Publication No. AT-146TE-3/S1-1E
01
Aerial Platform for Live Wire Work
AT-146TE-3
Applicable Serial No. 228376 --
Model

Safety
1
WA01-0042E
Safety
Most accidents that occur during machine operation
and maintenance are caused by failure to observe
basic safety rules and precautions. Before operating
your machine or performing maintenance, read and
become familiar with all the safety precautions and
recommendations given in this section.
Remember that failure to observe even a single
precaution could involve you and the people around
the machine in a serious accident.
Foreseeing potential dangers is vital for preventing
accidents. All personnel working with the machine,
including the supervisor, machine operator and oiler,
should be sensitive to potentially dangerous situations
and take the necessary measures to prevent
accidents.
Safety precautions and recommendations are outlined
in this section and are also included in the operation
and maintenance instructions given in subsequent
sections. Warning labels are also provided on the
machine.
The cautionary instructions in this manual are
identified as "DANGER", "WARNING", "CAUTION" or
"NOTICE". These terms are defined as follows:
[NOTICE]
NOTICE indicates an important measure or
condition for handling, and indicates that, if not
observed, there is a risk of damaging the equipment
or device, or degrading performance and function of
the machine.
It is virtually impossible to anticipate every situation
that might present a hazard. The safety precautions
given in this manual and on the machine labels are
not exhaustive.
It is important, therefore, to strictly follow the
instructions in this manual and be sensitive to
potential dangers in order to prevent bodily injury and
damage to the machine.
Remember that your most important duty is to ensure
the safety of you, your co-workers and any other
people in the area.
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
DANGER
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
WARNING
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
CAUTION

Safety
2
WA01-0042E
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
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.

Safety
3
WA01-0042E
7.Put disassembled parts in order so that parts such
as bolts are not left behind in the machine. And
check that no parts run short at assembly.
8.Watch your step in the following cases:
When stepping up to or stepping down from the
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder
When checking engine oil, radiator coolant, or
battery fluid.
When replacing a filter of air cleaner.
When getting on and off the cab.
Be careful not to slip in the above operations in
winter as snow and ice may attach to the exterior
of boom and it becomes very slippery.
2.2 Dismounting and disassembling
1.Before dismounting and disassembling, make sure
of the construction and part sales unit by reading
this manual and the separate parts catalog, then
understand the procedures of dismounting and
remounting and disassembling and reassembling.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging
the confined pressure.
3.Before removing, clean the part to be dismounted
and the area surround it. Seal the opening with a
plug or tape, etc. to prevent foreign material from
entering it.
4.Measure and record the data such as shim
thickness adjustment and pre-load at disassembly
that will be required at reassembly.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling.
6.If a part cannot be removed after removing bolts or
nuts fixing it, don't apply too much force to it but
check the part for the cause. Only after relieving
the cause, proceed disassembling.
7.Use lifting slings appropriate for the weight and
characteristics of a part. Lift up it in balanced
condition.
In case that the position of the center of gravity is
not clear and there is a possibility of swing of load
after removing, use two hoists.
8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
hinder removing.
2.3 Remounting and assembling
1.Before assembling, clean all the parts and repair
or replace defective parts.
2.As dirt and soil adversely affect sliding portions
and they may decrease the life of the machine,
pay special attention to avoid intrusion of dirt and
soil.
3.Use special tools for parts when specified to do so.
4.Remove dirt, soil, water, and resin completely from
surfaces where liquid gasket will be applied.
5.After remounting, be sure to inspect the machine
and verify that there is no error by oversight. If
adjustment or air bleeding is required, conduct it
according to instructions. Conduct function and
performance test to verify its integrity.
3. Cautions in operation
3.1 Brake fluid replenishment
1.When the brake-warning lamp (for fluid level) is
lighted, replenish brake fluid and check and make
sure of the thickness of disk brake pads. (Refer
to Chapter Y for periodical inspection periods.)
2.Check the thickness of disk brake pads whenever
brake fluid is replenished.
3.2 Handling of battery
1.Erroneous handling of a battery may cause it to
catch fire and explode.
Be extremely sure to avoid short circuits, sparks
and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
Charge up batteries and use them only in well
ventilated places.

Safety
4
WA01-0042E
2.Battery fluid (dilute sulfuric acid) may cause loss of
sight or burn injury.
If battery fluid stains an eye, skin, or clothes,
immediately wash down them with a great deal
of water.
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.
3.3 Handling of radiator
1.Don't open the radiator cap while the coolant is still
hot.
2.Check the coolant at the reservoir tank.
3.If high-pressure water is used for radiator cleaning,
fins may be damaged.
3.4 Cooling fan
1.Stop the engine completely before checking the
tension of the engine fan belt.
2.The oil cooler fan may rotate the moment the
engine is started. Be sure to pull out the ignition
key before accessing the cooling fan.
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 Gasoline
1.Spill or leak: Review fire and explosion hazards
before proceeding with clean up. Use appropriate
personal protective equipment during clean up.
Dike spill. Prevent liquid from entering sewers,
waterways, or low areas. Soak up with sawdust,
sand, oil dry or other absorbent material. Shovel or
sweep up.
2.Remove source of heat, sparks, flame, impact,
friction or electricity including internal combustion
engines and power tools. If equipment is used for
spill cleanup, it must be explosion proof and
suitable for flammable liquid and vapor.
Note: Vapors released from the spill may create an
explosive atmosphere.
3.Waste disposal method: Treatment, storage,
transportation and disposal must be in accordance
with applicable federal, state, provincial, and local
regulations. Do not flush to surface water or
sanitary sewer system.
4.By itself, the liquid is expected to be a RCRA
ignitable hazardous waste.
4.2 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.
4.3 Motor oil
See HYDRAULIC OIL above.

Foreword
1
WA04-3170E
Foreword
This service manual describes the composition of the
Model AT-146TE-3 aerial platform (AMC3
specification), its repair, checks and adjustment
methods and other relevant matters. Note that this
service manual does not provide the information in the
separate service manuals given below.
Read the separate operation and maintenance
manual and the parts catalog for repair and
maintenance of the aerial platform in conjunction with
this manual.
If the parts need to be replaced, check the
disassemble units and sales units in the parts catalog
before replacing them.
1. Applicable Spec. No.
This service manual applies to the aerial platform with
the specification numbers given below. Check the
specification number on the nameplate of your aerial
platform.
SPEC. NO.
SE RIAL.
KAGAWA, JAPAN
NO.
MFG.DATE.
ISA04-001601
Spec. No.
Applicable serial No.
AT-146-3-xxx98
228376---
Compare the lower 2 places of the 5 digits stamped
on the nameplate which represent the specification
with the No. in the above table.
Spec No. on the nameplate
The specification No. stamped on the nameplate
consists of the model, lower Spec. No. (upper 3
places of the 5 digits and representing the
specification of the carrier) and upper Spec. No.
(lower 2 places of the 5 digits and representing the
specification of the aerial platform device).
Example
AT-146-3 - 431 98
RepresentingupperSpec.
Representing lower Spec.
Representing model
2. Separate service manual
Separate Service Manual
Publication No.
1 General Cautions
SA01-01-2E
2
Service Manual
(Circuit Diagrams and Data)
AT-146TE-3/C3-1E
3
AMC3
(Automatic Motion Controller)
W319-0013E
Please note that, for product improvement, some
changes may have been incorporated in the
machine that are not covered in this manual.

Foreword
2
WA04-3170E
3. Outline of specifications
Spec. No.
No.
Item
AT-146-3-xxx98
1
Boom
3-section boom
Top boom section made of insulative F.R.P. (fiber-reinforced
plastics)
2
Jib
Jib made of insulative F.R.P.
3
Bucket
Bucket made of insulative F.R.P.
Bucket inner case made of insulative polyethylene
Automatic leveling system
Swing system driven by hydraulic motor
4
Winch
Hydraulic motor driven
Synthetic fiber rope
5
AMC3
Fitted
6
Boom interference prevention function
Fitted
7
Boom automatic stowing function
Fitted
8
Bucket vertical/horizontal movement
control device
Fitted
9
Automatic speed control device on
boom elevation and swing
Fitted
10
Jack interlock
Fitted
11
Boom interlock
Fitted
12
Hydraulic pressure takeout unit (upper)
Fitted
13
Automatic charger for the buttery on
bucket
Fitted
14
Hydraulic booster (upper)
Fitted
15
Shift lever interlock
Fitted
16
Parking brake warning device
Fitted
17
PTO switch-off reminder alarm
Fitted
18
Level gauge
Fitted

Foreword
3
WA04-3170E
4. Conversion table
Length
millimeter, mm centimeter, cm
meter, m
inch, in, "
foot, ft, '
mile, mi kilometer, km
1
1×10
-1
1×10
-3
3.93701×10
-2
3.28084×10
-3
1
1.60934
1×10
1
1×10
-2
3.93701×10
-1
3.28084×10
-2
6.21373×10
-1
1
1×10
3
1×10
2
1
3.93701×10 3.28084
2.54×10
2.54
2.54×10
-2
1
8.33333×10
-2
3.048×10
2
3.048×10 3.048×10
-1
1.2×10
1
Speed
km/h
mile/h
1
6.21373×10
-1
1.60934
1
Area
square millimeter, mm
2
square centimeter, cm
2
square meter, m
2
square inch, in
2
square foot, ft
2
1
1×10
-2
1×10
-6
1.55×10
-3
1.07639×10
-5
1×10
2
1
1×10
-4
1.55×10
-1
1.07639×10
-3
1×10
6
1×10
4
1
1.55×10
3
1.07639×10
6.4516×10
2
6.4516
6.4516×10
-4
1
6.94444×10
-3
9.2903×10
4
9.2903×10
2
9.2903×10
-2
1.44×10
2
1
Volume
cubic centimeter,
cm
3
,cc
cubic meter, m
3
cubic inch, in
3
cubic foot, ft
3
gallon, gal cubic inch, in
3
liter, lit, L
1
1×10
-6
6.10237×10
-2
3.53147×10
-5
1
2.31×10
2
3.78541
1×10
6
1
6.10237×10
4
3.53147×10
4.329×10
-3
1
1.63871×10
-2
1.63871×10 1.63871×10
-5
1
5.78704×10
-4
2.64172×10
-1
6.10237×10
1
2.83168×10
4
2.83168×10
-2
1.728×10
3
1
Force
N
kgf
lbf
1
1.01972×10
-1
2.24809×10
-1
9.80665
1
2.20462
4.44822
4.53592×10
-1
1
Mass
gram, g
kilogram, kg
ounce, oz
pound, lb
metric ton, ton, t short ton, s. t
1
1×10
-3
3.5274×10
-2
2.20462×10
-3
1×10
-6
1.10231×10
-6
1×10
3
1
3.5274×10
2.20462
1×10
-3
1.10231×10
-3
2.83495×10 2.8349×10
-2
1
6.25×10
-2
2.83495×10
-5
3.12494×10
-5
4.53592×10
2
4.53592×10
-1
1.6×10
1
4.53592×10
-4
5×10
-4
1×10
6
1×10
3
3.5274×10
4
2.20462×10
3
1
1.10231
9.07185×10
5
9.07185×10
2
3.2×10
4
2×10
3
9.07185×10
-1
1

