Cargo Crane

TM-ZT1000 Series
Serial No.: KZ0162– (TM-ZT1000-1)
TM-ZT1000-1_SC1-1E

2016

Publication No.: TM-ZT1000-1_SC1-1E

Printed in Japan
1608 E 01
 Safety

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

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

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

1 WA01-0170E
 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 WA01-0170E
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 a marker if necessary.
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.
 Safety

2.3 Remounting and assembling

8.Watch your step in the following cases:
(1) When stepping up to or stepping down from a
footing for replacing wire ropes and applying
grease.
(2) When greasing at the root of a elevating
cylinder.
(3) 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.
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.

2.When dismounting piping or equipment that may

3. Cautions in operation
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging
3.1 Handling of battery
the confined pressure.
1.Erroneous handling of a battery may cause it to
3.Before removing, clean the part to be dismounted
catch fire and explode.
and the area surround it. Seal the opening with a
(1) Be extremely sure to avoid short circuits,
plug or tape, etc. to prevent foreign material from
sparks and fire of cigarettes and the like when
entering it.
using a jumper cable. They are very
4.Measure and record the data such as shim dangerous.
thickness adjustment and pre-load at disassembly (2) Charge up batteries and use them only in well
that will be required at reassembly. ventilated places.

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.
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.
2.Battery fluid (dilute sulfuric acid) may cause loss of
sight or burn injury.
(1) If battery fluid stains an eye, skin, or clothes
immediately wash down them with a great
deal of water.
(2) If battery fluid enters into an eye, immediately
wash it down with water and see a doctor for
medical aid.
3.When removing terminals, remove the minus (–)
terminal first. When connecting terminals, connect
minus (–) terminal last.

8.If a part cannot be lifted smoothly, make sure that

all the fasteners are removed and other parts don't
hinder removing.

3 WA01-0170E
 Safety

4. About waste disposal

1.Waste oils, used filters, and other such
petrochemical-related products, if disposed of
thoughtlessly, will cause environmental
contamination.

2.Obtain a proper-sized vessel before releasing

waste oils from the machine. Never discharge
waste oils on the ground or into rivers, lakes or
marshes.

3.Follow all governing environmental rules and

regulations when disposing of oils, fuels, cooling
water, brake fluid, solvents, filters, batteries or any
other damaging substances.

4.1 Hydraulic oil

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,
followed by soaking up of residual fluids by use of
absorbent materials. Remove contaminated items
including contaminated soil and place in proper
containers for disposal. Avoid washing, draining or
directing material to storm or sanitary sewers.

2.Waste disposal method: Recycle as much of the

recoverable product as possible. Dispose of
nonrecyclable material as a RCRA hazardous
waste by such methods as incineration, complying
with federal, state, and local regulations.

4.2 Motor oil

Refer to "Hydraulic oil" above.

4 WA01-0170E
 Foreword

Foreword 1. Separate service manual

This service manual describes the systems and The repair manual documents for your crane are
components of the TM-ZT1000 series, its repair, comprised of this manual and the separate documents
check and adjustment methods and other relevant listed below.
matters.
Separate service manual Publication No.
Before removing or dismounting a component, read
this manual and obtain information on the component 1 General Cautions WA01-0121E

fully.
For repair and maintenance of the machine, read the
2. Applicable specification No.
separate service manual, the operation manual and
This manual is applicable to the machine of the
the mounting manual in conjunction with this manual.
specification Nos. given in the next page. Before using
To avoid damaging the hydraulic components, read
this manual, check the specification No. of your
the separate "General Cautions" and know the proper
machine in the nameplate on the machine.
handling of the hydraulic and mechanical
components. [Boom nameplate]
Before carrying out repairs, check the parts catalog for
structure and sales units of the parts.

Symbols representing crane specification

• This manual shows the crane specifications with (1) Boom specification No.
the symbols below. (2) Serial No.

H: Hook-in (hook stowing)

[Frame nameplate]

(1) Model
(2) Lifting capacity
(3) Frame specification No.
(4) Serial No.
(5) Date of manufacturing (Date of mounting)

Please note that, for product improvement, some

changes may have been incorporated in the machine 315-924-42011 △
0

that are not covered in this manual. 315-924-32011 △

0

1 WA04-5410E
 Foreword

2.1 ZT1000 series

Type Hook-in Boom specification No. Frame specification No. Remarks

ZT1004H  410-621-02014 410-621-01014 4-section boom

ZT1005H  410-621-02015 410-621-01015 5-section boom

[NOTICE]
Depending on the specifications, the actual machine and illustration shown below may partially be different.

2 WA04-5410E
 Foreword

3. Major specifications
Specifications
No. Item
ZT1000 series

Hydraulically telescoped (2nd boom section telescopes sequentially. 3rd and

4-section 4th boom sections telescope simultaneously.)
Employing 2 cylinders and 1 set of wire rope
Boom
1
type
Hydraulically telescoped (2nd and 3rd boom sections telescope sequentially.
5-section 4th and 5th boom sections telescope simultaneously.)
Employing 3 cylinders and 1 set of wire rope

Hydraulic motor driven; Worm gear and spur gear speed reduction
2 Slewing
Automatic slewing lock

Hydraulic motor driven

3 Winch
Spur gear speed reduction; provided with mechanical brake

4 Hook block 4 sheaves

5 Outriggers Hydraulically extended sliders and hydraulically extended jacks

Other equipments
6 (safety devices) Two-blocking alarm device, anti-two-block device

3 WA04-5410E
 Foreword

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

Speed
km/h mile/h, mph
-1
1 6.21373×10
1.60934 1

Area
square millimeter square centimeter square meter square inch square foot
2 2 2 2 2
mm cm m in ft
-2 -6 -3 -5
1 1×10 1×10 1.55×10 1.07639×10
2 -4 -1 -3
1×10 1 1×10 1.55×10 1.07639×10
6 4 3
1×10 1×10 1 1.55×10 1.07639×10
2 -4 -3
6.4516×10 6.4516 6.4516×10 1 6.94444×10
4 2 -2 2
9.2903×10 9.2903×10 9.2903×10 1.44×10 1

Volume
cubic centimeter liter cubic meter cubic inch cubic foot gallon (US)
3 3 3 3
cm , cc lit, L m in ft gal
-3 -6 -2 -5 -4
1 1×10 1×10 6.10237×10 3.53147×10 2.64172×10
3 -3 -2 -1
1×10 1 1×10 6.10237×10 3.53147×10 2.64172×10
6 3 4 2
1×10 1×10 1 6.10237×10 3.53147×10 2.64172×10
-2 -5 -4 -3
1.63871×10 1.63870×10 1.63871×10 1 5.78704×10 4.329004×10
4 -2 3
2.83168×10 2.83168×10 2.83168×10 1.728×10 1 7.48051
3 -3 2 -1
3.78541×10 3.78541 3.78541×10 2.31×10 1.33680×10 1

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

4 WA04-5410E
 Foreword

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

Pressure
pascal 2 2
kPa MPa kgf/cm lbf/in , psi bar
Pa
-3 -6 -5 -4 -5
1 1×10 1×10 1.01972×10 1.45038×10 1×10
3 -3 -2 -1 -2
1×10 1 1×10 1.01972×10 1.45038×10 1×10
6 3 2
1×10 1×10 1 1.01972×10 1.45038×10 10
4 -2 -1
9.80665×10 9.80665×10 9.80665×10 1 1.42233×10 9.80665×10
3 -3 -2 -2
6.89476×10 6.89476 6.89476×10 7.03072×10 1 6.89475×10
5 2 -1
1×10 1×10 1×10 1.01972 1.45038×10 1

Torque
foot-pound inch-pound
N-cm N-m kgf-cm kgf-m
ft-lbf in-lbf
-2 -1 -3 -3 -2
1 1×10 1.01972×10 1.01972×10 7.37562×10 8.85074×10
2 -1 -1
1×10 1 1.01972×10 1.01972×10 7.37562×10 8.85074
-2 -2 -2 -1
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10
2 2
9.80665×10 9.80665 1×10 1 7.23301 8.67961×10
2 -1
1.35582×10 1.35582 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

Power
watt
kW PS
W
-3 -3
1 1×10 1.35962×10
3
1×10 1 1.35962
2 -1
7.355×10 7.355×10 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

5 WA04-5410E
 Foreword

5. Drawing method of illustrations in this service manual

The third angle projection method of mechanical drawing is used for the illustrations in this service manual.
The third angle projection method is generally composed of the front view (the figure viewed from the front:
A), top view (the figure viewed from the top: B), and right-side view (the figure viewed from the right: C) as
shown below. Draw the top view immediately above the front view, and draw the right-side view on the right
side of the front view. Tridimensional shape can generally be drawn with the figures viewed from 3 directions.
For those which cannot be drawn with the figures viewed from 3 directions, the additional figures, such as
left-side view (the figure viewed from the left: D), back view (the figure viewed from the back: E), or bottom
view (the figure viewed from the bottom: F) may be used.
For other cases, when individual detailed drawing is required, an arrow view, sectional view, or detail drawing
may be used separately.

A: Front view
B: Top view
C: Right-side view
D: Left-side view
E: Back view
F: Bottom view

6 WA04-5410E
6. Group index

B Hydraulic Power Generating System B

C Outrigger System C
D Slewing System D
E Boom Elevating System E
F Winch System F
G Boom Telescoping System G
H Safety System H

Y Data, Adjustment and Checks Y

Z System Diagrams Z
7 WA04-5410E
 Foreword

7. Contents
Specifications
Chapter Section
ZT1000 series

General

A General Cautions Refer to separate service manual

Hydraulic Power Generating System

Manual Control Valve B-1

B Remote Control Valve (Outrigger) B-2

Center Joint B-3

Outrigger System

Jack Cylinder C-1

C Extension Cylinder C-2

Pilot Check Valve C-3

Slewing System

Hydraulic Motor D-1

D Slewing Speed Reducer D-2

Slewing Assy D-3

Boom Elevating System

Boom Elevating Cylinder E-1

E
Counterbalance Valve E-2

8 WA04-5410E
 Foreword

Specifications
Chapter Section
ZT1000 series

Winch System

Hydraulic Motor F-1

F Winch Speed Reducer F-2

Winch Assy F-3

Boom Telescoping System

4-section Boom G-1

5-section Boom G-2

Boom Telescoping Cylinder

G G-3
(4-section Boom)
Boom Telescoping Cylinder
G-4
(5-section Boom)

Counterbalance Valve G-5

Safety System

H Cord Reel H-1

Data, Adjustment and Checks

Service Data Y-1

Adjustment
Y Hydraulic Y-2
Procedure

Adjustment and Functional Check Y-3

System Diagrams

Hydraulic Circuit Z-1

Electric Circuit Z-2

Z
Electric Parts Location Diagram Z-3

Harness Z-4

9 WA04-5410E
 B B

Hydraulic Power Generating System

Contents

B-1 Manual Control Valve ...................... 1 B-3 Center Joint .................................... 12

1. Hydraulic circuit ........................................ 1 1. Structure ................................................. 12

2. General view ............................................. 2 2. Dismounting and mounting of center joint 14

3. Tightening tie-bolts.................................... 3 3. Specifications .......................................... 15

4. Replacing O-rings ..................................... 3

5. Main relief valve ........................................ 3

6. Front cover ............................................... 4

6.1 Function of each relief valve....................... 5

B-2 Remote Control Valve

(Outrigger Slide) ...................... 6

1. Hydraulic circuit ........................................ 6

2. General view ............................................. 7

3. Tightening tie-bolts.................................... 8

4. Removing solenoid valves ........................ 8

5. Replacing O-rings ..................................... 8

6. Removing and installing a filter ................. 8

7. Front cover ............................................... 9

8. Main relief valve, unload valve ................ 10

8.1 Function of each relief valve..................... 11

i
B-1 B-1
Manual Control Valve

B-1 Manual Control Valve

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

1. Hydraulic circuit
• For the setting pressure, refer to Y-2 "Adjustment Procedure (Hydraulic)".

1 W113-0641E
B-1 B-1
Manual Control Valve

2. General view

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
G G1/4 29.4 ± 3.0 3.0 ± 0.3

A1 to A6, B1 to B6 G3/8 49.0 ± 5.0 5.0 ± 0.5

P, T G1/2 98.1 ± 10.0 10.0 ± 1.0

2 W113-0641E
B-1 B-1
Manual Control Valve

3. Tightening tie-bolts
Tighten nuts for tie-bolts according to the shown
sequence in order to avoid deformation of valve
body.

First tighten the nuts (from 1 to 8) so that the

valve blocks are aligned correctly. Then tighten
the nuts to the torque specified below.

• Nut tightening torque: 19.6 N-m (2.0 kgf-m)

4. Replacing O-rings
Replace all O-rings in all valve blocks when even
only one valve block is replaced.

5. Main relief valve

1. Pilot seat 5. Packing 9. Body 13. Relief pipe

2. Poppet 6. Nut 10. Spool 14. O-ring
3. Spring 7. Cap nut 11. Return spring 15. Orifice
4. Adjuster screw 8. O-ring 12. O-ring 16. Heat shrinkable tube

[NOTICE]
When assembling the relief valve, replace the packing [5] if it has been used at least once.
When disassembling the relief valve, replace the O-rings [8, 12 and 14] with new ones.

3 W113-0641E
B-1 B-1
Manual Control Valve

6. Front cover

1. Front cover 9. Plug 17. Nut 25. Spring

2. Steel ball 10. O-ring 18. Cap nut 26. O-ring
3. Steel ball 11. Push rod 19. Orifice 27. Plug
4. Spool 12. Solenoid valve assy 20. O-ring 28. Plug
5. Spool 13. Solenoid valve assy 21. Seat 29. Cap
6. Spring seat 14. Screw 22. Poppet 30. O-ring
7. Spring 15. Screw 23. Shim
8. O-ring 16. Seal washer 24. Shim

[NOTICE]
When disassembling, replace the O-rings [8, 10, 20, 26 and 30] with new ones.

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
15 0.20 to 0.29 0.020 to 0.029

17 M4 1.47 to 1.97 0.15 to 0.20

18 0.78 to 1.28 0.08 to 0.13

4 W113-0641E
B-1 . B-1 .
Manual Control Valve

6.1 Function of each relief valve

Caution: The pressure setting values are for reference. Refer to Y-2 "Adjustment Procedure (Hydraulic)".

1. Main relief valve 4. Screw (installed in SV1) (for emergency)

(Unload relief valve, master valve) C If loading (increasing the circuit pressure) is not
This valve regulates the maximum pressure of the available due to the faulty unload solenoid valve
pump circuit (P). (SV1), you can load the circuit mechanically by
When the unload solenoid valve (SV1) and the tightening the screw.
low pressure solenoid valve (SV2) are
de-energized (the valve is opened), oil returns to
the tank and the circuit is not loaded (the pressure
in the circuit does not increase).

2. Low-pressure relief valve Z (slave valve) and

unload relief valve (master valve)
When the hook stowing lever is stowed in the
stowing direction, the low pressure solenoid valve
(SV2) is energized (the valve is closed). And then,
the low-pressure relief valve (Z) opens and the
pump circuit is regulated at the low pressure.

