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Safety

1

WA01-0041E

Safety

Most accidents that occur during machine operation
and maintenance are caused by failure to observe
basic safety rules and precautions. Before operating
your machine or performing maintenance, read and
become familiar with all the safety precautions and
recommendations given in this section.
Remember that failure to observe even a single
precaution could involve you and the people around
the machine in a serious accident.

Foreseeing potential dangers is vital for preventing
accidents. All personnel working with the machine,
including the supervisor, machine operator and oiler,
should be sensitive to potentially dangerous situations
and take the necessary measures to prevent
accidents.

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:

[NOTICE]

[NOTICE] indicates an important operational or

maintenance procedure or condition, which, if not
strictly observed, can result in damage to machine
components or deteriorated machine performance.

It is virtually impossible to anticipate every situation
that might present a hazard. The safety precautions
given in this manual and on the machine labels are
not exhaustive.
It is important, therefore, to strictly follow the
instructions in this manual and be sensitive to
potential dangers in order to prevent bodily injury and
damage to the machine.

Remember that your most important duty is to ensure
the safety of you, your co-workers and any other
people in the area.

DANGER indicates an imminently hazardous

situation, which, if not avoided, will result in death
or serious injury.

DANGER

WARNING indicates a potentially hazardous

situation, which, if not avoided, could result in
death or serious injury.

WARNING

CAUTION indicates a potentially hazardous

situation, which, if not avoided, may result in
a minor or moderate injury.

CAUTION

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Содержание TM-2000-1

Страница 1: ...Publication No TM 2000 1 S1 U 1E 01 Boom Truck TM 2000 1 Applicable Serial No EX0069 Model S e r v i c e M a n u a l TM 2000 1 S1 U 1E 2006 PRINTED IN JAPAN 0609 K...

Страница 2: ...instructions in this manual are identified as DANGER WARNING CAUTION or NOTICE These terms are defined as follows NOTICE NOTICE indicates an important operational or maintenance procedure or condition...

Страница 3: ...low the capacitors to discharge Pull out the ignition key and hang a tag saying Don t start the engine in the cab 6 Don t carry out maintenance while lifting the vehicle with only a jack or a hoist Su...

Страница 4: ...uts fixing it don t apply too much force to it but check the part for the cause Only after relieving the cause proceed disassembling 7 Use lifting slings appropriate for the weight and characteristics...

Страница 5: ...Spill or leak Review fire and explosion hazards before proceeding with clean up Use appropriate personal protective equipment during clean up Dike spill Prevent liquid from entering sewers waterways...

Страница 6: ...nit No 2 Lot No UNI T NO LOT NO IWA04 062001 1 2 Frame nameplate 1 Unit No 2 Serial No 3 Date of mounting SPEC NO SERIAL NO M FG DATE IWA04 062002 KAGAWA JAPAN 1 2 3 1 1 Unit No of the TM 2000 1 serie...

Страница 7: ...t Rear mount Rear stabilizers extended width Min 7 38 Max 11 48 Front outriggers extended width Min 7 15 Mid 13 1 Max 18 7 Swing Non continuous 375 rotation Continuous rotation Non continuous 375 rota...

Страница 8: ...cubic meter m 3 cubic inch in 3 cubic foot ft 3 gallon gal cubic inch in 3 liter lit L 1 0 000001 0 0610 0 0000353 1 231 3 785 1000000 1 61024 35 31 0 004329 1 0 01639 16 39 0 0000164 1 0 000579 0 264...

Страница 9: ...83 1 12 11 3 0 113 1 1525 0 01153 0 08333 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...

Страница 10: ...tem Boom Elevating System Winch System Boom Telescoping System Safety System Radio control System System Diagrams Data Adjustment and Checks B C D E F G H I J K L M N O P Q R S T U V W X Y Z A GROUP I...

Страница 11: ...anual Control Valve Outrigger B 2 Manual Control Valve Winch B 3 Hydraulic Pump B 4 Sequence Valve Pilot pressure B 5 Solenoid Valve Auto stop B 6 Solenoid Valve Winch high speed and swing brake B 7 S...

Страница 12: ...Cylinder Outrigger and front outrigger C 5 Power Slide Cylinder Rear stabilizer C 6 Relief Valve Front stabilizer C 7 Pressure Sensor Front stabilizer C 8 C Swing System Hydraulic Motor Swing D 1 Swi...

Страница 13: ...nterbalance Valve Telescoping G 4 G Safety Devices AMA Load moment indicator H 1 Boom Length Angle Detector H 2 Outrigger extension detector H 3 H Radio control System Configurations of Radio control...

Страница 14: ...00 1 104 114 204 214 Z 1 Hydraulic Circuit Spec No TM 2000 1 304 314 404 414 Z 2 Electric Circuit Spec No TM 2000 1 104 204 Z 3 Electric Circuit Spec No TM 2000 1 114 214 Z 4 Electric Circuit Spec No...

Страница 15: ...mp 13 1 Structure 13 B 5 Sequence Valve Pilot pressure 14 1 Structure 14 B 6 Solenoid Valve Auto stop 17 1 Structure 17 B 7 Solenoid Valve Winch high speed swing brake 19 1 Structure 19 B 8 Solenoid V...