Foreword
4
WA04-3170E
Pressure
Pa
kPa
MPa
kgf/cm
2
lbf/in
2
, psi
1
1×10
-3
1×10
-6
1.01972×10
-5
1.45038×10
-4
1×10
3
1
1×10
-3
1.01972×10
-2
1.45038×10
-1
1×10
6
1×10
3
1
1.01972×10
1.45038×10
2
9.80665×10
4
9.80665×10
9.80665×10
-2
1
1.42233×10
6.89476×10
3
6.89476
6.89476×10
-3
7.03072×10
-2
1
bar
MPa
kgf/cm
2
1
1×10
-1
1.01972
1×10
1
1.0972×10
9.80665×10
-1
9.80655×10
-2
1
Torque
N-cm
N-m
kgf-cm
kgf-m
foot-pound, ft-lbf
inch-pound,
in-lbf
1
1×10
-2
1.01972×10
-1
1.01972×10
-3
7.37562×10
-3
8.85074×10
-2
1×10
2
1
1.01972×10 1.01972×10
-1
7.37562×10
-1
8.85074
9.80665
9.80665×10
-2
1
1×10
-2
7.23301×10
-2
8.67961×10
-1
9.80665×10
2
9.80665
1×10
2
1
7.23301
8.67961×10
1.35582×10
2
1.35582
1.38255×10 1.38255×10
-1
1
1.2×10
1.12985×10 1.12985×10
-1
1.152513
1.15213×10
-2
8.33333×10
-2
1
N-m
kgf-m
ft-lbf
1
1.01972×10
-1
7.37562×10
-1
9.80665
1
7.23301
1.35582
1.38255×10
-1
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
o
F-32)/9, T°F=(9×t°C+160)/5

5
WA04-3170E
5. Group index
Outrigger System
Swing System
Boom Elevating System
Winch System
Boom Telescoping System
Safety System
Platform
Electric System
Option
System Diagrams
Data, Adjustment and Checks
B
C
D
E
F
G
H
J
N
W
Y
Z
Hydraulic Power Generating System

6
WA04-3170E
Foreword
6. Contents
Spec. No.
Chapter
Section
AT-146-3-xxx98
General
A General Cautions
Refer to separate service manual
Hydraulic Power Generating System
Hydraulic Pump (for PTO)
B-1
Manual Control Valve (for Bucket)
B-2
Proportional Solenoid Valve
B-3
Manual Control Valve (for Outriggers)
B-4
B
Center Joint
B-5
Outrigger System
C Pilot Check Valve (for Jack Cylinder)
C-1
Swing System
Hydraulic Motor (for Boom Swing)
D-1
Swing Speed Reducer (Boom Swing)
D-2
Swing Assembly
D-3
D
Pilot Check Valve (for Boom Swing Circuit)
D-4
Boom Elevating System
Counterbalance Valve
(for Leveling Cylinder)
E-1
Counterbalance Valve
(for Elevating Cylinder)
E-2
Select Valve (for Leveling Circuit)
E-3
E
Relief Valve (for Leveling Circuit)
E-4
Winch system
Winch
F-1
Hydraulic Motor (for Jib Swing)
F-2
F
Pilot Check Valve
(for Jib Elevating Cylinder)
F-3

7
WA04-3170E
Foreword
Spec. No.
Chapter
Section
AT-146-3-xxx98
Boom Telescoping system
Boom
G-1
Counterbalance Valve
(for Telescoping Cylinder)
G-2
G
Pilot Check Valve (for Telescoping Circuit)
G-3
Safety System
H Length Detector (for Boom)
H-1
Platform (Bucket)
Bucket
J-1
Hydraulic Motor (for Bucket Swing)
J-2
J
Pilot Check Valve
(for Bucket Elevating Cylinder)
J-3
Electric System
N Control Unit (Accelerator Controller)
N-1
Option
Overview of Booster
W-1
Hydraulic Booster
(with Temporary Hold Function)
W-2
Solenoid Valve
(for Final Tightening and Release)
W-3
W
Solenoid Valve
(for Temporary Hold)
W-4
Data, Adjustment and Checks
(Refer to separate service manual)
Service Data
Y-1
Hydraulic
Y-2
Adjusting
procedure
Electric
Y-3
Adjustment and Functional Check
Y-4
Y
Inspection and Maintenance
Y-5

8
WA04-3170E
Foreword
Spec. No.
Chapter
Section
AT-146-3-xxx98
System Diagrams
(Refer to separate service manual)
Hydraulic Circuit Diagram
Z-1
Bucket
Z-2
Swing Table
Z-3
Frame
Z-4
Electric
Circuit
Diagram
Carrier
Z-5
Bucket
Z-6
Winch, Booster
Z-7
Boom
Z-8
Swing Table
Z-9
Center Joint
Z-10
Frame
Z-11
Location of
Hydraulic
Parts
Pump, Hydraulic Oil Tank
Z-12
Bucket
Z-13
Booster
Z-14
Optical Fiber Cable
Z-15
Boom
Z-16
Swing Table
Z-17
Frame
Z-18
Z
Location of
Electric
Parts
Carrier
Z-19

i
B
Hydraulic Power Generating System
Contents
B-1 Hydraulic Pump (for PTO) ............... 1
1. Structure .................................................... 1
2. Removal and installation............................ 2
3. Disassembly and assembly ....................... 2
3.1 Replacing the oil seal ................................. 2
3.2 Replacing the gaskets and backup strip .... 2
4. Precautions after replacing the pump ........ 2
B-2 Manual Control Valve (for Bucket) . 3
1. Structure .................................................... 3
2. Function ..................................................... 5
2.1 Port relief valve ........................................... 5
2.2 Check valve ................................................ 5
3. Reed switch ............................................... 6
3.1 Removing the reed switch .......................... 6
3.2 Installing the reed switch ............................ 6
3.3 Operational check of reed switch ............... 7
3.4 Adjusting switch shifting points
(for a-contact type) ............................. 9
3.5 Adjusting switch shifting points
(for b-contact type) ............................. 10
B-3 Proportional Solenoid Valve ......... 11
1. Structure .................................................. 11
2. Function ................................................... 15
2.1 Bleed-off compensator valve (PC1)..........15
2.2 Meter-in compensator valve (PC2) ...........15
2.3 Shuttle valve .............................................15
2.4 Reducing valve (RDV1) ............................15
2.5 Solenoid proportional reducing valve........15
2.6 Unloading valve ........................................15
3. Disassembly ............................................ 16
3.1 Disassembling the end section [101] ........16
3.2 Removing the end covers [201, 202] ........17
3.3 Disassembling the valve section...............18
3.4 Separating the end blocks
from the casing ...................................19
3.5 Disassembling the lever pin ......................19
4. Assembly ................................................. 20
4.1 Assembling the end sections
and casing...........................................20
4.2 Assembling the end section [101].............21
4.3 Assembling the valve section ...................22
4.4 Installing the end cover [201, 202]............23
B-4 Manual Control Valve
(for Outriggers) ......................24
1. Structure and function.............................. 24
2. If the solenoid inside
the unloading valve burns out ...... 28
3. Replacing and adjusting
the reed switch............................. 29
3.1 Removing the reed switch.........................29

ii
3.2 Installing the reed switch .......................... 29
3.3 Operational check
after switch replacement .................... 30
3.4 Adjusting switch shifting points
(by shim adjustment).......................... 31
B-5 Center Joint .................................... 32
1. Structure .................................................. 32
1.1 General view............................................. 32
1.2 Brush Assy................................................ 34
2. Replacing the potentiometer .................... 37
3. Replacing a brush .................................... 41
4. Operation check after assembly .............. 44
5. Potentiometer specification...................... 44

B-1
B-1
Hydraulic Pump (for PTO)
1
W101-0191E
B-1 Hydraulic Pump (for PTO)
[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. Retaining ring
2. Oil seal
3. Gasket
4. Side plate
5. Body
6. Washer
7. Hexagon socket head bolt
8. Drive gear
9. Front cover
10. Bush
11. Driven gear
12. Gasket
13. Backup strip
14. Rear cover
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
Suction port
G1
97--119
9.9--12.1
Discharge port
G1/2
29.4--35.4
3.0--3.6
Hexagon socket
head bolt [7]
M12
98--108
10--11
Fixing bolt
M10
33--37
3.35--3.75

2
W101-0191E
B-1.
B-1.
Hydraulic Pump (for PTO)
2. Removal and installation
[NOTICE]
◆When replacing the pump, make sure that the
revolving direction of the new pump is same as the
old ones. (The revolving direction stamped on the
rear cover of the pump assumes the view from the
end of the revolution axis.)
IW101-005501
3. Disassembly and assembly
3.1 Replacing the oil seal
1. Remove the hexagon socket head bolt [7], and
take away the front cover [9].
2. Detach the retaining ring [1] from the front cover
[9], and remove the oil seal [2].
3. Install a new oil seal in the front cover [9] and fix it
using a retaining ring [1].
4. Pack grease (COSMOGREASE DYNAMAX No.3
or equivalent), between the lips of oil seal [2].
5. Wind a tape around the splines of the drive gear
[8] to prevent damage to the lip of the oil seal [2].
Then attach the front cover [9] and fix it using a
hexagon socket head bolt [7].
3.2 Replacing the gaskets and backup strip
1. Remove the hexagon socket head bolt [7], and
take away the front cover [9].
2. Detach the gaskets [3, 12] from and backup strip
[13] from the front cover [9] and the side plate [4].
3. Install new gaskets [3, 12] and a backup strip.
Then attach the front cover and fix it using a
hexagon socket head bolt [7].
4. Replace the gaskets and backup strip on the rear
cover according to the above 1.--3.
4. Precautions after replacing the pump
1. Before starting the pump, check the revolution
direction and pipings again. If the revolution
direction is contrary, the inlet and outlet become
reversed. This may cause the oil seal to run out
and lead to a failure.
2. Fill the piping on the suction side sufficiently with
oil beforehand. When starting the pump, operate it
slowly. Do not operate it at a high speed or high
pressure.
When the pump starts, air bubbles exist in the
pipings. Bleed the pipings completely. Before
bleeding is complete, operate the pump at a low
pressure (if possible, with no load) to run in the
pump.
3. After the run-in is completed, increase the load
gradually up to the one for actual operation.
Before starting actual operation, check for any
abnormalities such as oil temperature.
△
1
366-533-90000
△
0
366-533-30000
△
0
366-531-10000
△
1
366-522-90000
Do not touch the areas other than specified in
this section. Never move the gears inserted in
the body.
If the gear is pulled out of the body, the mesh
position of the teeth will change and the pump
may fail to work sufficiently.
The cover and the body are made of aluminium
alloy and easy to be scratched. Handle them
with care.
Do not leave any oil or grease on the mating
faces of the cover and body.

