Installation Process Deck Cutting

Version Date Total pages
2010-09 September-01-2010 20
Installation Process
page 1
2010-09 September-01-2010 20
1 Deck part
1. Cutting the deck

2. Installed Hook-ring
2 Reinforce a chassis frame
3 Assemble a Rear outrigger
4 P.T.O & Pump part

1. Assemble PTO & Pump
2. Air Circuit
5 Installed crane & deck
6 Piping
1. Pump
2. Rear outrigger
7 Installation of accelerator cable

1. Mechanical Engine
2. Electronic Engine
page 2
Deck part – Cutting the deck 2010-09 September-01-2010 20
Remove the U-
U-bolt from Mark the cutting point
chassis : Refer to cutting table
Separate the deck from chassis
Separate the
loadrest
Cutting the deck Mark the cutting point
page 3
Deck part – Cutting the deck 2010-09 September-01-2010 20
Cutting the loadrest in

Cutting the side panel order to avoid interference
Assemble the ladder Assemble the side panel
Assemble the loadrest
page 4
Deck part – Installed Hook-ring 2010-09 September-01-2010 20
Fix the U-
U-bolt on the deck that
located at the tip of boom head
Complete the installation

of Hook-
Hook-ring
page 5
Reinforce a chassis frame 2010-09 September-01-2010 20
Detach a battery box
Detach a fuel tank

from chassis
Detach an air tank
Mark the hole of interference with Fix the reinforced plate

bolt & rivet of chassis after decide position
page 6
Make the hole at Note:

marking position 1. Welding Bead – 40 mm
2. Welding pitch – 100 mm
After fix the reinforced plate,

progress the welding
Weld the flat bar behind Painting again after welding

reinforced plate
Assemble a battery box
page 7
Assemble a Fuel tank Assemble an air tank
Attach the stopper in order to

prevent sliding of sub frame (spacer)
Reinforce the chassis at

center between front I-
I-bolt Decide the position of I-
I-bolt in
and rear I-
I-bolt order to install a crane body
page 8
Assemble the cross-

cross-member in Assemble the mounting bracket in Attach the stopper in order to
order to fix the sub frame order to fix the sub frame prevent sliding of crane
page 9
Assemble a Rear outrigger 2010-09 September-01-2010 20
Decide suitable position

of rear outrigger
Fix the outrigger by I-

I-bolt
Attach the clamp for

piping of rear outrigger
Assemble the set plate

by cut sub frame
page 10
P.T.O & Pump part 2010-09 September-01-2010 20
(Assemble PTO & Pump)
Detach PTO cover of transmission
Hydraulic Pump Connection position of PTO
Connection port P.T.O

with air tank
Assemble a gasket
page 11
Assembly position with Pump Connection port Grease this point before assembly
with air tank
Pump Bracket Magnetic Valve Propeller Shaft
Decide suitable position to

Connect with Pump Connect with PTO
attach the pump bracket
page 12
Assemble the pump bracket Assemble the magnetic

: Welding or Bolting : Refer to Air circuit
Note:
1. Gap of shaft – 15~20
15~20 mm
2. Shaft angle – within 10 degree
PTO Switch
Connect air hose between

PTO and Magnetic valve
: Refer to Air circuit
page 13
P.T.O & Pump part– Air Circuit 2010-09 September-01-2010 20
№ CODE Parts name Q’ty Remark
1 A56169 P,T,O 1
2 B96109 P,T,O Switching unit 1
3 A56260 Propeller shaft 1 L1130
4 4002153 Hex. Bolt 8 M8xP1.25xL30
5 4211010 Spring washer 8 M8
6 4101211 Hex. Nut 8 M8xP1.25
7 A56121 Pump Flange 1
8 J16121 Pump Bracket 1
9 4002206 Hex. Bolt 4 M12xP1.75xL40
10 4101213 Hex. Nut 4 M12xP1.75
12 A Hyd. Pump 1 B
13 4300119 Spring Pin 1 Ф 8 x L20
14 4002235 Hex. Bolt 4 M14xP2.0xL40
15 4101214 Hex. Nut 4 M14xP2.0
page 14
Installed Crane & Deck 2010-09 September-01-2010 20
Put the crane on the sub frame (spacer)
Check whether the crane is situated

horizontally (if not, use the flat bar) Attach the stopper in
front of crane body
Stopper
Fix the crane by I-