Страница 16: ...crane Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this crane and the parts sales unit described in the parts catalog before star...

Страница 17: ...shift 2 W113 0400E 1 Body assy 2 Valve Swing 3 Body assy 4 Valve Elevation 5 Valve Telescoping 6 Valve Confluence 7 Plate 8 O ring 9 O ring 10 Relief valve RV1 11 Relief valve RV2 12 Relief valve RV3...

Страница 18: ...Relief valve RV3 22 Plug 23 O ring 33 Check valve 34 Spring 35 Retainer 36 O ring 37 Oil seal 38 Retainer 39 Retainer 40 Spring 41 Spool end 42 Cover 43 Hexagon socket bolt 44 Hexagon socket bolt 52...

Страница 19: ...1 33 Check valve 34 Spring 35 Retainer 36 O ring 37 Oil seal 38 Retainer 39 Retainer 40 Spring 41 Spool end 42 Cover 43 Hexagon socket bolt 44 Hexagon socket bolt 45 Plug 77 O ring 78 Retainer 79 Spri...

Страница 20: ...alve RV1 11 Relief valve RV2 62 O ring 103 O ring 104 Spring 105 Retainer 106 O ring 107 O ring 108 Body 109 Regulator valve 110 Spring 111 Screw 112 O ring 113 Nut 114 Cap nut 128 Stopper 129 Retaine...

Страница 21: ...trigger high low shift 12 Relief valve RV3 13 Relief valve PR1 109 Regulator valve 110 Spring 111 Screw 113 Nut 114 Cap nut 137 O ring 151 Body 154 O ring 155 Backup ring 156 Spring 157 Body 158 O rin...

Страница 22: ...ifference in functions and disassembly procedures make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations 1 Struct...

Страница 23: ...ody assy 3 Valve Swing 23 O ring 24 Oil seal 25 Retainer 26 O ring 27 Bracket 28 Retainer 29 Spring 30 Spool end 31 Cover 32 Retainer 33 Hexagon socket bolt 34 Hexagon socket bolt 35 Check valve 36 Sp...

Страница 24: ...utrigger Right 6 Valve 23 O ring 24 Oil seal 25 Retainer 26 O ring 31 Cover 32 Retainer 33 Hexagon socket bolt 56 Retainer 57 Spool end 58 Case 59 Spring 60 Retainer 61 Steel ball 63 Hexagon socket bo...

Страница 25: ...Spring 84 O ring 85 O ring 86 O ring 90 Spring 94 O ring Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf P V T G1 2 58 8 68 6 43 3 50 5 A B C3 G3 8 39 2 49 0 28 9...

Страница 26: ...e 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 pa...

Страница 27: ...seat 16 Packing 17 Bolt 18 Fork end 19 Poppet 20 Spring 21 Cap 22 O ring 23 Relif valve 24 Stud bolt 25 Nut 26 Spring washer 29 Flange 30 O ring 31 Hexagon socket bolt Thread size and tightening torqu...

Страница 28: ...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 Gear pump No 1 2...

Страница 29: ...hine 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 start...

Страница 30: ...Tightening torque Sign port Thread size N m ft lbf 1 M24 1 5 58 8 68 6 43 4 50 6 1 Body 2 Filter 3 Filter retainer 4 Back pressure regulating valve 5 Pressure reducing valve 6 Hex socket head bolt 7...

Страница 31: ...7 11 10 8 6 3 5 12 2 13 9 1 4 1 Body 2 Spool 3 O ring 4 Plug 5 Spring seat 6 Spring 7 Adjust screw 8 Body 9 O ring 10 Nut 11 Cap nut 12 O ring 13 O ring Pressure reducing valve illustrated as 5 in the...

Страница 32: ...though 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 dis...

Страница 33: ...21 0910E B 6 B 6 Solenoid Valve Auto stop 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 8A 30 37 22 1 27 3 T1 M5 6 9 8 9 5 6 5 0 367 402...

Страница 34: ...ions 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 IW121 067001...

Страница 35: ...326 324 P A T 311 Spool 312 Sleeve 324 Spring 326 Retaining ring 361 O ring 362 O ring 363 O ring 801 Solenoid valve 802 Seal nut 861 O ring Thread size and tightening torque Tightening torque Sign P...

Страница 36: ...er of this machine and the parts sales unit described in the parts catalog before starting disassembling operations 1 Structure IW121 0460E02 B A P P T T 1 Body 2 Plunger 3 Spring 4 Plug 5 Plug 6 O ri...

Страница 37: ...isassembly procedures make sure of the serial number of this machine and the parts sales unit described in the parts catalog before starting disassembling operations 1 Structure T1 IW121 0880E02 A1 70...

Страница 38: ...363 861 801 802 326 324 P A T 311 Spool 312 Sleeve 324 Spring 326 Retaining ring 361 O ring 362 O ring 363 O ring 801 Solenoid valve 802 Seal nut 861 O ring Thread size and tightening torque Tightenin...