B-2
B-2
Manual Control Valve (for Bucket)
3
W113-0490E
B-2 Manual Control Valve (for Bucket)
[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.
◆A sextuple valve is mentioned here as an example in this section.
For triple, quadruple and quintuple valves, skip the description of unnecessary blocks.
1. Structure
External view

B-2
B-2
Manual Control Valve (for Bucket)
4
W113-0490E
1. Cover Assy
2. Plug Assy
3. Stud bolt
4. Valve Assy
5. Valve Assy
6. Valve Assy
7. Valve Assy
8. Valve Assy
9. Valve Assy
10. Relief valve

B-2
B-2
Manual Control Valve (for Bucket)
5
W113-0490E
2. Function
1. This valve is a directional control valve, which
shifts the pressurized oil from the hydraulic pump
by the spool and sends it to the actuators
concerning the following operation:
・Bucket swing
・Bucket elevation
・Winch
・Jib elevation
・Jib swing
・Attachment (booster, hydraulic power takeout)
2. The valve incorporates a port relief valve, check
valves and reed switches.
2.1 Port relief valve
The valve is in the block for attachment control.
It restricts the maximum pressure of the oil sent to
the attachment (booster or hydraulic power
takeout) to prevent damage to the hydraulic
components.
・Valve set pressure:
13.7 MPa [140 kgf/cm
2
]
2.2 Check valve
This valve is in each block except the block for
winch control.
It prevents malfunction of the actuator caused by
the backward flow of oil due to internal pressure of
the actuator.
Hydraulic symbol

B-2
B-2
Manual Control Valve (for Bucket)
6
W113-0490E
3. Reed switch
3.1 Removing the reed switch
1. Detach the connector, and cut off the cable tie
which binds the cables.
2. Loosen the hexagon socket head bolts (M4×15,
2 pcs.), and remove the shim and reed switch.
3. Remove the coating on the switch mounting
surface or shim surface which sticks out of the
surface.
・Switch mounting surface
・Shim surface
[NOTICE]
Do not discard the shim because you must use it
again.
3.2 Installing the reed switch
1. Measure the thickness of the removed shim piece
to prepare the adjustment described in the
"Adjusting switch shifting points" section.
One of the following shims is installed.
・0.3-mm thick (Part No.: 366-364-35090)
・0.5-mm thick (Part No.: 366-364-35100)
・0.7-mm thick (Part No.: 366-364-35110)
2. Prepare a new reed switch.
[NOTICE]
◆Reed switches of a-contact type and b-contact type
are available. To avoid using a wrong switch, check
the color of the lead wire cover.
A b-contact type reed switch has a lead wire
covered in black.
3. Attach the shim and a new reed to the valve using
hexagon socket head bolts (M4×15, 2 pcs.)
Tightening torque: 2.94 N-m {0.3 kgf-m}

B-2
B-2
Manual Control Valve (for Bucket)
7
W113-0490E
3.3 Operational check of reed switch
Make sure that the reed switch shifts as listed below when the corresponding spool of the upper control
valve is moved. If it does not move as listed below, adjust the switch according to the "Adjusting switch
shifting points" section later.
[NOTICE]
◆Reed switches of a-contact type and b-contact type are available. To avoid using a wrong switch, check the
color of the lead wire cover. A b-contact type reed switch has a lead wire covered in black.
◆"White", "black" and "red" in the list below represent the color of the cable cover from the switch. (See the
wiring diagram below.)
Type
Color
When spool is pulled out
(Amount: 0.6--2.1 mm)
When spool is in
neutral
When spool is pushed in
(Amount: 0.6--2.1 mm)
White--Black Turns from ON into OFF.
OFF
OFF
a-contact type
Red--Black
OFF
OFF
Turns from OFF into ON.
White--Black Turns from OFF into ON.
ON
ON
b-contact type
Red--Black
ON
ON
Turns from ON into OFF.
Note: "ON" in the list means the closed circuit; "OFF" means the open circuit.
・Connector No. and type of the reed switch for each valve block
Valve block Bucket swing
Bucket
elevation
Winch Jib elevation Jib swing Attachment
Type of reed
switches
a-contact a-contact b-contact a-contact b-contact
a-contact
Connector No.
70
71
72
73
74
75
Detail of connectors
Wiring diagram of the detector switches
・a-contact type
・b-contact type

B-2
B-2
Manual Control Valve (for Bucket)
8
W113-0490E
Spool position
Closed/open condition between contacts
(Unit: mm)
・a-contact type
・b-contact type

B-2
B-2
Manual Control Valve (for Bucket)
9
W113-0490E
3.4 Adjusting switch shifting points (for a-contact
type)
If the shifting points of the detector switch (reed
switch) are improper, adjust and correct them.
You can adjust the shifting position by changing
the thickness of the shims inserted between the
switch and the valve.
Change the shim thickness and adjust the shifting
position of the switch in the following procedures.
Shims of 3 types are available.
・0.3-mm thick (Part No.: 366-364-35090)
・0.5-mm thick (Part No.: 366-364-35100)
・0.7-mm thick (Part No.: 366-364-35110)
Usually replacing 1 piece of shim is enough for
adjustment.
Adjustment using shim
Case 1. The neutral position of the reed switch is
deviated toward the pushed-in position of the
spool.
・Wiring between white and black is closed while
the pulled-out amount of the spool exceeds 2.1
mm
or
・Wiring between red and black is open while the
pushed-in amount of the spool is less than 0.6
mm.
Procedure: Replace the shim with a thicker one.
(If a shim 0.5 mm thick is used, replace it
with the one 0.7 mm thick.)
Case 2. The neutral position of the reed switch is
deviated toward the pulled-out position of the
spool.
・Wiring between white and black is open while the
pulled-out amount of the spool is less than 0.6
mm
or
・Wiring between red and black is closed while the
pushed-in amount of the spool is exceeds 2.1
mm.
Procedure: Replace the shim with a thinner one.
(If a shim 0.5 mm thick is used, replace it with the
one 0.3 mm thick.)
Ex.:
The wiring between white and black becomes
open when the pulled-out amount of the spool is
0.5 mm, and the wiring between red and black
becomes closed when the pushed-in amount of
the spool is 2.2 mm.

10
W113-0490E
B-2.
B-2.
Manual Control Valve (for Bucket)
3.5 Adjusting switch shifting points (for b-contact
type)
If the shifting points of the detector switch (reed
switch) are improper, adjust and correct them.
You can adjust the shifting position by changing
the thickness of the shims inserted between the
switch and the valve.
Change the shim thickness and adjust the shifting
position of the switch in the following procedures.
Shims of 3 types are available.
・0.3-mm thick (Part No.: 366-364-35090)
・0.5-mm thick (Part No.: 366-364-35100)
・0.7-mm thick (Part No.: 366-364-35110)
Usually replacing 1 piece of shim is enough for
adjustment.
Adjustment using shim
Case 1. The neutral position of the reed switch is
deviated toward the pushed-in position of the
spool.
・Wiring between white and black is open while the
pulled-out amount of the spool exceeds 2.1 mm
or
・Wiring between red and black is open while the
pushed-in amount of the spool is less than 0.6
mm.
Procedure: Replace the shim with a thicker one.
(If a shim 0.5 mm thick is used, replace it with the
one 0.7 mm thick.)
Case 2. The neutral position of the reed switch is
deviated toward the pulled-out position of the
spool.
・Wiring between white and black is open while the
pulled-out amount of the spool is less than 0.6
mm
or
・Wiring between red and black is closed while the
pushed-in amount of the spool is exceeds 2.1
mm.
Procedure: Replace the shim with a thinner one.
(If a shim 0.5 mm thick is used, replace it with the
one 0.3 mm thick.)
△
0
366-385-00000
△
0
366-384-70000
△
0
366-384-80000
△
0
366-384-90000

B-3
B-3
Proportional Solenoid Valve
11
W136-0350E
B-3 Proportional Solenoid 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
External view
Detail of solenoid for unloading valve

B-3
B-3
Proportional Solenoid Valve
12
W136-0350E
NOTICE]
Do not take away the parts whose Nos. are marked with *.
B-B section

B-3
B-3
Proportional Solenoid Valve
13
W136-0350E
NOTICE]
Do not take away the parts whose Nos. are marked with *.
101. End section (1)
102. End section (2)
122. Casing
151. Plug* (Do not take it away.)
152. Plug
153. Plug* (Do not take it away.)
154. Plug* (Do not take it away.)
155. Plug
156. Plug
158. Plug
161. O-ring
162. O-ring
163. O-ring
166. O-ring
181. Filter
182. Filter holder
201. End cover (1)
202. End cover (2)
203. Cover
204. Solenoid protective cover
251. Plug
254. Plug
255. Bleeder valve
258. Cap
257. Plug* (Do not take it away.)
261. O-ring
262. O-ring
263. O-ring
267. O-ring
268. O-ring
271. Hexagon socket head bolt
273. Hexagon socket head bolt
274. Hexagon socket head bolt
275. Setscrew with orifice
306. Spool
311. Spool
312. Spool
321. Spring
322. Spring
331. Spring seat
401. Spacer bolt
403. Spool pin
404. Lever pin
405. Control pin
406. Lever
407. Knob
408. Cap
410. Spring pin
411. Needle
461. O-ring
511. Seat (1)
512. Seat (1)
513. Steel ball
551. Plug
561. O-ring
562. O-ring
563. O-ring
611. Bleed-off compensator
valve
612. Reducing valve
613. Meter-in compensator
valve
614. Unloading valve
621. Spring
622. Spring
623. Spring
624. Spring
651. Plug
661. O-ring
872. Tie bolt
879. Nut
880. Spring washer
901. Solenoid proportional
reducing valve
902. Solenoid
903. Harness
A-A section

B-3
B-3
Proportional Solenoid Valve
14
W136-0350E
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-cm
Remarks
152
G1/4
34--39
350--400
155, 158
R1/4
20--24
200--240
Apply a sealing tape.
251
G1/4
34--39
350--400
255
M7×1
2.5--3.4
25--35
Bleeder valve
271, 274
M5
5.9--7.8
60--80
273
M6
11--13
110--130
275
M4
1--1.4
10--14
Apply Loctite 241.
401
M8
15--20
150--200
Apply Loctite 241.
403
M8
15--20
150--200
Apply Loctite 241.
407
M6
2.5--3.4
25--35
Apply Loctite 241.
551
G3/8
69--78
700--800
651
G3/8
69--78
700--800
879
M10
39--44
400--450
901 (solenoid) M22×1
39--49
400--500
Solenoid proportional reducing
valve
901 (nut)
M6
6.9--7.8
70--80
Lock nut for adjuster screw
902 (solenoid) M20×1
39--49
400--500
Unloading solenoid
902 (nut)
M16×1.5
6.9--8.8
70--90
Cap

B-3
B-3
Proportional Solenoid Valve
15
W136-0350E
2. Function
This valve is a multi-control valve with pressure
compensation function. It controls the solenoids in
the solenoid proportional reducing valves, and
thus controls the operational directions and
speeds of the actuators.
The function of each component is described
below.
Also see the "Hydraulic symbol" and "External
view".
2.1 Bleed-off compensator valve (PC1)
1. Sends surplus oil to the PB port or T port.
2. During operation, it changes its relief pressure of
the valves according to the pressure in the valve
block whose load is highest among the valve
blocks.
2.2 Meter-in compensator valve (PC2)
Each valve changes its relief pressure according
to the pressure in the corresponding valve block.
2.3 Shuttle valve
Each valve selects the port whose pressure is
higher. Finally the pressure from the highest port
pressure is led to the bleed-off compensator valve
(PC1).
2.4 Reducing valve (RDV1)
This valve keeps the primary pressure of the
solenoid proportional reducing valve at the
constant pressure.
2.5 Solenoid proportional reducing valve
This valve generates secondary pilot pressure
according to the electronic input, and controls the
stroke of the main control spool by the secondary
pilot pressure.
2.6 Unloading valve
1. While the solenoid is not energized, this valve
sends the oil from the P port or PB port to the T
port.
2. While the solenoid is energized, the valve blocks
the path to the T port to make the oil from the P
port go to the PB port.

B-3
B-3
Proportional Solenoid Valve
16
W136-0350E
3. Disassembly
3.1 Disassembling the end section [101]
1. Remove the plugs [651] (3 pcs.) on the bottom of
the end section, and remove the springs [621, 622,
624].
[NOTICE]
◆Do not open the plug [651] on the top of the block
first. Otherwise the springs will extend and may
damage the land.
2. Remove the plugs [651] (2 pcs.) on the top of the
end section [101], and pull out the spools of the
bleed-off compensator valve [611] and reducing
valve [612] carefully.
[NOTICE]
◆If a spool is inserted inversely during assembly, a
failure may occur.
Put marks on the spools to facilitate installation in
correct orientation.
3. Remove the solenoids [101] on the top of the end
section [101], and pull out the spool of the
unloading valve [614] carefully.
[NOTICE]
◆If a spool is inserted inversely during assembly, a
failure may occur.
Put marks on the spool to facilitate installation in
correct orientation.
4. Remove the plug [152], and pull out the filter
holder [182] using a pulling screw.

B-3
B-3
Proportional Solenoid Valve
17
W136-0350E
3.2 Removing the end covers [201, 202]
1. Loosen the hexagon socket head bolts [271]
which fix the head covers [201, 202].
2. Remove the end cover [202].
3. While tilting the lever [406] toward the center of
the casing [122], remove the end cover [201].

