラグ
52 14 35 155 B P
470 470 470 470 156 156 347 349 250 253 250 252 348 378
Y GB Br RW 3５ F 250 487 925 157
M6

75
562
E E
LgY LgY LgY LgY 1.25RY1.25RY YL YG 1.25Lg LgB 1.25Lg LgW BW BL
200

RG
J76
80 Br 1.25Lg
R9 R11 RB5 R53 401 411 402 412 298 321 0 0 301 0 304 0 0 0 07
0 0 348 O GL YR GW YG LW B B LgY B G B B B
B B BW 875 B
F F 639 M
352 250 379 260 234 234 303 285
Earth

120

120

120

120

120

120

120
F MDT保守用 213 154 156 LW 1.25Lg Y YW YR YR RL LR
J63 42 157 72 157 WB Y 1.25RY
J73 804 800 802 J46 0 353 0 303 559 5５8 0 292 J16 J1５ J14 J13 J12 J11 J10 J9
400 WR RG Sb RG Br LR LG 152 238 B O B RL YB RW B RG
コンビネーションメータ O/R(ALL) 1.25LO R 35 35 35 35 35 35 30
O/R(RL) 501 498 801 803

80

130

120

120

120

120
169 171 170 9 908 810 LW LB
100

YG Y YL LR LgW
F F
1 1
1.25W 1.25W
1
1.25W
F J94 J95 J96 J100 J29 R1 R26 RA5 RA6 RA14 RA10 RA26
191 24 143 08 211 35 820
W YB Y B WR Br 1 1 1 1 ヒューズ（左） 22 156 22 159 180 179 202 179 155 155 30 251 150 0
J77 J86 41 157 44 157 35 35 35 75

75
1.25W 1.25W 1.25W 1.25W
100

100
W RG WY RG 877 G 1.25RY G YB GB L GR L RW RW RL RY 1.25LR 1.25B

40
400 156
F F
239 192 912 915 O/R(RR) 863 0 250 0 470 0 9 0 13 178 130 0 572 176 195
BL B LgY WY 502 O/R(FR) 500 1.25RY F
155 015 0 10 13 09 564 250
1
1.25W
F 1
1.25W
144
LY
157
RG
M 563
G
784
GB
35
Br
793
GW
182
LG
193
YG 80
B 1.25Lg B LgY B LR B LB Sb LY B LR YB YO

120

120

120

120

120

120
811 1.25Lg
F

120
F
60

RW 1.25B B LB B システムチェック 615 214 4 1 1 1 160 151 218 572

LR
614
L
324
LW
130
LY
0
B
J28
コンデンサ 非常ミッション GL Y YW 圧抜き用 J4５ 1.25W 1.25W 1.25W RB 1.25LB1.25YG J22 J21 J19 J18 J20 J99 J110 J17
(パワーウインド用) Earth 45 157
非常アクセル 214 20 157 ターミナルASSY

80
PB RG 878 876 35 35 35 35 35 35 35
Y YG RG
343-536-21020

218 100 130 08 0 10 RF1-1

M6 ∼ O/R(FL) 499

0
1.25YG J78 B B

10
F エンジンストップ
M RC1 RC2 R46 RC7 RC3
300

（834
834） 336 0 938
171 170 169
Y YL YG
AMLベﾝﾄ
SOL P B F M 158 183 0 150 181 0 274 784 783 539 538 2 150 181 190
ウォッシャモータ ウォッシャモータ 31 32 33 40

75
17 1.25L 1.25LG 1.25B 1.25LR 1.25BW 1.25B LB GB LY YB 1.25LB 1.25Y 1.25LR 1.25BW1.25YW
(ルーフ) (フロント) 821 LW 517 22 22A RY RB RW R