Страница 39: ...d disassembly procedures make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 2 O ring 3 Spring 5 Pl...

Страница 40: ...sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure B T Dr AC P P IW123 012001 IW123 012002 T B P P AC D...

Страница 41: ...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 oper...

Страница 42: ...ations 1 Body 2 Core 3 Slip ring assy 4 Plain bearing 5 Plain bearing 6 Plate 7 Plate 8 Packing 9 Ring seal 10 Bolt 11 Bolt 12 Spring washer 13 Plain washer 14 Bolt 15 Bolt 16 Bolt 17 Bolt 18 Grease n...

Страница 43: ...inder 2 1 Structure 2 C 3 Pilot Check Valve Front and rear stabilizer 3 1 Structure 3 C 4 Pilot Check Valve Outrigger jack 4 1 Structure 4 C 5 Power Slide Cylinder Outrigger 5 1 Structure 5 C 6 Power...

Страница 44: ...ch 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 S...

Страница 45: ...dures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 Cylinder 2 Spring pin 3 Piston 4 Plai...

Страница 46: ...d disassembly procedures make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 Plug 2 O ring 3 Spri...

Страница 47: ...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...

Страница 48: ...ugh 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 disass...

Страница 49: ...ctions 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 Dust seal...

Страница 50: ...ke sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW111 012002 3 Spring 4 O ring 5 O ring 6 O rin...

Страница 51: ...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...

Страница 52: ...Swing 1 1 Structure 1 D 2 Swing Speed Reducer 3 1 Structure 3 2 Removing of hydraulic motor 4 3 Disassembly of reducer 4 4 Assembly of reducer 5 5 Installation of hydraulic motor 5 D 3 Swing Bearing...

Страница 53: ...ance 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...

Страница 54: ...Ring 12 O ring 13 O ring 14 O ring 16 Spring 17 Distance Piece 20 Plug Assy 31 Shaft 32 Bearing 33 Bearing 34 Retaining Ring 35 Retaining Ring 41 Cover 43 Plate 44 Pin 46 Hexagon Socket Bolt Thread si...

Страница 55: ...es 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 This reducer is two stage planetary gear...

Страница 56: ...prevent the swing frame from self rotating 1 Before disassembly mark to each mating surface 2 Drain oil from the hydraulic motor and the reducer 3 After removing bolts 2 eight places securing the hydr...

Страница 57: ...tainer B 7 and hold it in position with snap ring 8 5 Hereafter assemble carrier B 10 to sun gear A 20 in reverse order of Disassemly of reducer NOTICE Confirm sun gear A 20 turns lightly by your hand...

Страница 58: ...here 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 disassembli...

Страница 59: ...ow Tighten all the bolts temporarily with approximately half the specified tightening torque Then tighten the bolts securely After tightening one bolt in this case tighten the diagonally opposite bolt...

Страница 60: ...i E Boom Elevating System Contents E 1 Boom Elevating Cylinder 1 1 Structure 1 2 Pressure detector for AMA 2 E 2 Counterbalance Valve Elevating 3 1 Structure 3 E...

Страница 61: ...ly 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 Grease nipple 2 Spring pin 3...

Страница 62: ...2 W155 0310E E 1 E 1 Boom Elevating Cylinder 2 Pressure detector for AMA NOTE The adjustment of pressure detector is unnecessary Cylinder side Rod side 0 360 275 80000 1 361 500 70000 1 361 801 10000...

Страница 63: ...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 st...

Страница 64: ...Elevating Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf Mounting bolt M10 34 3 39 2 25 3 28 9 A B port Plug 3 9 G 3 8 44 1 53 9 32 5 39 8 Plug 7 G 1 2 53 9 63 7...

Страница 65: ...i F Winch System Contents F 1 Winch 1 1 Structure 1 F 2 Hydraulic Motor Winch 5 1 Operational explanation 5 2 Structural explanation 5 3 Structure 6 F 3 Counterbalance Valve Winch 7 1 Structure 7 F F...

Страница 66: ...sassembling operations 1 Structure NOTICE 1 The amount of the projection in the bolt thread should be 5mm 0 2in or less 2 A proper oil quantity is shown by the oil level line in the drum state for che...

Страница 67: ...W526 0350E 1 Winch ASSY 1 Winch ASSY 2 Support 3 Hydraulic motor 4 Bolt 5 Spring washer 6 O ring 7 Plug ASSY Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf 4 M16...

Страница 68: ...Kingpin A 19 Snap ring 20 Hexagon socket head bolt 21 Ball bearing 22 Steel bearing ring 23 Housing 24 Sun gear A 25 Drum 26 Slust plate 27 Sun gear B 28 Carrier A 29 Internal gear 30 Kingpin B 31 Idl...

Страница 69: ...6 80 93 NOTICE 1 Caulking 2 Apply THREE BOND 1373N 5 Apply lithium grease or spindle oil 6 wrap sealing tape Plug must not project from the surface 7 Apply THREE BOND 1215 when shrinkage fitting 8 App...

Страница 70: ...that corresponds to the sectional area of the piston F piston stroke h is supplied from one of slits in the control plate at the process of the piston of UT to OT 2 Structural explanation Cylinder bl...