B-3
B-3
Proportional Solenoid Valve
18
W136-0350E
3.3 Disassembling the valve section
1. Pull the spool [306] carefully out of the casing
[122].
Pull out other spools [311, 312] in the same way.
[NOTICE]
◆If a spool is inserted inversely during assembly, a
failure may occur.
Put marks on the spools to facilitate installation in
correct orientation.
IW136-027012
101
879
872
102
306
122
312
311
2. Loosen and remove the bleeder valve [255], and
take out the steel ball.
3. Loosen the hexagon socket head bolt [273], and
take away the cover [203].
4. Pull out the spring [623] and meter-in
compensator valve [613] carefully.
5. Loosen the hexagon socket head bolts [274], and
take away the solenoid protective cover [204].
6. Turn the hexagonal section of the solenoid at
which the width across the parallel side is 32 mm
to remove the solenoid proportional reducing
valve [901].
[NOTICE]
◆Do not disassemble the solenoid proportional
reducing valve [901] further. Do not tamper with the
adjuster screw to keep the correct setting.

B-3
B-3
Proportional Solenoid Valve
19
W136-0350E
3.4 Separating the end blocks from the casing
Loosen the nuts [879] and pull out the tie bolts [872].
The end blocks [101, 102] will be separated from
the casing [122].
IW136-027012
101
879
872
102
306
122
312
311
3.5 Disassembling the lever pin
When you must disassemble the lever pin due to
replacement of O-rings, prepare a suitable tool
such as shown in the figure below.

B-3
B-3
Proportional Solenoid Valve
20
W136-0350E
4. Assembly
[NOTICE]
For the tightening torque for the bolts, see the
"Thread size and tightening torque" in the "1.
Structure" section.
4.1 Assembling the end sections and casing
1. Attach O-rings [161, 162] to the end section [101],
and install the tie bolts [872].
[NOTICE]
◆Orient the face of the end section with the O-rings
upward.
IW136-027013
161
122
161
162
162
101
872
2. Attach O-rings [161, 162] to the casing [122].
3. Pile the casing [122] and end section [102] on the
end section [101]. Pay attention to their
orientation.
[NOTICE]
◆Orient the face of the end section with the O-rings
upward.
4. After attaching a spring washer [880] to each tie
bolt, attach a nut [879] to each tie bolt and tighten
the nuts.
Then change the orientation of the end sections
and casing to make the A and B ports face
upward.
IW136-027014
122
101
102
879
880
5. While checking alignment of the end sections and
casing, tighten the nuts [879].

B-3
B-3
Proportional Solenoid Valve
21
W136-0350E
4.2 Assembling the end section [101]
1. Attach an O-ring [661] to each plug [651].
2. Screw the plugs [651] (2 pcs.) into the top face of
the end section.
3. Screw the solenoid [902] into the end section.
4. Insert the bleed-off compensator valve [611], the
spool of the reducing valve [612], the spool of the
unloading valve [614] into the bottom face of the
end section, paying attention to their orientation.
After installing the spools, attach the springs [621,
622, 624] and screw in the plugs [651] (3 pcs.)
[NOTICE]
◆Insert the spools in a correct orientation. If a spool
is inserted inversely during assembly, a failure may
occur.
5. Attach an O-ring [166] to the filter holder [182],
and insert the filter holder into the end section.
6. Attach an O-ring [163] to the plug [152].
7. Screw the plug [152] into the bottom face of the
end section.

B-3
B-3
Proportional Solenoid Valve
22
W136-0350E
4.3 Assembling the valve section
1. Screw the plug [158] into the casing.
2. Insert the meter-in compensation valve [613] and
spring [623] into the casing.
3. Attach an O-ring [267] to the cover [203], and
attach the cover to the casing using a hexagon
socket head bolt [273].
4. Put a steel ball in the cover [203] and attach the
bleeder valve [255].
5. Screw the solenoid proportional reducing valve
[901] into the casing.
6. Attach the solenoid protective cover [204] using
hexagon socket head bolt [274].
7. Insert the spools [306, 311, 312], paying attention
to their orientation.
[NOTICE]
◆Insert the spools in a correct orientation. If a spool
is inserted inversely during assembly, a failure may
occur.
IW136-027012
101
879
872
102
306
122
312
311

23
W136-0350E
B-3.
B-3.
Proportional Solenoid Valve
4.4 Installing the end cover [201, 202]
1. Attach O-rings [261, 262] to the end cover [201].
[NOTICE]
◆Apply grease to the O-rings beforehand.
202
262
268
201
261
271
271
405 262
IW136-027016
A
B
2. While gradually raising the lever tilted on the
valves, insert the end cover [201].
[NOTICE]
◆Do not let the O-ring drop.
3. Make sure that the control pin [405] is engaged
with the spool correctly. Then screw in the
hexagon socket head bolt [271].
4. Attach O-rings [262, 268] to the end cover [202].
Then fix the end cover using a hexagon socket
head bolt [271].
△
1
366-414-30000

B-4
B-4
Manual Control Valve (for Outriggers)
24
W113-0234E
B-4 Manual Control Valve
(for Outriggers)
1. Structure and function
1. In this integrally assembled directional valve, 4
selector valves (4 valve blocks), a selector valve
(cross section B--B), a pilot check valve, a relief
valve and an unloading valve are placed and fixed
in series.
2. It delivers pressurized oil to the extension
cylinders and jack cylinders to extend or retract
them.
3. The oil from the pump goes to the P port. While
the spools of the selector valve are in the neutral
position, all the pressurized oil goes to the
hydraulic components on the upper structure
through the C port.
4. When the spool of a selector valve is shifted
toward the EXT. or RET. side, the pressurized oil
is sent to the P port or A1 port of each valve block
among S1--S4.
5. The A2 through A5 and B2 through B5 ports are
connected to the jack cylinders and extension
cylinders.
6. When the spool of a selector valve is shifted
toward EXT., the oil is sent to the corresponding
cylinder by the shifted spool in the selector valve.
When the spool of a selector valve is shifted
toward RET., the valve sends the oil returning
from each cylinder through the T port to the tank.
7. In this way this valve can extend and retract any
cylinders for the outriggers steplessly. This valve
also incorporates the relief valve (RV1) which
controls the rated operating pressure for each
cylinder, unloading valve (SOL1E) which halts
operation in case of emergency, and the pilot
check valve which prevents spontaneous
extension of each cylinder while the machine is in
traveling configuration.
8. If an emergency stop signal is output from the
AMC3 (working range restriction is activated,
emergency stop switch is operated, the foot
switch is released, an error occurs in the solenoid
control valve, etc.), the unloading valve (SOL1E)
opens, because the power is turned off and the
solenoid in the valve is deenergized, letting the
spring push back the pilot spool. Then the oil from
the pump goes through RV1 into the tank directly.
This halts the operation of the aerial platform.

B-4
B-4
Manual Control Valve (for Outriggers)
25
W113-0234E

B-4
B-4
Manual Control Valve (for Outriggers)
26
W113-0234E

B-4
B-4
Manual Control Valve (for Outriggers)
27
W113-0234E
1. Relief valve Assy
2. Unloading valve Assy
3. Pilot check valve
4. Valve block Assy
5. End cover
6. Bolt
7. Nut
8. Cap nut
9. Solenoid Assy
10. Margin for adjustment
11. Pilot spool
12. O-ring
13. Spring
14. Check valve
15. O-ring
16. Pilot valve
17. O-ring
18. Plug
19. O-ring
20. Socket
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
Pressure gauge G(PF) 1/4
24.5--29.4
2.5--3.0
A2--A5
B2--B5
G(PF) 3/8 39.2--49.0
4.0--5.0
P,T,C,A1
G(PF) 1/2
58.8--68.6
6.0--7.0
G(PF) 1/8
9.8--14.7
1.0--1.5
M18
39.2--49.0
4.0--5.0
Accessory valve,
plug
M22
58.8--68.6
6.0--7.0
Assembling bolt
M8
18.6--20.5
1.9--2.1
End of valve rod
M8
17.6--19.5
1.8--2.0
Margin for adjusting
relief valve
M14
18.6--20.5
1.9--2.1
Hexagon socket
head bolt
M6
9.8--10.8
1.0--1.1
Reed switch
M4
2.9
0.3
Unloading valve
Distance
between
parallel
sides: 19
2.9--3.9
0.3--0.4
Socket [20]
29.4--39.2
3.0--4.0

B-4
B-4
Manual Control Valve (for Outriggers)
28
W113-0234E
2. If the solenoid inside the unloading
valve burns out
[NOTICE]
Perform the procedure described below only in
emergency.
After the push screw is tightened, the condition of
this control valve changes into the on-load state
(that is, pressurized oil from the pump is sent to the
selector valves), and the automatic stop by various
safety system fails to work.
When the cause which requires the following
procedure is eliminated, immediately loosen the
push screw to the original position.
If the solenoid inside the unloading valve (SOL1E)
burns out, the valve always unloads the circuit
(that is, pressurized oil from the tank is returned to
the tank directly), making operation of the aerial
platform impossible.
Change the valve condition to on-load state
according to the following procedures:
Unloading valve: type A
1. Loosen and remove the cap nut on the top.
(Cap nut: M4)
2. Tighten the push screw slightly.
(Use a flatblade screwdriver.)
3. When the push screw presses the inside
(movable core), the pilot spool is pushed via the
movable core and the push pin. Thus the valve
condition turns into the on-load state.
Unloading valve: type B
1. Loosen and remove the cap nut on the top.
(Cap nut: M3)
2. Tighten the push screw slightly.
(Use a 1.5-mm Allen wrench.)
3. When the push screw presses the inside
(movable core), the pilot spool is pushed via the
movable core and the push pin. Thus the valve
condition turns into the on-load state.
The above procedures turn the solenoid valve into
the on-load state, making operation of the aerial
platform available.

B-4
B-4
Manual Control Valve (for Outriggers)
29
W113-0234E
3. Replacing and adjusting the reed
switch
[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.
3.1 Removing the reed switch
1. Detach the connector, and cut off the cable tie
which binds the cables.
2. Loosen the hexagon socket head bolts (M4×15, 2
pcs.), and remove the shim and reed switch.
3. Remove the coating on the switch mounting
surface or shim surface which sticks out of the
surface.
・Switch mounting surface
・Shim surface
[NOTICE]
Do not discard the shim because you must use it
again.
3.2 Installing the reed switch
1. Measure the thickness of the removed shim piece
to prepare the adjustment described in the "3.4
Adjusting switch shifting points (by shim
adjustment)" section.
One type of the following shims is provided.
・0.3-mm thick (Part No.: 366-364-35090)
・0.5-mm thick (Part No.: 366-364-35100)
・0.7-mm thick (Part No.: 366-364-35110)
2. Prepare a new reed switch.
[NOTICE]
◆Make sure that the cover of the lead wire is black.
・b-contact type (Lead wire is covered in black.)
(Part No.: 366-364-35130)
3. Attach the shim and a new reed to the valve using
hexagon socket head bolts (M4×15, 2 pcs.)
Tightening torque: 2.94 N-m {0.3 kgf-m}

B-4
B-4
Manual Control Valve (for Outriggers)
30
W113-0234E
3.3 Operational check after switch replacement
After replacement of a reed switch, make sure that the reed switch shifts as listed below when the pulled-out
or pushed-in amount (stroke) of the corresponding spool is 0.6--2.1 mm.
("White", "black" and "red" in the list below represent the color of the cable cover from the switch. See the
wiring diagram below.)
If it does not move as listed below, the shifting position of the reed switch is deviated.
Adjust the switch according to the "Adjusting switch shifting points (by shim adjustment)" section later.
Type
Color
When spool is pulled
out
(Amount:0.6--2.1 mm)
Neutral
When spool is pushed in
(Amount:0.6--2.1mm）
White--Black
Turns from ON into
OFF.
ON
ON
b-contact type
(Lead wire is covered in
black.)
Red--Black
ON
ON Turns from ON into OFF.
Note: "ON" in the list means the closed circuit; "OFF" means the open circuit.
Spool position
Wiring diagram of the reed switch (b-contact
type)
Closed/open condition between contacts
(Unit: mm)

