Publication No.

TM-1000-1/S2-1E

01

Cargo Crane
Model TM-1000-1
Applicable Serial No. 655935--
 Safety

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.
[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.

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
Servicemen inexperienced in the units of this machine
should be cautious about safety operations. They
must acquire sufficient knowledge about the
equipment before dismounting and disassembling it.
Before dismounting each component, a serviceman
should read this service manual thoroughly and find
out the weight of the component, then lift it by proper
means.
The following are cautions to be observed all the time.
1.Before starting repairs, find out the origin of the
problem. When it becomes clear that
disassembly and maintenance are necessary, first
of all read this manual and parts catalog and
thoroughly understand the principle of operation
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,
new troubles or decline in performance may be
induced.
2.Before operating the machine, oiling or repairing,
read warning labels and instructions on the
machine and understand the contents.
3.Wear a safety helmet and safety shoes whenever
you carry out maintenance operation around the
machine. Be sure to wear safety goggles when
you hit the machine or its attachments with a
hammer. In welding operation, wear safety gears
such as leather gloves, helmet, goggles, apron
and proper working clothes, but don't wear loose
or torn clothes. Take a ring and so on off your
finger when you conduct maintenance or repair.
4.Park the machine on as level and hard ground as
possible. Place chocks under wheels to prevent
the vehicle from moving when doing maintenance
on or below the machine.
5.Before starting maintenance, remove cables to the
battery and allow 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. Sustain the
vehicle positively with blocks and so on to prevent
2 WA01-0041E
fatal accidents, as there is a possibility that the
vehicle loses its balance and falls down on a
worker in a dismounting process of certain units.
7.When the working is done on a team of more than
one person, make arrangements about
co-operation and communication between workers
beforehand. Give a sign without fault and make
sure that the sign has been transmitted to other
workers before starting the next operation.
8.When it is inevitable to measure oil pressure,
rotational speed, and temperature for machine
inspection without stopping the engine, be careful
not to be caught or pinched in rotating or moving
parts such as a fan, fan belt. Make sure that
there is no obstruction or no person around the
machine before operating it.
2. Cautions in working
2.1 General
1.When hoisting up components weighing more than
20 kg, use hoist or the like to prevent injury to your
lumbar or spine. For specific components, their
weights are listed on the chapter for "service data"
in this manual.
2. When using eyebolts, lift parts vertically so that
only tension is applied to them.
3.Protect wire ropes and plastic lifting slings by
covering corners with pads so that they are not
bent sharply by directly contacting corners.
Keep the sling angle of wire ropes within 60°and
as vertical as possible.
4.Be careful about hot or heated portions when
conducting repair or maintenance just after the
vehicle has stopped or the machine operation has
been finished or interrupted.
5.When hitting parts, be sure to either hit on a pad
placed on the parts or use a plastic hammer.
6.Put units, especially similar parts, in order. Mark
them with tags or marker if necessary.
 Safety
7.Put disassembled parts in order so that parts such
as bolts are not left behind in the machine. And
check that no parts run short at assembly.
8.Watch your step in the following cases:
When stepping up to or stepping down from the
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder
When checking engine oil, radiator coolant, or
battery fluid.
When replacing a filter of air cleaner
When getting on and off the cab
Be careful not to slip in the above operations in
winter as snow and ice may attach to the exterior
of boom and it becomes very slippery.
2.2 Dismounting and disassembling
1.Before dismounting and disassembling, make sure
of the construction and part sales unit by reading
this manual and the separate parts catalog, then
understand the procedures of dismounting and
remounting and disassembling and reassembling.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging
the confined pressure.
3.Before removing, clean the part to be dismounted
and the area surround it. Seal the opening with a
plug or tape, etc. to prevent foreign material from
entering it.
4.Measure and record the data such as shim
thickness adjustment and pre-load at disassembly
that will be required at reassembly.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling.
6.If a part cannot be removed after removing bolts or
nuts 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 of a part. Lift up it in balanced
condition.
3 WA01-0041E
In case that the position of the center of gravity is
not clear and there is a possibility of swing of load
after removing, use two hoists.
8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
hinder removing.
2.3 Remounting and assembling
1.Before assembling, clean all the parts and repair
or replace defective parts.
2.As dirt and soil adversely affect sliding portions
and they may decrease the life of the machine,
pay special attention to avoid intrusion of dirt and
soil.
3.Use special tools for parts when specified to do so.
4.Remove dirt, soil, water, and resin completely from
surfaces where liquid gasket will be applied.
5.After remounting, be sure to inspect the machine
and verify that there is no error by oversight. If
adjustment or air bleeding is required, conduct it
according to instructions. Conduct function and
performance test to verify its integrity.
3. Cautions in operation
3.1 Brake fluid replenishment
1.When the brake-warning lamp (for fluid level) is
lighted, replenish brake fluid and check and make
sure of the thickness of disk brake pads. (Refer
to Chapter Y for periodical inspection periods.)
2.Check the thickness of disk brake pads whenever
brake fluid is replenished.
3.2 Handling of battery
1.Erroneous handling of a battery may cause it to
catch fire and explode.
Be extremely sure to avoid short circuits, sparks
and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
Charge up batteries and use them only in well
ventilated places.
 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
Boom nameplate
This service manual describes the systems and (1) Unit No.
components of the TM-1000-1 series cranes, its repair, (2) Lot No.
check and adjustment methods and other relevant
(1)
matters.
(2)
Read the separate operation and maintenance manual, UNI T NO. LOT NO.

the mounting manual and the parts catalog for repair

IWA04-062001
and maintenance of the crane in conjunction with this
manual. Frame nameplate
(1) Unit No.
When carrying out repairs, check the parts catalog for
(2) Serial No.
structure and sales units of the parts beforehand. (3) Year and month of mounting

(1)
1. Applicable unit No. (2)

The unit Nos. of the cranes to which this manual is

applicable are listed below. Check the unit No. of your SPEC. NO.
SERIAL. NO.

crane on the nameplate attached to the crane before MFG. DATE.

KAGAWA,JAPAN

using this manual.

(3) IWA04-062002

Boom nameplate Frame nameplate

Spec. No.
unit No. unit No.
2. Separate service manual
The repair manual documents for your crane are
TM-1000-1-104 411-331-20030 411-421-10040
comprised of this manual and the separate documents
listed below.

Separate service manual Publication No.

General Cautions SA01-01-2E

Please note that, for product improvement, some

changes may have been incorporated in the
machine that are not covered in this manual.