3. Unload solenoid valve (SV1)

WARNING
In the following case [1], the valve is de-energized
Use this method only for stowing the crane in
(the valve is open) and unloaded.
an emergency. Do not perform usual crane
work in this condition.
[1] A lever is operated (toward either of boom
raising, hoisting up or boom extending
direction) while two-blocking occurs.

366-388-90000 △
0

5 W113-0641E
B-2 B-2
Remote Control Valve (Outrigger Slide)

B-2 Remote Control Valve (Outrigger Slide)

[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. Hydraulic circuit
• For the setting pressure, refer to Y-2 "Adjustment Procedure (Hydraulic)".

6 W135-0540E
B-2 B-2
Remote Control Valve (Outrigger Slide)

2. General view

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
G, PA1, PA2, TA1 G1/4 29.4 ± 3.0 3.0 ± 0.3

A1, A2, B1, B2 G3/8 49.0 ± 5.0 5.0 ± 0.5

P, T, C G1/2 98.1 ± 10.0 10.0 ± 1.0

7 W135-0540E
B-2 B-2
Remote Control Valve (Outrigger Slide)

3. Tightening tie-bolts 5. Replacing O-rings

Tighten nuts for tie-bolts according to the shown Replace all O-rings in all valve blocks when even
sequence in order to avoid deformation of valve only one valve block is replaced.
body.

First tighten the nuts (from 1 to 4) so that the
valve blocks are aligned correctly. Then tighten
the nuts to the torque specified below.
• Nut tightening torque: 19.6 N-m (2.0 kgf-m)
6. Removing and installing a filter
Loosen the plug [111], and remove the filter [109].
(Handle the filter with care because it is
breakable.) Check the O-ring [119] for wear or
damage before installing the filter.

(Inside the front cover)

4. Removing solenoid valves

Remove the solenoid valve with the valve body
laid on a rag to catch the balls.

8 W135-0540E
B-2 B-2
Remote Control Valve (Outrigger Slide)

7. Front cover

9 W135-0540E
B-2 B-2
Remote Control Valve (Outrigger Slide)

8. Main relief valve, unload valve

1. Body 5. Poppet 9. Nut 13. O-ring

2. Spool 6. Spring 10. Cap nut
3. Spring 7. Adjusting screw 11. Shrinkable tube
4. --- 8. Packing 12. O-ring

[NOTICE]
When disassembling, replace the O-rings with new ones.
The "stop valve" shown in the diagram is normally "open". If the outrigger slide fails to operate due to electrical
trouble, etc., turn this valve to "close" and retract the outrigger slide.

10 W135-0540E
B-2 . B-2 .
Remote Control Valve (Outrigger Slide)

8.1 Function of each relief valve

Caution: The pressure setting values are for reference. Refer to Y-2 "Adjustment Procedure (Hydraulic)".

1. Main relief valve C (slave valve for high pressure)
and unload relief valve (master valve)
This valve regulates the maximum pressure of the
pump circuit (P).
When the unload solenoid valve (SV1) is
de-energized (the valve is opened), oil returns to
the tank and the circuit is not loaded (the pressure
in the circuit does not increase).
5. Stop valve (for emergency)
If loading (increasing the circuit pressure) is not
available due to the faulty unload solenoid valve
(SV1), you can load the circuit mechanically by
tightening the stop valve.

2. Back pressure regulating valve D

It ensures the minimum hydraulic pressure
required to actuate control cylinders.

3. Reducing valve E
It reduces hydraulic pressure applied to control
cylinders to the constant pressure.
4. Unload solenoid valve (SV1)
It becomes energized and loads the circuit in
either condition of [1] as follows:
WARNING
The procedure described in this section is used
to retract the outrigger slide in an emergency.
Do not perform this procedure during normal
outrigger slide operation.

[1] Turn on PTO.

367-407-60001 △
1

11 W135-0540E
B-3 B-3
Center Joint

B-3 Center 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
• For the notes in the figure, refer to following page.

1. Body 6. Button bolt (M8) 11. Support 16. Plate (3-poles, male)
2. Core 7. Spring washer 12. Bolt (M10) 17. Cap
3. Packing 8. Bolt (M8) 13. Connector (2-poles, male) 18. Harness
4. Ring seal 9. Plain washer 14. Plate (2-poles, male) 19. Harness
5. Slip ring assy 10. Spring washer 15. Connector (3-poles, male)
316-322-61000 △
0

12 W181-0780E
B-3 B-3
Center Joint

Note

1. During assembly of the center joint, insert a 0.5

mm thick rubber seal to the position indicated by
"Note 1".

2. During assembly of the center joint, apply grease

(use TADANO genuine grease, and other than
grease for booms.) to the area indicated by "Note
2" (upper/lower 2 places).

3. Install the part [A] of the slip ring assy (indicated

by "Note 3") so that Ø10.5 hole (hole with greater
bore) and the Ø17 hole in the core [2] come close
to each other.

4. Degrease the threaded section of each bolts [12]

(M10), apply adhesive (Loctite 262T or equivalent)
Color of center joint taping to the bolts, and tighten the bolts.
Port no. Thread size Taping color • Tightening torque: 32.4 to 36.8 N-m
(3.3 to 3.75 kgf-m)
A4
Red
(Boom raising)
5. Degrease the threaded section of each bolts [6, 8]
A5
G3/8 Yellow (M8), apply thread locking agent (ThreeBond
(Boom retracting)
A6 1401) to the threaded section on the bolt holes,
Green
(Hoisting up) and tighten the bolts.
B4
G1/4 Blue • Tightening torque: 7.4 ± 0.5 N-m
(Boom lowering)
B5
(0.75 ± 0.05 kgf-m)
White
(Boom extending)
G3/8 6. Before assembly of the parts [13], [14], [15] and
B6
No tape [16], draw the lead wires through the hole of the
(Hoisting down)
D core [2] and check the wire color in the specified
R1/8 No tape
(Drain) position. And then assemble the parts.
Note: Wrap the seal tape around male thread of the joint.
7. The wiring of the same color must have continuity.

Refer to the No.3 ring

13 W181-0780E
B-3 B-3
Center Joint

8. When assembling the center joint, orient the A5

hose port of the core [2] toward the port in the
body [1].

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
A4, A6, B4, B5, B6
G3/8 49.0 ± 5.0 5.0 ± 0.5
A5 (side of the center joint)
A5 (lower part of the center joint) G1/4 29.4 ± 3.0 3.0 ± 0.3

D R1/8 8.8 to 11.8 0.9 to 1.2

2. Dismounting and mounting of center joint

[NOTICE]
Depressurize the hydraulic circuits beforehand.
Otherwise oil may spout and cause serious injury.

1. Remove the post-side hose and wiring connected

to the body [1].

2. Remove the frame-side hose and wiring

connected to the core [2].

3. Remove the bolts [12] (4 places).

14 W181-0780E
B-3 . B-3 .
Center Joint

3. Specifications
4. Lift up the center joint assy (approx. 20 kg), and
then pull it out of the opening on the side of the Allowable current (1 circuit)
post.
• CN2: 5 A (24 V)
[NOTICE]
Pay attention to avoid getting your hands and finger • CN3: 3 A (24 V)
caught.
Pull out the center joint while tilting its upper part
toward you.
If the center joint is hard to pull out, make someone
to thrust the hoses and wiring upward from below
when you pull it.
If you damage the hose when removing the center
joint, replace the new hose.

Install the center joint assy in the reverse

order of the steps 1. to 4.

316-322-60000 △
0

15 W181-0780E
 C C
Outrigger System

Contents

C-1 Jack Cylinder.................................... 1

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

2. Jack cylinder dismounting procedure ........ 3

C-2 Extension Cylinder .......................... 6

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

C-3 Pilot Check Valve ............................. 8

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

i
C-1 C-1
Jack Cylinder

C-1 Jack Cylinder

[NOTICE]
The appearance and hydraulic symbols of the parts shown here may differ from those of actual machine parts.
Such differences do not indicate great difference in functions and disassembly procedures. Before starting
disassembly work, however, you should verify the machine's serial number and verify the part sales unit
shown in the parts catalog.

1. Structure
• For the notes in the figure, refer to following page.

1. Cylinder 4. Plain bearing (*) 7. Packing 10. Rod

2. Piston 5. Rod cover 8. Backup ring 11. Set screw
3. O-ring 6. O-ring 9. Dust seal

*: This part is the set of the plain bearing and packings.

1 W151-0690E
C-1 C-1
Jack Cylinder

Note

1. After installing the set screw [11], punch it (2

places).

2. Before installing the rod cover [5], be sure to

degrease both external and internal threaded
areas.
Subsequently, apply rust preventive agent
(ThreeBond 1184 or equivalent) to the threaded
area (marked with * in the figure).

3. After screwing in the rod cover [5], bend one place

on the end of the cylinder [1] toward the rod cover
[5].

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
2 M42 500 51

5 M95 98 10

11 M8 13.2 to 16.2 1.35 to 1.65

360-378-90000 △
0

2 W151-0690E
C-1 C-1
Jack Cylinder

2. Jack cylinder dismounting procedure

(reference)

[NOTICE]
Extend the jack cylinder approx. 50 mm (in order to make it easy to pull out the jack inner case).
◆Operate each control lever to the full strokes repeatedly beforehand to depressurize the hydraulic system.

1. Remove the hydraulic hoses [1] (four lines).

2. Remove the split pin [2].

3. Lift the extension cylinder slightly, and remove the pin [3].

3 W151-0690E
C-1 C-1
Jack Cylinder

4. Lift up the jack outer case (approx. 230 kg) using a device such as a crane, and pull it out of the frame.

5. Put the jack outer case temporarily on a block.

6. Loosen the machine screws [4] and remove the cover [5].

7. Remove the hexagon socket bolt [6], and remove the check valve on the top of the jack cylinder (leave the
hydraulic hoses as it is).

[NOTICE]
Be careful not to lose the o-rings (2 pieces) on the valve surface.

4 W151-0690E
C-1 . C-1 .
Jack Cylinder

8. Remove the retaining rings [7] and the pins [8], and pull out the jack inner case (including the cylinder).

[NOTICE]
If the case is difficult to pull out, remove the anti-drop spring [11].

9. Remove the retaining rings [9] and the pin [10], and pull out the jack cylinder.

5 W151-0690E
C-2 C-2
Extension Cylinder

C-2 Extension Cylinder

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

1. Structure
• For the notes in the figure, refer to following page.

1. Cylinder 4. Packing 7. Plug 10. Packing

2. Rod cover 5. Backup ring 8. Rod 11. O-ring
3. Dust seal 6. O-ring 9. Piston 12. Nut (M18)

6 W153-0410E
C-2 . C-2 .
Extension Cylinder

Note

1. Before the rod cover [2] is screwed in, be sure to
degrease both external and internal threaded
areas.
Subsequently, apply rust preventive agent
(ThreeBond 1184 or equivalent) to the threaded
area.
2. After screwing in the rod cover [2], bend one place
on the end of the cylinder [1] toward the rod cover
[2].
3. Before the nut [12] is screwed in, be sure to
degrease both external and internal threaded
areas.
Subsequently, apply adhesive (Loctite 638) to the
area described below.
• 3rd through 8th threads of the external threads
on the rod [10] from edge face of the piston [9].
4. Wrap the seal tape around male thread of the
joint.

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
12 M18 98 10

360-441-00000 △
0

7 W153-0410E
C-3 . C-3 .
Pilot Check Valve

C-3 Pilot Check Valve

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

1. Structure

Hydraulic symbol
A B

C D IW115-022001

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
A, B G1/4 29.4 ± 3 3.0 ± 0.3

1 G3/8 49.0 ± 5 5.0 ± 0.5

Valve mounting bolt M10 43.1 to 49.0 4.4 to 5.0

366-239-30000 △
1

8 W115-0062E
 D
Slewing System D

Contents

D-1 Hydraulic Motor................................ 1

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

D-2 Slewing Speed Reducer .................. 2

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

2. Dismounting .............................................. 3

3. Disassembly ............................................. 3

4. Reassembly .............................................. 3

5. Gear oil replacement procedure ................ 4

D-3 Slewing Assembly ........................... 5

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

i
D-1 . D-1 .
Hydraulic Motor

D-1 Hydraulic Motor

[NOTICE]
The appearance and hydraulic symbols of the parts shown here may differ from those of actual machine parts.
Such differences do not indicate great difference in functions and disassembly procedures. Before starting
disassembly work, however, you should verify the machine's serial number and verify the part sales unit
shown in the parts catalog.
After replacing the motor, fill it with hydraulic oil before actuating it. Then, actuate the motor slowly (to prevent
seizing).

1. Structure

1. Shaft 8. Thrust plate 15. Bolt 22. O-ring

2. Bearing 9. Cylinder barrel assy 16. Key 23. Backup ring
3. Housing 10. Valve plate 17. Plug 24. Spring
4. O-ring 11. Bottom cover 18. --- 25. Cap
5. Oil seal cover 12. Bearing 19. O-ring
6. Oil seal 13. Pin 20. Body
7. C-ring 14. O-ring 21. Piston

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
A, B G3/8 39.2 to 49.0 4 to 5

D, L G1/4 19.6 to 29.4 2 to 3

366-639-50000 △
1

1 W102-0632E
D-2 D-2
Slewing Speed Reducer

D-2 Slewing Speed Reducer

[NOTICE]
There is a case that the appearance differs 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. Retaining ring 7. Dipstick 13. Gear case 19. Bearing

2. Spacer 8. Seal washer 14. Bearing 20. Nut
3. Shim set 9. Plug 15. Bearing 21. Pin
4. Bearing 10. Spur gear 16. Bolt 22. Air breather
5. Worm 11. Sleeve 17. Worm wheel 23. Key
6. Bearing 12. Oil seal 18. Gear case 26. Washer

2 W511-0333E
D-2 D-2
Slewing Speed Reducer

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
7 ― 88.3 to 147 9.0 to 15.0

9 R3/8 32.4 to 35.3 3.3 to 3.6

16 M10 57 5.8

20 ― 167 to 216 17.0 to 22.0

22 ― 0.44 0.045

2. Dismounting 4. Reassembly

WARNING [NOTICE]
When the slewing speed reducer is removed, Install the bearings [14, 15] in correct order.
the slewing post is freed.
Before removing the slewing speed reducer,
fasten the slewing post to the lower frame with
a rope to prevent its rotation. (Shield type)

3. Disassembly (Seal type)

1. Remove the dipstick [7].

2. Remove the plug [9], and drain the oil.

3. Remove the retaining ring [1] first, then spacer [2],
and then shim set [3].
4. Twist the worm [5] together with the bearing [4, 6]
to extract them toward the motor side.
Before you install the plug [9] (on the oil drain port),
wrap it with a seal tape.
Add gear oil (Mobilgear 600XP 320) up to the
center position of the dipstick with the dipstick
inserted unscrewed.
(Oil amount: approx. 0.9 L)

5. Remove the bearings [4, 6] from the worm [5].

6. Remove the bolts [16] (8 pcs).

7. Remove the spur gear [10] with the gear case [13]
attached on it.

8. Remove the nut [20], bearing [19], worm wheel

[17], and the key [23] from the spur gear [10].

9. Remove the spur gear [10] together with the

sleeve [11] out of the gear case [13] because the
sleeve [11] is shrink-fit.