31
W113-0234E
B-4.
B-4.
Manual Control Valve (for Outriggers)
3.4 Adjusting switch shifting points (by shim
adjustment)
If the shifting points of the reed switch are
improper, adjust and correct them.
You can adjust the shifting position by changing
the thickness of the shims inserted between the
switch and the valve.
Change the shim thickness and adjust the shifting
position of the switch in the following procedures.
Shims of 3 types are available.
・0.3-mm thick (Part No.: 366-364-35090)
・0.5-mm thick (Part No.: 366-364-35100)
・0.7-mm thick (Part No.: 366-364-35110)
Usually replacing 1 piece of shim is enough for
adjustment.
Adjustment using shim
Case 1. The shifting point of the reed switch is
deviated toward the pushed-in position of the
spool.
・Wiring between white and black is open while the
pulled-out amount of the spool exceeds 2.1 mm
or
・Wiring between red and black is open while the
pushed-in amount of the spool is less than 0.6
mm.
Procedure: Replace the shim with a thicker one.
(If a shim 0.5 mm thick is used, replace it
with the one 0.7 mm thick.)
Case 2. The shifting point of the reed switch is
deviated toward the pulled-out position of the
spool.
・Wiring between white and black is open while the
pulled-out amount of the spool is less than 0.6
mm
or
・Wiring between red and black is closed while the
pushed-in amount of the spool is exceeds 2.1
mm.
Procedure: Replace the shim with a thinner one.
(If a shim 0.5 mm thick is used, replace it with the
one 0.3 mm thick.)
△
3
366-374-90000

B-5
B-5
Center Joint
32
W181-0530E
B-5 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
1.1 General view
[NOTICE]
◆When installing the brush Assy, apply Grease SR2
to the body [1], the top face of the core [9] (hatched
area C in the figure) for rust prevention (except for
the mounting surface for the brush Assy).
◆Apply ThreeBond 1215 to the D section (surface
mating the brush Assy to prevent permeation of
water.
◆After assembly, the positional relation among the
brush Assy [2], the punch mark on the body [1] and
the hydraulic ports shall be as shown in the figure.

B-5
B-5
Center Joint
33
W181-0530E
1. Body
2. Brush Assy
3. Bolt
4. Spring washer
5. Spring pin
6. Spacer
7. Cover
8. Plain bearing
9. Core
10. Packing
11. Ring seal
12. Cap
13. Grease nipple
14. Retaining ring
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
P
G3/8
49.0
5.0
G1/4
29.4
3.0
D
G3/8
49.0
5.0
G1/4
29.4
3.0
Body
T
G1/2
98.0
10.0
P
G1/2
98.0
10.0
D
G3/8
49.0
5.0
Core
T
G1/2
98.0
10.0
Bolt [3]
M8
12--14
1.2--1.4
Grease nipple [13]
R1/8
7.8--10.6
0.8--1.08
△
1
426-308-91000
△
2
426-308-90000

B-5
B-5
Center Joint
34
W181-0530E
1.2 Brush Assy
(with no angle sensor to detect swing blind spot)
・Contact a TADANO distributor or dealer for ordering contact-point activator. Part No.: 999-900-41794
(Quantity: 20 cm
3
)
View A
Detail of B (waterproofing of grommet)
△
0
424-418-73001

B-5
B-5
Center Joint
35
W181-0530E
1. Nameplate
2. Housing
3. O-ring
4. Base
5. Spacer
6. Shaft base
7. Holder
8. Bush
11. Coupling Assy
12. Bearing A
13. Bearing B
14. Brush table (bottom)
15. Brush table (filler)
16. Brush table (upper)
17. Washer
18. Machine screw
19. Machine screw
20. Machine screw
21. Bolt
22. Spring washer
23. Plain washer
24. Cover
25. Potentiometer
26. Setscrew
27. Guide plate
28. Arm Assy
29. Latch
30. Machine screw
31. Potentiometer bracket
32. Terminal insulating plate
33. Slip ring
34. Insulating plate
35. Faston terminal
36. Brush Assy
37. Grommet
38. Clamp
39. Machine screw
40. Clamp seat
41. Hexagon socket head bolt
42. Spring washer
45. Pin
46. Stud
48. Bush
50. Spring washer
View C

B-5
B-5
Center Joint
36
W181-0530E
11
3
3
10
2
2
9
1
1
8
4
4
7
3
3
6
2
2
5
1
1
4
4
4
3
3
3
2
2
2
1
1
1
CNR2
CNR3
CNR1
CNR13
CNR12
13
2
2
12
1
1
CNR4
CNR14
CNR11
IW181-031004E
P1
P2
CNR5
6
2
3
1
2
3
1
5
4
2
3
1
B
A
C
-
out
+
-
out
+
E
D
F
Potentiometer
Spacer
Spacer
(male)
(female)
(female)
(male)
(female)
(male)
(female)
(male)
(male)
No.
Color
1
R
2
B
3
L
4
W
5
Y
6
Br
7
G
8
Gy
9
O
10
W/R
11
W/B
12
G/W
13
L/R
A
R
B
B
C
L
D
W
E
Y
F
Br
IW181-019002E
23
1
11
10
7
6
3
12
8
4
9
5
12
4
3
2
1
21
3
3
4
1
2
2
1
1
2
P3 male
P12 male
P4 male
P3 female P4 female
P2 male
P2 female
Connection diagram
Connector pin arrangement (viewed from the mating end)

B-5
B-5
Center Joint
37
W181-0530E
2. Replacing the potentiometer
1. Remove the sealing compound around the cover
with a pointed tool such as a toothpick.
[NOTICE]
The sealing compound is applied at the depression
on the housing where the cover is engaged.
2. Remove the hexagonal bolts M5 (4 pcs.), and
detach the cover from the housing.
If the sealant hinders the cover to be removed, put
a screwdriver in a bolt hole. Then hit it with a
hammer to turn and remove the cover.
[NOTICE]
Do not let the sealant attached to the cover fall in
flakes into the housing. If a flake is in the housing,
always remove it because it may cause poor
contact.
Scrape the sealant completely because silicone will
be applied during reassembly.
Before scraping off the sealant remaining on the
cover and housing, put a plastic bag, etc. in the
housing to catch falling flakes.
3. Remove the M4 machine screw (1 pc.) to detach
the cable clamp.
Then cut the potentiometer wiring at the root
where epoxy resin is filled up.
[NOTICE]
As the cable will be reused by soldering, cut the
cable as close as possible to the epoxy resin.

B-5
B-5
Center Joint
38
W181-0530E
4. Remove the M4 machine screws (3 pcs.) to
detach the potentiometer and potentiometer
bracket.
[NOTICE]
As the arm Assy is installed to the potentiometer
shaft, lift the potentiometer bracket upward when
removing it.
5. Remove the M3 setscrews (2 pcs.) to detach the
arm Assy from the potentiometer.
6. Remove the M3 machine screws (2 pcs.) and
latches (2 pcs.) to detach the potentiometer from
its bracket.
7. Temporarily install a new potentiometer to the
potentiometer bracket using M3 machine screw (2
pcs.) and latches (2 pcs.)
[NOTICE]
As the potentiometer needs to be adjusted after
installation, just temporarily attach it by allowing it to
turn slightly.
8. Fix the arm Assy on the potentiometer shaft using
M3 setscrews (2 pcs.)
Before fixing the arm Assy, turn the shaft so that
the resistance between 1--2 in the potentiometer
P1 is 758±10 Ω when the arm Assy is directed as
shown in the figure below. Then fix the shaft with
setscrews.
[NOTICE]
Before fixing the arm Assy, place the terminals at
suitable position to facilitate soldering cables.

B-5
B-5
Center Joint
39
W181-0530E
9. Put a potentiometer bracket on the studs, and fix it
using M4 machine screws (3 pcs.) avoiding the
position of cable clamp.
Place the bracket to fit the pin within the slit of the
arm Assy.
[NOTICE]
If the pin is out of the slit of the arm Assy, correct
swing angle will not be output.
10.Solder cables to the potentiometer terminals
according to the wiring table below.
[NOTICE]
When soldering the cables, do not touch a soldering
iron to the terminals continuously for 5 seconds or
longer. Otherwise the potentiometer may be
damaged.
Do not short-circuit terminals.
・Wiring table
Terminal No. on
potentiometer
Signal
name
Color
Terminal No. on
connector
P1-1
-
Black
6
P1-2
OUT Red
5
P1-3
+
Blue
4
P2-1
-
Yellow
2
P2-2
OUT White
3
P2-3
+
Brown
1
11. Apply voltage of 5 V to the terminals 4--6 of the
connector (CNR5; 12-pin) for the potentiometer.
Then turn the potentiometer body to make the
voltage between the terminals 5 and 6 within 3.79
± 0.002 V.
[NOTICE]
If the supply voltage is other than specified, the
result of adjustment becomes incorrect accordingly.
This adjustment assumes configuration for index
point.

B-5
B-5
Center Joint
40
W181-0530E
12.Coat the potentiometer terminals with epoxy resin,
and fully tighten the M3 machine screws.
[NOTICE]
Cover the terminals fully with the resin. If a terminal
is exposed to the ambient air, it may be corroded.
13. Fix the cables with cable clamps. Reassemble
the whole assembly in the reverse order of
disassembly.
Before applying silicone sealant between the
cover and housing, fix the cover using bolts first.
Then fill the circular gap with silicone sealant by
rubbing it into the gap.
Use silicone sealant KE4898 (Shin-etsu
Chemical) or equivalent.
[NOTICE]
If a residue of silicone sealant remains at the time
of new sealant application, sealing performance
may be deteriorated. Before applying new silicone
sealant, make sure that the previous sealant has
been completely removed. (Do not coat silicone
sealant on remaining silicone.)

B-5
B-5
Center Joint
41
W181-0530E
3. Replacing a brush
1. Remove the sealing compound around the cover
with a pointed tool such as a toothpick.
[NOTICE]
The sealing compound is applied at the depression
on the housing where the cover is engaged.
2. Remove the hexagonal bolts M5 (4 pcs.), and
detach the cover from the housing.
If the sealant hinders the cover to be removed, put
a screwdriver in a bolt hole. Then hit it with a
hammer to turn and remove the cover.
[NOTICE]
Do not let the sealant attached to the cover fall in
flakes into the housing. If a flake is in the housing,
always remove it because it may cause poor
contact.
Scrape the sealant completely because silicone will
be applied during reassembly.
Before scraping off the sealant remaining on the
cover and housing, put a plastic bag, etc. in the
housing to catch falling flakes.
3. Remove the M4 machine screw (1 pc.) to detach
the cable clamp.
4. Remove the M4 machine screws (3 pcs.) to
detach the potentiometer and potentiometer
bracket.
[NOTICE]
Remember that the cables remain connected to the
potentiometer. Handle the potentiometer with care.
As the arm Assy is installed to the potentiometer
shaft, lift the potentiometer bracket upward when
removing it.

B-5
B-5
Center Joint
42
W181-0530E
5. Remove the M4 machine screws (4 pcs.) to
detach the guide plate.
6. Remove the hexagonal bolts M5 (4 pcs.), and
detach the housing.
[NOTICE]
When removing the housing, pull it up vertically.
7. Pull out the Faston terminal connected to the
brush to be replaced.
[NOTICE]
If you pull the cable to pull out the terminal, the
wires in the cable may be broken. Always hold the
terminal when you pull it out.
8. Remove the M4 machine screws (2 pcs.) which fix
the brush to be replaced.
When removing the machine screws, press the
brush holders from the top.
[NOTICE]
If you remove the machine screws without pressing
the brush holders from the top, the brush Assys will
fall apart, because the brush holders are not
connected with one another and are easy to fall.
9. Pull the brush Assy out of the brush holders.
[NOTICE]
Pull the brush Assy straight.