1 WA04-2450E
 Foreword

3. Outline of specifications

Spec. No.
Item
TM-1000-1-104

No. of boom sections 5-section

Hydraulic motor driven, spur gear speed reduction,

Winch
provided with automatic brake and cable follower

Outriggers extended width Min. 2,250 mm Mid. 3,300 mm Max. 4,300 mm

Operation Manual

Maximum lifting capacity 82,000 kg

Overwinding with alarm

Hook safety latch
Level gauge
Hydraulic safety valves, check valves and holding valves
Safety devices
Load meter
Load indicator
Hoisting limiter

2 WA04-2450E
 Foreword

4. Conversion table
Length
millimeter, mm centimeter, meter, m inch, in, ” foot, ft, ’ mile, mi kilometer,
-1 -3 -2 -3
1 1×10 1×10 3.93701×10 3.28084×10 1 1.60934
-2 -1 -2 -1
1×10 1 1×10 3.93701×10 3.28084×10 6.21373×10 1
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,
cubic inch, in3 cubic foot, ft3 gallon, gal cubic inch, in3 liter, lit, L
cm3, cc 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 WA04-2450E
 Foreword

Work, energy
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
in-lbf
-2 -1 -3 -3
1 1×10 1.01972×10 1.01972×10 7.37562×10 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

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 WA04-2450E
5. Group index

B Hydraulic Power Generating System

C Outrigger System

D Swing System

E Boom Elevating System

F Winch System

G Boom Telescoping System

Y Data, Adjustment and Checks

Z System Diagrams

5 WA04-2450E
 Foreword

6. Contents
Spec. No.
Chapter Section
TM-1000-1-104

General

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

Hydraulic Power Generating System

Manual Control Valve

B-1
(Boom elevating, winch, telescoping, swing)

B Manual Control Valve (Outrigger) B-2

Rotary Joint B-3

Outrigger System

Jack Cylinder (Front) C-1

Jack Cylinder (Rear)-Option C-2

C
Pilot Check Valve (Jack) C-3

Power Slide Cylinder (Front) C-4

Swing System

Hydraulic Motor (Swing) D-1

D Swing Speed Reducer D-2

Swing Bearing D-3

Boom Elevating System

Boom Elevating Cylinder E-1

E
Counterbalance Valve (Elevating) E-2

6 WA04-2450E
 Foreword

Spec. No.
Chapter Section
TM-1000-1-104

Winch System

Explanation of Winch System F-1

F Hydraulic Motor (Winch) F-2

Winch F-3

Boom Telescoping System

Boom (Five-section boom) G-1

G Telescoping Cylinder (Five-section boom) G-2

Counterbalance Valve (Telescoping) G-3

Data, Adjustment and Checks

Service Data Y-1

Y Adjustment (Hydraulic) Y-2

Adjustment (Electric) Y-3

System Diagrams

Hydraulic Circuit Z-1

Electric Circuit Z-2

Z
Location of Hydraulic Parts Z-3

Location of Electrical Parts Z-4

7 WA04-2450E
 B B

Hydraulic Power Generating System

Contents

B-1 Manual Control Valve

(Boom elevating, winch,
telescoping, swing) ................. 1

1. Structure .................................................... 1

B-2 Manual Control Valve

(Outrigger)................................ 5

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

B-3 Rotary Joint ...................................... 8

1. Structure .................................................... 8

i
B-1 B-1
Manual Control Valve (Boom elevating, winch, telescoping, swing)

B-1 Manual Control Valve

(Boom elevating, winch, telescoping, 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
General view

1. Bolt 5. Valve assembly 8. Valve assembly (Swing) 12. Machine screw

2. Nut (Boom elevating) 9. Cover 13. Fastener
3. Cover 6. Valve assembly (Winch) 10. Solenoid valve 14. Plug
4. O-ring 7. Valve assembly 11. Plain washer
(Boom telescoping).

1 W113-0412E
B-1 B-1
Manual Control Valve (Boom elevating, winch, telescoping, swing)

Boom elevating

33. Bracket 37. Adapter 40. Spring 43. Cap (Seal)

34. Spring seat 38. Bolt 41. Cap 44. Seal
35. Spring 39. Poppet 42. O-ring 45. Link
36. Cap

Winch

33. Bracket 37. Adapter 40. Spring 43. Cap (Seal)

34. Spring seat 38. Bolt 41. Cap 44. Seal
35. Spring 39. Poppet 42. O-ring 75. Plate
36. Cap

2 W113-0412E
B-1 B-1
Manual Control Valve (Boom elevating, winch, telescoping, swing)

Boom telescoping

34. Spring seat 38. Bolt 41. Cap 44. Seal

35. Spring 39. Poppet 42. O-ring 75. Plate
36. Cap 40. Spring 43. Cap (Seal) 93. Bracket
97. Adapter

Swing

34. Spring seat 38. Bolt 41. Cap 44. Seal

35. Spring 39. Poppet 42. O-ring 45. Link
36. Cap 40. Spring 43. Cap (Seal) 75. Plate
127.Adapter

3 W113-0412E
B-1. B-1.
Manual Control Valve (Boom elevating, winch, telescoping, swing)

Solenoid valve

3.Spring seat 13. Spring 21. Adapter 31. Seal washer

4. Spring 14. Adjusting screw 22. Spring 32. Nut
5. Spring 15. Packing 25. O-ring 33. Cap nut
6. O-ring 16. Nut 26. O-ring 34. Tube
7. Cover 17. Cap nut 27. Push rod 40. Seat assembly
8. Bolt 18. Nut 28. Solenoid 41. Spool assembly
9. O-ring 19. Packing 29. Machine screw
12. Spring seat 20. O-ring 30. Set screw

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m ft-lbf
A1 - A4,
B1 - B4, G1/2 88.1 - 108.1 9.0 - 11.0 64.9 - 79.7
P port
T port G3/4 150 - 184 15.3 - 18.8 111 - 136

G port R1/4 17.6 - 30.9 1.8 - 3.2 13.0 - 22.8 Pressure gauge

(QS10025-A81002)
366-382-70000 △
0

4 W113-0412E
B-2 B-2
Manual Control Valve (Outrigger)

B-2 Manual 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

General view

1. Cover assembly 4. Valve assembly 6. Relief valve 9. Valve assembly

2. Valve assembly (Front-right) 7. O-ring (Rear-right)
(Extension/retraction) 5. Valve assembly 8. Bolt 10. Valve assembly
3. Valve assembly (Front-left) (Rear-left)

5 W113-0422E
B-2 B-2
Manual Control Valve (Outrigger)

Extension/retraction

33. O-ring 38. O-ring 42. Spool end 45. Hexagon socket head bolt
34. Oil seal 40. Retainer (Spring) 43. Cover 46. Hexagon socket head bolt
37. Retainer 41. Spring 44. Cover 57. Bracket

Front-right

33. O-ring 44. Cover 67. Spool end 70. Retainer

34. Oil seal 45. Hexagon socket head bolt 68. Case 71. Steel ball
39. Retainer 66. Retainer 69. Spring 75. Hexagon socket head bolt
43. Cover

6 W113-0422E
B-2. B-2.
Manual Control Valve (Outrigger)

Front-left

Rear-right

Rear-left

33. O-ring 39. Retainer 66. Retainer 70. Retainer

34. Oil seal 43. Cover 67. Spool end 71. Steel ball
37. Retainer 44. Cover 68. Case 75. Hexagon socket head bolt
38. O-ring 45. Hexagon socket head bolt 69. Spring

Relief valve

83. Spring 85. O-ring 90. Spring

84. O-ring 86. O-ring 94. O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m ft-lbf
A, B, C port G3/8 44.0 - 54.0 4.5 - 5.5 32.4 - 39.8

E, P, T, V port G1/2 88.1 - 108.1 9.0 - 11.0 64.9 - 79.7

G port G1/4 26.4 - 32.4 2.7 - 3.3 19.4 - 23.8 Pressure gauge

(QS10025-A81002)
366-379-10000 △
0

7 W113-0422E
B-3 B-3
Rotary Joint

B-3 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
AMP (2P )
G R/G
General view G
5 F
3