Страница 71: ...escribed in the parts catalog before starting disassembling operations 1 Piston motor 2 Counterbalance valve 3 Housing 4 Cover 5 Parallel pin 6 O ring 7 Hexagon socket head bolt 8 Plug 9 Cylinder bloc...

Страница 72: ...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 Spool 3 Piston 4 Orifice 5 Cover 6...

Страница 73: ...erbalance Valve Winch Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf 12 M6 12 15 9 11 13 M8 28 35 21 26 14 M10 55 69 41 51 15 M12 88 65 A M10 43 49 32 36 B M10 43...

Страница 74: ...traction 4 4 Boom telescoping order 4 4 1 Extending 4 4 2 Retracting 4 G 2 Boom Five section boom 5 1 Structure 5 2 Dismounting the boom assembly and preparation of the boom disassembly 7 2 1 Dismount...

Страница 75: ...ssembling the boom telescoping cylinder 28 7 5 Assembling the 2nd boom section 29 7 6 Assembling the base boom section 34 8 Mounting the boom assy 37 G 3 Telescoping Cylinder 38 1 Structure 38 G 4 Cou...

Страница 76: ...act at a speed in proportion to the oil quantity supplied to the telescoping cylinder This valve further serves to prevent the telescoping cylinder from retracting when the piping between this valve a...

Страница 77: ...2nd boom section rear end of the 4th boom section 2 3 Wire rope mechanism C for extending the 4th boom section retracting the 3rd boom section The wire rope mechanism C serves for both extending and...

Страница 78: ...e boom in the following order Front end of the 3rd boom section front end of the 4th boom section rear end of the top boom section 2 5 Wire rope mechanism E for retracting the top boom section This me...

Страница 79: ...ed by the wire rope mechanism E 4 Boom telescoping order 4 1 Extending 1 When the 2nd boom section is extended the 3rd boom section is also extended at the same time by the wire rope mechanism A 2 Whe...

Страница 80: ...5 G 2 Boom Five section boom 5 G 2 W536 1040E G 2 G 2 Boom Five section boom 1 Structure General View 3 312 049 90100...

Страница 81: ...pacer 64 Button bolt 65 Pin 66 Plate 67 Slide plate 68 Machine screw 69 Plain bearing 70 Plate 71 Retainer 72 Retainer 73 Slide plate 74 Retainer 75 Retainer 76 Slide plate 77 Slide plate 78 Support 7...

Страница 82: ...ame 7 Lower the boom until the elevating cylinder comes in contact with the spacer 8 Stop the engine 9 Relieve the pressure in the circuit by operating all control levers back and forth 10 Remove hydr...

Страница 83: ...ter H before disassembling the boom 1 Dismount Winch Assy 2 Prepare 30 6 9300mm electric cable Dummy cable 3 Lock the Boom Length Detecter BLD cable drum to prevent it from turning If BLD drum is over...

Страница 84: ...G 2 Boom Five section boom 9 W536 1040E G 2 7 Disconnect dummy cable from BLD cable Leave dummy cable inside boom 8 Disconnect Hose Joint from tel cylinder Put plug 7 8...

Страница 85: ...moving the wire rope measure and record the dimension Lb which can be used for reference during reassembly 3 Remove the wire ropes for extending the 3rd boom section from the rear end of the base boom...

Страница 86: ...n and others from the base boom section 3 2 Pulling out the boom telescoping cylinder 1 Remove the sheaves for extending the top boom section and the wire rope guide from the front end of the 4th boom...

Страница 87: ...pport A from the rear end of the 3rd boom section NOTICE When it is attempted to remove the support A it will hit the wire rope for retracting the 4th boom section To avoid this slacken the wire rope...

Страница 88: ...of the 3rd boom section 2 Remove the wire ropes for extending the 4th boom section from the front end of the 3rd boom section and fix them at the front end of the 4th boom section with a wire etc NOTI...

Страница 89: ...wire rope guide from the rear end of the 4th boom section 4 Release the wire ropes for retracting the top boom section and pull out them to the rear of the 4th boom section 5 Remove the slide plates f...

Страница 90: ...res in one strand in one lay 2 Wear of one third of the original diameter of outside individual wires Evidence of kinking crushing bird caging or any other damage resulting in distortion of the rope s...

Страница 91: ...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 th...

Страница 92: ...following tools are needed to assemble the boom They should be prepared by yourself 6 1 Tool A NOTICE All dimensions in the drawings are in millimeters The materials thread sizes and pitches are descr...

Страница 93: ...E G 2 Tool fixing pin and plate Material SS400 6 2 Tool B NOTICE The thread size is based on JIS Japanese Industrial Standard Bolt M12 coarse thread with thread length 50 mm 2 in or more Nut M12 coars...

Страница 94: ...rd through the cord guide for the boom length angle detector and pull it out to the rear of the top boom section NOTICE Pull out the temporary cord at least 1500 mm 4 ft 11 in from the rear end of the...

Страница 95: ...easured at step 7 Adjust the clearances to the following by increasing or decreasing the number of shims 0 5 mm 1 64 in or less in total when the values at right and left are added NOTICE After this a...