B-5
B-5
Center Joint
43
W181-0530E
10. Prepare a new brush.
[NOTICE]
When putting a brush between the brush holders,
put it in a correct position and correct orientation.
11.Install a brush Assy in the reverse order of the
removal. If the brush touches a wrong ring, pull
out the brush Assy and install it again.
[NOTICE]
When installing a brush Assy, prevent it from
interfering with another brush (that is, short circuit
with another brush).
When eliminating interference with another brush,
do put pull or bend the brush. Otherwise the brush
will be deformed and become unusable.
12. Fix the brush Assy using M4 machine screws (2
pcs.) (See the steps 7 and 8.)
13. Wipe off contact-point activator remaining on the
ring.
Then apply new contact-point activator.
Apply appropriate amount of contact-point
activator according to the figure below.
Contact a TADANO distributor or dealer for
ordering contact-point activator.
[NOTICE]
After replacing a brush, always apply new
contact-point activator.
Wipe off previous contact-point activator as far as
possible.
Use a clean lint-free rag for wiping.
14. Connect a Faston terminal to the terminal
leading to the new brush.
[NOTICE]
Insert a Faston terminal up to the base of the
terminal leading to the brush.
15. Reassemble the whole assembly in the reverse
order of disassembly.
Before applying silicone sealant between the
cover and housing, fix the cover using bolts first.
Then fill the circular gap with silicone sealant by
rubbing it into the gap.
Use silicone sealant KE4898 (Shin-etsu
Chemical) or equivalent.
[NOTICE]
If a residue of silicone sealant remains at the time
of new sealant application, sealing performance
may be deteriorated. Before applying new silicone
sealant, make sure that the previous sealant has
been completely removed. (Do not coat silicone
sealant on remaining silicone.)

44
W181-0530E
B-5.
B-5.
Center Joint
4. Operation check after assembly
After assembling the brush Assy, conduct the
operational check described in 1. and 2. below to
make sure that the potentiometer has been
appropriately installed.
1. Place the base and coupling as shown in the
figure below. Then check that the resistance
between the output terminal and the ground
terminal (5--6 of CNR5) of the potentiometer P1
increases as the potentiometer is turned
clockwise.
・The figure below shows the brush Assy from the
coupling side (that is, the bottom view of the brush
Assy.
P1
P2
CNR5
6
2
3
1
2
3
1
5
4
2
3
1
9
8
7
B
A
C
-
out
+
-
out
+
E
D
F
G
H
I
IW181-005009E
+
Potentiometer
(male)
2. Turn the coupling to make its direction relative to
the base as shown in the above figure.
While applying voltage to between the power
supply terminal and ground terminal (4--6 of
CNR5) of the potentiometer P1, check that the
voltage between the output terminal and the
ground terminal (5--6 of CNR5) is within the range
listed below.
Voltage applied to
4--6 of CNR5
Voltage between 5--6
of CNR5
4.5 V
3.410 ± 0.002 V
5.0 V
3.790 ± 0.002 V
5. Potentiometer specification
Effective
electrical angle
0--350
+1°
-2°
Total resistance
1kΩ±15%
Linearity
± 0.1%
△
2
426-308-90000

i
C
Outrigger System
Contents
C-1 Pilot Check Valve
(for Jack Cylinder) ................... 1
1. Structure .................................................... 1

C-1.
C-1.
Pilot Check Valve (for Jack Cylinder)
1
W115-0660E
C-1 Pilot Check Valve (for Jack Cylinder)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1.Valve Body
2.Cap seal
3.Piston
4. ---
5.Sleeve
6.O-ring
7.Backup ring
8.Check valve
9.O-ring
10.Spring
11.Plug
12.O-ring
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m
kgf-m
ft-lbf
A
G1/4
29.4
3
22
B
G1/4
29.4
3
22
11
M24×1.5
98-118
10-12
72-87
Mounting
bolt
M8
23-27
2.4 - 2.8
17.7 - 20
AB
C
D
IW115-003001
△
0
366-257-40001

i
D
Swing System
Contents
D-1 Hydraulic Motor
(for Boom Swing)..................... 1
1. Structure .................................................... 1
2. Disassembly .............................................. 2
3. Reassembly ............................................... 2
D-2 Swing Speed Reducer
(Boom Swing) .......................... 3
1. Structure .................................................... 3
2. Dismounting ............................................... 4
3. Reassembly ............................................... 4
D-3 Swing Assembly .............................. 5
1. Structure .................................................... 5
2. Reassembly ............................................... 6
2.1 Swing bearing............................................. 6
2.2 Swing speed reducer.................................. 6
D-4 Pilot Check Valve
(for Boom Swing Circuit) ........ 7
1. Structure .................................................... 7

D-1
D-1
Hydraulic Motor (for Boom Swing)
1
W102-0104E
D-1 Hydraulic Motor (for Boom Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
A,B
D
9-6
9-1
1
19
3
15
9-5
11
12
13
14
10
9
8
4
7
6
5
2
9-3
9-2
9-4
IW102-010201
1. Shaft
2. Bearing
3. Housing
4. O-ring
5. Oil seal cover
6. Oil seal
7. Retaining ring
8. Thrust plate
9. Cylinder barrel assy
9-1. Cylinder barrel
9-2. Plunger
9-3. Plunger bearing
9-4. Plunger spring
9-5. Retaining ring
9-6. Center spring
10. Valve plate
11. Bottom cover
12. Bearing
13. Pin
14. O-ring
15. Bolt
19. Key

2
W102-0104E
D-1.
D-1.
Hydraulic Motor (for Boom Swing)
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m
kgf-m
A
G3/8
39.2 - 49.0
4.0 - 5.0
B
G3/8
39.2 - 49.0
4.0 - 5.0
D
G1/4
19.6 - 29.4
2.0 - 3.0
15
M10×35 29.4 - 34.3
3.0 - 3.5
Mounting bolt M12×35 68.6 - 82.4
7.0 - 8.4
2. Disassembly
1. Loosen the bolts (15) to separate the bottom
cover (11) about 10 mm. This is necessary to
prevent the shaft (1) from popping out by the force
of the center spring (9-6).
2. Remove the retaining ring (7).
3. Insert the flat blade of a screwdriver into the slot
of the oil seal cover (5) to remove the oil seal
cover (5), together with the oil seal (6).
[NOTICE]
Do not pull out the shaft (1).
As it is difficult to engage the male spline teeth of
the shaft (1) with the female ones of the cylinder
barrel (9-1), reassembly will be troublesome.
3. Reassembly
1. Make sure that the O-rings (4) and (14) are placed
in position.
2. Apply grease to the lip area of the oil seal (6).
Install the oil seal (6), together with the oil seal
cover (5), into the housing (3).
3. Securely put the retaining ring (7) into the groove
of the housing (3).
[NOTICE]
When putting the retaining ring (7), be sure to place
the rounded edge inside (next to the bearing).
If the rounded edge is place outside, there is a
possibility that the retaining ring may come off
because of an internal force such as spring force
and hydraulic force.
4. Install the bottom cover (11) as before.
△
1
366-625-90000

D-2
D-2
Swing Speed Reducer (Boom Swing)
3
W511-0124E
D-2 Swing Speed Reducer (Boom Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
7654321
8,9
10
11
12
14
13
15 16 17 18 19,20
21
22,23
IW511-0124E01
(Oil drain port)
1. Spur gear
2. Sleeve
3. Oil seal
4. Gear case
5. Ball bearing
6. Key
7. Worm wheel
8. Bolt
9. Spring washer
10. Ball bearing
11. Retaining ring
12. Gear case
13. Tapered roller bearing
14. Worm
15. Tapered roller bearing
16. Shim set
17. Spacer
18. Retaining ring
19. dipstick
20. Seal washer
21. Plug
22. Nameplate
23. Rivet
Thread size and tightening torque
Tightening torque
Sign / port
Thread size
N-m
kgf-m
8
M10
35.3 - 42.2
3.6 - 4.3
21
R1/4
10.6 - 30.9
1.8 - 3.2
Mounting bolt
M18
329 - 363
33.5 - 37

4
W511-0124E
D-2.
D-2.
Swing Speed Reducer (Boom Swing)
2. Dismounting
3. Reassembly
Application of thread locking agent
Part
Type of thread locking agent
Remarks
Sleeve (2)
ThreeBond 1215
Applied for shrinkage fit.
Oil seal (3)
ThreeBond 1215
Applied to the periphery.
Apply lithium-based grease to the lip area.
Bolt (8)
ThreeBond 1104
Applied to the tapped through hole.
Gear case (12) ThreeBond 1104
Applied to the mating surface with the gear case (4).
1. As for the tapered roller bearings (13) and (15),
adjust the axial play to 0.05 to 0.10 mm with the
shim set (16).
2. Replenish fresh gear oil to the specified level
through the screw hole of the dipstick (19).
Gear oil : Mobil Gear 632 (Mobil)
Quantity : 1.1 L
Dipstick indication
Remove the oil dipstick to check the oil level.
When the dipstick is not screwed in, the oil level
should be within the limits as shown below.
If the level is low, add proper amount of oil
through the screw hole for the dipstick.
IW511-012102E
Swing speed reducer
Before removing the swing speed reducer,
fasten the swing frame to the lower frame with
wire ropes or the like so that the swing frame
should not start to rotate freely.
CAUTION
△
0
360-815-70000
△
0
360-815-60000

D-3
D-3
Swing Assembly
5
W514-0400E
D-3 Swing Assembly
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Swing bearing
2. Swing speed reducer
3. Bolt
4. Plain washer
5. Nut
6. Bolt
7. Set screw
8. Nut
9. Hexagon socket head bolt
10. Spring washer
11. Hydraulic motor
12. O-ring
13. Bolt
14. Plain washer
15. Bolt

6
W514-0400E
D-3.
D-3.
Swing Assembly
Thread size and tightening torque
Tightening torque
Thread
Thread size
N-m
kgf-m
Bolt 3
M18
329--363
33.5--37.0
Bolt 6
M12
19.6--23.5
2.0--2.4
Nut 8
M12
34.3--41.2
3.5--4.2
Hexagon socket head bolt 9
M12
69--82
7.0--8.4
Bolt 13
M16
240--265
24.5--27.0
Bolt 15
M16
240--265
24.5--27.0
2. Reassembly
[NOTICE]
Install the high strength plain washer, orienting its
chamfer to the bolt head side as shown below.
2.1 Swing bearing
1. Mount the swing bearing on the lower frame,
rotating the "S" mark from the carrier front by 10°
clockwise.
2. Apply torque control agent to the threaded
sections of the bolts-15 for inner ring and the
bolts-13 for outer ring.
3. Install the high strength plain washer (4 and 14)
with its chamfer facing the bold head.
2.2 Swing speed reducer
1. Apply thread locker (LOCTITE 262T) to the set
screws (7).
2. After once making the backlash between gears 0
mm with the set screws (7), back off the two set
screws by 1/16 turn and fix them. This results in
the circular backlash 0.08 mm.
3. The bolts (6) are temporarily put before the swing
speed reduce is installed. After installation of the
swing speed reducer, they are adjusted.
4. The adjustment is made in the following way.
First apply thread locker (LOCTITE 262T) to the
bolts (6) and turn them until they hit the swing
speed reducer.
5. Then with pushing the bolts (6) to the swing speed
reducer, tighten the nuts (8) to the specified
torque.
△
0
423-011-00000