ビニール(φ5×φ6)
G G KR27 187 184 193 185 0 782 0 128 182 189

100
849 158 158 850 実長4000 614 V 1.25LW YG 1.25GB B LG B 1.25LY LG 1.25YB
G Rと記入 1.25L 1.25L L
接続して納入のこと 0 629 F 10 250 285 F 284 0
G

120

120

120

120

120
130
188 195 B GR GY 1.25Lg LR L B
サスロック解除用
(300)

YW YO 20 12 8 276 0 782 0 783 J26 J25 J24 J97 J23

Fと記入 YG YO YR LW B LG B LY
100 RF1-2 35 35 35 70 60
0 16

150
2B

80
(100) J43 0
J84 J44
50

J41 50 85 M6 2B
コンデンサ 水準器 Earth
M6
200

(ウォッシャモータ用) Earth エアコン電源 011

F （926
926）

100
802 472 ファンASSY 1.25B
（オプション）

13
158
（837
837） 200 J83 0
M6
130 80 0 563
100 LR M6
(オプション）

0
1.25L ビニール(φ4×φ5)
2B J62 100
B G 225 558 F 226 35

H H
1.25LR RW YG Br 80 J40 J36 J27
コンデンサ ミッション切換 805 0 16 238 250 80 410
(ワイパーモータ用) 513 F 2B R
150 150 （835
835）

200
35
300

0
150

1.25LR Br
Earth
B F 804 （ルームランプON位置） 887 ブーム
F
563 50 50

100
6 0 0 174 305 304 301
189 190 ル−ムランプ 1.25O B J88 B 1.25YR R G LgY
J8５ J102 30 214 F 40
80

1.25YB 1.25YW 50 785 781 35

RL Y R J61 J５8 J37 J38 J39 100 GL GR Br
150 185 200 50 150 250 367 012
1.25LR 1.25GB 31 32 33 100 850 250 350 130 1900 1.25Lg GW 1.25B
812 RY RB RW
850
COTφ13

250

フロントワイパ M ドラムインジケータ（S） AMLハ−ネス 旋回台(左)

350

Earth 次段伸長 タダノ配列 450 ウインチ 894

100 100 F
I I
344 操作レバー格納検出 0
タダノ配列 886 10

130
BY RB M M 881 F
261 267 263 265 266 286 287 22 336
130 0 W V WG WB WL GL GR G P
80

J79 M6 2B 組立て納入 F 507 F 253

LgB
305
R
252
LgW
378
BL
384
WY
385
WR 270 280 271 281 272 282 273 283 290 291 013
3 626 5 911 918
ドアジャンクション 813
1100

WR WB LY WL PB RB YB RW YW RG YG RL YL LgR LgY 1.25B

277
LG
0
B
343
GY
311
GR
349 367 333 275 0 11 0 11 880
F 937 YG GW BW LgY B B
M6
936 892 893 F
50

F Earth
250

548 530 256 348 337 343 353 746

586 538 127 50 371 250 250 22 22 882
50

YG BW LgW GY O RY
0 GR 1.25Lg1.25Lg G G F 012 014
620 621 622
1.25LB 1.25LO
ドラムインジケータ（M）
932 1.25B ∼ 1.25B 262 268 303
B 467 パワ−ウィンド 10 9 8 2 WR WY RL
R W B 896
50

626 342 J60 J５9 M GY LR YR

915 緊急停止 1.25Y
WB 610
R
611
W
612
B
F 128 127F R
50 50 250
256
YG
781
GR
259
YR
260
YW
746
RY
257
YO
793
GW 884 614
L
13
LB
12
YO 6 17 889 F
旋回台（右）
22 25180 80 1.25LY 1.25LO
G RY J80 933 270 280 271 281 272 282 273 283 1.25O 1.25LW 785 781 412 411 174 275 156 333
アクセルSW アクセルセンサ 130 0 218 0 ドラムインジケータ（S） RB YB RW YW RG YG RL YL GL GR GW GL 1.25YR LgY 1.25RY BW
1.25B 1.25YG 1.25B ISO配列
駆動切換 250 451 321 130 441 294 296 298 470 014