Страница 96: ...ves for extending the top boom section at the front end of the 4th boom section 5 Release the wire ropes for extending the top boom section and place them in the grooves of the sheaves for extending t...

Страница 97: ...eft wire rope guides are reversed they will hit the 3rd boom section when the 4th boom section is inserted into the 3rd boom section Make sure that the wire rope guides are installed in the following...

Страница 98: ...ent apply thread locker ThreeBond 1305 to bolts that are used for fixing the sheave pins and tighten them 14 Fix both ends of the wire ropes for extending the 4th boom section at the front end of the...

Страница 99: ...for fixing the slide plates Then lightly tighten the screw and back off a quarter turn 19 Apply grease to the surfaces outside the 4th boom section on which the slide plates of the 3rd boom section s...

Страница 100: ...ease the wire ropes for extending the 4th boom section Attach the support to an end of the wire rope for extending the 4th boom section for two wire ropes NOTICE Pay attention to the direction of the...

Страница 101: ...op boom section and pass them through the supports at the front end of the 3rd boom section 9 Measure the following internal widthwise dimension of the 2nd boom section At 1 0 to 1 4 m 3 3 to 4 5 ft f...

Страница 102: ...ond 1305 to screws that are used for fixing the slide plates Then lightly tighten the screw and back off a quarter turn 13 Apply grease to the surfaces outside the 3rd boom section on which the slide...

Страница 103: ...of the boom telescoping cylinder 4 Install the tool A to the rear end of the boom telescoping cylinder 5 Hook the unthreaded ends of the wire ropes for extending the 3rd boom section on the tool A 6...

Страница 104: ...om section 1 Install the slide plates to the lower surface at the front end of the 2nd boom section 2 Install the slide plates to the side surfaces at the front end of the 2nd boom section Adjust the...

Страница 105: ...ope guide NOTICE Install the sheave with its clinched side facing outwardly 6 Pass the wire rope for retracting the 4th boom section through the adjuster assy Then pass the wire rope for retracting th...

Страница 106: ...inder approx 600 kg 1325 lbs NOTICE Be careful not to pinch the wire ropes for extending the 3rd boom section between the boom telescoping cylinder and the boom Be careful not to drop the side with th...

Страница 107: ...eful not to damage the wire ropes and then install the boom telescoping cylinder again 15 Fully insert the boom telescoping cylinder into the 2nd boom section and fix it with two pins Put retaining ri...

Страница 108: ...the slide plates on the side faces of the boom based on the dimension measured at step 21 Adjust the clearances to the following by increasing or decreasing the number of shims 0 5 mm 1 64 in or less...

Страница 109: ...t the front end of the adjuster assy NOTICE Be sure to remove the nuts at the front end of the adjuster assy and apply molybdenum disulfide grease to the whole area of the adjusting screw 5 Fix the ad...

Страница 110: ...support A Pull the lower wire ropes at the same time until the lower rope ends come out of the boom as much as shown in the figure below 10 Pass the ends of the wire ropes for extending the 3rd boom...

Страница 111: ...ighten the nut 14 Remove the tool B Screw a locknut to lock the wire rope for extending the 3rd boom section NOTICE The dimension La that was measured during disassembly can be used as the reference t...

Страница 112: ...g according to Chapter Y Adjustment procedure of boom telescoping wire ropes 17 Install the boom length angle detector according to Chapter H Boom length angle detector replacement procedure 8 Mountin...

Страница 113: ...erations 1 Structure 1 Roller assy 2 Retaining ring 3 Pin 4 Split pin 5 Plug 6 Cylinder 7 Nut 8 Setscrew 9 Plain bearing 10 Packing 11 Backup ring 12 O ring 13 Piston 14 Rod 15 O ring 16 Backup ring 1...

Страница 114: ...ping Cylinder 39 W157 480E Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf 7 515 721 380 531 8 M8 13 2 16 2 9 7 11 9 23 1030 1442 760 1063 24 M10 34 3 39 2 25 3 28 9...

Страница 115: ...s 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...

Страница 116: ...Telescoping Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf Mounting bolt M10 34 3 39 2 25 3 28 9 A B port Plug 3 9 G 3 8 44 1 53 9 32 5 39 8 Plug 7 G 1 2 53 9 63...

Страница 117: ...t procedure 10 7 1 Pulling out cord from boom 10 7 2 Passing cord through boom 13 H 2 Boom Length Angle Detector 17 1 Construction and function 17 2 Disassembly and reassembly 18 2 1 Disassembly of co...

Страница 118: ...H 1 H 1 AMA Load Moment Indicator 1 W301 0270E H 1 AMA Load Moment Indicator 1 Structure...

Страница 119: ...tate indicator lamp While the boom is in over front area this lamp is lit When the boom is swung out on the over front area this lamp goes out 3 Display window display alteration switch The display wi...

Страница 120: ...s shown in the drawing when the boom is fully retracted 2 A stopper is attached to the cord Do not remove the stopper from the cord when installing the detector on the boom other wise the cord will be...