D-4.
D-4.
Pilot Check Valve (for Boom Swing Circuit)
7
W115-0214E
D-4 Pilot Check Valve (for Boom Swing Circuit)
[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
AB
CD
IW115-021001
C
D
B
987 6
354
1
2
A
IW115-0212E01
10
Thread size and tightening torque
Tightening torque
Thread
Thread size
N-m
kgf-m
PortA,B,C,D
G1/4
29.4
3.0
Plug 9
M24
74-83
7.5 - 8.5
Mounting bolt
M10
23-27
2.35 - 2.65
1. Body
2. Piston
3. Housing
4. Poppet
5. Packing
6. Spring
7. O-ring
8. Stop pin
9. Plug
10. Spacer
Hydraulic symbol
△
1
366-250-00000

i
E
Boom Elevating System
Contents
E-1 Counterbalance Valve
(for Leveling Cylinder) ............ 1
1. Construction............................................... 1
E-2 Counterbalance Valve
(for Elevating Cylinder) ........... 3
1. Construction............................................... 3
E-3 Select Valve
(for Leveling Circuit) ............... 5
1. Construction............................................... 5
2. Reassembly ............................................... 6
E-4 Relief Valve
(for Leveling Circuit) ............... 7
1. Construction............................................... 7

E-1
E-1
Counterbalance Valve (for Leveling Cylinder)
1
W119-0630E
E-1 Counterbalance Valve (for Leveling 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. Construction

2
W119-0630E
E-1.
E-1.
Counterbalance Valve (for Leveling Cylinder)
1. Body
2. Plug
3. O-ring
4. Plug
5. O-ring
6. Sleeve
7. Poppet
8. O-ring
9. Spring
10. Spring
11. Plug
12. Plug
13. O-ring
14. O-ring
15. Sleeve
16. Spool
17. O-ring
18.--
19. O-ring
20. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port
Thread size
N-m
kgf-m
Plug [2]
G1/8
19.6
2.0
Plug [4] and [11]
G3/8
49.0
5.0
Plug [12]
M22×1.5
245.2--274.6
25.0--28.0
PortAandB
G1/4
29.4
3.0
Mounting bolt
M8
25--29
2.6--3.0

E-2
E-2
Counterbalance Valve (for Elevating Cy linder)
3
W119-0591E
E-2 Counterbalance Valve (for 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. Construction
A
C
B
Hydraulic symbol

4
W119-0591E
E-2.
E-2.
Counterbalance Valve (for Elevating Cy linder)
1. Body
2. Plug
3. O-ring
4. Spool
5. Orifice
6. Check valve
7. Spring
8. Piston
9. O-ring
10. Spring
11. Cap
12. O-ring
13. O-ring
14. Backup ring
15. Cap
16. Plug
17. O-ring
18. O-ring
19. O-ring
20. Backup ring
21. Orifice
22. O-ring
23. Body
24. Plug
25. Check valve assy
26. Plug
27. O-ring
28. Hexagon socket head bolt
29. Orifice
Thread size and tightening torque
Tightening torque
Sign / Port
Thread size
N-m
kgf-m
2
--
11.8±1
1.2±0.1
11
--
196±10
20±1
15
--
186±10
19±1
16
--
8.8--9.8
0.9--1.0
24
HEX. 30
147±10
15±1
26
HEX. 30
147±10
15±1
28
--
6--8
0.6--0.8
B
G3/8
49.0±5
5.0±0.5
Mounting bolt
M8
12.3--14.7
1.25--1.5
△
0
366-064-50000

E-3
E-3
Select Valve (for Leveling Circuit)
5
W129-0111E
E-3 Select Valve (for Leveling Circuit)
[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. Construction
12
13
14
34
56
7
8
9
1,2
10
11
A2
A1B
P
N
A1, B
A2
P
View N
A2 A1
B
P
Apply sealant for waterproofing.
Apply grease to sliding portions
during assembly.
Apply thread locker
super to threads.
Apply grease to threads.
IW129-0110E01
1. Bolt
2. Spring washer
3. Needle
4. Holder
5. O-ring
6. Backup ring
7. Body
8. Poppet
9. Spring
10. O-ring
11. Plug
12. Knob
13. Plate
14. Machine screw
Hydraulic symbol

6
W129-0111E
E-3.
E-3.
Select Valve (for Leveling Circuit)
2. Reassembly
During assembly, apply grease to the surface of the
needle (3) and the sliding portions (threaded area
and hole of 10 mm in diameter) of the holder (4).
Thread size and tightening torque
Tightening torque
Thread Thread size
N-m
kgf-m
Bolt (1) G1/4
29.4
3.0
Holder (4) G1/4
29.4
3.0
Plug (11) G3/8
49.0
5.0
Port A1
G1/4
29.4
3.0
Port A2
G1/4
29.4
3.0
Port B
G3/8
49.0
5.0
Port P
G3/8
49.0
5.0
△
1
366-363-40000

7
W111-0342E
E-4.
E-4.
Relief Valve (for Leveling Circuit)
E-4 Relief Valve (for Leveling Circuit)
[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. Construction
1. Body
2. Guide
3. Poppet
4. Plug
5. O-ring
6. Spring
7. Spacer
8. Plug
Thread size and tightening torque
Tightening torque
Sign / port Thread size
N-m
kgf-m
Plug (4)
M33×1.5
167
17
Plug (8)
R1/8
7.8--10.6
0.8--1.08
P1, P2, T
G1/4
29.4±3
3.0±0.3
Mounting bolt
M8
12.3--14.7
1.25--1.5
△
1
366-066-70000
△
1
366-066-50000
Hydraulic symbol
IW111-034102
T
P1
P2
△
1
366-066-60000

i
F
Winch System
Contents
F-1 Winch ................................................ 1
1. Winch Assy ................................................ 1
1.1 General view............................................... 1
1.2 Main body ................................................... 2
1.3 Replacing oil seal of the winch motor......... 6
1.4 Performance confirmation test after
disassembly and assembly of the motor .... 8
2. Support ...................................................... 9
2.1 General view............................................... 9
2.2 Adjusting the jib swing free/lock lever ...... 12
F-2 Hydraulic Motor
(for Jib Swing) ....................... 13
1. Structure .................................................. 13
1.1 General view............................................. 13
1.2 Main body ................................................. 14
1.3 Counterbalance valve............................... 16
F-3 Pilot Check Valve (for Jib
Elevating Cylinder) ................ 17
1. Structure .................................................. 17

F-1
F-1
Winch
1
W526-0430E
F-1 Winch
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Winch Assy
1.1 General view
△
2
423-119-10100

F-1
F-1
Winch
2
W526-0430E
1.2 Main body
Hydraulic symbol
Main unit
△
1
423-119-17000

F-1
F-1
Winch
3
W526-0430E
Drum rotational direction and oil flow direction
Rotational direction
(viewed from the control
valve)
Inlet port
Outlet port
Counterclockwise (hoist-up)
B
A
Clockwise (hoist-down)
A
B
△
0
360-738-20000

F-1
F-1
Winch
4
W526-0430E
△
0
360-738-20000

F-1
F-1
Winch
5
W526-0430E
1. Drum
2. Spindle (*1)
3. Flange (*1)
4. RV gear (*2)
5. Shaft
6. Input gear
7. Spur gear (*3)
8.------
9. Crank shaft (*2)
10. Bush
12. Retaining ring
13. Sleeve
14. Distance piece
15. Oil seal
16. Oil seal
17. Pin
18. Parallel pin
19. Hexagon socket head bolt
20. Bearing
21. Bearing
22. Bearing (*2)
23. Bearing (*2)
24. Retaining ring
25. Retaining ring
26. Retaining ring
27. O-ring
30. O-ring
33. Plug
34. Orifice
101. Rear flange (*4)
102. Shaft
103. Thrust plate
104. Cylinder block
105. Piston (*5)
106. Shoe (*5)
107. Retainer plate
108. Thrust ball
109. Timing plate
110. Washer
112. Piston
113. Spring
114. Spring
115. Friction disc
116. Mating disc
118. O-ring
119. O-ring
120. O-ring
121. O-ring
122. Spool (*4)
123. Plug
124. Stopper
125. Stopper
126. Spring
127. Spring
128. Orifice plug
129. Plug
130. Valve
131. Spring
132. Oil seal
133. Bearing
134. Bearing
135. Parallel pin
136. Parallel pin
137. Needle roller
138. Retaining ring
139. Hexagon socket head bolt
143. Retaining ring
199. Nameplate (*4)
(*1) Parts comprising the spindle Assy (shown in the Figure B). When replacing the spindle Assy, replace all the
parts marked with (*1).
(*2) Parts comprising the RV gear Assy (shown in the Figure C). When replacing the RV gear Assy, replace all
the parts marked with (*2).
(*3) For replacement, replace the 2 pieces at the same time.
(*4) Parts comprising the rear flange Assy (shown in the Figure D). When replacing the rear flange Assy, replace
all the parts marked with (*4).
(*5) Parts comprising the piston Assy (shown in the Figure E). When replacing the piston Assy, replace all the
parts marked with (*5).
Thread size and tightening torque
Tightening torque
Sign/port Thread size
N-m
kgf-m
19
M12
102±16
10.4 ± 1.6
33
R3/8
39±15
4.0 ±1.5
123
―
196±25
20.0 ± 2.5
129
―
78±5
8.0 ± 0.5
139
M8
29±5
3.0 ± 0.5

F-1
F-1
Winch
6
W526-0430E
1.3 Replacing oil seal of the winch motor
[NOTICE]
◆Once disassembled, oil seals should be replaced
with new ones.
◆When disassembling, matchmark every mating face
of component to facilitate reassembly.
1. Remove the plug [33] and drain the gear oil. Then
remove the flange [101].
2. Send pressurized air into the duct hole for the
mechanical brake of the spindle [2] until the piston
[112] is protruded slightly out of the spindle [2].
[NOTICE]
◆Do not send pressurized air abruptly. Otherwise the
piston may pop out of the spindle and create hazard.
Reference
Pressure of the air: 0.29--0.49 MPa {3--5 kgf/cm
2
}
3. Remove the cylinder block [104].
4. Remove the drum [1].
[NOTICE]
◆Prevent the retaining ring [26] from being lost
because it is necessary for adjusting clearance.
◆Pull the drum vertically upward.
If it is pulled up obliquely, it cannot be pulled out
because it will interfere with the component inside
the winch.
◆While the drum is being pulled out, a pin [17] may
drop off onto the surrounding area. When picking up
the pin, do not use a sharp tool.

F-1
F-1
Winch
7
W526-0430E
5. Remove the oil seal [16].
5-1.Apply a punch on the inner ring surface of the
bearing [21] and hit the punch with a hammer. Hit
all around the inner ring evenly and remove the
bearing from the drum.
5-2.Apply a punch on the oil seal [16] and hit the
punch with a hammer. Hit all around the oil seal
evenly and remove the oil seal from the bearing.
6. Remove the oil seal [15].
6-1.Apply a punch on the inner ring surface of the
bearing [20] and hit the punch with a hammer. Hit
all around the inner ring evenly and remove the
bearing from the drum.
6-2.Thrust tools (2 pcs.) with flat and thin ends such
as flathead screwdrivers between the oil seal [15]
and the drum. Then pry the tools to remove the oil
seal [15] from the drum.