J J
ハザード 440 旋回,起伏 899 M 1.25Lg RY LW LY O BrR Y YG LgY 1.25B
100

199 198 197 196

50 51 157 BR 450 344 操作レバー格納検出 F 883 890
476 B R G W
F
YL YB RG 35 180 F 0 BY RB
F 897
19 16 615 292
157 35 0 80 Br GB B M WG 1.25YL GL 1 1 RG
J81
450

RG Br B 130 202 6 次段伸長 311 250

GR 1.25Lg
261 262 267 268 263 4
YW
22
G
21
LG
20
YG
2W 2W
W WR V WY WG
GR 1.25O ISO配列 1 1 891
５

265 266 286 287 318

885 629 F 旋回台サブハーネス用
80

ステアモ−ド切換 494 506 935 934 2W 2W

0

514 F GR
５

WB WL GL GR LY 157 279 259 295 352 165

パーキング 529
0

50
５0

RG BrW YR BrY LW LgR

75 53 76 F 35 0 277
LG
0
B 898
GL BrW G Br B 80
逆ステア
19
WG
F 402
F
401
スイベルジョイント
157 29 73 48 74 47 J82 YR O
80 ホーン
50

RG L RW LR LG LB 144
35 F 157
LY F 50 50 200
319
YL
80

Br RG
850

0
K 510
K
470 324
B J93
0 177 57 LgY LW 964 M
B RB PB
特殊伸縮表示灯 531 748
BW
289
LB
276
LW
277
LG
290
LgR
285 473
５0

291 288 294 295 279

（978
978） LR 50 LgY WL BrR BrY BrW

伸縮方式切換 （977
977） パワーウインドSW F
250
1.25Lg
F 0
B 539 2
YB 1.25Y
274 35 0 461 IWZ04-2270E01
0 284
976 LB Br 2B B 通常伸縮表示灯
L

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

33 WZ04-2270E 343-536-21020 △
1 33
Z-18. Z-18. Z-18.
Harness (Swing Table, Left)

Z-18 Harness (Swing Table, Left)

343-536-22020 △
1

34 WZ04-2280E 34
Z-19. Z-19. Z-19.
Harness (Swing Table Right)

Z-19 Harness (Swing Table Right)

343-536-22010 △
2

35 WZ04-2291E 35
Z-20. Z-20. Z-20.
Harness (Boom)

Z-20 Harness (Boom)

Boom, base

Boom, top

343-536-22030 △
0

343-536-22040 △
0

36 WZ04-2300E 36
Z-21. Z-21. Z-21.
Harness (AML, Upper)

Z-21 Harness (AML, Upper)

343-632-31300 △
1

343-632-31200 △
1

343-632-81100 △
0

343-632-31100 △
1

37 WZ04-2350E 37
Z-22. Z-22. Z-22.
Harness (Overwind)

Z-22 Harness (Overwind)

343-724-40000 △
3

343-724-40010 △
1

343-721-83000 △
1

343-723-61000 △
2

38 WZ04-2320E 38
Z-23. Z-23. 4 :546173 - - Z-23.
Harness (Lower, Main) Applicable serial No. 3 :546027 - -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Z-23 Harness オペASSY,アウトリガ
ダイオードASSY
249A 249B
F 959
236A 236B
236B 561
LY R
RB7
560
RY
141
RB
RB6

(Lower, Main)
R LR RY LY
（オプション） 249 142 563 564 236 0 30 141A 0 30 561
RL 0.85BrW G GL YB B BR B R
A A

80

80

80
DIAG LAMP J55 J54
(黄褐） オペASSY,アウトリガ
35 35 （オプション） バックアップ
638 98 RB8 RA11 RA8 M 721 ランプ
Br WR 236A 561 40 124 124 124 M 168
DIAG LAMP RY R R RY RY RY YL
エンジン付属部品 0 43 0 44
719