Страница 121: ...d with the outriggers extended as specified See the Table 1 on the next page 2 Remove the cover from the AMA main unit and select the crane model and the capacity data before confirming accuracy 3 Run...

Страница 122: ...tend the boom fully and press the span adjustment button Retract the boom fully again Is the displayed valve within the zero point adjustment range shown in the Table 2 Yes Completed IW301 017007 No T...

Страница 123: ...ied load depend on the table 1 Set the elevating angle to the specified angle 1 Shift the rotary switch to 6 Is the moment displayed value within the range of 95 0 104 Turn the rotary switch to 0 posi...

Страница 124: ...th detector Fully retract the boom and measure the resistance of the potentiometer 1 2 of CN3 5000 750 1 3 of CN3 460 40 If a measured value is out of the standard range replace the boom length detect...

Страница 125: ...ent performed while it is maladjusted i e the crane is inclined Make sure that the error occurs on the occasions that the boom is almost fully raised or almost fully lowered Adjust the boom angle valu...

Страница 126: ...ty serial data received Error caused by broken wiring of the serial circuit or noise Check the cable between the AMA main body and control unit Repair or replace the cable is displayed Boom angle reac...

Страница 127: ...sed through the above pipe to the front end of the top boom section This should be longer than 9 m 29 5 ft with a diameter of approx 2mm 5 64 in Fastener 2 pieces To be used for fixing the cord at the...

Страница 128: ...ng the cord 4 Pulling out the cord from the boom 1 Remove the fastener for fixing the cord and remove the cord from the support 2 Pull out the cord from the boom rear end Before pulling out the cord p...

Страница 129: ...ot be pulled out through the rollers C and D Then the following steps will be needed If the cord is cut halfway and the portion of the cord with the terminals can be pulled out from the side of the bo...

Страница 130: ...cord through boom 1 Removing the rollers etc Pass the cord only when no roller or pin is installed If they are in position remove them according to the following steps 1 Remove the split pin from the...

Страница 131: ...top boom section It may be difficult to do this as the inside of the boom is dark As the support at the rear end of the top boom section is painted in white use it as a guide for this operation 3 Pass...

Страница 132: ...1 to 3 of 1 above Then pass the cord through the hole and into the boom 2 Pass the cord over the roller C and install the roller C in the reverse order of the steps 1 to 3 of 1 above Then join the co...

Страница 133: ...its portion covered with a poly tube through the support and tie a bowline Then tie the poly tube portion that is looped back with a fastener 3 Fix the support with bolts to the upper surface of the b...

Страница 134: ...reduced by the reduction gear which in turn rotates the shaft of the potentiometer 3 The electric resistance of the potentiometer shaft varies proportional to the reduction of the shaft rotation and...

Страница 135: ...er 56 Bolt 57 Plain washer 58 Spring washer 2 Disassembly and reassembly 2 1 Disassembly of cord 1 Remove connector and cord lock on the end of cord Allow drum to slowly wind cord until the spiral spr...

Страница 136: ...s on drum wind cord 1 turn additionally and fix it with gummed tape to prevent it from loosening IW305 0130E08 Gummed tape Slip ring 5 Insert the shaft of the drum assembly into the boss hole in the p...

Страница 137: ...ate slack and tighten clamp 2 places 17 Install cord lock on the end of cord and install lead wires and connector to the end of cord Completely insulate soldered connections 9700 mm 31 82ft 50 mm 0 16...

Страница 138: ...on the shaft of speed reducer and gear on potentiometer shaft to allow both gears to rotate freely Rotate gear on potentiometer shaft about 1 4 turn by hand and confirm that gear is returned to its o...

Страница 139: ...the upper surface of the outrigger box Then loosen the switch 2 5 turns 3 32 and lock the switch in place 2 Retract the outriggers and check the switch indicator to confirm that there is no detection...

Страница 140: ...23 W313 0210E 23 Outrigger Extension Detector H 3 H 3 H 3 3 Rear stabilizer Extension Detector 0 314 803 36200...

Страница 141: ...p alarm function 4 2 5 Alarm function 5 V 2 Radio control Valve 6 1 Structure 6 1 1 Hydraulic circuit 6 1 2 Electric circuit 7 1 3 General View 8 1 4 Cross section 9 1 5 Unloading valve 10 V 3 Acceler...

Страница 142: ...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 m...

Страница 143: ...V 1 V 1 Configurations of Radio control System 2 V02 0021E 1 1 Names and functions of each part...

Страница 144: ...off to save battery consumption The power LED of the transmitter is turned off To resume the radio control operation press the power switch once again to turn on the power LED 2 2 Switch failure dete...

Страница 145: ...ion selection switches 2 4 Instant stop alarm function If the radio wave from the transmitter is hindered during the radio control operations due to changing surrounding conditions and the like the sp...

Страница 146: ...n the operation lever of the crane does not return to the neutral position even after the motion selection switch of the transmitter is returned to the neutral position Crane operation The radio contr...

Страница 147: ...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 uni...

Страница 148: ...V 2 V 2 Radio control Valve 7 W135 0180E 1 2 Electric circuit...