10. Separate the bearing [14, 15] and oil seal [12]
from the gear case [13].

3 W511-0333E
D-2 . D-2 .
Slewing Speed Reducer

5. Gear oil replacement procedure

[NOTICE]
Replace the oil within 300 hours or 3 months (whichever comes earlier) after the machine is delivered.
Replace it every 1200 hours or once a year thereafter.

1. Stop the vehicle on a level ground.

2. Place an oil pan.

3. Remove the drain plug and dipstick to drain the

oil.

4. After the oil has been completely drained, wrap a

seal tape around the drain plug, and tighten the
plug.

5. Add new gear oil through the threaded hole for the
dipstick.

[NOTICE]
Check the oil level using the dipstick.

6. Tighten the dipstick.

360-817-60000 △
1

360-817-50000 △
1

4 W511-0333E
D-3 D-3
Slewing Assembly

D-3 Slewing Assembly

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

1. Structure

1. Slewing 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. --- 11. Plain washer
4. Bolt 8. Slewing speed reducer 12. Hydraulic motor

5 W512-0320E
D-3 . D-3 .
Slewing Assembly

Note

1. When installing the inner ring of the slewing bearing, face the soft zone (stop plug) to the [R] position shown
in the diagram.

2. To tighten the bolts [2, 4, 10, and 13] 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.

3. Install the center joint so that the hose [A5] (with yellow tape) comes to the position shown in the diagram,
and tighten the center joint and the bearing together using the bolts [4].

Thread size and tightening torque

Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m

2 M20 560 ± 30 57.0 ± 3.0 Apply DAPHNE EPONEX

SR2 (IDEMITSU) to the
threaded sections of the
4 M22 745 ± 35 76.0 ± 3.5 bolts.
Apply thread lock agent
10 M16 180 to 200 18.4 to 20.4
(Loctite 262T) to the bolts.

13 M12 68.6 to 82.3 7.0 to 8.4

313-017-40000 △
0

6 W512-0320E
 E
Boom Elevating System
E

Contents

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

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

E-2 Counterbalance Valve ..................... 3

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

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

1. --- 8. Plain bearing 14. Retaining ring 20. Plug

2. Plain bearing 9. O-ring 15. Retaining ring 21. Orifice
3. Piston 10. Rod cover 16. O-ring 22. Backup ring
4. Plain bearing 11. Packing 17. Plate 23. Packing
5. O-ring 12. Backup ring 18. Set screw 24. Spacer
6. Cylinder 13. Dust seal 19. Grease nipple 25. Spacer
7. Rod

1 W155-0590E
E -1 . E -1 .
Boom Elevating Cylinder

Note

1. Before installing the set screw [18], be sure to
degrease the threaded area.
Subsequently, apply adhesive (Loctite 638) to the
threaded area.
After installing, punch it. (Refer to Detail [A])
2. Before installing the rod cover [10], be sure to
degrease both external and internal threaded
areas.
Subsequently, apply rust preventive agent to the
threaded area.
4. Before installing the spacer [24 and 25], be sure
to degrease it.
5. Before installing the plain bearing [2], apply
Loctite 638 or equivalent.
6. Wrap the seal tape around male thread of the plug
[20].
7. Before installing the orifice [21], be sure to
degrease it. Subsequently, apply adhesive (Loctite
638) to the threaded area.

3. Bend the plate [17] toward the notch of the rod

cover [10] to stop rotation (1 place).

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
3 M109 500 51.0

10 M180 340 34.7

360-286-80000 △
0

2 W155-0590E
E -2 . E -2 .
Counterbalance Valve

E-2 Counterbalance Valve

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

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

2. Spool 6. O-ring 10. Poppet 14. O-ring
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
A, B, C, D G3/8 49.0 ± 5 5.0 ± 0.5 366-056-00000 △
2

366-051-80001 △
3
Valve mounting bolt M10 34.3 to 39.2 3.5 to 4.0 366-065-50000 △
2

366-055-20000 △
3

366-052-00001 △
3

3 W119-0645E
 F
Winch System

FF
Contents

F-1 Hydraulic Motor................................ 1

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

F-2 Winch Speed Reducer ..................... 3

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

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

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

i
F-1 F-1
Hydraulic Motor

F-1 Hydraulic Motor

[NOTICE]
The appearance and hydraulic symbols of the parts shown here may differ from those of actual machine parts.
Such differences do not indicate great difference in functions and disassembly procedures. Before starting
disassembly work, however, you should verify the machine's serial number and verify the part sales unit
shown in the parts catalog.
After replacing the motor, fill it with hydraulic oil before actuating it.

1. Structure

1. Front case 10. Collar 19. Thrust roller bearing 27. O-ring (*)
2. Rear case 11. --- 20. Plate 28. ---
3. Shaft 12. Spring 21. Hexagon socket head 29. ---
4. Cylinder block 13. Key button bolt 30. ---
5. Piston retainer 14. Washer 22. Bearing 31. ---
6. --- 15. --- 23. C-ring 32. Piston assy
7. Spherical head retainer 16. Oil seal (*) 24. ---
8. Spherical socket pin 17. Needle bearing 25. Hexagon socket head bolt
9. --- 18. --- 26. ---

*: Seal kit

1 W102-0196E
F-1 . F-1 .
Hydraulic Motor

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
A, B G3/8 39.2 ± 4.9 4.0 ± 0.5

D Rc1/8 6.9 0.7

Motor mounting bolt [E] M8 11.8 to 16.7 1.2 to 1.7

366-631-00000 △
0

2 W102-0196E
F-2 F-2
Winch Speed Reducer

F-2 Winch Speed Reducer

[NOTICE]
There is a case that the appearance and so on differs 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. Gear case (A) 12. Spring 28. Oil level gauge 30. Spring washer
10. Ratchet 13. Cap 29. Screw 38. Pin
11. Shaft 14. Pin

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
29 M4 1.77 0.18

3 W526-0720E
F-2 . F-2 .
Winch Speed Reducer

1. Gear case (A) 9. Disk assy 22. Bolt 34. Ball bearing
2. Gear case (B) 15. Nut 23. Nord-lock washer 35. Nut
3. Spur gear 16. Ball bearing 24. Split pin 36. Spacer
4. Spur gear 17. Ball bearing 25. Key 37. Spur gear
5. Spur gear 18. Ball bearing 27. Plug 39. Nut
6. Brake disk 19. Ball bearing 31. Spur gear 40. Eyebolt
7. Ratchet wheel 20. Oil seal 32. Sleeve 41. Plug
8. C-ring 21. Retaining ring 33. Ball bearing

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
15 - 95 9.7

22 M10 45 4.6

35 - 80 8.16

360-740-30000 △
0

4 W526-0720E
F-3 . F-3 .
Winch Assembly

F-3 Winch Assembly

[NOTICE]
There is a case that the appearance and so on differs 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. Winch speed reducer 9. Bolt (1 pc.) 12. Hexagon socket head bolt 15. Hexagon socket head bolt
2. Winch drum 10. Spring washer (3 pcs.) 24. Spring washer
8. Pin 11. Spring washer 14. Hydraulic motor

Thread size and tightening torque

Tightening torque
Sign / Port Thread size
N-m kgf-m
9, 12 M14 115.7 to 133.4 11.8 to 13.6

15 M8 11.8 to 16.7 1.2 to 1.7

313-118-40000 △
1

5 W526-0730E
 G
Boom Telescoping System

Contents G
G-1 4-section Boom ................................ 1 G-2 5-section Boom .............................. 22

1. Boom telescoping mechanism .................. 1 1. Boom telescoping mechanism................. 22

2. Structure ................................................... 3 2. Structure ................................................. 24

2.1 Top boom assy ........................................... 3 2.1 Top boom assy .......................................... 24
2.2 3rd boom assy ............................................ 4 2.2 4th boom assy........................................... 25
2.3 2nd boom assy ........................................... 5 2.3 3rd boom assy .......................................... 26
2.4 Base boom assy ......................................... 6 2.4 2nd boom assy.......................................... 27
2.5 Base boom assy ....................................... 28
3. Disassembly of the boom .......................... 7
3.1 Preparation ................................................. 7 3. Disassembly of the boom ........................ 29
3.2 Pulling out the 2nd and 3.1 Preparation................................................ 29
further boom sections ........................... 8 3.2 Pulling out the 2nd and
3.3 Pulling out the 3rd and further boom sections ......................... 30
further boom sections ........................... 9 3.3 Pulling out the 3rd and
3.4 Pulling out the top boom section .............. 10 further boom sections ......................... 31
3.5 Pulling out the boom telescoping cylinder 11 3.4 Pulling out the 4th and
3.6 Checking the slide plates ......................... 13 further boom sections ......................... 31
3.5 Pulling out the top boom section ............... 32
4. Assembly of the boom ............................ 13 3.6 Pulling out the boom telescoping cylinder 32
4.1 Installing procedure of the wire rope 3.7 Checking the slide plates .......................... 32
(for the top boom retracting)............... 13
4.2 Inserting the boom telescoping cylinder 4. Assembly of the boom ............................. 33
into the top boom section ................... 14 4.1 Inserting the boom telescoping cylinder
4.3 Inserting the top boom section into the top boom section.................... 33
into the 3rd boom section ................... 15 4.2 Inserting the top boom section
4.4 Inserting the 3rd boom section into the 4th boom section.................... 34
into the 2nd boom section .................. 18 4.3 Inserting the 4th boom section
4.5 Inserting the 2nd boom section into the 3rd boom section ................... 35
into the base boom section ................ 19 4.4 Inserting the 3rd boom section
into the 2nd boom section................... 36
5. Adjustment.............................................. 21 4.5 Inserting the 2nd boom section
into the base boom section ................. 37

i
5. Adjustment.............................................. 39

G-3 Boom Telescoping Cylinder

(4-section Boom) ................... 40

1. Structure ................................................. 40
1.1 Check valve A ........................................... 40
1.2 Check valve B .......................................... 40
1.3 Telescope assy ......................................... 41
1.4 Cylinder assy ............................................ 42

2. Description of operation .......................... 44

2.1 Control of extension sequence ................. 44
2.2 Control of retraction sequence ................. 46

G-4 Boom Telescoping Cylinder

(5-section Boom) ................... 48

1. Structure ................................................. 48
1.1 Check valve A ........................................... 48
1.2 Check valve B .......................................... 48
1.3 Telescope assy ......................................... 49
1.4 Cylinder assy ............................................ 50

2. Description of operation .......................... 52

2.1 Control of extension sequence ................. 52
2.2 Control of retraction sequence ................. 55

G-5 Counterbalance Valve ................... 58

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

ii
G -1 G -1
4-section Boom

G-1 4-section Boom

1. Boom telescoping mechanism

Extension sequence: First the 2nd boom section extends,
and then the 3rd and top boom section extend simultaneously.

Retraction sequence: First the top and 3rd boom section retracts simultaneously,
and then the 2rd boom section retracts.

Telescope assy

1 W536-1830E
G -1 G -1
4-section Boom

Boom telescoping cylinder

312-061-70000 △
1

360-194-70000 △
0

2 W536-1830E
G -1 G -1
4-section Boom

2. Structure

2.1 Top boom assy

4. Top boom section 6. Wire rope 7. Wire rope 16. Button bolt (M6)
5. Nut (M12) (for boom retracting) (for boom extending) 20. Slide plate (t15)
(L = 14240, Ø = 8) (L = 8640, Ø = 11.2)

Note

1. After installation of wire rope, bend the plates

(6 places).

3 W536-1830E
G -1 G -1
4-section Boom

2.2 3rd boom assy

3. 3rd boom section 31. Spring washer 52. Shim (t1.0) 60. Pin
15. Slide plate (t15) 40. Set screw 53. Shim (t0.5) 61. Hexagon socket head bolt
16. Button bolt (M6) 45. Plate (t4.5) 54. Slide plate (t12) (M10)
19. Spacer 46. Plate (t3.2) 55. Machine screw (M4) 67. Nut (M10)
21. Pin 48. Bolt (M8) 56. Sheave assy 71. Hexagon socket head bolt
22. Retaining ring 49. Spring washer 58. Sheave assy (M10)
23. Roller assy 50. Slide plate (t22) 59. Plate (t6.0)

Note

1. Because the shims [52, 53] are used only when
they are necessary for adjustment, all of them are
not necessarily used.
2. Apply grease to the boom inside surfaces that rub
against slide plates.
3. Tighten the bolts [48] to a torque of 19 to 21 N-m
(1.9 to 2.1 kgf-m).

4 W536-1830E
G -1 G -1
4-section Boom

2.3 2nd boom assy

2. 2nd boom section 15. Slide plate (t15) 40. Set screw 67. Nut (M10)
7. Wire rope 16. Button bolt (M6) 43. Slide plate (t12) 68. Shim (t1.0)
(for boom extending) 17. Pin 44. Slide plate (t15) 69. Shim (t0.5)
(L = 8640, Ø = 11.2) 18. Retaining ring 48. Bolt (M8) 70. Plate (t9.0)
8. Nut (M18) 19. Spacer 49. Spring washer

Note

1. Because the shims [68, 69] are used only when 3. Tighten the bolts [48] to a torque of 19 to 21 N-m
they are necessary for adjustment, all of them are (1.9 to 2.1 kgf-m).
not necessarily used.

2. Apply grease to the boom inside surfaces that rub

against slide plates.

5 W536-1830E
G -1 G -1
4-section Boom

2.4 Base boom assy

1. Base boom section 27. Plate (t9.0) 38. Pin 63. Bolt (M8)
10. Grease nipple 28. Plate (t1.6) 39. Pin 66. Plain washer
11. Plain bearing 29. Bolt (M12) 40. Set screw 67. Nut (M10)
12. Roller assy 30. Bolt (M10) 44. Slide plate (t15) 68. Shim (t1.0)
13. Pin 31. Spring washer 48. Bolt (M8) 69. Shim (t0.5)
14. Retaining ring 33. Slide plate (t12) 49. Spring washer 70. Plate (t9.0)
26. Pin 37. Sheave 62. Cover

Note

1. Insert plain bearings [11] with the seam facing
upward and the grease grooves facing outside,
and lock them with adhesive (Loctite 638).
2. Because the shims [68, 69] are used only when
they are necessary for adjustment, all of them are
not necessarily used.
3. Apply grease to the boom inside surfaces that rub
against slide plates.
4. Bend the plate [28] on the boom elevating cylinder
pivot pin [26] after installing the bolts [29].
5. Tighten the bolts [48] to a torque of 19 to 21 N-m
(1.9 to 2.1 kgf-m).

6 W536-1830E
G -1 G -1
4-section Boom

3. Disassembly of the boom

9. (Cord reel assy)
Removing the 2nd and further boom sections. -1. To prevent the cord reel from being damaged,
secure the wiring with something like a stopper
3.1 Preparation or a clip.

Before disassembling the boom, perform the

following works:
- Removing the hook block
- Depressurizing the hydraulic circuits
- Removing the weight for the two-blocking alarm
device
- Removing the electrical wiring of the cord reel

1. Fully lower the boom, and lay the hook block on

the ground.

2. Remove the rope socket from the boom head (or
hook block).
3. Remove the wire clip, hammer out the wedge,
and remove the wire rope from the rope socket.
-2. Put a marker to the wiring.
-3. Cut off the cable ties (2 places), and separate
the wiring.
-4. Haul the wiring of the cord reel to the head of
the boom, and fix it temporarily on the top
boom.