125
98
(赤） (734) (733)
0 30 141B 0 30 168 35 142
MPK015-01022(MH058959)
B B
(731) B RL B YL Br 0.85BrW M
WR
50  363-613-22210（コネクタASSY) スライド ジャッキ
(RR) 9
795

80

80

80
J57 J49 J48 J47
B B
組立て納入 サブハーネス F 789 F (RR) 720 0.85LR
J46 F 26 F 27
50
20 150 70 35 50 MDT保守用 F 434 （4ヶ所） F 788 50 101 124 82 8B エンジン側ハーネスへ

13
50 619 YL WY RY BW 108 0 40 109 0 41 101
B B

0
F

0
41 46 45A 0 54

10
YO B YG B
637
(732) RA28 RA21 RA17 DIAG F 730 W WL LB B
655
BW
79
Gy
035
1.25B
175
GW
19
WG
WY 142
BrR 54 679 600 600 94 94 804 800 802 249A 43 44 42A 51 83 0.85BrW
Br LR LG 556 117 244
近接ｽｲｯﾁ

100

50

50
636 0 45 R WB WY WL
LO L R 1.25R G G YB BL RW GW YO

75
LR B 801 803
0 30 79 609 602 247 248 LW LB
141A 62 236A
BR Y RY
(直進検出) 409 コンビネ−ションランプ

300
B Gy BY 1.25RB GB GL F 408 350 85 ※ （R．H）
下部アウトリガ 80 RL F 424 200 バックブザー
ビニール(φ4×φ5) BR
797

80

80

80
123 0 36 78
F 50 操作BOX(R)
RF3-1 J56 J41 J40 J39
RG B Y
ロープレッシャスイッチ RL RL RL
J52
40 200
98 635 R B W R
（エンジンオイル） ビニール(φ4×φ5)

350
オペASSY,アウトリガ 35 35 50 WR LY ピックアップセンサ 80 751
50
F メモリ 0

30
0 30 44 45 4
RB12 RB3 RB1 （スピ−ド）

600
B WY PB （オプション） クリア

300
RD4 614 689 22 22 20 96 M ※ 30 940 575 COTφ7
421 スタ−タリレ−

50
46 41 42 0 54 025 0 30 F LR
L R G G YG YL 0 38 0 45 0 53
F 1.25B ∼ B

75
WL W WR 0 30 42 B SW F 747 J33
B B B B B
C
135 129
0 31 035
C

750
B WR 0 30 21 245 246 0 30 89 350
RF3-2 Q−ADJ ∼1.25B W B
696

250
B LG YR GY B GB B 13

800

COTφ7
M 46 45A 45 42A

800
WL
0

1050 950
106 108 110 112 Earth M6 M6 Earth

0
50 647 50

13
WL LB PB WL

80

80

80
YW YO RW RL 0 58 400
J37 J36 BW
M6 Earth 31 3
3 00

50
J35 B

700
ビニ

130
107 109 111 113
ール 000 Earth M6 M6 Earth

250
642

130

100
YB YG RB RG
80
35 35 50 0 トルコン油温
LgR 13 (φ4
50

J20
RD5 J38 RB11 RB4 150 200 J22 150 200 110℃ ×φ
RC6 5)

3
0 43 0 44 0 46
F
F 690 COTφ28 COTφ22 0 42

50
0 30 41 98 689 614 649 J42 J9 J43 J23

550
B B B B
0 30 615 623 624 604 B W WR R L 1.25BY J25 , ,

75
B GL YL YB Y J21
350 200 400 200 500 450 950 1550 380 300

∼
46 44B 44 41B 694 696 0 30 601
RF2-1 WL RL WY RW YW WL B 1.25WY 0 40
35

フューエルフィルタ B

130

130
F

350
50
0 30 629 10 ウォータレベル検出

80

80

350
B GR GY J18 J17 J10
J19 416 0 58 0 39
D M
D

400
570 723

0
Earth B B

10
20 12 8 35 35 50 120 142
0 38 684 50 RB アワメータ
YG YO YR
J16 B BG M6 M6 Earth M6 0.85BrW