Страница 149: ...V 2 V 2 Radio control Valve 8 W135 0180E 1 3 General View Thread size and tightening torque Tightening torque Sign Port Thread size N m ft lbf G 1 4 24 5 29 4 18 22 P T port G 1 2 53 9 63 7 40 47...

Страница 150: ...V 2 V 2 Radio control Valve 9 W135 0180E 1 4 Cross section...

Страница 151: ...10 W135 0180E 1 5 Unloading valve Relif valve C 19 61 20 10 Mpa 2843 45 2914 45 psi at 60L min Relif valve F 2 06 2 65 Mpa 298 70 384 30 psi at 1 5L min Reducing valve E 1 86 1 96 Mpa 270 284 5 psi P...

Страница 152: ...ake 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 Flange 2 Differential transformer assy 3 Shi...

Страница 153: ...the transmitter is turned on while the motion selection switch and speed control lever are operated indications 1 as shown in the table are displayed In either case once again turn the power on 2 If t...

Страница 154: ...onds to the error number is manually returned to the neutral position check if the error number disappears When the mode indicator lamp displays L1 and when the error number does not reappear after op...

Страница 155: ...is made the operation can be continued If the operation lever cannot be moved or if the error number does not disappear then radio control operation is impossible Change to the manual operation and t...

Страница 156: ...hen no operation is made for approximately one hour the power of the transmitter is automatically turned off to save battery consumption Turn on the power again The power is turned off during the radi...

Страница 157: ...n a noise generating device such as a revolving light electric fan or vehicle s air conditioner is used nearby the radio control operation is influenced by the source Turn off the noise generating dev...

Страница 158: ...shift 1 1 2 Manual Control Valve Outrigger 2 1 3 Manual Control Valve Winch 3 2 Hydraulic Units 4 2 1 Swing Motor 4 2 2 Swing Speed Reducer 4 2 3 Winch Motor 4 2 4 Winch Speed Reducer 4 2 5 Winch Moto...

Страница 159: ...re at engine speed 1960 rpm Over load relief valve RV3 12 5 13 0 1813 1885 1 Pressure adjustment is not necessary because the pressure is set in factory Relief valve RV2 at 95L min 21 1 21 6 3060 3132...

Страница 160: ...min 1 Note Relief valve RV5 at 95L min 20 6 21 1 2987 3060 1960 1 Connect a pressure gauge to the PG port 2 Turn the PTO switch ON 3 Set the outrigger extension jack selection levers of the right and...

Страница 161: ...ngine speed min 1 Note Relief valve RV4 at 216L min 20 1 20 6 2915 2987 1960 1 Plug the hoses connected to the hoist up and hoist down ports 2 Connect a pressure gauge to the PG port 3 Turn the PTO sw...

Страница 162: ...indicated engine speed is 1960 rpm or more on a tachometer when PTO is in OFF position and the accelerator pedal is depressed from driver s seat 3 2 Engine rpm at rated flow Pump Engine revolution Pum...

Страница 163: ...Adjustment and Checks 5 WY05 1510E 5 Y 2 Y 2 Y 2 Y 2 Adjustment and Checks 1 Adjustment procedure of boom telescoping wire ropes 0 312 049 90970...

Страница 164: ...Non continuous 375 rotation Radio controls spec 5a 1 Applicable serial No EX0309 5a 2 Applicable serial No EX0310 5b Z 6 Electric Circuit Spec TM 2000 1 314 414 Continuous rotation Radio controls spec...

Страница 165: ...5 1 Main harness 17 5 2 Sub harness 18 6 Frame Rear 19 7 Vehicle 20 8 Angle limit alarm 21 Z 9 Harness 22 1 Harness Post and Boom point 22 2 Harness Operation box 23 2 1 Harness 1 23 2 2 Harness 2 24...

Страница 166: ...Hydraulic Circuit 1 WZ01 1351E 1 Z 1 Z 1 Z 1 Z 1 Hydraulic Circuit Spec TM 2000 1 104 114 204 214 Manual spec 1 314 022 60200...

Страница 167: ...Hydraulic Circuit Z 2 Z 2 Z 2 2 WZ01 1501E 2 Z 2 Hydraulic Circuit Spec TM 2000 1 304 314 404 414 Radio controls spec 1 314 022 90200...

Страница 168: ...400 No CN No SWP L100 423 521 30100 CN30 AMP L125 200 313 612 22302 CN4 AMP L100 316 533 03300 L150 L75 L125 CN11 AMP L1100 316 520 30200 CN51 AMP L1200 313 601 91600 10A KEY SW engine stop circuit st...

Страница 169: ...REV detector 2 Drum REV detector 1 Serial output Spare Display O R MID Spare Spare Shield GND Angle detector input Length detector input Detector power supply output Spare GND Spare swing detector Ro...

Страница 170: ...FB5 2 FB4 1 FB4 2 FB3 1 FB3 2 FB2 1 FB2 2 FB1 1 FB1 2 FBG OSC2 OSC1 SB5 SA5 OUT1 OUT2 SB4 SA4 SB4 SA3 SB2 SA2 SB1 SA1 BOOT LOW UNLOD MBSRC OUT4 SW8 RSRXD RSTXD WB LY YG GW LW B B GR B RL B 28 27 26 25...