[NOTICE]
Before disconnecting the wiring, put a marker on it
in order to restore the same positional relationship
easily.

4. Pull out the wire rope from the hook block and
weight for the two-blocking alarm device.

5. Fix the weight for the two-blocking alarm device

to the top boom head temporarily.

6. While pulling up the wire rope, perform hoisting

up operation, roll up the rope into the winch drum,
and damp it temporarily.

7. Stop the engine.

8. Operate each control lever to the full strokes

repeatedly beforehand to depressurize the
hydraulic system.

7 W536-1830E
G -1 G -1
4-section Boom

3.2 Pulling out the 2nd and further boom

sections -2. Remove the retaining rings [14] and pull out
the pin [13].
CAUTION
Depressurize the hydraulic circuits beforehand.
Otherwise oil may spout and cause serious
injury.

10. (Tail end of the boom)

-1. Remove the piping joints for the
counterbalance valve.

[NOTICE]
Do not remove the counterbalance valve.
Wipe up the oil spilling out of the joints with waste
11. (Head of base boom section)
rags.
Cover the removed joints and hydraulic ports of the
counterbalance valve with waste rags or something
to prevent entry of dust.
-1. Loosen the nuts [67] and set screws [40].
-2. Remove the bolts [48], plates [70], shims
[68, 69] and slide plates [44] (4 places).
-3. Pull out the 2nd boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [33] (2 places).
-5. Pull out the 2nd and further boom sections
(approx. 660 kg).

[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.

8 W536-1830E
G -1
4-section Boom
3.3 Pulling out the 3rd and further boom
sections
12. Measure and record the lengths (L1 to L2, each
two places) as illustrated in the following figure.
(Distance from the wire rope end to the nut)
13. (Tail end of the 2nd boom section)
Remove the retaining rings [18]. Screw a bolt (M8)
into the pins [17], and pull out it.
9 W536-1830E
G -1
14. (Head of the 2nd boom section)
Remove the fixing nuts [8] for the wire rope (for
the top boom extending) [7].
[NOTICE]
Before loosening the nuts [8], be sure to clean the
threads at the end of the wire rope [7] with a wire
brush.
15. (Head of the 2nd boom section)
-1. Loosen the nuts [67] and set screws [40].
-2. Remove the bolts [48], plates [70], shims
[68, 69] and slide plates [44] (4 places).
-3. Pull out the 3rd boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [43] (2 places).
-5. Pull out the 3rd and further boom sections
(approx. 480 kg).
[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.
Pull out the 3rd and further boom sections while
being careful not to allow the wire rope (for the top
boom extending) [7] to be caught by the support of
the 2nd boom section.
G -1 G -1
4-section Boom

3.4 Pulling out the top boom section

17. (Head of the 3rd boom section)
16. (Tail end of the 3rd boom section) -1. Remove the bolts [61] and plates [45, 59].
-1. Remove the bolts [71] and roller assy [23]. -2. Pull out the pins [60] and remove the sheaves
-2. Put a suitable spacer between the top boom [58].
and boom telescoping cylinder.
-3. Remove the retaining rings [22]. Screw a bolt
(M8) into the pins [21], and pull out it.

[NOTICE]
Temporarily fix the wire rope (for the top boom
extending) to the top boom section while keeping it
a little tense to prevent it from hanging loose
sideways.

10 W536-1830E
G -1 G -1
4-section Boom

3.5 Pulling out the boom telescoping cylinder

18. (Head of the 3rd boom section)
-1. Loosen the nuts [67] and set screws [40]. 19. (Head of the top boom section)
-2. Pull out the top boom section by approx. Loosen the adjusting nuts and remove the lock
1.0 m. nuts for the wire rope (for the top boom
-3. Remove the bolts [48], plates [46], shims retracting) [6].
[52, 53] and slide plates [50] (4 places).
[NOTICE]
-4. Lift the boom slightly, and remove the slide
Do not remove the adjusting nuts.
plates [54] (2 places).
Before loosening the nuts [5], be sure to clean the
-5. Pull out the top boom section (approx. 180 kg). threads at the end of the wire rope [6] with a wire
brush.
[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.
Perform this operation slowly.
Pay particular attention to the ropes for boom
extension to prevent them from being damaged.

20. (Tail end of the boom telescoping cylinder)

Remove the support which prevent the rope from
coming off.

11 W536-1830E
G -1 G -1
4-section Boom

21. Remove the wire rope (for the top boom
retracting) around the sheave of the boom
telescoping cylinder.
23. Pull out the boom telescoping cylinder approx.
1.0 m.
24. Lift the boom telescoping cylinder again, and pull
it out until the guide roller at the tip of the cylinder
appears at the end of the top boom section.

[NOTICE]
Be sure to pull the wire rope (for the top boom
retracting) in the same direction while pulling out the
cylinder.

22. Lift the boom telescoping cylinder slightly, and

remove the spacer.

25. Lift the boom telescoping cylinder (approx.

150 kg) again, and pull it out of the top boom
section.

[NOTICE]
Perform this operation slowly.
Pay particular attention to the wire rope (for the top
boom retracting) to prevent them from being
damaged.

12 W536-1830E
G -1 G -1
4-section Boom

4. Assembly of the boom

26. Place the boom telescoping cylinder approx.
1.5 m behind the boom.
4.1 Installing procedure of the wire rope (for the
[NOTICE] top boom retracting)
If it is difficult to place the boom telescoping cylinder [NOTICE]
temporarily behind the boom, remove the wire rope
If the wire rope (for the top boom retracting) has not
(for the top boom retracting) from the top boom
removed from the top boom, procedures of this
section.
section are not necessary.

1. Install an eye bolt or the like to the M5-threaded

hole at each end of the wire rope (for the top
boom retracting).

3.6 Checking the slide plates

- Check the slide plates for wear and damage.

[NOTICE] 2. Thread piano wires through the rope guides

Check the slide plates on the top of the boom tail (each 4 places) in the top boom section. Hook the
end also for wear and damage. ends of the piano wires to the eye bolts at the
Refer to the chapter Y for the time for replacement. ends of the wire rope (for the top boom
retracting).

3. Pulling the piano wires to thread the wire rope

(for the top boom retracting) through the rope
guides, and temporarily fix the wire rope to the
head of the top boom section.

13 W536-1830E
G -1 G -1
4-section Boom

4.2 Inserting the boom telescoping cylinder into

the top boom section 5. (Tail end of the boom telescoping cylinder)
-1. Pass the wire rope (for the top boom
[NOTICE] retracting) around the sheaves of the boom
Make sure that the wire ropes for the boom telescoping cylinder.
telescoping cylinder are adjusted to meet the
standards (Refer to the "Adjustment Procedure" in
the chapter Y for the checking procedure).
Check the portion not covered by the stoppers of
(indicated by "D" in the figure) horizontally.

-2. Install the support to prevent the wire rope

from coming off.

4. Lift the boom telescoping cylinder (approx.

150 kg), and insert it into the top boom section.

[NOTICE]
Perform this operation slowly and cautiously.
Perform this operation while paying attention to the
wire rope (for the top boom retracting) to prevent
them from kinking.
While inserting the boom telescoping cylinder, keep
the wire rope for the top boom retracting) lightly
tense by pulling them.
When insert the boom telescoping cylinder into the
top boom section, insert the position until that the
wire rope (for the top boom retracting) can be pass
around the sheaves of the boom telescoping
cylinder.

14 W536-1830E
G -1 G -1
4-section Boom

4.3 Inserting the top boom section into the 3rd

6. Pull the boom telescoping cylinder until that the boom section
little tension is applied.
8. (Tail end of the top boom section)
Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolts, and tighten them to
fix the slide plates. Then turn back the bolts for half
a turn.

[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.

7. (Tail end of the top boom section)

Put a suitable spacer between the top boom and
boom telescoping cylinder.

15 W536-1830E
G -1 G -1
4-section Boom

9. (Upper surface of the top boom section)
Set the wire rope (for the top boom extending),
and temporarily fix it at the head of the boom.
[NOTICE]
Temporarily fix the wire rope (for the top boom
extending) while keeping it a little tense to prevent it
from hanging loose.
After setting the wire rope, bend the parts as shown
[NOTICE]
in the preventing the wire rope from coming off
(4 places in the following figure).
11. (Head of the 3rd boom section)
-1. Lift the boom slightly, and install the slide
plates [54] (2 places).
-2. Install the plates [46], shims [52, 53], and slide
plates [50] (4 places) by the bolts [48].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).
Install parts as before.
To prevent the slide plates from falling inside the
boom, apply grease to them before installing them.
The nuts [67] and set screws [40] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).

10. Lift the top boom section (approx. 180 kg), and
insert it into the 3rd boom section to the point
approx. 1.0 m before full retraction.

[NOTICE]
Perform this operation slowly.
Pay particular attention to the wire rope (for the top
boom retracting) to prevent them from being
damaged.

16 W536-1830E
G -1 G -1
4-section Boom

12. Fully insert the top boom section. 14. (Tail end of the 3rd boom section)
-1. Insert the pins [21].
-2. Fit the retaining rings [22] in the groove.

13. (Head of the 3rd boom section)

-1. With the wire rope (for the top boom -3. Remove the spacer.
extending) wound around the sheaves [58], -4. Install the roller assy [23].
and insert the pins [60].
-2. Install the plates [45, 59].

[NOTICE]
When installing the sheaves, be careful to direction
(direct the side which install the bearing to outward).

17 W536-1830E
G -1
4-section Boom
4.4 Inserting the 3rd boom section into the 2nd
boom section
15. (Tail end of the 3rd boom section)
Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolts, and tighten them
to fix the slide plates. Then turn back the bolts for
half a turn.
[NOTICE]
Make sure that the slide plate can be moved
backward and forward.
Apply grease to the slide plate.
16. Lift the 3rd boom section (approx. 480 kg), and
insert it into the 2nd boom section to the point
approx. 1.0 m before full retraction.
[NOTICE]
Take care to avoid scratching the slide plate
surface.
18
G -1
17. (Head of the 2nd boom section)
-1. Lift the boom slightly, and install the slide
plates [43] (2 places).
-2. Install the plates [70], shims [68, 69] and slide
plates [44] (4 places) by the bolts [48].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).
[NOTICE]
Install parts as before.
The nuts [67] and set screws [40] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).
18. Fully insert the 3rd boom section.
[NOTICE]
While fully inserting the 2nd boom section, pass the
wire rope (for the top boom extending) [7] around
the supports of the 3rd boom section.
19. (Tail end of the 2nd boom section)
-1. Insert the pins [17].
-2. Fit the retaining rings [18] in the groove.
W536-1830E
G -1 G -1
4-section Boom

4.5 Inserting the 2nd boom section into the base

20. Tighten the each wire rope adjusting nuts and boom section
lock nuts (each 2 places).
21. (Tail end of the 2nd boom section)
[NOTICE] Apply threadlocker (ThreeBond 1305 or
Make adjustments to restore the dimensions back equivalent) to the button bolts, and tighten them
to the original values that were measured during the to fix the slide plates. Then turn back the bolts for
disassembly operation.
half a turn.

[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.

22. Lift the 2nd boom section (approx. 680 kg), and
insert it into the base boom section to the point
approx. 1.0 m before full retraction.

[NOTICE]
Take care to avoid scratching the slide plate
surface.

19 W536-1830E
G -1 G -1
4-section Boom

23. (Head of the base boom section) 26. (Tail end of the base boom section)
-1. Lift the boom slightly, and install the slide Install the piping joints to the counterbalance
plates [33] (2 places). valve.
-2. Install the plates [70], shims [68, 69] and slide
plates [44] (4 places) by the bolts [48].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).

[NOTICE]
Install parts as before.
The nuts [67] and set screws [40] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).

27. (Cord reel assy)

24. Fully insert the 2nd boom section.
25. (Tail end of the base boom section)
-1. Insert the pin [13].
-2. Fit the retaining rings [14] on each groove in
the pin.
-1. Attach the wiring of the cord reel to the rear of
the boom, as shown in the figure in "bowline
knot". Attach the wiring to the boom support,
making the marker located on the same
position when disassembly has been done.
-2. Connect the wiring of the cord reel and the
harness (frame side).
-3. Fix the wiring by the cable tie (2 places), as
shown in the figure.

[NOTICE]
To prevent the retaining rings from dropping off,
insert it so that its rounded corner faces inward.

20 W536-1830E
G -1 . G -1 .
4-section Boom

-4. Unfix the wiring that has been temporarily fixed [NOTICE]
at the top boom. Make sure that the wedge protrudes slightly from
the rope socket before the wire rope is installed.

After the installation of the wire rope, make sure

28. Start the engine and engage the PTO.
that the wedge does not protrude from the rope
socket.
29. While pulling down the wire rope, perform
hoisting down operation to unwind the wire rope.
32. Perform boom telescoping operation and check
30. Attach the hook block and the weight for for any oil leakage.
two-blocking alarm device.

31. Reeve the wire rope through the rope socket, and
secure it with the wire clip.
Tightening torque: 29.4 N-m (3.0 kgf-m)
5. Adjustment
Once the boom has been assembled, make the
following adjustment.
Refer to the chapter Y for the adjustment procedure.

1. Adjustment of boom clearance

(Refer to Y-3.)

2. Adjustment of telescoping wire ropes

(Refer to Y-3.)

313-736-80000 △
0 312-061-70000 △
1

21 W536-1830E
G -2 G -2
5-section Boom

G-2 5-section Boom

1. Boom telescoping mechanism

Extension sequence: First the 2nd boom section extends, then the 3rd boom section extends.
After that, the 4th and top boom sections extend simultaneously.

Retraction sequence: First the top and 4th boom sections retract simultaneously,
and then the 3rd boom section retracts. After that, the 2nd boom section retracts.

Telescope assy

22 W536-1840E
G -2 G -2
5-section Boom

Boom telescoping cylinder

312-061-80000 △
1

312-127-00000 △
0

360-194-90000 △
0

23 W536-1840E
G -2 G -2
5-section Boom

2. Structure

2.1 Top boom assy

5. Top boom section 32. Slide plate (t10) 49. Button bolt (M8) 60. Nut (M12)
16. Button bolt (M6) 48. Spring washer 50. Bolt (M12)

Note

1. Install the top boom telescoping support in
accordance with the following steps:
(1) Apply thread locking agent (ThreeBond 1305 or
equivalent) to the button bolts [49] and use them
to loosely fit the top boom telescoping support.
(2) Tighten the bolts [50] until the top boom
telescoping support's longitudinal play is
eliminated, then lock them in position with the
nuts [60].
Verify through the inspection holes that the top
boom telescoping support is pressed firmly
against the stopper.

(3) Tighten the button bolts [49] to a torque of 24.5

N-m (2.5 kgf-m).

24 W536-1840E
G -2 G -2
5-section Boom

2.2 4th boom assy

4. 4th boom section 21. Pin 39. Set screw 52. Shim (t1.0)
15. Slide plate (t12) 22. Retaining ring 40. Nut (M10) 53. Shim (t0.5)
16. Button bolt (M6) 31. Slide plate (t10) 47. Bolt (M8) 59. Spacer
19. Spacer 34. Slide plate (t15) 48. Spring washer 66. Plate (t9.0)

Note

1. Because the shims [52, 53] are used only when

they are necessary for adjustment, all of them are
not necessarily used.