50
RF2-2 50 765 F 100 13 941 ライセンスランプ J34
0 50

1850
M (オプション）

130
50
147 118 117 681 660 606 647 607

0
RC5 0 36 M5

12
WR Lg LY BW GY 1.25B Earth 0 46

13
GR GL GW B 0 39
F 617 B

0
31 32 33 40 B B

500
626 615 606 604 607 1500

50
RY RB RW R ダイオードASSY

50
WB GL LY Y GY
水準器右 R F2 F3 F1 COTφ7
F 791 F 726 M
F 42 F 44 F 45 F 43
655 681 617 609 54 Earth M8 0 53 563 (755) 8B コイル+側
コンビネーションランプ BW WR B BY LO B G 40 0 31 32 0 32 33 0 33 31 0 34 (762)
（R） 683 638 637 635 98 679 R B RB B RW B RY B グリッドヒータ

80
L Br BrR LY WR L 0 21 0 24 組立て納入 70Aヒューズ 134 バッテリリレー
∼

300
142 サイドターンシグナル B B ソレノイドバルブ M6 1.25RL
E 9
0.85LR
0.85BrW （R）
F 790 オペASSY,アウトリガ （ミッションセレクト）
M4
接点-側
(763) E
予備回路用

250
9 680 52 21 694 626 601 636 22 1.25B （オプション）
710 0.85LR RL Y LG YW WB 1.25WY LR G
100
F 957

0
642 602 203 910 644 624 616 625 647

25
3R
946 LgR 1.25RB W WB LgB YB YR YG BW 630 628 627 M8
709 80 02 電子ガバナハーネスへ
GO GW GB 200
0.85B スイベルジョイント J26
(761)
Earth
CN6 606 CN11 612 F 766 100 M8
接点
01
M5
200 F F
M 783 16 134 0 42 696 100 1F
+側
B J1 FL FR RL RR 220 FL FR RL RR 222 91 90 87 45 44 42 41 8W
100 100 1.25YL 1.25RL B WL
130

R R R R R B B B B B GO GR P PB WY WR W
780 ヒューズボックス（R）771 M8 (760)

250
918 911 5
FL FR RL RR 221 シールド シールド シールド シールド シールド J11 43 62 46 560 029 F PB WL LY ダイオードASSY 200
W W W W W B B B B B 220 WB Y WL RY 1.25B
772 1B
145
702 221 626 3
1B M8 5W
250

FL FR RL RR WB WR 100
BrW 222
784 5W J28 J27 M8
F F
60
M 3R 1C
CN5 F 605 CN10 F 611 F 781 100
1B 80 (758) 8W
8 9 10

100
146 ジャッキ スライド 3W 1D
80

800 801 802 803 95 79 6 2 YR 0.85LR GY 3R

1.25BrB （FR） （FR） LR LW LG LB 100 100 RL Gy J8 1.25O 1.25Y 12 13 614
3W
J7 774

100
778

1150
804 804 804 804 J12 50 51 570 52 36 028 YO 0.85LB L
M
23 22 17
M

0
F F Br Br Br Br YL YB RB Y BrR 1.25B 400 123 124 141

10
05 1.25LW
COTφ10

1.25B 703 113 03 112 04 RG RY RB

上部電源用 1F (759)
RG B RL B CN4 F 604 M 8W
1000

F 782 125 98 556

ヒューズ
60

135 129 203 918 913 911 615 16 19

ヘッドランプ W B W PB WG WL 1A 1A GL 1.25YL WG
1.25RL WR RW 1A
773 （上側）

80
50

610 8W

225
50

（RH） 914 0 24 910 616 623 625 617 CN9 F 2W 2W 20 21 22 4

426 775

50
200 200 WR B WB YR YL YG B YG LG G YW
100
644
LgB
660
Lg
1A
2W
1A
2W 627 628 629 630
118
600 M
2 1D M
100

GB GW GR GO 1.25R 1.25Y W
CN3 F 603 J13 0 27 0 27 0 27 0 27 027 GL サーモ
5 3 0 23 4
B B B B 1.25B 17 6 105 メイン 1C
G 50 LY WR B YW 785 センダ 1.25LW 1.25O W 8W
G
COTφ13