Страница 171: ...Serial output Serial input Spare M unload Output when crane is operated Engine stop Output at emergency stop Engine start Output at engine start Speaker Speaker AA accelerator cutoff Over winding cut...

Страница 172: ...allation R B W Br BrW RL R W R BW LW RW CN 74 F CN 73 F F CN11 M BW BW GW G B F CN22 YR Y BrW B F CN21 RW R RB B F CN24 O B GR B F CN23 R Br LO R 4 1 2 3 3 2 1 4 R 13 14 5 9 5SEC T 1 4 3 2 1 R R 1 2 3...

Страница 173: ...sed at the middle extension 1 2 3 4 R CN75 F CN76 F R 4 3 2 1 2 1 1 2 L B Br W L M CN42 F B Br W W B 4 3 1 2 M CN79 F M CN42 F 390 M CN77 F 2 1 GO Br O M CN50 F 2 1 B W W B G R G R 2 1 M CN49 F B W GO...

Страница 174: ...Location of Hydraulic Parts Z 7 Z 7 Z 7 7 WZ07 1810E 7 Z 7 Location of Hydraulic Parts 1 Frame 4 316 484 20000...

Страница 175: ...375 non continuous swing Connect the 7 hoses from the hose assembled section of the swing frame and the winch drain hoses Connect the hoses with the same marks Arrange clearance of at least 1 2 inch...

Страница 176: ...10E 2 2 With 360 continuous swing Notice 1 Connect the hose between same marks 2 Cover the hoses with spiral tube wraps on the position shown in figure at the passage part of the post side face and se...

Страница 177: ...Location of Hydraulic Parts Z 7 Z 7 Z 7 10 WZ07 1810E 10 3 Outrigger 4 316 481 21001...

Страница 178: ...11 WZ07 1810E 11 Location of Hydraulic Parts Z 7 Z 7 Z 7 4 Lower 1 316 134 30300 0 319 233 61000 0 319 233 63000...

Страница 179: ...onnector In upper part fix the wiring from the post 4 Tighten both wirings for the SWP connector and the wirings for the metal connector 5 Adjust the switch to operate at 5 8mm 0 2 0 32in before the t...

Страница 180: ...13 WZ02 3270E 13 Location of Electrical Parts Z 8 Z 8 Z 8 2 Post and Boom point 2 1 Non continuous 375 rotation spec 0 316 558 14000...

Страница 181: ...14 WZ02 3270E 14 Location of Electrical Parts Z 8 Z 8 Z 8 2 2 Continuous rotation spec 1 316 558 04000...

Страница 182: ...Then loosen the switch 2 5 turns 3 32 and lock the switch in place 1 2 Retract the outriggers and check the switch indicator to confirm that there is no detection error When shipped the proximity swit...

Страница 183: ...16 WZ02 3270E 16 Location of Electrical Parts Z 8 Z 8 Z 8 4 Operation box 4 316 558 02000...

Страница 184: ...17 WZ02 3270E 17 Location of Electrical Parts Z 8 Z 8 Z 8 5 Radio control system 5 1 Main harness 2 316 558 03000...

Страница 185: ...18 WZ02 3270E 18 Location of Electrical Parts Z 8 Z 8 Z 8 5 2 Sub harness 1 316 557 30000...

Страница 186: ...19 WZ02 3270E 19 Location of Electrical Parts Z 8 Z 8 Z 8 6 Frame Rear 0 314 803 36000...

Страница 187: ...20 WZ02 3270E 20 Location of Electrical Parts Z 8 Z 8 Z 8 7 Vehicle 0 319 329 00000...

Страница 188: ...Location of Electrical Parts Z 8 Z 8 Z 8 21 WZ02 3270E 21 8 Angle limit alarm 0 314 803 40000...

Страница 189: ...ness Z 9 Z 9 Z 9 22 WZ04 2600E 22 Z 9 Harness 1 Harness Post and Boom point 2 316 558 04400 0 316 558 04300 0 316 558 14400 0 313 612 24100 1 313 612 24200 0 316 558 14300 0 313 613 74200 0 316 558 04...

Страница 190: ...Harness Z 9 Z 9 Z 9 23 WZ04 2600E 23 2 Harness Operation box 2 1 Harness 1 3 316 558 02300...

Страница 191: ...Harness Z 9 Z 9 Z 9 24 WZ04 2600E 24 2 2 Harness 2 3 316 558 02100...

Страница 192: ...Harness Z 9 Z 9 25 WZ04 2600E 2 3 Switch 3 313 612 23400...

Страница 193: ...26 WZ04 2600E 26 Harness Z 9 Z 9 Z 9 3 Harness Radio controls 0 316 558 03600...

Страница 194: ...ad Office Ko 34 Sinden cho Takamatsu Japan Overseas Service Group Tadano Ryogoku Bldg 4 12 Kamezawa 2 chome Sumida ku Tokyo Japan Tel 81 3 3621 7765 Tel fax 81 3 3621 7785 History of revision 1 2 3 4...

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