1
R/G
2

AVS W AMP
1.25 R
Apply thread locking
compound (Threebond L 20
1401) to thread, then
tighten to torque of Fit 0.5mm-thick packing between parts
6.9-7.9N·m 5
9 8 7
(0.7-0.8kgf·m) Apply Three Bond 1104 or
(5.1-5.8ft·lbf) equivalent to body·1and plate·21
9 7 6 21
D1
14 3 Rc3/8
Apply grease before
installation
1 A3
G1/2
2
B4 A2 B3
G3/8 G3/8 G1/2
4
A4
G3/8 Apply grease before installation
Apply thread locking
compound (Threebond
18
1401) to thread, then
16 17 tighten to torque of
B2
15 32.4-36.8N·m
G3/8 (3.3-3.8kgf·m)(24-27ft·lbf) AMP ( 2P )

10 11 22 G
M R/G
Mounting bolt 19
R
(Tighten the bolts to Apply thread locking AVS
M L
secure the as well compound (Loctite 1.25
as the swing bearing) 262T) then tighten to 12 13 23 W
T=628-672N·m torque of 59-67N·m AMP ( 3P )
(64-68.5kgf·m)(463-496ft·lbf) (6.0-6.8kgf·m)(43-49ft·lbf)

B2

A3
B3

A4
A2

B4 D1
IW181-0243E01

8 W181-0243E
B-3. B-3.
Rotary Joint

1. Body 7. Spring washer 13. Cap 19. Bolt

2. Core 8. Bolt 14. Plate 20. Cap
3. Packing 9. Plain washer 15. Support 21. Plate
4. Ring seal 10. Housing 16. Bolt 22. Harness
5. Slip ring assembly 11. Cap 17. Spring washer 23. Harness
6. Bolt 12. Housing 18. Plate

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
A2, B2, A4, B4 G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8

A3, B3 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7

Body side R3/8 44.1 - 61.7 4.5 - 6.3 32.5 - 45.5

D1
Core side R1/4 19.6 - 34.3 2.0 - 3.5 14.5 - 25.3

316-313-71002 △
0

9 W181-0243E
 C C
Outrigger System

Contents

C-1 Jack Cylinder

(Front)....................................... 1

1. Structure .................................................... 1

2. Tightening Torques (Check Valve) ............. 1

C-2 Jack Cylinder

(Rear)-Option ........................... 2

1. Structure .................................................... 2

2. Tightening Torques (Check valve) ............. 2

C-3 Pilot Check Valve

(Jack) ........................................ 3

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

C-4 Power Slide Cylinder

(Front)....................................... 4

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

i
C-1. C-1.
Jack Cylinder (Front)

C-1 Jack Cylinder (Front)

[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
General View After having screwed the cover•10, bend one
place of the cylinder end•1 on the cover.

** *10 mm
(0.39 in)

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

Apply adhesive (Threebond 1104) to the screw part

(* mark range) when you thrust it.

In mounting the piston•2 on the rod•8, apply adhesive (Locktite 638)

to the 3rd through 4th crests of the male screw on the rod (** portion).
IW151-0242E01
Tightening torques: 98 N•m (10 kgf•m) {72.2 ft•lbf}

1. Cylinder 4. Backup ring 7. Plain bearing 10. Rod cover

2. Piston 5. O-ring 8. Rod 11. Packing
3. Packing 6. Backup ring 9. O-ring 12. Backup ring
13. Dust seal

2. Tightening Torques (Check Valve)

Check Valve

Tightening torque:
43.1-49.0 N•m (4.4-5 kgf•m)
(31.7-36.1 ft•lbf)

IW151-0242E02

360-348-10000 △
0

1 W151-0242E
C-2. C-2.
Jack Cylinder (Rear)-Option

C-2 Jack Cylinder (Rear)-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
General View

1. Cylinder 3. Rod cover 5. Packing 7. Dust seal

2. Plain bearing 4. O-ring 6. Backup ring 8. Rod

2. Tightening Torques (Check valve)

Check Valve

Tightening torque:
43.1-49.0 N•m (4.4-5 kgf•m)
(31.7-36.1 ft•lbf)

360-356-40000 △
0

IW151-0271E02 360-355-90000 △
0

360-355-70000 △
0

2 W151-0271E
C-3. C-3.
Pilot Check Valve (Jack)

C-3 Pilot Check Valve (Jack)

[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
General view

1. Plug 3. Spring 5. Piston 7. Body

2. O-ring 4. Poppet 6. O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
A, B port G1/4 26.4 - 32.4 2.7 - 3.3 19.5 - 23.9

Plug-1 G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8

Mounting bolt M10 43 - 49 4.4 - 5.0 31.7 - 36.1

366-239-30000 △
1

3 W115-0353E
C-4. C-4.
Power Slide Cylinder (Front)

C-4 Power Slide Cylinder (Front)

[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
General View

Slide ext. port

3-G1/4
1 2 3 4 5 6 7 8 9 10 11 12

Retracting port
Jack ext. port
To lock Rod Cover•5, bend one palce of the
In mounting the nut•12 on the rod•7,
cylinder end•6 into a groove of Rod Cover•5.
apply adhesive (Locktite 638) on the rod.
Tightening torque: 98N•m (10 kgf•m) {72.2 ft•lbf}

IW153-0062E01

1. Dust seal 4. O-ring 7. Rod 10. Backup ring

2. Backup ring 5. Rod cover 8. Piston 11. O-ring
3. Packing 6. Cylinder 9. Packing 12. Nut

360-430-80000 △
0

360-430-40000 △
0

4 W153-0062E
 D
Swing System D

Contents

D-1 Hydraulic Motor (Swing).................. 1

1. Structure .................................................... 1

2. Disassembly .............................................. 2

3. Reassembly ............................................... 2

4. Operation Test............................................ 2

D-2 Swing Speed Reducer ..................... 3

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

2. Dismounting and remounting..................... 4

3. Disassembly .............................................. 4

D-3 Swing Bearing .................................. 6

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

2. Note for installation .................................... 7

i
D-1 D-1
Hydraulic Motor (Swing)

D-1 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

16 1 19 3 5 2
15

11
20

12

13

6 7 4 8 21 9 10 14
IW102-0510E01
IW102-0510E01

Drain

Pliot

A B
Lock cylinder assembly
Hydraulic symbol
IW102-0512E01

1. Shaft 6. Oil seal 11. Bottom cover 16. Lock cylinder assembly
2. Bearing 7. Retaining ring 12. Bearing 17. ------
3. Housing 8. Thrust plate 13. Pin 18. ------
4. O-ring 9. Cylinder block 14. O-ring 19. Parallel key
5. Oil seal cover 10. Valve plate 15. Bolt 20. Plug
21. Thread protector

1 W102-0513E
D-1. D-1.
Hydraulic Motor (Swing)

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
A, B G3/8 39.2 - 49.0 4.0 - 5.0 28.9 - 36.1

Pilot and Drain G1/4 19.6 - 29.4 2.0 - 3.0 14.5 - 21.7

Mounting bolt M12 68.6 - 82.4 7.0 - 8.4 50.6 - 60.8

2. Disassembly 4. Operation Test

1. Loosen the bolts (15) to separate the bottom
cover (11) about 10 mm (0.4 in). This is necessary
to prevent the shaft (1) from popping out by the
force of the center spring.
2. Remove the retaining ring (7).
3. Insert the flat blade of a screwdriver into the slot
of the oil seal cover (5) to remove the oil seal (6).
[NOTICE]
Do not pull out the shaft (1).
As it is difficult to engage the male spline teeth of
the shaft (1) with the female ones of the cylinder
block (9), reassembly will be troublesome.
3. Reassembly
1. Make sure that the O-rings (4) and (14) are placed
in position.
1. Run the motor at idling speed under no load for 15
to 20 minutes, and check for the following.
• Excessive rise in oil temperature
• Unusual noise
• Vibration
• Leakage
2. If the test above reveals no fault, gradually
increase the load up to the maximum operating
pressure. During this process, check for the above
listed four points again.
3. At the maximum pressure, run the motor for 1 to 2
minutes and check for abnormality. If there is no
abnormality, reduce the pressure to the normal
level.