75 ※ ヒューズ
60

86 245 35 247 0 23
0 FL 422 (冷却水) 1E
100

F BG YR Br GB B
CN8 609 ヒューズボックス（L） 767 （下側） RA22

200
F 8W

ビニール(φ4×φ5)
FL FL FL 88 89
768 779 16 17
R B W CN2 F 602 100 100 GY GB
1D
J31 50 1.25YL 1.25LW
J50 105 105 105 022 0 22 0 22 J14 0 26 680 026 1D 2W 0 42 649
50
1100

W W W 1.25B B B B RL 1.25B
2W J29
B 1.25BY

1000 920
1D

100
1D

75
CN1 F 600 2W
2W
SE-08BK

60

82 85 83 78 244 70
BW BR BL Y YO GB 769 J32
700

Earth
175
GW
161
G
71
GL
575
LR
637
BrR
638
Br
0 21
B
0 21
B CN7 F 608 748 M 87
P
90
GR 150 50
93 248 58 31 32 33
100 (707)

50
130 F

3
GW GL LgY RY RB RW
100

01 04 10 96 79 88
M6 CN1 601
H H

50
B ∼ B F J15 40 37 566 567 48 47 57 53 025 YL Gy GY 50
683 684 R BrY LY LG LR LB PB BrW 1.25B 86 1B 150
05
L BG BG W
0 150 770 (708) (706)
21 236 249 0 21 0 21
10 0 M
550

1.25B COTφ10 95
LG TB RL B B
25 RL M4 M4
S2 M4 S1 50
RA9
749 M8 3 94 93 91
B
06 0 37 J3 J5 G GW GO 36 37 (704) (705) 86 17
2200 150 1E BrR 125 BrY BG 1.25LW
B 1.25B
オルタネータ 8W 1.25RL M4 M4
350

25 L2 M4 0 42 134
∼

Earth F ステアモード切換
250

ヘッドライトリレー B 1.25RL
13

09 130 ジャッキ 111 06 SL31 F 31 146 145

M6
0

RB B
0.85B （FL） 1.25BrB 0 42 BrW
50

53 0 10
オペASSY,アウトリガ（オプション） ※ B L1
BrW B スライド ジャッキ 425 ヘッドライトリレー S
F 24 RR F 0 47 0 49
50

M6 F 942 M (RL) F 28 (RL) F 29 ∼

I I
SE-08BK

スライド B B
110 07 SL32 F 32 Earth M
RR RR RR
700

0 10 0 13 45 46 41B 0 56 R B W
RW B （FL） 106 0 47 107 0 48
900

47 0 11 B ∼ B
PB WL RW B
YW B YB B
200

LB B 249B 43 42 44B Earth M6

150

LR WB WR RL
50

50
141B 62 236B
300

100 200 SL30 30

580
F

50
50
943 RL Y LY

130
F
50

57
PB
0 12
B
組立て納入 0 55 564
J53
ソレノイドバルブ B GL 水準器左 組立て納入
85
50

0 SL33 F 33 サスフリー 下部アウトリガ操作BOX(L) 200 50 560 650

F 3 格納 F 20 張出 F 21
50

COTφ10
48 0 13
717
1300(COTφ7)