I-Bolt
Assemble the outrigger
and connect the hose
page 15
Cutting the main-

main-room of deck in order
to avoid interference with sub frame Attach the plate in order to prevent
Assemble the deck-
deck-bracket transformation when assemble the U- U-bolt
(Keep horizontality)
Assemble the U-
U-bolt
Assemble the Boom-
Boom-pin
Check whether the deck is situated
horizontally (if not, use the flat bar)
page 16
Assemble the Bearing-

Bearing-Nut Assemble the
Derrick-
Derrick-Pin
Assemble the hose of

telescopic cylinder
Fix the socket

Assemble the Hook Assemble the wire rope
page 17
Piping - Pump 2010-09 September-01-2010 20
OUT-line of pump
IN-
IN-line of pump
The IN-
IN-line of pump connects
to oil tank of crane body
The Out-
Out-line of pump connects
to out-
out-line of diverter valve
page 18
Piping – Rear outrigger 2010-09 September-01-2010 20
Pipe bending
Attach the adapter after

The hoses connect to the pipe of R/O cutting the sub frame
Piping of expand cylinder
Piping of jack cylinder
page 19
Installation of accelerator cable 2010-09 September-01-2010 20
Mechanical
Mechanical Engine
Engine
On the opposite side of cable

connects with plunger of engine
The cable connects with

accelerator lever of crane
Electronic
Electronic Engine
Engine
Connect the cable after make
a hole under the pedal
Bolting the bracket on accelerator

pedal to connect the cable
page 20

Installation Process Deck Cutting

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Version Date Total pages

1. Cutting the deck

2 Reinforce a chassis frame

3 Assemble a Rear outrigger

4 P.T.O & Pump part

5 Installed crane & deck

7 Installation of accelerator cable

Cutting the deck Mark the cutting point

Cutting the loadrest in

Assemble the ladder Assemble the side panel

Assemble the loadrest

Complete the installation

Detach a battery box

Detach a fuel tank

Detach an air tank

Mark the hole of interference with Fix the reinforced plate

Make the hole at Note:

After fix the reinforced plate,

Weld the flat bar behind Painting again after welding

Assemble a battery box

Assemble a Fuel tank Assemble an air tank

Attach the stopper in order to

Reinforce the chassis at

Assemble the cross-

Decide suitable position

Fix the outrigger by I-

Attach the clamp for

Assemble the set plate

(Assemble PTO & Pump)

Detach PTO cover of transmission

Hydraulic Pump Connection position of PTO

Connection port P.T.O

(Assemble PTO & Pump)

Pump Bracket Magnetic Valve Propeller Shaft

Decide suitable position to

(Assemble PTO & Pump)

Assemble the pump bracket Assemble the magnetic

Connect air hose between

№ CODE Parts name Q’ty Remark

2 B96109 P,T,O Switching unit 1

3 A56260 Propeller shaft 1 L1130

4 4002153 Hex. Bolt 8 M8xP1.25xL30

5 4211010 Spring washer 8 M8

6 4101211 Hex. Nut 8 M8xP1.25

7 A56121 Pump Flange 1

8 J16121 Pump Bracket 1

9 4002206 Hex. Bolt 4 M12xP1.75xL40

10 4101213 Hex. Nut 4 M12xP1.75

11 4211012 Spring washer 4 M12

13 4300119 Spring Pin 1 Ф 8 x L20

14 4002235 Hex. Bolt 4 M14xP2.0xL40

15 4101214 Hex. Nut 4 M14xP2.0

16 4211013 Spring washer 4 M14

Put the crane on the sub frame (spacer)

Check whether the crane is situated

Fix the crane by I-

Cutting the main-

Assemble the Bearing-

Assemble the hose of

Fix the socket

Attach the adapter after

Piping of expand cylinder