2. Apply grease to the boom inside surfaces that rub

against slide plates.

3. Tighten the bolts [47] to a torque of 19 to 21 N-m

(1.9 to 2.1 kgf-m).

25 W536-1840E
G -2 G -2
5-section Boom

2.3 3rd boom assy

3. 3rd boom section 22. Retaining ring 39. Set screw 53. Shim (t0.5)
14. Slide plate (t12) 23. Roller assy 40. Nut (M10) 65. Hexagon socket head bolt
16. Button bolt (M6) 30. Spring washer 47. Bolt (M8) (M10)
19. Spacer 31. Slide plate (t10) 48. Spring washer 66. Plate (t9.0)
20. Pin 34. Slide plate (t15) 52. Shim (t1.0)

Note

1. Because the shims [52, 53] are used only when

they are necessary for adjustment, all of them are
not necessarily used.

2. Apply grease to the boom inside surfaces that rub

against slide plates.

3. Tighten the bolts [47] to a torque of 19 to 21 N-m

(1.9 to 2.1 kgf-m).

26 W536-1840E
G -2 G -2
5-section Boom

2.4 2nd boom assy

2. 2nd boom section 18. Retaining ring 39. Set screw 52. Shim (t1.0)
13. Slide plate (t12) 19. Spacer 40. Nut (M10) 53. Shim (t0.5)
16. Button bolt (M6) 31. Slide plate (t10) 47. Bolt (M8) 66. Plate (t9.0)
17. Pin 34. Slide plate (t8.0) 48. Spring washer

Note

1. Because the shims [52, 53] are used only when

they are necessary for adjustment, all of them are
not necessarily used.

2. Apply grease to the boom inside surfaces that rub

against slide plates.

3. Tighten the bolts [47] to a torque of 19 to 21 N-m

(1.9 to 2.1 kgf-m).

27 W536-1840E
G -2 G -2
5-section Boom

2.5 Base boom assy

1. Base boom section 26. Pin 37. Pin 51. Cover

6. Roller assy 27. Plate (t9.0) 38. Pin 52. Plate (t1.0)
7. Pin 28. Plate (t1.6) 39. Set screw 53. Plate (t0.5)
8. Retaining ring 29. Bolt (M12) 40. Nut (M10) 54. Bolt (M10)
10. Grease nipple 30. Spring washer 45. Bolt (M8) 64. Plain washer
11. Plain bearing 34. Slide plate (t15) 47. Bolt (M8) 66. Plate (t9.0)
12. Slide plate (t12) 36. Sheave 48. Spring washer 67. Plain washer

Note

1. Insert plain bearings [11] with the seam facing
upward and the grease grooves facing outside,
and lock them with adhesive (Loctite 638).
2. Because the shims [52, 53] are used only when
they are necessary for adjustment, all of them are
not necessarily used.
3. Bend the plate [28] on the boom elevating cylinder
pivot pin [26] after installing the bolts [29].
4. Apply grease to the boom inside surfaces that rub
against slide plates.
5. Tighten the bolts [47] to a torque of 19 to 21 N-m
(1.9 to 2.1 kgf-m).

28 W536-1840E
G -2 G -2
5-section Boom

3. Disassembly of the boom

9. (Cord reel assy)
Removing the 2nd and further boom sections. -1. To prevent the cord reel from being damaged,
secure the wiring with something like a stopper
3.1 Preparation or a clip.

Before disassembling the boom, perform the

following works:
- Removing the hook block
- Depressurizing the hydraulic circuits
- Removing the weight for the two-blocking alarm
device
- Removing the electrical wiring of the cord reel

1. Fully lower the boom, and lay the hook block on

the ground.

2. Remove the rope socket from the boom head (or

hook block).
3. Remove the wire clip, hammer out the wedge,
and remove the wire rope from the rope socket.
-2. Put a marker to the wiring.
-3. Cut off the cable ties (2 places), and separate
the wiring.
-4. Haul the wiring of the cord reel to the head of
the boom, and fix it temporarily on the top
boom.

[NOTICE]
Before disconnecting the wiring, put a marker on it
in order to restore the same positional relationship
easily.

4. Pull out the wire rope from the hook block and
weight for the two-blocking alarm device.

5. Fix the weight for the two-blocking alarm device

to the top boom head temporarily.

6. While pulling up the wire rope, perform hoisting

up operation, roll up the rope into the winch drum,
and damp it temporarily.

7. Stop the engine.

8. Operate each control lever to the full strokes

repeatedly beforehand to depressurize the
hydraulic system.

29 W536-1840E
G -2 G -2
5-section Boom

3.2 Pulling out the 2nd and further boom

sections -2. Remove the retaining rings [8], and pull out the
pin [7].
CAUTION
Depressurize the hydraulic circuits beforehand.
Otherwise oil may spout and cause serious
injury.

10. (Tail end of the boom)

-1. Remove the piping joints for the
counterbalance valve.

[NOTICE]
Do not remove the counterbalance valve.
Wipe up the oil spilling out of the joints with waste
rags.
Cover the removed joints and hydraulic ports of the
counterbalance valve with waste rags or something
to prevent entry of dust.
11. (Head of base boom section)
-1. Loosen the nuts [40] and set screws [39].
-2. Remove the bolts [47], plates [66], shims
[52, 53] and slide plates [34] (4 places).
-3. Pull out the 2nd boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [12] (2 places).
-5. Pull out the 2nd and further boom sections
(approx. 960 kg).

[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.

30 W536-1840E
G -2
5-section Boom
3.3 Pulling out the 3rd and further boom
sections
12. (Tail end of the 2nd boom section)
Remove the retaining rings [18]. Screw a bolt (M8)
into the pins [17], and pull out it.
13. (Head of the 2nd boom section)
-1. Loosen the nuts [40] and set screws [39].
-2. Remove the bolts [47], plates [66], shims
[52, 53] and slide plates [34] (4 places).
-3. Pull out the 3rd boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [13] (2 places).
-5. Pull out the 3nd and further boom sections
(approx. 730 kg).
[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.
31
G -2
3.4 Pulling out the 4th and further boom
sections
14. (Tail end of the 3rd boom section)
-1. Remove the bolts [65] and roller assy [23].
-2. Remove the retaining rings [22]. Screw a bolt
(M8) into the pins [20], and pull out it.
15. (Head of the 3rd boom section)
-1. Loosen the nuts [40] and set screws [39].
-2. Remove the bolts [47], plates [66], shims
[52, 53] and slide plates [34] (4 places).
-3. Pull out the 4th boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [14] (2 places).
-5. Pull out the 4th and further boom sections
(approx. 540 kg).
[NOTICE]
Be sure to clarify the locations where the removed
parts should be reassembled.
W536-1840E
G -2 G -2
5-section Boom

3.5 Pulling out the top boom section 3.6 Pulling out the boom telescoping cylinder

16. (Tail end of the 4th boom section) 18. (Tail end of the top boom section)
Remove the retaining rings [22]. Screw a bolt (M8) -1. Lift the boom telescoping cylinder slightly.
into the pins [21], and pull out it. -2. Loosen the nuts [60] and bolts [50].
-3. Remove the button bolts [49] (6 places).

17. (Tail end of the 4th boom section)

-1. Loosen the nuts [40] and set screws [39].
-2. Remove the bolts [47], plates [66], shims
[52, 53] and slide plates [34] (4 places).
-3. Pull out the top boom section by approx.
1.0 m.
-4. Lift the boom slightly, and remove the slide
plates [15] (2 places). 19. Lift the boom telescoping cylinder and pull it out
-5. Pull out the top boom section (approx. 400 kg). of the top boom section (approx. 230 kg).

[NOTICE] 3.7 Checking the slide plates

Be sure to clarify the locations where the removed
- Check the slide plates for wear and damage.
parts should be reassembled.
[NOTICE]
Check the slide plates on the top of the boom tail
end also for wear and damage.
Refer to the chapter Y for the time for replacement.

32 W536-1840E
G -2
5-section Boom
4. Assembly of the boom
4.1 Inserting the boom telescoping cylinder into
the top boom section
[NOTICE]
Make sure that the wire ropes for the boom
telescoping cylinder are adjusted to meet the
standards (Refer to the "Adjustment Procedure" in
the chapter Y for the checking procedure).
Check the portion not covered by the stoppers of
(indicated by "D" in the figure) horizontally.
[NOTICE]
33
G -2
1. Lift the boom telescoping cylinder (approx.
230 kg), and insert it into the top boom section.
2. (Tail end of the top boom section)
-1. Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolts [49] (6 places),
and temporarily install the wire rope support
with them on the top boom section.
-2. Tighten the bolts [50] until there is no backlash
of the wire rope support in forward-backward
direction, and lock them.
Check the inspection hole to make sure that the
wire rope support is in firm contact with the stopper.
Before attaching the wire rope supports and bolts
[49], degrease their threaded section completely.
-3. Tighten the button bolts [49] (6 places)
securely.
Tightening torque: 24.5 N-m (2.5 kgf-m)
W536-1840E
G -2 G -2
5-section Boom

4.2 Inserting the top boom section into the 4th

boom section
3. (Tail end of the top boom section)
Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolts, and tighten them
to fix the slide plates. Then turn back the bolts for
half a turn.
[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.
5. (Head of the 4th boom section)
-1. Lift the boom slightly, and install the slide
plates [15] (2 places).
-2. Install the plates [66], shims [52, 53] and slide
plates [34] (4 places) by the bolts [47].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).
[NOTICE]
Install parts as before.
The nuts [40] and set screws [39] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).

4. Lift the top boom section (approx. 400 kg), and

insert it into the 4th boom section to the point
approx. 1.0 m before full retraction.
6. (Telescoping cylinder)
[NOTICE] Install the spacers.
Take care to avoid scratching the slide plate
surface. [NOTICE]
To prevent the spacers from falling inside the boom,
apply grease to them before installing them
(2 places).

34 W536-1840E
G -2
5-section Boom
7. Fully insert the top boom.
8. (Tail end of the 4th boom section)
-1. Insert the pins [21].
-2. Fit the retaining rings [22] in the groove.
[NOTICE]
To prevent the retaining rings from dropping off,
insert it so that its rounded corner faces inward.
35
G -2
4.3 Inserting the 4th boom section into the 3rd
boom section
9. (Tail end of the 4th boom section)
Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolt, and tighten them to
fix the slide plate. Then turn back the bolt for half
a turn.
[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.
10. Lift the 4th boom section (approx. 540 kg), and
insert it into the 3rd boom section to the point
approx. 1.0 m before full retraction.
[NOTICE]
Take care to avoid scratching the slide plate
surface.
W536-1840E
G -2 G -2
5-section Boom

4.4 Inserting the 3rd boom section into the 2nd

11. (Head of the 3rd boom section)
-1. Lift the boom slightly, and install the slide
plates [14] (2 places).
-2. Install the plates [66], shims [52, 53] and slide
plates [34] (4 places) by the bolts [47].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).
[NOTICE]
Install parts as before.
The nuts [40] and set screws [39] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).
boom section
14. (Tail end of the 3rd boom section)
Apply threadlocker (ThreeBond 1305 or equivalent)
to the button bolts, and tighten them to fix the slide
plates. Then turn back the bolts for half a turn.
[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.

15. Lift the 3rd boom section (approx. 730 kg), and
insert it into the 2nd boom section to the point
12. Fully insert the 4th boom. approx. 1.0 m before full retraction.
13. (Tail end of the 3rd boom section)
[NOTICE]
-1. Insert the pins [20].
Take care to avoid scratching the slide plate
-2. Fit the retaining rings [22] in the groove. surface.
-3. Install the roller assy [23].

[NOTICE]
To prevent the retaining ring from dropping off,
insert it so that its rounded corner faces inward.

36 W536-1840E
G -2
5-section Boom
16. (Head of the 2nd boom section)
-1. Lift the boom slightly, and install the slide
plates [13] (2 places).
-2. Install the plates [66], shims [52, 53] and slide
plates [34] (4 places) by the bolts [47].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).
[NOTICE]
Install parts as before.
The nuts [40] and set screws [39] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).
17. Fully insert the 3rd boom section.
18. (Tail end of the 2nd boom section)
-1. Insert the pins [17].
-2. Fit the retaining rings [18] in the groove.
[NOTICE]
To prevent the retaining ring from dropping off,
insert it so that its rounded corner faces inward.
37
G -2
4.5 Inserting the 2nd boom section into the base
boom section
19. (Tail end of the 2nd boom section)
Apply threadlocker (ThreeBond 1305 or
equivalent) to the button bolts, and tighten them
to fix the slide plates. Then turn back the bolts for
half a turn.
[NOTICE]
Make sure that the slide plates can be moved
backward and forward.
Apply grease to the slide plates.
20. Lift the 2nd boom section (approx. 960 kg), and
insert it into the base boom section to the point
approx. 1.0 m before full retraction.
[NOTICE]
Take care to avoid scratching the slide plate
surface.
W536-1840E
G -2 G -2
5-section Boom

21. (Head of the base boom section) 24. (Tail end of the base boom section)
-1. Lift the boom slightly, and install the slide Install the piping joints to the counterbalance
plates [12] (2 places) valve.
-2. Install the plates [66], shims [52, 53] and slide
plates [34] (4 places) by the bolts [47].
Tightening torque: 19 to 21 N-m
(1.9 to 2.1 kgf-m).

[NOTICE]
Install parts as before.
The nuts [40] and set screws [39] are not tightened
at this time. Adjust by the boom clearance
adjustment (Y-3).

25. (Cord reel assy)

22. Fully insert the 2nd boom section.
23. (Tail end of the base boom section)
-1. Insert the pin [7].
-2. Fit the retaining rings [8] on each groove in the
pin.
-1. Attach the wiring of the cord reel to the rear of
the boom, as shown in the figure in "bowline
knot". Attach the wiring to the boom support,
making the marker located on the same
position when disassembly has been done.
-2. Connect the wiring of the cord reel and the
harness (frame side).
-3. Fix the wiring by the cable tie (2 places), as
shown in the figure.

[NOTICE]
To prevent the retaining rings from dropping off,
insert it so that its rounded corner faces inward.

38 W536-1840E
G -2 . G -2 .
5-section Boom

[NOTICE]
-4. Unfix the wiring that has been temporarily fixed
Make sure that the wedge protrudes slightly from
at the top boom. the rope socket before the wire rope is installed.

After the installation of the wire rope, make sure

26. Start the engine and engage the PTO. that the wedge does not protrude from the rope
socket.
27. While pulling down the wire rope, perform
hoisting down operation to unwind the wire rope. 30. Perform boom telescoping operation and check
for any oil leakage.
28. Attach the hook block and the weight for
two-blocking alarm device.
5. Adjustment
29. Reeve the wire rope through the rope socket, and
secure it with the wire clip. Once the boom has been assembled, make the
Tightening torque: 29.4 N-m (3.0 kgf-m) following adjustment.
Refer to the chapter Y for the adjustment procedure.

1. Adjustment of boom clearance

(Refer to Y-3.)

2. Adjustment of telescoping wire ropes

(Refer to Y-3.)