LR B 567 0 50 62 0 14 43 0 15
J51

400
LG B Y B WB B 101
ヘッドランプ 50 FR F
1200

WY 142

1000
（LH）
1300

FR FR FR

J R B W 0.85BrW
J
50

50

50

145
701 ソレノイドバルブ F 2 Earth
BrW ※ 423 J44
サスロック 50 130 0 55 0 57
566 0
LY
51

B M6 B ∼ B
コンビネ−ションランプ 13 718
100 500 100 150 350 550 （L．H） 0.85LB

100
146
80

1.25BrB
400

Earth
200

ソレノイドバルブ ソレノイドバルブ プレッシャ、スイッチ 0 49

037 スイッチ,ロープレッシャ 130 0 14 0 17 B
(ロックアップ） (P.T.O.） （4WD検出） M6
180

944 （ステアポンプ） ∼
1.25B 700 F 49 F 41 F 413 F B B
50 123 0 57 161 (オプション）
58 0 20 246 0 19 70 0 18 0 50 0 51
08 200 LgY B GY B GB B
RG B G 組立て納入 B B
B M5 J4 ,
50 M ※
420
K 419
K
80

F
50

Earth 09 F
Earth
150
0
13

0.85B
711 0 18 0 20
914 0 16 913 222 221 220 プレッシャ、センダ
WR B WG
945 ∼ M8 13 50
B W R
（トルコン油圧）
COTφ7

B B
COTφ7

0 J45
センサ、スピ−ド 50
400
100

13 サイドターンシグナル
142 712 0.85LB （L） 200 0 F 440
0.85BrW 13
サーモセンダ 147 200 COTφ7 J6 3050 スイッチ,リード
0.85LB 71 0 17
(トルコンオイル) GR ビニール(φ4×φ5) 1350 600 450
GL B （Hi−Lo検出）
コンビネーションランプ 427
（L） (COTφ10)
IWZ04-2331E01

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
39 WZ04-2331E 349-310-00100 4 39
Z-24. Z-24. Z-24.
Harness (Lower, Sub)

Z-24 Harness (Lower, Sub)

349-310-00200 △
2

40 WZ04-2340E 40
Z-25. Z-25. Z-25.
Harness (Lower, Electronic Governor) 2△：560870, 545960 - - △：546030 - -
4
Applicable serial No. △
1 ：545870, 545960 - - △
3 ：545979 - -

Z-25 Harness (Lower, Electronic Governor)

349-310-00300 △
4

41 WZ04-2450E 41
Z-26 Z-26 Z-26
Outdoor Air (Minus 25°C or less) System

Z-26 Outdoor Air (Minus 25°C or less) System

1. Structure

344-925-00000 △
2

42 WZ02-3230E 42
Z-26. Z-26.
Outdoor Air (Minus 25°C or less) System

2. Harness

344-925-00100 △
0

43 WZ02-3230E
Z-27 Z-27 Z-27
Anemometer System

Z-27 Anemometer System

1. Structure

344-924-41000 △
0

344-924-42000 △
1

44 WZ02-3240E 44
Z-27 Z-27
Anemometer System

2. Harness

344-915-91100 △
0

344-924-42100 △
0

45 WZ02-3240E
Z-27. Z-27.
Anemometer System

3. Cord reel

Output cable assy specificastion

Total length: 45m (147.65ft)
Installation length: 5.5m (18.05ft)
Stroke: 38m (124.68ft)
Extra turns remain on the drum: 1.5m (4.92ft)

1.Frame 7.Coller 13.Bearing nut 19.Clip

2.Drum assy 8.Ring 14.Bearing washer 20.Input cable assy
3.Cover (outer) 9.Holder 15.Cord clamp 21.Liner bearing
4.Bearing case 10.Contact point 16.Cord clamp 22.Cover (inner)
5.Bearing 11.Packing 17.Output cable assy
6.Coller 12.Seal washer 18.Rubber bush

361-608-80001 △
0

46 WZ02-3240E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

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

History of revision
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