2. Apply grease to the lip area of the oil seal (6).

Install the oil seal (6), together with the oil seal
cover (5), into the housing (3).

3. Securely put the retaining ring (7) into the groove

of the housing (3).

4. Install the bottom cover (11) as before.

[NOTICE]
When putting the retaining ring (7), be sure to place
the rounded edge inside (next to the bearing).
If the rounded edge is place outside, there is a
possibility that the retaining ring may come off
because of an internal force such as spring force
and hydraulic force.
When dismounting and remounting the motor
assembly, always keep it in its horizontal position.
After remounting, fill the motor housing with
hydraulic oil through the drain port. 366-626-00000 △
1

2 W102-0513E
D-2 D-2
Swing Speed Reducer

D-2 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
Hydraulic Motor (Swing)

Apply THREE BOND 1215 when shrink-fitting

Fill lithium grease between the lips

(Oil supply
opening) Take care of the installing order
(The seal of the upper bearing is different
from the one of the lower bearing )

Apply THREE BOND 1104

Apply THREE BOND 1305

(Oil exhaust opening)
IW511-014001E

1. Snap ring 8. Seal washer 15. Bearing 22. Pin

2. Spacer 9. Plug 16. Bolt 23. Air breather
3. Shim set 10. Spur gear 17. Key 24. Nameplate
4. Bearing 11. Sleeve 18. Worm wheel 25. Rivet
5. Worm 12. Oil seal 19. Gear case 26. Washer
6. Bearing 13. Gear case 20. Bearing
7. Oil gauge 14. Bearing 21. Nut

3 W511-0173E
D-2 D-2
Swing Speed Reducer

2. Dismounting and remounting

[NOTICE]
When the swing speed reducer is removed, the swing post is freed. Before removing the reducer, fasten the
swing post to the lower frame with a wire rope to prevent its rotation.
Fill the reducer with gear oil (Mobil Gear 632) to the middle point on the oil gauge. (To check the oil level, just
place the gauge on the gauge hole)
Quantity: 1.1 L (0.3 gal)

3. Disassembly
1. Remove plug-9 , and drain the oil.

2. Remove oil gauge-7.

3. Remove snap ring-1 and remove spacer-2 and thim set-3.

To facilitate extracting worm-5, turn the spur gear-10 while shaking it slightly.

4. Extract worm-5 together with bearing-4 and-6 toward the motor side.

5. Separate the spur gear-10 and gear case-13 from the gear case-19.
Use the separating tap (M12, coarse thread) to separate them following the procedure below because the
pin-22 is tightly fit. (The separating tap is made on the hole for the bolt-16.)

Put a spacer on the bottom of the separating tap to prevent damage to the hole in the gear case-19 for the
bolt-16.

Then screw a bolt into a separating tap in the gear case-13 to separate the gear case-13 from the gear
case-19.

6. Remove bolt-16, then remove spur gear-10 together with gear case-13 and bearings-14, 15 and 20.

7. Remove nut-21, then remove bearing-20, worm wheel-18, and key-17 from spur gear-10.

8. Remove spur gear-10 from gear case-13, then remove bearings-14 and-15, oil seal-12 and sleeve-11.

Notes for reassembly

With regard to the handling of oil seals and bearings, refer to the separate service manual, "General Cautions"
("Sealing Parts" and "Mechine Elements" sections).

Maintenance Standards

Item Maintenance standards Correction

Bearing damage/wear No vibration/shakiness caused by damage/wear Replace

Backlash between 0.11 - 0.19 mm

Standard value Replace
worm and worm wheel (0.004 - 0.007 in)

4 W511-0173E
D-2. D-2.
Swing Speed Reducer

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m ft-lbf
7 – 88.3 - 147 9.0 - 15.0 65.1 - 108

9 R3/8 32.4 - 35.3 3.3 - 3.6 23.9 - 26 Seal tape

16 M10 57 5.8 42
Apply adhesive
21 AN11 167 - 216 17.0 - 22.0 123 - 159
(Threebond 1305)

360-813-80000 △
3

360-815-50000 △
1

360-817-50000 △
0

5 W511-0173E
D-3 D-3
Swing Bearing

D-3 Swing Bearing

[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
General View

1. Swing bearing 5. Plain washer 9. O-ring 13. Hexagon socket head bolt
2. Bolt 6. Grease nipple 10. Bolt 14. Spring washer
3. Plain washer 7. Cap 11. Plain washer
4. Bolt 8. Swing speed reducer 12. Hydraulic motor

6 W512-0172E
D-3. D-3.
Swing Bearing

2. Note for installation

When installing the inner ring of the swing bearing, face the soft zone (stop plug) to the R position shown in
the figure on the previous page.

To tighten the bolts•2,4,10, follow the procedures below.

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.

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m ft-lbf
2 M20 466 - 505 47.5 - 51.5 343.7 - 372.4
Apply a torque control
4 M22 628 - 672 64 - 68.5 463.2 - 495.6 agent to the threaded
sections of the bolts.
10 M16 171 - 200 17.4 - 20.4 126.1 - 147.5

13 M12 68.6 - 82.3 7.0 - 8.4 50.6 - 60.7

313-012-00001 △
1

7 W512-0172E
 E
Boom Elevating System
E

Contents

E-1 Boom Elevating Cylinder ................ 1

1. Structure .................................................... 1

E-2 Counterbalance Valve

(Elevating) ................................ 2

1. Structure .................................................... 2

i
E-1. E-1.
Boom Elevating Cylinder

E-1 Boom 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
General View

1. ------- 7. Rod 13. Dust seal 19. Grease nipple

2. Plain bearing 8. Plain bearing 14. Retaining ring 20. Plug
3. Piston 9. O-ring 15. Retaining ring 21. --------
4. Plain bearing 10. Rod cover 16. O-ring 22. Backup ring
5. O-ring 11. Packing 17. Plate 23. Packing
6. Cylinder 12. Backup ring 18. Set screw

360-263-50000 △
2

1 W155-0211E
E-2. E-2.
Counterbalance Valve (Elevating)

E-2 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

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

2. Spool 6. O-ring 10. Poppet
3. Plug 7. Plug 11. Spring
4. Backup ring 8. Plug 12. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
Plug-3, 9
G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
Port-A, B
Plug - 7 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7

Mounting bolt M10 34.3 - 39.2 3.5 - 4.0 25.3 - 28.9 366-051-80001 △
2

366-065-50000 △
1

366-055-20000 △
2

366-056-00000 △
1

2 W119-0284E
 F
Winch System

FF
Contents

F-1 Explanation of Winch System......... 1

1. General ...................................................... 1
1.1 Electrical circuit........................................... 1
1.2 Hydraulic circuit .......................................... 1

2. Principle of operation ................................. 2

2.1 Anti-twoblock device................................... 2

F-2 Hydraulic Motor (Winch) ................. 3

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

F-3 Winch ................................................ 5

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

i
F-1 F-1
Explanation of Winch System

F-1 Explanation of Winch System

1. General
[NOTICE]
◆The circuit diagrams in this chapter are used only for the purpose of explaining the operation principle.
As there is a possibility that some portions may differ from the actual circuits, please refer to the circuit
diagrams in Chapter Z when conducting service or repairs.