313-736-90000 △
1 312-061-80000 △
2

39 W536-1840E
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

G-3 Boom Telescoping Cylinder 1.2 Check valve B

(4-section Boom) ([30] in the section of “cylinder assy”)

1. Structure
This mechanism consists of 2 double-acting
cylinders which extend and retract the boom and
2 wire ropes.

The check valve B is incorporated in the head of the

cylinder (No.1), and the check valve A is
incorporated in the bottom of the cylinder (No.2).
These valves control the boom telescoping
sequence.

1.1 Check valve A

([3] in the section of “cylinder assy”)

1. O-ring 8. Body
2. Spring 9. O-ring
3. Check valve 10. O-ring
4. Rod 11. Hexagon socket head bolt (M8)
5. O-ring 12. Plug
6. Backup ring 13. Spacer
7. Cap

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

360-116-72000 △
1 366-252-70000 △
0

40 W157-1020E
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

1.3 Telescope assy

Note

1. Align each middle point mark on the wire rope (for

boom retracting) with the center of the
corresponding wire rope guide.

2. Before installing the telescope assy, orient the

portion not covered by the stoppers of (indicated
by [D] in the figure) horizontally.

3. Apply grease to the areas where the slide plates

on the cylinder (No.1) and cylinder (No.2) slide
over each other.

4. Through the wire rope for boom retracting to the

wire guide at the head of the telescoping cylinder,
and then bend the plates which prevent the wire
rope from coming off.

312-126-90000 △
0

41 W157-1020E
G -3 G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

1.4 Cylinder assy [NOTICE]

(Refer to the next page for the notes.) 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. Hexagon socket head bolt 26. Piston

2. O-ring 27. Plain bearing (*)
3. Check valve A 28. Plain bearing (*)
(for boom extending) 29. Stopper
4. O-ring 30. Check valve B
5. Dust seal (for boom retracting)
6. Packing 31. Roller assy
7. Backup ring 32. Retaining ring
8. Rod cover 33. Roller
9. O-ring 34. Pin
10. Cylinder (No.2) 35. Retaining ring
11. Rod (No.2) 36. Ball bearing
12. Piston (No.2) 37. Slide plate
13. Plain bearing (*) 38. Machine screw
14. O-ring 39. Slide plate
15. Spring washer 40. Set screw
16. Nut 41. Pin
17. Dust seal 42. Machine screw
18. Packing 43. Plain bearing
19. Backup ring 44. Spring washer
20. Rod cover 45. Hexagon socket head bolt
21. O-ring 46. Support
22. Cylinder (No.1) 47. Spring washer
23. Rod (No.1) 48. Bolt
24. Pipe 49. Counterbalance valve
25. O-ring
*: These parts are the set of the
plain bearing and packings.

42 W157-1020E 42
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

Thread Tightening torque

Note Sign / Port Remarks
size N-m kgf-m
To prevent the rod covers [8, 20] from
loosening, bend the ends of the cylinders [10,
1 10, 22 - - -
22] to the rod covers (one place for each rod
cover).

2 1 M12 74 to 82 7.6 to 8.4

Apply threadlocker (ThreeBond 1305 or
equivalent) to the threaded section.
3 N M8 19.6 2.0

4 38, 42 M4 - -

8 M90 Before installing, apply rust inhibitor

5 392 to 441 40 to 45 (ThreeBond 1184 or equivalent) to the
20 M85 threaded section.
Tighten the set screw [40] in the shown range
to avoid contact with pushrod of the check
valve [3].
Before installing, apply adhesive (Loctite 638)
6 40 M8 17.0 1.7
to the threaded sections.
After tightening, punch 3 points on the
threaded inside surfaces in order to prevent
the screw from coming off.
7 45 M8 19.6 2.0 -
Before installing, apply adhesive (Loctite 638)
8 26 M48 490 to 539 50 to 55 to the designated range (fig.1) on the external
threaded area of the rod [23].
Before installing, apply adhesive (Loctite 638)
9 16 M36 285 to 335 29.1 to 34.2 to the designated range (fig.1) on the external
threaded area of the rod [11].
10 48 M10 34.3 to 39.2 3.5 to 4.0 -

360-194-70000 △
0

43 W157-1020E
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

2. Description of operation

2.1 Control of extension sequence

1. The cylinder (No.1) is extended from the boom full retraction state.
The pressurized oil for extension flows (red arrows) through the rod (No.1) (inner side of dual structure) and
check valve B, then enters into the cylinder (No.1) extension side. Then, the cylinder (No.1) is extended.
(At the same time, the pressurized oil runs through the check valve B and oil feed pipe, then enters into the
check valve A. However, because the check valve A is closed, the cylinder (No.2) is not extended.)

44 W157-1020E
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

2. When the cylinder (No.1) has been fully extended, the cylinder (No.2) is extended.
When the spool of the check valve A is pushed up, the pressurized oil runs through the rod (No.2), and
enters into the top of the cylinder (No.2). Then, the cylinder (No.2) is extended.

45 W157-1020E
G -3 G -3
Boom Telescoping Cylinder (4-section Boom)

2.2 Control of retraction sequence

1. The cylinder (No.2) is retracted from the boom full extension state.
The pressurized oil for retraction flows (red arrows) through the rod (No.1) (outer side of dual structure) and
rod (No.2) (outer side of dual structure), and enters into the cylinder (No.2) retraction side. Then, the cylinder
(No.2) is retracted.
(Although the pressurized oil enters into the cylinder (No.1) retraction side at the same time, because the
cylinder (No.1) return side port of the check valve B is closed, the cylinder (No.1) is not retracted.)

46 W157-1020E
G -3 . G -3 .
Boom Telescoping Cylinder (4-section Boom)

2. When the cylinder (No.2) has been fully retracted, the cylinder (No.1) is retracted.
When the spool of the check valve B is pushed, the oil from the cylinder (No.1) extension side is sent to the
tank. Then, the cylinder (No.1) is retracted.

47 W157-1020E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

G-4 Boom Telescoping Cylinder 1.2 Check valve B

(5-section Boom) ([23] in the section of “cylinder assy”)

1. Structure
This mechanism consists of 3 double-acting
cylinders which extend and retract the boom and
2 wire ropes.

The check valve B is incorporated in each head of

the cylinders (No.1 and No.2), and the check valve A
is incorporated in each bottom of the cylinders (No.2
and No.3). These valves control the boom
telescoping sequence.

1.1 Check valve A

([17] in the section of “cylinder assy”)

1. O-ring 8. Body
2. Spring 9. O-ring
3. Check valve 10. O-ring
4. Rod 11. Hexagon socket head bolt (M8)
5. O-ring 12. Plug
6. Backup ring 13. Spacer
7. Cap

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

360-116-72000 △
1 366-252-70000 △
0

48 W157-1030E
G -4 G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

1.3 Telescope assy [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. Cylinder assy 14. Spring washer

2. Wire rope 15. Support
(for boom extending) 16. Bolt
3. Support assy 17. Support
4. Nut 18. Sheave assy
5. Wire rope 19. Retaining ring
(for boom retracting) 20. Pin
6. Sheave assy 21. Plate
7. --- 22. Bolt
8. --- 23. Support
9. --- 24. Plate
10. --- 25. ---
11. --- 26. Plate
12. --- 27. Machine screw
13. Hexagon socket head bolt 28. Nut

Note
1. Install the support [23] and plate [24] before installing the wire rope (for boom
extending) [2].
2. Align each middle point mark on the wire ropes for boom extending [2] and
boom retracting [5] with the center of the corresponding wire rope guide.
3. Before installing the telescope assy, orient the portion not covered by the
stoppers of (indicated by [D] in the figure) horizontally.

4. Before installing the machine screw [27], apply threadlocker (ThreeBond 1401
or equivalent) to their threaded section.
5. Apply grease to the areas where the slide plates on the cylinder (No.1) and
cylinder (No.2) slide over each other.
6. Through the wire rope (for boom extending) to the wire guide at the head of
the telescoping cylinder, and then bend the plates which prevent the wire rope
from coming off.
312-127-00000 △
0

49 W157-1030E 49
G -4 G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

1.4 Cylinder assy

(Refer to the next page for the notes.)
1. Nut 32. Rod (No.1)
2. Spring washer 33. Cylinder (No.1)
3. Piston 34. O-ring
4. O-ring 35. Packing
5. Plain bearing (*) 36. Backup ring
6. Plain bearing (*) 37. Dust seal
7. Plain bearing (*) 38. Rod cover
8. Piston 39. Roller assy
9. Cylinder (No.3) 40. Retaining ring
10. Rod (No.3) 41. O-ring
11. Rod cover 42. Hexagon socket head bolt
12. O-ring 43. Slide plate
13. Packing 44. Machine screw
14. Backup ring 45. Button bolt
15. Dust seal 46. Slide plate
16. O-ring 47. Slide plate
17. Check valve assy 48. Machine screw
18. O-ring 49. Roller assy
19. Packing 50. Roller assy
20. Backup ring 51. Plain bearing
21. Dust seal 52. Roller assy
22. Rod cover 53. Hexagon socket head bolt
23. Check valve assy 54. Plain bearing
24. Stopper 55. Hexagon socket head bolt
25. Pipe 56. Spring washer
26. Cylinder (No.2) 57. Support
27. Rod (No.2) 58. Spring washer
28. Plain bearing (*) 59. Bolt
29. O-ring 60. Counterbalance valve
30. Piston
31. Set screw *: These parts are the set of the
plain bearing and packings.

50 W157-1030E 50
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

Thread Tightening torque

Note Sign / Port Remarks
size N-m kgf-m
1 59 M10 34.3 to 39.2 3.5 to 4.0 -

Before installing, apply adhesive (Loctite 638)

2 30 M48 490 to 539 50 to 55 to the designated range (fig.1) on the external
threaded area of the rod [32].
3 42, 53 M12 74 to 82 7.6 to 8.4

4 N M8 19.6 2.0
Apply threadlocker (ThreeBond 1305 or
M4 - - equivalent) to the threaded section.
44, 48
5
45 M6 - -

11 M80
Before installing, apply rust inhibitor
6 22 M72 392 to 441 40 to 45 (ThreeBond 1184 or equivalent) to the
threaded sections.
38 M85
Bend the edges of the cylinders [9] toward
the rod cover [11], the edges of the cylinder
7 9, 26, 33 - - - [26] toward the rod cover [22], and the edges
of the cylinder [33] toward the rod cover [38]
(one place for each rod cover).
Before installing, apply adhesive (Loctite 638)
8 1 M30 150 to 200 15.3 to 20.4 to the designated range (fig.1) on the external
threaded area of the rod [10].
Before installing, apply adhesive (Loctite 638)
9 8 M39 345 to 395 35.2 to 40.3 to the designated range (fig.1) on the external
threaded area of the rod [27].
When installing, apply grease to the surface
10 39, 49, 50 - - -
of the pins.
Tighten the set screw [31] in the shown range
to avoid contact with pushrod of the check
valve [17].
Before installing, apply adhesive (Loctite 638)
11 31 M8 17 1.7
to the threaded sections.
After tightening, punch 3 points on the
threaded inside surfaces in order to prevent
the screw from coming off.
12 55 M8 19.6 2.0 -

360-194-90000 △
0

51 W157-1030E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

2. Description of operation

2.1 Control of extension sequence

1. The cylinder (No.1) is extended from the boom full retraction state.
The pressurized oil for extension flows (red arrows) through the rod (No.1) (inner side of dual structure) and
check valve B (No.1), then enters into the cylinder (No.1) extension side. Then, the cylinder (No.1) is
extended.
(At the same time, the pressurized oil runs through the check valve B (No.1) and oil feed pipe, then enters
into the check valve A (No.1). However, because the check valve A (No.1) is closed, the rod (No.2) is not
extended.)

52 W157-1030E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

2. When the cylinder (No.1) has been fully extended, the cylinder (No.2) is extended.
When the spool of the check valve A (No.1) is pushed up, the pressurized oil runs through the rod (No.2)
(inner side of dual structure), and enters into the cylinder (No.2) extension side. Then, the cylinder (No.2) is
extended.
(At the same time, the pressurized oil runs through the check valve B (No.2) and oil feed pipe, then enters
into the check valve A (No.2). However, because the check valve A (No.2) is closed, the cylinder (No.3) is not
extended.)

53 W157-1030E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

3. When the cylinder (No.2) has been fully extended, the cylinder (No.3) is extended.
When the spool of the check valve A (No.2) is pushed up, the pressurized oil runs through the rod (No.3)
(inner side of dual structure), and enters into the cylinder (No.3) extension side. Then, the cylinder (No.3) is
extended.

54 W157-1030E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

2.2 Control of retraction sequence

1. The cylinder (No.3) is retracted from the boom full extension state.
The pressurized oil for retraction flows (red arrows) through the rod (No.1) (outer side of dual structure)/rod
(No.2) (outer side of dual structure) and flows through the rod (No.3) (outer side of dual structure), and
enters into the cylinder (No.3) retraction side. Then, the cylinder (No.3) is retracted.
(Although the pressurized oil enters into the cylinders (No.1 and No.2) retraction side at the same time,
because the return side port of the check valve B is closed, the cylinders (No.1 and No.2) are not retracted.)

55 W157-1030E
G -4 G -4
Boom Telescoping Cylinder (5-section Boom)

2. When the cylinder (No.3) has been fully retracted, the cylinder (No.2) is retracted.
When the spool of the check valve B is pushed, the oil from the cylinder (No.2) extension side is sent to the
tank. Then, the cylinder (No.2) is retracted.

56 W157-1030E
G -4 . G -4 .
Boom Telescoping Cylinder (5-section Boom)

3. When the cylinder (No.2) has been fully retracted, the cylinder (No.1) is retracted.
When the spool of the check valve B is pushed, the oil from the cylinder (No.1) extension side is sent to the
tank. Then, the cylinder (No.1) is retracted.

57 W157-1030E
G -5 . G -5 .
Counterbalance Valve

G-5 Counterbalance Valve

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

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

2. Spool 6. O-ring 10. Poppet 14. O-ring
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
A, B, C, D G3/8 49.0 ± 5 5.0 ± 0.5 366-056-00000 △
2

366-051-80001 △
3
Valve mounting bolt M10 34.3 to 39.2 3.5 to 4.0 366-065-50000 △
2

366-055-20000 △
3

366-052-00001 △
3

58 W119-0645E
 H
Safety System

Contents

H-1 Cord Reel .......................................... 1 H

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

2. Specification ............................................. 2

3. Replacement the cord reel assy ................ 2

i
H-1 H-1
Cord Reel

H-1 Cord Reel

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

1. Structure

1. Case 4. Spring assy 7. Grommet 22. Collar

2. Base plate 5. Slip ring assy 8. Cord guide 24. Cord
3. Packing 6. Contactor assy 10. Washer

1 W308-0240E
H-1 H-1
Cord Reel

2. Specification

4- or 5-section boom

Cord length 16.6 m

Specified length out of the case 3.8 m
1. Cord
Stroke 12.0 m
Dead turns 0.8 m
2. Distance from the cord tip to the yellow tape 3.8 m
3. Number of the spring turns
7 to 10 turns
(The yellow tape should be close to the cord guide)

Force to winding the cord vs. Stroke

18
Force to winding the cord (N)

15

12

0
1 3 5 7 9 11 12
Stroke (m)

3. Replacement the cord reel assy

[NOTICE]
Check that the yellow tape is close to the cord
guide.