1.1 Electrical circuit 1.2 Hydraulic circuit

When the hook is hoisted up too high and touches The circuit pressure of the winch system is
the weight of the anti-twoblock device, the buzzer regulated by the relief valve in the manual control
will be activated. If the buzzer switch is set to the valve.
off position, the buzzer will not be activated.

Winch system

[NOTICE]
◆These circuit diagrams are for the ZR300 series (standard specifications).
As some portions may differ from your machine, refer to the circuit diagrams in Chapter Z at the same time.
◆These circuit diagrams show the de-energized condition.

1 WF02-0042E
F-1. F-1.
Explanation of Winch System

2. Principle of operation

2.1 Anti-twoblock device

1. When the PTO is turned on: 3. When the hook is hoisted up too high and
First, the contact of the power supply relay is touches the weight of the anti-twoblock device:
closed. Second, DC 12V is outputted to the No. 2 First, the contact of the anti-twoblock detection
& 4 terminals of the anti-twoblock detection relay switch is opened.
from the No. 3 terminal of the power supply relay. Second, the contact of the anti-twoblock detection
relay is closed.
2. When the hook does not touch the weight of the
Third, the buzzer is activated.
anti-twoblock device:
As the contact of the anti-twoblock detection
switch is closed, the contact of the anti-twoblock
detection relay becomes open, which does not
activate the buzzer.

2 WF02-0042E
F-2 F-2
Hydraulic Motor (Winch)

F-2 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
General view

3 W102-0433E
F-2. F-2.
Hydraulic Motor (Winch)

1. Shaft 17. Air bleeding screw 40-1. Body; relief valve 56. Oil seals
2. Bearing 18. O-ring 40-2. Poppet; relief valve 57. Retaining ring
3. Retaining ring 19. O-ring 40-3. Spring seat 58. Spring; brake
4. Housing 20. Bottom cover 40-4. Spring 59. Plate; spring
5. Cam Plate 21. Plug 40-5. O-ring 60. Facing
6. Spring pin 22. Choke M4 40-6. Adjusting screw 61. Disk brake
7. Cylinder barrel assembly 23. Spool; counter balance 40-7. S-nut 62. Retaining ring
7-1. Cylinder barrel 24. Piston 40-8. O-ring 63. Sleeve
7-2. Seat; center spring 25. O-ring 40-9. O-ring 64. Pin
7-3. Center spring 26. Spring washer 41. Spool; change 65. Pin
7-4. Retaining ring 27. Nut 42. Spring seat 66. O-ring
7-5. Plunger 28. Spring seat 43. Spring; change 67. Backup ring
7-6. Plunger bearing 29. Counter balance piston 44. Plug; change 68. O-ring
8. Pin; cylinder barrel 30. Return spring 45. O-ring 69. Backup ring
9. Plunger holder assembly 31. Return spring 46. Cap; check valve 70. Piston
9-1. Plunger holder 32. Cap 47. O-ring 71. O-ring
9-2. Spherical ring 33. O-ring 48. Hexagon socket head bolt 72. Spring washer
10. Parallel pin 34. Cap; pilot 49. Hexagon socket head bolt 73. Hexagon socket head bolt
11. Plate cylinder barrel 35. Hexagon socket plug 50. Spring washer 74. Spring washer
12. Valve plate 36. Poppet 51. O-ring 75. Hexagon socket head bolt
13. Retaining ring 37. Spring; check 52. O-ring 76. Plug; sleeve
14. Spring pin 38. Plug 53. Choke 77. O-ring
15. Bearing 39. O-ring 54. Key 78. Retaining ring
16. Hexagon socket plug 40. Relief valve assembly 55. Flange

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
A, B G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7

Drain R3/8 44.1 - 61.7 4.5 - 6.3 32.5 - 45.5

Mounting bolt M12 106 - 120 10.8 - 12.2 78.2 - 88.5

366-604-90000 △
2

4 W102-0433E
F-3. F-3.
Winch

F-3 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
25 19
2 1

8
9
22
17

18
16

21
7
26 27
3

HOIST GEAR
DATA
NO.
4
TADANO LTD.

20
6

11,12 10 13,14
M14 23
15 5
Mounting bolt IW526-0270E01

1. Gear case 8. Ball bearing 15. Hexagon socket plug 22. Spur gear
2. Gear case 9. Oil seal 16. Hexagon socket plug 23. Washer
3. Motor bracket 10. Oil seal 17. U-Nut 24. -----------
4. Spur gear 11. Hexagon socket head bolt 18. Spacer 25. Cap
5. Ball bearing 12. Spring washer 19. Spur gear 26. Nameplate
6. Ball bearing 13. Hexagon socket head bolt 20. Key 27. Rivet
7. Ball bearing 14. Spring washer 21. Pin

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
Bolt-11 M8 33.3 3.4 24.6
Bolt-13 M10 65.7 6.7 48.5
Plug-15 R3/8 15.7 1.6 11.6
Plug-16 R1/8 9.8 1.0 7.2
Mounting bolt M14 119 - 133 12.1-13.6 87.8 - 98.1
360-732-00000 △
0

5 W526-0273E
 G
Boom Telescoping System

Contents G
G-1 Boom (Five-section boom).............. 1 G-3 Counterbalance Valve
(Telescoping) .........................16
1. Structure .................................................... 1
1. Structure .................................................. 16
2. Notes for reassembly................................. 2

3. Boom adjustment procedures .................... 3

3.1 Top slide plate installation procedure ......... 3
3.2 Adjustment of clearance between boom
sections ................................................ 3

G-2 Telescoping Cylinder

(Five-section boom) ................ 4

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

2. Description of operation............................. 7
2.1 Control of telescoping sequence ................ 7

3. Notes for reassembly of cylinder

assembly ........................................ 9

4. Notes for reassembly of telescoping

cylinder......................................... 11

5. Telescoping wire rope adjustment

procedure ..................................... 13
5.1 Wire rope adjustment with the telescoping
cylinder out of the boom..................... 13
5.2 Wire rope adjustment with the telescoping
cylinder installed in the boom............. 15

i
G-1 G-1 G-1
Boom (Five-section boom)

G-1 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
1. Structure much difference in functions and disassembly procedures, make sure of the serial number of this machine and
General view the part sales unit described in the parts catalog before starting disassembling operations.

1. Base boom section 36. Flange bolt

2. 2nd boom section 37. Sheave
3. 3rd boom section 38. Pin
4. 4th boom section 39. Pin
5. Top boom section 40. Set screw
6. Roller assembly 41. Nut
7. Pin 42. Spacer
8. Retaining ring 43. Shim
9. Grease nipple 44. Slide plate
10. Grease nipple 45. Cap
11. Plain bearing 46. Flange bolt
12. Slide plate 47. Shim
13. Slide plate 48. Bolt
14. Slide plate 49. Spring washer
15. Slide plate 50. Button bolt
16. Button bolt 51. Bolt
17. Pin 52. Cover
18. Retaining ring 53. Plate
19. Spacer 54. Plate
20. Pin 55. Bolt
21. Pin 56. Slide plate
22. Retaining ring 57. Shim
23. Roller 58. Shim
24. Pin 59. Plate
25. Retaining ring 60. Spacer
26. Pin 61. Nut
27. Plate 62. Nameplate
28. Plate 63. -------------
29. Bolt 64. Plate
30. Tapping screw 65. Hexagon socket head bolt
31. Spring washer 66.Plug
32. Slide plate
33. Slide plate
34. Plate
35. Slide plate

312-030-30101 △
4

312-043-70100 △
3

1 W536-0533E 1
G-1 G-1
Boom (Five-section boom)

2. Notes for reassembly

4. Install the top boom telescoping support in
1. Apply grease to the boom inside surfaces that rub accordance with the following steps (see Fig. 4):
against slide plates.
• Apply thread locking compound (Threebond 1305
2. Press-fit the plain bearings at the base of the or equivalent) to the button bolts and use them to
boom with their grease grooves on the outside loosely fit the top boom telescoping support.
(see Fig. 2).
• Tighten the bolts until the top boom telescoping
support's longitudinal play is eliminated, then lock
them in position with the nuts.
Verify through the inspection holes that the top
boom telescoping support is pressed firmly
against the stopper.

• Tighten the button bolts to a torque of 24.5 N-m

(2.5 kgf-m) (18.1 ft-lbf).

Fig. 2

3. Bend down the plate on the boom elevating

cylinder pivot pin after installing the bolts
(see Fig. 3).

Base boom sec.

Second boom sec. Fig. 4
Third boom sec.

Telescoping
cylinder

Boom elevating
cylinder pivot pin

Bolt
Plate

IW536-0530E02

Fig. 3

2 W536-0533E
G-1. G-1.
Boom (Five-section boom)

3. Boom adjustment procedures

Before performing this work, supply grease (TNR) to
each slide plate and to each grease cup.

a
A
3.1 Top slide plate installation procedure Slide plate

Apply thread locking compound (Threebond 1305 b

or equivalent) to the button bolts before using
them to secure the slide plate.
After tightening the button bolts, loosen each of 1 Shim (For the fixation)
them by half a turn and make sure the slide plate
2 Shim (For the adjustment)
can move longitudinally (see Fig. 5).
3 Shim (For the adjustment)
Button bolt

View A IW536-0532E02

Fig. 6

Slide plate
Boom fully retracted
IW536-0272E02

Fig. 5 Max. 35 mm
(1.38 in)
3.2 Adjustment of clearance between boom Boom fully extended
sections

1. Adjust dimension "a" (see Fig.6) to the following

Adjustment of boom lateral bending
values: IW536-0272E05

Fig. 8
• With boom fully extended: a = 2 mm (0.08 in)
And locks it with the nut.
100 N
2. Adjust dimension "b" (see Fig. 6) using shims-1, (10kgf)
-2, and 3 such that the boom's degree of lateral (22 lbf)
bending and the boom's degree of lateral play
Max. 80 mm
comply with the following values: (3.15 in)

• Boom lateral bending: max. 35 mm (1.38 in) 100 N Boom fully extended
(10kgf)
(see Fig. 8) (22 lbf)
Adjustment of boom lateral play
• Boom lateral play: max. 80 mm (3.15 in) IW536-0533E01
(see Fig. 9) Fig. 9

[NOTICE]
Install the slide plates before assembling the boom.
Shim-1 serves to retain the other shims, so it must
be installed last.

312-030-36001 △
0

3 W536-0533E
G-2 G-2 G-2
Telescoping Cylinder (Five-section boom)

G-2 Telescoping Cylinder (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
1. Structure much difference in functions and disassembly procedures, make sure of the serial number of this machine and
General view the part sales unit described in the parts catalog before starting disassembling operations.

Tightening torque: 19.6 N-m (2kgf·m)

7
(14.5 ft-lbf)
8

Apply grease 3 9 10 12
11
Extending wire rope Tightening torque
1 2 4 28 5 6 Clinched part on inside 34.3-39.2 N-m (3.5-4.0 kgf·m)
Apply grease to the top surface of the cylinder
(25.3-28.9 ft-lbf)

A 2-G3/8

Wire rope guide support (2 places) Retracting wire rope

Wire rope guide Apply grease
(2 places) 29 1. Cylinder assembly 16.Bolt
2. Wire rope 17. Support
13,14 3. Support assembly 18. Sheave assembly
4. Nut 19. Retaining ring
5. Wire rope 20. Pin
6. Sheave assembly 21. Plate
15
7. Hexagon socket head bolt 22. Bolt
29 8. Spring washer 23. Support
16 9. Support 24. Plate
13,14
10. Spring washer 25. -------------
11. Bolt 26. Plate
15
12. Counterbalance valve 27. Machine screw
17 18 19 20 21
13. Hexagon socket head bolt 28. Nut
Clinched part on outside 23 26 27 14. Spring washer 29. Plate
Section B-B
15. Plate

22 Section C-C
24
View A IW157-0353E01
312-116-30001 △
1

4 W157-0353E 4
G-2 G-2 G-2
Telescoping Cylinder (Five-section boom)

Cylinder assembly

1. Nut 28. Plain bearing

2. Spring washer 29. O-ring
3. Piston 30. Piston
4. O-ring 31. Set screw
5. Plain bearing 32. Rod (No. 1)
6. Plain bearing 33. Cylinder (No. 1)
7. Plain bearing 34. O-ring
8. Piston 35. Packing
9. Cylinder (No. 3) 36. Backup ring
10. Rod (No. 3) 37. Dust seal
11. Rod cover 38. Rod cover
12. O-ring 39. Roller assembly
13. Packing 40. Retaining ring
14. Backup ring 41. O-ring
15. Dust seal 42. Hexagon socket head bolt
16. O-ring 43. Slide plate
17. Check valve assembly 44. Machine screw
18. O-ring 45. Button bolt
19. Packing 46. Slide plate
20. Backup ring 47. Slide plate
21. Duet seal 48. Machine screw
22. Rod cover 49. Roller assembly
23. Check valve assembly 50. Roller assembly
24. Stopper 51. Plain bearing
25. Pipe 52. Roller assembly
26. Cylinde r (No. 2) 53. Hexagon socket head bolt
27. Rod (No. 2)

360-167-20001 △
4

5 W157-0353E 5
G-2 G-2
Telescoping Cylinder (Five-section boom)

Check valve assembly (cylinder assembly part-17)

1. O-ring 6. O-ring
2. Backup ring 7. Spring
3. Check valve 8. Plug
4. O-ring 9. O-ring
5. Valve seat 10. Plug

Check valve assembly (cylinder assembly part-23)

1. O-ring 8. Body
2. Spring 9. O-ring
3. Check valve 10. O-ring
4. Rod 11. Hexagon socket head bolt
5. O-ring 12. Plug
6. Backup ring 13. Spacer
7. Cap

6 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

2. Description of operation
2.1 Control of telescoping sequence

1. When the No. 1 cylinder has been fully extended, the No. 2 cylinder is extended.

2. When the No. 2 cylinder has been fully extended, the No. 3 cylinder is extended.

7 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

3. When the No. 3 cylinder has been fully retracted, the No. 2 cylinder is retracted.

4. When the No. 2 cylinder has been fully retracted, the No. 1 cylinder is retracted.

8 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

3. Notes for reassembly of cylinder

5. Apply thread locking compound to the items listed
assembly below before installing the items (see Figs. 4 - 6).

1. Make sure each seal, O-ring, and plain bearing is • Check valve mounting bolts-N
correctly aligned.
• Machine screws and button bolts used to mount
2. Before installing the piston of the No. 1 cylinder, slide plates at front ends of No.1 and No.2
apply adhesive (Loctite 638) to the three cylinders
consecutive crests of the rod's external thread,
starting with the second crest (see the areas
marked with "※" in Fig. 3).