2 W308-0240E
H-1 H-1
Cord Reel

1. Fully retract the boom.

2. Remove the bolts [A] (2 pieces).

3. Remove the head cover (including the cord reel assy) on the top boom section.

(Head of the 4-section boom)

(Head of the 5-section boom)

4. Remove the roller in the head cover, and replace the new cord reel.

5. Fix the cord reel assy by the bolts [B] (2 pieces).

3 W308-0240E
H-1 H-1
Cord Reel

6. Install the head cover to the head of the top boom section, and fix it by the bolts [A] (2 pieces).

[NOTICE]
Install the cord reel as shown in the following figure so that the cord does not contact with the cord guide If the
position of the cord reel is differ from the following figure, the cord may break.

7. Thread the cord through the supports on the head of each boom sections.

(Head of the 4-section boom)

(Head of the 5-section boom)

4 W308-0240E
H-1 . H-1 .
Cord Reel

8. Fix the cord to the support at the tail end of the base boom section as shown in the following figure.

(Tail end of the 4-section boom) (Tail end of the 5-section boom)

9. Check that the yellow tape is close to the cord guide.

[NOTICE]
If the yellow tape cannot be found, go back to step 8.

361-617-00000 △
1

5 W308-0240E
 Y
Data, Adjustment and Checks

Contents

Y-1 Service Data ..................................... 1 Y-3 Adjustment and Functional Check11

1. Amounts of oil ........................................... 1 1. Adjusting the boom ................................. 11

1.1 Upper slide plate installation procedure
2. Operating speed ....................................... 1 (tail end of each boom sections) ......... 11
1.2 Adjustment of clearance between boom
3. Hydraulic device ....................................... 2 sections ............................................... 11
3.1 Hydraulic pump .......................................... 2 1.3 Greasing procedures ................................ 12
3.2 Hydraulic motor .......................................... 2
3.3 Hydraulic cylinder ....................................... 2 2. Adjustment of telescoping wire ropes
(4-section boom) .......................... 13
4. Slewing section ......................................... 3
3. Adjustment of telescoping wire ropes
5. Boom section ............................................ 4 (5-section boom) .......................... 14
5.1 Slide plate (4-section boom)....................... 4 2.1 Wire rope adjustment with the telescoping
5.2 Slide plate (5-section boom)....................... 4 cylinder installed in the boom ............. 14
5.3 Boom bending and deformation ................. 5 2.2 Wire rope adjustment with the telescoping
5.4 Wire rope .................................................... 6 cylinder out of the boom ..................... 15
5.5 Sheave ....................................................... 6
5.6 Inspection the hook block ........................... 7

6. Mass table ................................................ 8

Y-2 Adjusting Procedures (Hydraulic) .. 9

1. Pressure setting ........................................ 9

1.1 Manual control valve .................................. 9
1.2 Remote control valve (outrigger slide) ..... 10

i
Y-1 Y-1
Service Data

Y-1 Service Data

[NOTICE]
Standard values are values at time of shipment from Tadano.
Limit values are the limits at which adjustment or part replacement is necessary.

1. Amounts of oil
Standard
Item Remarks
value (L)
Oil amount in
tank Total oil capacity varies depending
Hydraulic oil 91 on the number of boom sections.
Amounts of oil

(between H (approx. 140 L to 143 L)

and L marks)

Slewing 0.95
Gear oil for speed reducer
Winch 1.9

2. Operating speed
Item Standard value Remarks

4-section boom: 8.6 m / 34 s

Extending
5-section boom: 11.5 m / 41 s
Telescoping
Retracting –

Raising 1° to 82° / 17 s
Operating
speed Elevating
Lowering –

Winch rope (hoisting up) speed 44 m/min At 4th layer

-1
Slewing 2.2 min
(Pump delivery : 60 L/min)

1 WY01-3250E
Y-1
3. Hydraulic device
3.1 Hydraulic pump
Refer to “Mounting Manual” for displacement, reduction gear ratio, and revolution on the pump.
3.2 Hydraulic motor
Item
Winch Displacement (cm /rev)
Slewing Displacement (cm /rev)
3.3 Hydraulic cylinder
Item
Amount of spontaneous
retraction when lever is in
neutral and the engine is
stopped
[NOTICE]
To be the same as much as
possible outside air
temperature and hydraulic oil
temperature.
Y-1
Service Data
Standard value Remarks
3 (Reference) Leakage
24.0
: 0.4 L/min or less (when operating)
3 (Reference) Leakage
39.3
: 0.6 L/min or less (when operating)
Standard Remarks
Boom length: "2nd boom section"
Elevating angle: "30°"
4 mm or less
Elevating Lifting load: "No load"
/30 min.
Set by raising operation.
(to pressurize the load side)
Boom length:
"Approx. 10 cm to full extension"
6 mm or less Elevating angle: "Maximum"
Telescoping
/30 min. Lifting load: "No load"
Set by extending operation.
(to pressurize the load side)
Boom: "Stowed"
Cargo bed loading state: "No load"
[Retraction holding]
Raise the tires off the ground by extending
operation, and set the cylinders so that the
5 mm or less remaining stroke is approx. 10 mm.
Jack [Extension holding]
/15 hours
Set the cylinders by retracting operation so
that the remaining stroke is approx. 10 mm.
However, for hydraulic cylinders with fall
preventing leaf springs, approx. 50 mm shall
be set (to prevent any contact with the leaf
springs).
2 WY01-3250E
Y-1 Y-1
Service Data

4. Slewing section
Item Standard value Remarks

Amount of horizontal play 2.5 mm or less Refer to measurement method (1).

Amount of
slewing play
Amount of vertical play 1.0 mm or less Refer to measurement method (2).
Remarks: Measurement methods: [Setting procedure of dial gauge]
(1) Amount of horizontal play 1. Hold the connecting rod of the control lever link using
[Conditions] the support, and fix it using bolts.
- Boom length: "3rd boom section" 2. Fix the dial gauge on the back side of the post frame
using a magnet, and adjust it so that the pointer is
- Elevating angle: "0°"
located above the support, then set the pointer to the
- Lifting load: "No load" zero-point.
• Press the boom head with a force of 200 N in the
horizontal direction.
• Mark the measuring position (slewing post flange
section), and measure the amount of movement
(L: amount of horizontal play).

(2) Amount of vertical play

[Conditions]
- Set the boom (fully retracted) to the stowing
configuration at rear.
• Lift the vehicle cab so that the measurement
operation can be performed easily.
• Set the dial gauge to the post frame section.
• Lift the top end of the base boom using a device
such as a bridge crane just before the frame is
inclined in longitudinal direction.
(Note: If the frame is inclined in longitudinal
direction, the hoist-up operation is performed
excessively.)
• Measure the amount of displacement of the dial
gauge (vertical play).

3 WY01-3250E
Y-1 Y-1
Service Data

5. Boom section

5.1 Slide plate (4-section boom)

Standard thickness Replacement standard
Location used Part No.
(mm) (mm)
Bottom 12 9 33
Base boom section Front
Side 15 13 44
Bottom 12 9 43
Front
2nd boom section Side 15 13 44
Rear Top 15 12 15
Bottom 12 9 54
Front
3rd boom section Side 9 7 50
Rear Top 15 12 15
Top boom section Rear Top 15 12 20

5.2 Slide plate (5-section boom)

Standard thickness Replacement standard
Location used Part No.
(mm) (mm)
Bottom 12 9 12
Base boom section Front
Side 15 13 34
Bottom 12 9 13
Front
2nd boom section Side 15 13 34
Rear Top 10 7 31
Bottom 12 9 14
Front
3rd boom section Side 15 13 34
Rear Top 10 7 31
Bottom 12 9 15
Front
4th boom section Side 15 13 34
Rear Top 10 7 31
Top boom section Rear Top 10 7 32

4 WY01-3250E
Y-1 Y-1
Service Data

5.3 Boom bending and deformation

Standard value (mm)
Item Remarks
4-section boom 5-section boom
Overall boom bending(at full extension, No significant vertical or horizontal bends Place pads as
maximum elevation angle, with rated load) shall be found along the entire boom appropriate to set
length. the machine level.

IWY01-001001

Bend of individual Base boom B ≤ 5.6 B ≤ 5.5 B ≤ 1.5×L /1000

boom sections 2nd boom section B ≤ 5.8 B ≤ 5.7 L: length of each
Vertical

3rd boom section B ≤ 5.7 B ≤ 5.7 boom section

4th boom section - B ≤ 5.6
OR

Top boom section B ≤ 5.7 B ≤ 5.7

B

L
Base boom C ≤ 3.7 C ≤ 3.7 C ≤ 1.0×L /1000
IWY01-0010E02
2nd boom section C ≤ 3.8 C ≤ 3.8 L: length of each
Lateral

3rd boom section C ≤ 3.8 C ≤ 3.8 boom section

4th boom section - C ≤ 3.7
Top boom section C ≤ 3.8 C ≤ 3.8
Indentations at boom 2nd boom section D ≤ 4.0 D ≤ 3.0 In vertical direction
overlap sections 3rd boom section D ≤ 3.5 D ≤ 2.5 D ≤ t/2
(Bending at boom lower
4th boom section - D ≤ 2.0
plate)
Top boom section D ≤ 3.5 D ≤ 1.6

D
IWY01-001003

Check for deformation of side plates There must be no large deformation

particularly on the lower half surface of
side plate where pressure concentrates.

Check for twisting in the lengthwise direction E≤5

when boom is fully extended

IWY01-001004

Check for dents and other localized indentation F ≤ 2

Depth F
(at L1 ≥ 50)
Generally dent G on the 4 corners cannot
be repaired.

L1
G IWY01-0010E05

5 WY01-3250E
Y-1 Y-1
Service Data

5.4 Wire rope

Item Standard value Limit value Remarks

10 mm Construction
Wire rope diameter 9.3 mm
(Nominal diameter) 7×7+6×Fi (29) O/O
For winch (IWRC 6×Fi(29) O/O)
Number of broken wire – 13

11.2 mm Construction
Wire rope diameter 10.4 mm
For boom (Nominal diameter) IWRC 6×Fi (29) O/O
extending
Number of broken wire – 13
4-section
boom 8 mm Construction
Wire rope diameter 7.5 mm
For boom (Nominal diameter) IWRC 6×Fi (29) O/O
retracting
Number of broken wire – 13

10 mm Construction
Wire rope diameter 9.3 mm IWRC 6×Fi (29) O/O
For boom (Nominal diameter)
extending
Number of broken wire – 13
5-section
boom 8 mm Construction
Wire rope diameter 7.5 mm IWRC 6×Fi (29) O/O
For boom (Nominal diameter)
retracting
Number of broken wire – 13

1. Replace the wire rope if it is deformed or corroded.

2. Replace the wire rope if it is kinked.
3. Replace the wire rope if 10% or more of the wires (except for filler wires) in a lay
Criteria for wire rope
are broken.
replacement
4. Replace the wire rope if the diameter is reduced by more than 7% of the nominal
diameter.
5. Replace the wire rope if it has been degraded by heat.

5.5 Sheave
Standard of Limit of
Item Remarks
minor diameter minor diameter
Determination of limit minor
Only sheaves of the diameter
hoisting systems are (When rope of nominal diameter
listed here. less than 25 mm are used)
ZT1000 170 mm 167 mm
• Boom head sheave
• Sheave of Limit minor dia.
hook block = Standard minor dia.
- (Nominal rope dia. × 0.3)

6 WY01-3250E
Y-1 Y-1
Service Data

5.6 Inspection the hook block

[NOTICE]
The hook block is an important safety part. Follow the procedure to inspect it and be sure to use it only under
safe conditions.
If any problems are found during inspections, repair or replace the part immediately.

1. The sheave groove must be smooth to avoid Hook service limits (table 1) (mm)
damaging the wire rope. Use a grinder to smooth
Crane Model
and correct any sharp corners.
Item
ZT1000
2. Check whether or not the sheave turns lightly. If it
is heavy, the wire rope will slide against the Dimension [a] 118
sheave, and the rope may be damaged. This may (Deformation) (5.9)
also impede free-fall. If the sheave is heavy,
Limit wear [b] 2.25
inspect the sheave bearings, and lubricate or
replace them if necessary. Thickness [c] 75

3. Check that the sheave split pins and installation

bolts are securely installed.

4. Check that the hook nuts are securely installed. If

necessary, tighten them further or take steps to
prevent their rotation.

5. Replace any worn or damaged hook nuts

immediately.

6. Check that the wire rope latch functions correctly.

If necessary, replace the spring.

7. Perform a magnetic flaw detection test at least

once a year to check for cracks or other flaws in
the hook. Replace the hook immediately if any
cracks are found.

8. Replace the hook when the deformation of the

dimension [a] has increased by 5%.

9. The wear limit of the hook [b] is 3% of the whole

thickness [c].

360-965-10000 △
0

7 WY01-3250E
Y-1 . Y-1 .
Service Data

6. Mass table
The dry mass of the major components are shown in the table 2.
Select appropriate hoisting devices when removing and installing the component.

(Table 2)

Mass (kg)
Assembly name
ZT1000

4-section boom
1000
(including telescoping cylinder 150 kg)
Boom section
5-section boom
1350
(including telescoping cylinder 240 kg)

Outrigger assembly (1 piece)

230
(including slide section, jack cylinder)

8 WY01-3250E
Y-2 Y-2
Adjusting Procedures (Hydraulic)

Y-2 Adjusting Procedures (Hydraulic)

[NOTICE]
Oil temperature: 50 ± 5°C (122 ± 9°F)
Shift a control while the engine is idling, then increase engine speed.

1. Pressure setting

1.1 Manual control valve

Set pressure
Item Remarks
2
MPa {kgf/cm }

Main relief valve: C (*1) 20.6 +0.49

–0 {210 +5
–0 } Condition: flow rate of 60 L/min.

Low-pressure relief valve: Z 2.94 to 4.9 {30 to 50} Condition: flow rate of 20 L/min.

(*1): Pressure [C] adjustment procedures

Screw in a pressure gauge to the G port of the manual control valve, and make measurement by setting
the control lever to the retraction side with the jack cylinder fully retracted. (Pump speed: MAX.)

366-388-90000 △
0

9 WY02-2080E
Y-2 . Y-2 .
Adjusting Procedures (Hydraulic)

1.2 Remote control valve (outrigger slide)

Set pressure
Item 2
Remarks
MPa {kgf/cm }

Main relief valve: C (*1) 21.58 +0.49

–0 {220 +5
–0 } Condition: flow rate of 60 L/min

Back pressure regulating valve: D 2.16 +0.39

–0 {22 +4
–0 } Condition: flow rate of 6 L/min

Condition:
Reducing valve: E 2.00 +0.20
–0 {20.4 +2
–0 } with P-port flow rate of 6 L/min
with pilot flow rate of 0.4 L/min
Condition: with flow rate of 1.5 L/min
Pilot circuit relief valve: E 2.26 +0.59
–0 {23 +6
–0 }
Function is shared with reducing valve.

(*1): Pressure [C] adjustment procedures

Screw in a pressure gauge to the G port of the remote control valve, and make measurement by setting
the control lever to the retraction side with the extension cylinder fully retracted. (Pump speed: MAX.)

367-407-60001 △
1

10 WY02-2080E
Y-3 Y-3
Adjustment and Functional Check

Y-3 Adjustment and Functional 1.2 Adjustment of clearance between boom

Check sections
1. Adjust the bolts so that the dimension [a] is 2 mm
when the boom is fully extended. Then fix the nuts
1. Adjusting the boom (fig. 2).