• Tightening torque: 98.1 N-m (10.0kgf-m)

(72.4 ft-lbf)

Fig. 3

3. Before installing the piston of the No.2 cylinder,

apply adhesive (Loctite 638) to the two
Fig. 4
consecutive crests of the rod's external thread,
starting with the second crest (see the area
marked with "※※" in Fig. 3).

• Tightening torque: 98.1 N-m (10.0 kgf-m)

(72.4 ft-lbf)

4. Before installing the piston of the No.3 cylinder,

apply adhesive (Loctite 638) to the four
consecutive crests of the rod's external thread,
starting with the second crest (see the area
marked with "※※※" in Fig. 3).

• Tightening torque: 98.1 N-m (10.0 kgf-m)

(72.4 ft-lbf)

9 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

• Machine screws used to mount slide plate at rear • Hexagon socket head bolts at rear end of cylinder
end of No. 2 and No. 3 cylinder assembly

Fig. 6

6. Before fitting the rod cover, apply rust inhibitor

(Threebond 1104 or equivalent) to the thread.
Perform this step with each rod cover.

• Tightening torque: 343 - 392 N-m (35 - 40 kgf-m)

(253 - 289 ft-lbf)

7. After installing the cylinder, bend the end of the

cylinder down onto the rod cover in one place.
Perform this step with each cylinder.

Fig. 5

Fig. 8

10 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

4. Notes for reassembly of telescoping

8. When reassembling each roller assembly, apply
grease to the pin. cylinder
1. Install the sheave assembly at the rear end of the
No. 3 cylinder with the clinched part on the inside.

Fig. 9
Fig. 10

2. Install the sheave assembly at the front end of the

No. 3 cylinder with the clinched part on the
outside.

Fig. 11

3. Before installing the extending wire rope, install

the retracting wire rope end loop support and the
plate.

Fig. 12

11 W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

4. When passing the extending and retracting wire
ropes through their respective wire rope end loop
support, be sure to follow these instructions:
• Align the wire rope's center mark with the center
of the wire rope end loop support.
6. When installing the telescoping cylinders in the
boom, align as shown in Fig. 15 the groove
(marked with a "A") in the outside of the sheave at
the rear end of the No. 3 cylinder.

• After passing each wire rope through the wire

rope end loop support, bend down the wire rope
guides.

• Extending wire rope: two wire rope guides

Fig. 15
After passing the retracting wire rope through the
7. Apply grease to the surface that rubs against the
retracting wire rope end loop support, apply
slide plate (see Figs. 4 and 5). At the same time,
thread locking compound to the machine screws
apply grease to the top surface of the No. 3
and use the machine screws to install the wire
cylinder.
rope guide supports.

• Retracting wire rope: two wire rope guide

supports

Fig. 13

5. Tighten each of the support mounting bolts shown

in Fig. 14 to a torque of 19.6 N-m (2 kgf-m)
(14.5 ft-lbf).

Fig. 14

12 W157-0353E
G-2
Telescoping Cylinder (Five-section boom)
5. Telescoping wire rope adjustment
3. With the heads of the extending wire rope
procedure
5.1 Wire rope adjustment with the telescoping
cylinder out of the boom
1. Fully retract the telescoping cylinder. At this time,
maintain pressure on the retraction side of the
telescoping cylinder to prevent dimension "D" (see
Fig. 16) from changing.
Dimension "D": 156.1 mm (6.146 in)
Fig. 16
4 With the head of the retracting wire rope adjusting
2. Attach the extending wire rope and retracting wire
rope, and fold the two wire rope guides.
Then attach the two wire rope guide supports after
applying screw locking agent to the threaded
portion of the machine screw.
Fig. 17
13
G-2
adjusting bolts pressing firmly against the
adjusting bolt mounting surface, adjust dimension
"E" (see Fig. 18) to 120 - 121 mm (4.72 - 4.76 in).
(The bolts should be tightened for a turn from the
position where the pin becomes forced against
cylinder assembly.)
At this time, make sure the most external flats of
the adjusting bolts are horizontal as shown in Fig.
18.
Fig. 18
bolt pressing firmly against the adjusting bolt
mounting surface, tighten the adjusting bolt until
the plate is slightly separated from the cylinder
support (see Fig. 19).
At this time, make sure the most external flat of
the adjusting bolt is horizontal as shown in Fig.
19.
Fig. 19
W157-0353E
G-2 G-2
Telescoping Cylinder (Five-section boom)

5. Use the specified jig to retain the top boom
telescoping support in the position at which
dimension "C" (see Fig. 20) is 300 mm (11.8 in).
9. After adjustment is completed, thrust the adjusting
bolt locking plate against the horizontal face of the
extending wire rope adjusting bolt and secure the
plates using the hexagon socket head bolts and
the spring washers (see the Fig. 21).

Fig. 20

6. With the jig still fitted, tighten the extending wire

rope adjusting nut (see Fig. 20).
Adjusting nut tightening torque:
4.9 N-m (0.5 kgf-m) (3.6 ft-lbf)
• If the length of the wire rope projecting from the
adjusting nut is too short to tighten the nut using
the jig, tighten the extending wire rope adjusting
bolts on the right and left close to the boom head
equally.
Adjusting bolt tightening torque:
9.8 N-m (1.0 kgf-m) (7.2 ft-lbf)
Fig. 21
10.After adjustment is completed, thrust the
adjusting bolt locking plate againt the horizontal
face of the retracting wire rope adjusting bolt and
secure the plates using the hexagon socket head
bolts and the spring washers. (see Fig. 22)

7. With the jig fitted, tighten the retracting wire rope

adjusting nut until the jig slightly comes off.

• If the length of the wire rope projecting from the

adjusting nut is too short to tighten the nut using
the jig, tighten the retracting wire rope adjusting
bolt close to the boom head.

8. After 7., secure the nuts using the lock nuts.

Fig. 22

14 W157-0353E
G-2.
Telescoping Cylinder (Five-section boom)
5.2 Wire rope adjustment with the telescoping
cylinder installed in the boom
Telescope the boom for several strokes and check
the dimension of "F" (clearance between the top
boom section and 3rd boom section).
Fig. 23
15
G-2.
1. When "F" is 2 mm (0.08 in) or shorter
re-adjustment is not necessary.
2. When "F" is longer than 2 mm (0.08 in) and does
not exceed 4 mm (0.16 in)
Make adjustment in the following order:
• Remove the top cover. (Take care not to damage
the cord on the cord reel.)
• Remove the adjusting bolt locking plates,
hexagon socket head bolts, and the spring
washers, and loosen the extending wire rope
adjusting bolts on the right and left for one turn
(see the Fig. 21).
• Remove the adjusting bolt locking plates,
hexagon socket head bolts and the spring
washers, and tighten the retracting wire rope
adjusting bolt until "F" is 2 mm (0.08 in) or shorter
(see the Fig. 22).
• Attach the adjusting bolt locking plates, hexagon
socket head bolts and spring washers (both for
the retracting wire rope and for the extending
wire rope). Then attach the top cover.
3. When "F" is longer than 4 mm (0.16 in)
Perform the "5.1 Wire rope adjustment with the
telescoping cylinder out of the boom" again.
312-116-31101 △
0
W157-0353E
G-3. G-3.
Counterbalance Valve (Telescoping)

G-3 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

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

2. Spool 6. O-ring 10. Poppet
3. Plug 7. Plug 11. Spring
4. Backup ring 8. Plug 12. O-ring

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
Plug-3, 9
G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
Port-A, B
Plug - 7 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7
366-051-80001 △
2
Mounting bolt M10 34.3 - 39.2 3.5 - 4.0 25.3 - 28.9 366-065-50000 △
1

366-055-20000 △
2

366-056-00000 △
1

16 W119-0284E
 Y
Data, Adjustment and Checks

Contents

Y-1 Service Data ..................................... 1 Y-3 Adjustment (Electric) .......................3

1. Set pressure .............................................. 1 1. Detection switches for elevating up,

1.1 Manual control valve (outrigger)................. 1 winch up and telescoping extended
1.2 Manual control valve ....................................................... 3
(boom elevating, winch, telescoping,
swing) (for manual spec.)..................... 1

2. Hydraulic units ........................................... 1

Y-2 Adjustment (Hydraulic) ................... 2

1. Adjusting relief valve pressure................... 2

1.1 Main relief valve ......................................... 2

i
Y- 1 . Y-1.
Service Data

Y-1 Service Data

1. Set pressure
1.1 Manual control valve (outrigger)
Set pressure
Item Symbol Remarks
MPa kgf/cm2 Psi

Main relief valve RV2 20.6 210 2990 at 43 L/min (11 gal/min)

For the measuring points and measuring methods, refer to Y-2 “Adjustment (Hydraulic).”

1.2 Manual control valve (boom elevating, winch, telescoping, swing)

Set pressure
Item Symbol Remarks
MPa kgf/cm2 Psi

Relief valve RV1 20.6 210 2990 at 80 L/min (21 gal/min)

2. Hydraulic units
1. Swing motor
Displacement: 39.3 cm3/rev (2.40 in3/rev)

2. Winch motor
Displacement: 45 cm3/rev(2.75 in3/rev)

3. Swing speed reducer

Reduction ratio: 42 : 1

4. Winch speed reducer

Reduction ratio: 19.21 : 1

1 WY01-1610E
Y- 2 . Y-2.
Adjustment (Hydraulic)

Y-2 Adjustment (Hydraulic)

[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. Adjusting relief valve pressure

1.1 Main relief valve

[NOTICE]
Hydraulic oil temperature: 50±5°C (113 to 131°F)

Set pressure
Item Symbol Remarks
MPa kgf/cm2 Psi

Main relief valve RV2 20.6 210 2990 at 43 L/min(11 gal/min)

Connect a pressure gauge to the G port of the manual control valve (outrigger).
Measure the pressure with the jack cylinder fully retracted and the control lever placed in the retracting
position.

• Manual control valve (outrigger)

2 WY02-0920E
Y- 3 . Y-3.
Adjustment (Electric)

Y-3 Adjustment (Electric)

[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. Detection switches for elevating up, winch up and telescoping extended
When each operation lever of elevating, winch and telescoping is operated into elevating up, winch up and
telescoping extended directions respectively; dangerous side operations, set for each switch to become OFF
with the spool of each valve beginning to move. (Fix the switch with the roller pushed by about 1 mm (0.04
in) against the spool surface.)

316-562-60000 △
0

3 WY04-1220E
 Z
System Diagrams

Contents

Z-1 Hydraulic Circuit .............................. 1

Z-2 Electric Circuit.................................. 2

Z-3 Location of Hydraulic Parts ............ 3

Z-4 Location of Electrical Parts............. 4

1. Boom ....................................................... 4

2. Frame ....................................................... 5

Z
i
Z-1. Z-1. Z-1.
Hydraulic Circuit

Z-1 Hydraulic Circuit

314-021-30200 △
0

1 WZ01-2220E 1
Z-2. Z-2. Z-2.
Electric Circuit

Z-2 Electric Circuit

M CN1 F
RB
3
R
2
G
1
PTO SW Fuse box KEY SW

Vehicle battery
Carrier frame

M CN6 F F CN5 M
(W) R R (W) S B H
2 G G 1
Horn switch (B) Y B B Y (B) Horn switch
4 3
(W) R RW L W (Y) Horn relay
Emergency (B) Y
1
WR YR
2
R (R) Overwinding device Carrier
3 4
overwinding alarm buzzer switch frame
cut-out
F CN19 M
switch WR R
1 SOL1 Unload valve
B B
2 (on-load when energized.)
F CN20 M
WR B
1
Y
2
R Detection switch for winch up
3

F CN20 M
Y B
1
Br
2
R Detection switch for telescoping extended
3

F CN20 M
Br B
1
RW
2
R Detection switch for elevating up
3

10A F CN21
RB
4
RW
3
R
2
Power supply relay
B
1 R

F CN23
RW
4
WR
3 Overwinding detection relay
RW
2
W
1 R

F CN22
RW
4
L
3
RW
2
Overwinding detection relay
W
1 R

F CN11 M
YR R
B
2
B
Overwinding
1 device alarm buzzer

Frame
Rotary Length detector
joint Y B

F CN3 M
W W Overwinding
1
LR
2
L detection
RG R
3 switch
RW

F CN2 M F CN1 M
G
1 1
RG
2 2

IWZ03-4110E01

314-026-90100 1

2 WZ03-4110E 2
Z-3. Z-3. Z-3.
Location of Hy draulic Parts

Z-3 Location of Hydraulic parts

Rotary joint

Swing motor

RV2

Regulator valve

Unload valve Manual control valve Manual control valve (Outrigger)

CN19 RV1 (Boom elevating, winch, telescoping, swing)

Load meter

IWZ07-2140E01

316-486-61000 0

316-480-92000 1

316-316-20000 0

3 WZ07-2140E 3
Z-4 Z-4 Z-4
Location of Electric Parts

Z-4 Location of Electric Parts

1. Boom

Vinyl tube

Bowline knot
A

D
C
E Cord reel

Detail A

View F

View C,D
H Overwinding
detection switch

View E

Detail H
IWZ02-3850E01

313-724-20000 5

4 WZ02-3850E 4
Z-4. Z-4. Z-4.
Location of Electric Parts

2. Frame
Outrigger extension state detecting swich (right)

Detection switch
for elevating up
CN20 winch up
telescoping extended

G
Detaction switch for telescoping extended
Detaction switch for winch up
Detaction switch for elevating up
View G

Connector Red Blue

(Buzzer)

11

23 21 22

Connect RW plug receptacle with RG plug

Detail A

C
E F

Relay assembly

View C
B A
Emergency overwinding Overwinding device
cut-out switch alarm buzzer switch
Horn switch Horn switch
Outrigger extension state Level gauge
CN11 detecting switch (left)
Overwinding device alarm buzzer

CN1 CN6 CN5

Connect to carrier
Detail B Detail E Detail F
IWZ02-3850E02

316-562-60000 0

5 WZ02-3850E 5
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785

History of revision
1
2
3
4
5