[NOTICE]
Before performing this work, supply grease (TNR-C)
to each slide plate and grease cup.

1.1 Upper slide plate installation procedure (tail

end of each boom sections)
1. Apply thread locking agent (ThreeBond 1305 or
equivalent) to the button bolts before using them
to secure the slide plate.

2. After tightening the button bolts, loosen each of (Fig. 2) Clearance between boom sections
(case of installing set screw)
them by half a turn, and make sure the slide plate
can move longitudinally (fig. 1).
2. Adjust the dimension [b] (fig. 3) and [c] (fig. 4)
using the shims [1, 2, 3 and 4] so that the boom's
degree of lateral bending (fig. 5) and lateral play
(fig. 6) are not greater than the values listed in the
Table 1.

(Fig. 1) Upper slide plate

(tail end of each boom sections)

(Fig. 3)

(Fig. 4)

11 WY05-5130E
Y-3 Y-3
Adjustment and Functional Check

1.3 Greasing procedures

Apply grease (NICHIMOLY N-115 grease spray or

equivalent) to the gap between the pin and support
of roller assy (fig. 7).

(Fig. 5) (Fig. 6)
Lateral bending of boom Lateral play of boom (Fig. 7)

(Table 1) (mm)

Lateral bending Lateral play

4-section
35 80
5-section

312-061-80500 △
0

312-061-70500 △
0

12 WY05-5130E
Y-3 Y-3
Adjustment and Functional Check

2. Adjustment of telescoping wire ropes

5. Additionally tighten the adjusting nuts for the wire
(4-section boom) rope (for boom retracting) by 2 turns.

1. Loosen the lock nuts for the wire ropes (for boom 6. Telescope the 3rd and top boom sections as in
extending and retracting). step 2., and check that both boom sections retract
fully.

If not, slightly loosen the adjusting nuts for the

wire rope (for boom retracting) until both boom
sections retract fully.

• If dimension [E] does not agree with the value

recorded in step 2. but the stopper for the top
boom section touches the 3rd boom section,
slightly loosen the adjusting nuts for the wire rope
(for boom retracting) until both boom sections fully
retract.

• If dimension [E] agrees with the valve recorded in

step 2. but the stopper for the top boom section
does not touch the the 3rd boom section, slightly
2. Lower the boom to the horizontal position and loosen the adjusting nuts for the wire rope (for
extend the 3rd and top boom sections 500 mm boom retracting) until both boom section fully
each. retract.
Then fully retract the boom at idling speed (flow
rate: approx. 15 L / min.). Lock the 3rd boom
section to the 2nd boom section using a
turnbuckle or similar tool.
If there is enough residual pressure in the
retraction side, the boom section need not be
locked but measure and record dimension [E].

[NOTICE]
Make sure that the 2nd and 3rd boom sections are
locked together.
Otherwise, the 3rd boom may extend when
performing step 3., rendering adjustments
Impossible.

3. Tighten the adjusting nuts for the wire rope (for

boom retracting) until the stopper on the top boom
bottom plate comes in contact with the 3rd boom
section.

4. Tighten the adjusting nuts for the wire rope (for

boom extending) until they are 1 to 2 mm away
from the top boom section.

312-061-70500 △
0

13 WY05-5130E
Y-3 Y-3
Adjustment and Functional Check

3. Adjustment of telescoping wire ropes

2. Remove the wire rope (for boom extending)
(5-section boom) adjusting bolt fixing support [1-1], and loosen the
adjusting bolts [3-1] on the right and left for a turn.
2.1 Wire rope adjustment with the telescoping
cylinder installed in the boom

Telescope the boom for several strokes, and check

the dimension [F] between the top and 4th boom
sections.

[NOTICE]
When [F] is 2 mm or less, re-adjustment is not
necessary.

3. Remove the wire rope (for boom retracting)

adjusting bolt fixing support [1-2], and tighten the
adjusting bolt [3-2] to make the dimension [F] not
greater than 2 mm.

If [F] exceeds 2 mm and is not greater than 4 mm

4. Attach the adjusting bolt fixing supports [1-1, 1-2],
1. Remove the boom head cover. then attach the boom head cover.

[NOTICE]
If [F] exceeds 4 mm
Take care to avoid damaging the cord on the cord
reel. Adjustment with the telescoping cylinder out of the
boom is required.

After pulling the telescoping cylinder out of the boom,

perform "2.2 Wire rope adjustment with the
telescoping cylinder out of the boom".

14 WY05-5130E
Y-3
Adjustment and Functional Check
2.2 Wire rope adjustment with the telescoping
cylinder out of the boom
[NOTICE]
Before adjustment, fully retract the telescoping
cylinder. During the wire rope adjustment, prevent
the dimension [D] from varying from 156.1 mm.
During the adjustment, maintain pressure on the
retraction side of the telescoping cylinder to keep
the cylinder fully retracted.
1. Reeve each rope for boom extension and
retraction.
[NOTICE]
Fold the 2 wire rope guides.
Attach 2 wire rope guide supports after applying
thread locking agent to the threaded section of the
support fixing bolts.
15
Y-3
2. While the wire rope (for boom extending) adjuster
bolts [3-1] are pressed firmly on the mounting
surface for the adjuster bolts, adjust so that the
dimension [E] on each right and left side is 121 +0
–1
mm.
[NOTICE]
The wire rope (for boom extending) adjusting bolts
[3-1] shall be tightened for a turn from the position
where the pin for the sheave is forced against the
cylinder root.
3. While the wire rope (for boom retracting) adjuster
bolt [3-2] is pressed firmly against the mounting
surface for the adjuster bolt, tighten the adjuster
bolt until the plate is a little separated from the
cylinder support.
WY05-5130E
Y-3
Adjustment and Functional Check
4. Attach a jig with a length of [C] = 300, and tighten
the nut [4-1].
Tightening torque: 4.9 N-m (0.5 kgf-m)
[NOTICE]
If the length of the wire rope projecting from the
adjusting nut is too short to tighten the nut [4-1]
using the jig, tighten the wire rope (for boom
extending) adjusting bolt [3-1] close to the boom
head.
Tightening torque: 9.8 N-m (1.0 kgf-m)
16
Y-3
5. With the jig fitted, tighten the nut [4-3] until the jig
slightly comes off.
[NOTICE]
If the length of the wire rope projecting from the
adjusting nut is too short to tighten the nut [7] using
the jig, tighten the wire rope (for boom retracting)
adjusting bolt [3-2] close to the boom head.
6. After the adjustment described in step 5., fix the
nuts [4-2] [4-4].
WY05-5130E
Y-3 . Y-3 .
Adjustment and Functional Check

7. After adjustment is completed, thrust the adjusting

bolt lock support [1-1, 1-2] against the side of the
wire ropes (for boom extending and retracting)
adjusting bolts [3-1, 3-2], and fix the support by
the bolts [2-1, 2-2].

[NOTICE]
Make 2 sides of each adjuster bolts [3-1, 3-2]
horizontal. And press the lock support [1-1, 1-2]
against the horizontal sides of the adjuster bolts
[3-1, 3-2].

[NOTICE]
In order to prevent interference between the
sheaves and the wire ropes, adjust the dimensions
of [A] is 108 mm or less, and [B] is 72 mm or less.

312-116-31101 △
1

17 WY05-5130E
 Z
System Diagrams

Contents

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

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

Z-3 Electric Parts Location Diagram ..... 3

Z-4 Harness............................................. 4

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

Z-1 Hydraulic Circuit

C
PA1 TA1

Slide 2 (right)
SA2 A2 (retracting)
SB2 B2 (extending)

P1
Slide 1 (left)
SA1 A1 (retracting)
SB1 B1 (extending)
PA2
D
C
E
SV1
P T

M Hydraulic
gear pump

T P
C G
SV2 SV1 Return filter

Load meter
Oil tank
Hoisting
B6 (Down) Hydraulic motor for winch
5-section boom with wire rope
A6 (Up) telescoping mechanism
Telescoping
B5 (Extending) Counterbalance valve

A5 (Retracting)
Elevating
B4 (Lowering) 4-section boom with wire rope
telescoping mechanism
A4 (Raising)
Center joint Boom telescoping cylinder
Slewing
B3 (Right)
A3 (Left) Slewing lock
Jack2 (Right) Boom elevating cylinder
B2 (Retracting)
Hydraulic motor
A2 (Extending) Counterbalance valve
for slewing
Jack1 (Left)
B1 (Retracting)
A1 (Extending)

Pilot check valve

IWZ01-3790E01
Jack cylinder
Left Right
Extension cylinder Left Right

1 WZ01-3790E 314-041-00200 0 1
Z-2. Electric Circuit Z-2. Z-2.

Z-2 Electric Circuit Battery on

Note
1. This diagram shown the circuit with the power supply off and the winch is two-blocking.
PTO lamp PTO switch Fuse box Key switch vehicle 2. The vehicle circuit shown here is typical. It may differ from the circuit of your vehicle.
M CN1 F
R/Y 1
R/W 2
R/B 3
B
4
Chassis (ground)
Manual control valve

F CN31 M SV1 Unload solenoid valve

L 1 R
B B (energized: loading)
Gy 2 R
3 SV2 Low-pressure solenoid valve
Br 4 B
(energized: low-pressure relief)

M CN33 F
F CN73 B 1 B Hoisting up detection switch
R
R 1 O 2 R (Opens when hoisting up operation is performed.)
2 O
Hook-in relay Lg M CN32 F
4
G Boom extending detection switch
5 G 1 B
B
3 Y 2 R (Opens when boom extending operation is performed.)
Remote control valve (outrigger)
M CND1 F M CN34 F
Diode for 2 R/Y Y 1 B Boom raising detection switch
R/L W 2 R F CN75 M
power source relay 1 (Opens when boom raising operation is performed.) R 1 R SV1 SV1 Unloading
F CN71 B 2 B GND
R 1 R/W
2 R/L F CN76 M
Power source W/R 1 R SB1 SB1 Extending (out)
4
relay R W/B 2 R SA1 Slide 1 (left)
5
3 R/B F CN11 M B/R 3 R SB2 SA1 Retracting (in)
B 1 B B/Y 4 R SA2
F CN72 P 2 R Two-blocking alarm buzzer SB2 Extending (out)
R Slide 2 (right)
R 1
2
W SA2 Retracting (in)
Onload/ Gy
4
buzzer relay 5
L
R F CN25 M
3
R 1 R
L Y Emergency switch
Gy 2 R
3 Right of vehicle side Left of vehicle side
M CN4/24 F P W Buzzer switch (up: contact close) M CN30/CN35 F F CN36/CN30 M
Hook-in Y 1 Lg Lg 4 R (Retracting) R 1 B/Y W/B 1 R (Retracting)
5
switch
R 2 Br Br 6 Y Hook-in switch Slide 2 (right) (Extending) B 2 B/R W/R 2 B Slide 1 (left) (Extending)
W 3 R R 3 W
B R 4 W/B B/Y 4
(Retracting) B 5 W/R B/R 5 B (Retracting)
Frame (ground) Slide 1 (left) Slide 2 (right)
(Extending) W 6 R R 6 W (Extending)

R
B

Cord reel Two-blocking

W B B B R B detection
Center joint switch

F CN3 M
W 1 W
L/R 2 L L
R/G 3 R

CN2 M F CN2 IWZ03-8340E01

1 W/R W/R 1
2 W/G W/G 2

2 WZ03-8340E 314-041-00100 0 2
Z-3. Electric Parts Location Diagram Z-3. Z-3.

Z-3 Electric Parts Location Diagram Note

1. The table of switch connector is the following table (table 1).
2. No protrusion of the harness below surface of the crane mounting.

CN31 CN1 Surface of the crane mounting (table 1) Switch function and connector to be connected
(Male, 4 poles) (Note 2)
CN32 Switch assy Connector No.
Location of switch
(Female, 2 poles) Purpose Type Function Connector No. (harness side)
CN33 Hook-in Push Push : ON
(Female, 2 poles) Relay assy Up : ON
CN34 Buzzer Toggle CN25 CN25
Detail of Down : OFF
(Female, 2 poles)
manual control valve Left side Two-blocking Push Push : ON
Slide 1 (left) Up : Retracting
Toggle Neutral : Stop CN30 CN36
Slide 2 (right) Down : Extending
Hook-in Push Push : ON CN4 CN24
CN76 Right side Slide 2 (right) Up : Retracting
(Male, 4 poles) CN31, CN32 Toggle Neutral : Stop CN30 CN35
Tank support CN33, CN34 Harness Slide 1 (left) Down : Extending
CN75
(Male, 2 poles) Front
Detail of remote control valve A8 B1
(outrigger)
Two-blocking alarm buzzer

Diode CN72 CN4/CN24

CN30/CN35 Front Right
CN71 CN75,
CN73 A9 (Note 1)
CN77
CN11
Left CN25 Right
CND1 (Note 1)
Emergency
C
View A Buzzer B
(Relay assy) Rear
Hook-in

Slide 1 (left) CN30/CN36 Left

A1
(Note 1)
Slide 2 (right)
Relay assy
Detail B Manual control valve
Rear
Two-blocking
alarm buzzer
Remote control valve (outrigger)
Switch support

Slide 1 (left)

Slide 2 (right)

Hook-in

A7
Detail C

A Ground terminal CN2, CN3

IWZ02-7450E01

3 WZ02-7450E 316-579-91000 1 3
Z-4. Harness Z-4. Z-4.

Z-4 Harness

CN31
Unload solenoid valve (SV1) and Manual control valve
Low-pressure solenoid valve (SV2) Remote control valve (outrigger)
CN3
Center joint F
CN76
F B L
CN75 Solenoid valve
Br Gy CN32
R/G L/R W Unload solenoid for slide
M
Boom extending valve (SV1) F
G Y detection switch F
W/B W/R

30
CN33

30
CN25 M B/Y B/R
B R

30
Switch assy B O
Hoisting up
(emergency, buzzer 30 detection switch
and hook-in)
M
CN34 CN24
30 Boom raising

30

30
F Hook-in switch
0 YW
25 detection switch

900
Gy L R F
Br Lg P
30

Br Lg
30
50

50

50
50

50
200 410 1250 850

F F

30
30

R W/R W/B R R B/R B/Y

B
120

R B/R B/Y L/R R W/R W/B

600

R/G
CN35

50
CN36 R/L R/W

50
50
CN71 Slide switch
Slide switch

50
R Power source relay
(left side of vehicle) (right side of vehicle)
R/B
0
M6 10
W Gy R
B 100 CN72
L Onload/buzzer relay
Frame (ground) R
150 10
0
O Lg R
CN73

30

30
G Hook-in relay
Connect
400

B
F
F
1.5 A
P B CN11
R/Y R/L
Two-blocking
CND1 alarm buzzer
Diode for
power source relay
30

M
R/Y R/W
R/B B

CN1
To vehicle

IWZ04-5690E01

4 WZ04-5690E 316-579-91100 1 4
 500/70 Moo.2, T.Tasit, A.Pluak Daeng,
Rayong 21140, Thailand
Tel.: +66-(0)33-010-939
Tel fax: +66-(0)33-010-940

Document Completion: August, 2016

History of revision
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