F-1
F-1
Winch
8
W526-0430E
1.4 Performance confirmation test after disassembly and assembly of the motor
1
Warmup before test: Warm up the machine until the following conditions are
obtained.
・Hydraulic oil temperature: 45--55°C
・Temperature at outer surface of speed reducer hub:
40--80°C
2
Confirmation test: Check the following points and qualify/disqualify the result.
(The criteria are described below.)
・Driving pressure by motor: 1.96 MPa {20 kgf/cm
2
}orbelowat40min
-1
with
the hoist-up rotational direction
・Drain amount from the hydraulic motor: 0.1 L/min or below at 40 min
-1
Qualified
Disqualified
Install a wire rope.
Disassemble and adjust again.
Installing the
motor and
arranging piping
・Arrange piping after the motor is installed.
・Do not install a wire rope because the test is performed with no load.
・Arrange piping so that attaching a pressure gauge and measuring the drain
amount from the hydraulic motor are possible.
Running in the
motor
Performance
test of motor
Motor
revolution
Loaded
condition
Rotational
direction
Running
duration
40 min
-1
No load Hoist-up
1 min. or
longer

F-1
F-1
Winch
9
W526-0430E
2. Support
2.1 General view

F-1
F-1
Winch
10
W526-0430E
△
9
423-119-11000

F-1
F-1
Winch
11
W526-0430E
1. Pin
2. Retaining ring
3. Castle nut
4. Split pin
5. Pin
6. Plain washer
7. Pin
8. Split pin
9. Plate
10. Guide
11. Machine screw
12. Guide
13. Slewing table
14. Frame Assy
15. Catch
16. Wire rope
17. Sleeve
18. Pin
19. Hydraulic motor Assy
20. Hexagon socket head bolt
21. Plain washer
22. Cap
23. Cylinder Assy
24. Grease nipple
25. Nut
26. Spring washer
27. Retaining ring
28. Support
29. Ball bearing
30. Ball bearing
31. Pinion gear
32. Spring
33. Bolt
34. Nut
35. Spring
36. Hexagon socket head bolt
37. Check valve Assy
38. Lever
39. Support
40. Support
41. Steel ball
42. Key
43. ―――――――
44. Pin
45. Bolt
46. Spacer
47. Retaining ring
48. Ball bearing
49. Coupling
50. Bolt
51. Nut
52. Bolt
53. Grip
54. Pin
55. Split pin
56. Plain washer
57. Support
58. Support
59. Bolt
60. Plain washer
61. Machine screw
62. Plain washer
63. Split pin
64. Plain bearing
65. Guide
66. Button bolt
67. Plate
68. Gear Assy
Thread size and tightening torque
Tightening torque
Sign/port Thread size
N-m
kgf-cm
Treatment
20
M12
122
1250
Apply torque control agent.
36
M10
21.6--24.5
220--250
52
M12
74.0--82.0
760--840
Apply Loctite 2701.
[NOTICE]
◆To avoid the plain washers [21] going off center
because of the contact between their edge and the
motor, orient the cut-off side of each washer toward
the motor.
Before installing the steel balls [41], apply sufficient
grease to their surfaces.
Install the pins [44] in correct orientation.
◆Deterioration of paint on the hydraulic motor flange
or the mounting surface for the hydraulic motor
decreases the tightening force of the bolts [20] and
will make the bolts loosened.
Before installing the bolts [20], make sure that
neither the motor flange surface nor the mounting
surfaces for the motor are painted.

12
W526-0430E
F-1.
F-1.
Winch
2.2 Adjusting the jib swing free/lock lever
1. Detach the spring [35] from the pin [39]. (See the
figure below.)
2. Tighten the bolt [34] slightly to make the
dimension X 15mm.
3.Move the jib swing free/lock lever toward the Y
side shown in the figure below.
Adjust the bolt [34] to make the force required to
shift the lever end when making the steel ball
disengaged from the groove on the pin. (See the
figure below.)
・ Force required to operate the lever:
24.5 N (2.5 kgf) on the end
・ When the bolt [34] is tightened, the required force
increases.
・ When the bolt [34] is loosened, the required force
decreases.
4. After the adjustment, lock the bolt [34] with the nut
[33].
5. Attach the spring [35] to the pin [39].
6. Move the jib swing free/lock lever toward the Z
side shown in the figure below.
Adjust the bolt [50] to make the force required to
shift the lever end when making the steel ball
disengaged from the groove on the pin. (See the
figure below.)
・ Force required to operate the lever:
24.5 N (2.5 kgf) on the end
・ When the bolt [50] is tightened, the required force
decreases.
・ When the bolt [50] is loosened, the required force
increases.
[NOTICE]
◆Adjust so that the forces required to shift the lever
toward the Y side and Z side are equal.
7. After the adjustment, lock the bolt [50] with the nut
[51].
8. Check the following:
・ When the frame is shaken horizontally while the
steel ball is engaged in the groove on the pin, the
steel ball does not go off the groove.
If the steel ball goes off the groove, tighten the
bolt [34] for 1/8 turn.
△
2
423-119-10100
△
9
423-119-11000

F-2
F-2
Hydraulic Motor (for Jib Swing)
13
W102-0670E
F-2 Hydraulic Motor (for Jib Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1.1 General view
Hydraulic symbol

F-2
F-2
Hydraulic Motor (for Jib Swing)
14
W102-0670E
1.2 Main body
1. Screw
2. Geroler set
3. Drive
4.--
5. Backup washer
6. End cap
7. Spacer plate
8. Flange
9. Poppet
10. Housing
11. Output shaft
12. --
13. Thrust bearing race
14. Thrust needle bearing
15. Screw
16. Oil seal
17. Dust seal
18. O-ring
19. O-ring
20. --
21. Nameplate
22. Rivet
23. Spring pin
24. Plug end cap
25. O-ring
26. --
27. --
28. --
29. Retaining ring
30. Wheel gear
31. Needle bearing
32. O-ring
33. Spring pin
34. Bush plate
35. Bush
36. Mating disc
37. Piston
38. Spring
39. Friction disc
40. Bearing housing

F-2
F-2
Hydraulic Motor (for Jib Swing)
15
W102-0670E
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
Remarks
Screw [1]
－
31--34
3.1--3.4
Screw [15]
－
26--31
2.6--3.2
Apply Loctite 277.
Plug end cap [24]
－
10--15
1.0--1.5
Port Av
G 3/8
49.0
5.0
Port Bv
G 3/8
49.0
5.0
Drain port
G 1/4
29.4
3.0

16
W102-0670E
F-2.
F-2.
Hydraulic Motor (for Jib Swing)
1.3 Counterbalance valve
1. Valve body
2. Spool
3. Poppet
4. Spring
5. Spring
6. Plug
7. Plug
8. Washer
9. O-ring
10. O-ring
11. O-ring
12. Plug
13. Seat
14. Ball screw
15. --
16. --
17. --
18. Plug
19. Pipe kit
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
Remarks
Plug [6]
－
31--34
3.1--3.4
Plug [7]
－
26--31
2.6--3.2
Apply Loctite 242.
Plug [18]
－
10--15
1.0--1.5
Wrap a sealing tape.
Valve mounting bolt
－
29.5--34.0
3.0--3.5
△
0
366-639-60000

F-3.
F-3.
Pilot Check Valve (for Jib Elevating Cylinder)
17
W115-0650E
F-3 Pilot Check Valve (for Jib 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. Body
2. Plug
3. Seat
4. Spring
5. Plunger
6. Piston
7. O-ring
8. O-ring
9. ---
10. Packing
Thread size and tightening torque
Tightening torque
Sign/port Thread size
N-m
kgf-m
Remarks
Plug [2]
38.2--45.1
3.9--4.6
Apply thread
locker.
A port
G1/4
29.4±3
3.0 ± 0.3
B port
G1/4
29.4±3
3.0 ± 0.3
Mounting bolt
M10
21.6--24.5
2.2--2.5
Hydraulic
△
1
366-246-30000

i
G
Boom Telescoping System
Contents
G-1 Boom................................................. 1
1. Structure .................................................... 1
1.1 Boom .......................................................... 1
1.2 Piping for the boom .................................... 3
1.3 Wiring for automatic charging system ........ 4
1.4 Optical fiber cable....................................... 5
1.5 Wiring for the boom length detector and
boom angle detector ............................ 6
2. Disassembly .............................................. 7
2.1 Removing the bucket.................................. 7
2.2 Removing the 2nd boom section ................ 8
2.3 Removing the top boom section............... 11
3. Inspection ................................................ 14
3.1 Boom ........................................................ 14
3.2 Slide plate................................................. 14
3.3 Sheave ..................................................... 14
3.4 Boom telescoping wire rope ..................... 14
4. Adjusting the clearance
around the FRP boom .................. 15
4.1 Adjusting the clearance between
the frame and the FRP boom ............. 15
4.2 Adjusting clearance in the frame
outer support ...................................... 17
4.3 Adjusting clearance between
the saddle and the FRP boom ........... 19
5. Assembly ................................................. 20
5.1 Assembling the top boom section ............ 20
5.2 Assembling the 2nd boom section ........... 24
5.3 Assembling the base boom section ......... 30
5.4 Installing the bucket ..................................34
6. Adjustment............................................... 35
6.1 Tension adjustment of hoses and optical
fibers (during boom assembling) ........35
6.2 Tension adjustment of hoses and optical
fibers (during wire rope adjustment) ...36
6.3 Tension adjustment of hoses and optical
fibers (after wire rope adjustment) ......36
6.4 Adjusting wire ropes..................................37
G-2 Counterbalance Valve
(for Telescoping Cylinder) ....38
1. Structure .................................................. 38
G-3 Pilot Check Valve
(for Telescoping Circuit) .......40
1. Structure .................................................. 40

G-1
G-1
Boom
G-1
1
W536-1260E
1
G-1 Boom
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit
described in the parts catalog before starting disassembling operations.
1. Structure
1.1 Boom
△
20
422-025-90000

G-1
G-1
Boom
2
W536-1260E
1. ―――――
2. Top boom section (FRP)
3. Saddle
4. 2nd boom section
5. Base boom section
6. Wire rope
7. Wire rope
8. Roller Assy
9. Pin
10. Castle nut
11. Split pin
12. Plain washer
13. ―――――
14. ―――――
15. ―――――
16. Pin
17. Retaining ring
18. Plate (t0.8)
19. Plate (t0.5)
20. Plate (t0.5)
21. Slide plate
22. Slide plate
23. Plate (t0.6)
24. Plate (t0.5)
25. Plate (t0.5)
26. Plate (t0.8)
27. Nut
28. Plain washer
29. Spacer
30. ―――――
31. Spring washer
32. Button bolt
33. Frame (top boom section)
34. ―――――
35. ―――――
36. ―――――
37. Button bolt
38. Pin
39. Plate
40. Sheave Assy
41. Plate (t0.8)
42. Plate
43. Slide plate Assy
44. Plate (t1.0)
45. Slide plate
46. Button bolt
47. Grease nipple
48. Cap
49. ―――――
50. Retaining ring
51. Plate (t0.8)
52. Plate (t0.5)
53. Plate (t0.5)
54. Plate (t1.0)
55. Hexagon socket head bolt
56. Plate Assy
57. Slide plate
58. Slide plate
59. Plate (t1.0)
60. Plate (t1.0)
61. Plate (t0.6)
62. Pin
63. Plate (t0.8)
64. Slide plate
65. Plate (t0.8)
66. Machine screw
67. Slide plate
68. Slide plate
69. Button bolt
70. Pin
71. Spacer
72. Multi-sheave Assy
73. Retaining ring
74. Cap
75. Sheave Assy
76. Retaining ring
77. Pin
78. Retaining ring
79. Pin
80. Plain bearing
81.―――――
82. Support
83.―――――
84. Bolt
85. Disc spring
86. Bolt
87. Bolt
88. Nut
89. Slide plate
90. Slide plate
91. Plate
92. Nut
93. Spring washer
94. Hose
95. Fastener
96. Nut
97. Bolt
98. Plate
99. Pin
100. Bolt
101. Plate
102. Pin
103. Roller
104. Plate
105. Bolt
106. Plain washer
107. ―――――
108. Button bolt
109. Plain washer
110. Plate
111. Plate
112. Plate (t0.8)
113. Button bolt
114. Support
115. Plate (t0.2)

G-1
G-1
Boom
G-1
3
W536-1260E
3
1.2 Piping for the boom
△
10
423-473-40000

G-1
G-1
Boom
G-1
4
W536-1260E
4
1.3 Wiring for automatic charging system
△
8
423-563-50000

G-1
G-1
Boom
G-1
5
W536-1260E
5
1.4 Optical fiber cable
△
2
424-348-40000

G-1
G-1
Boom
G-1
6
W536-1260E
6
1.5 Wiring for the boom length detector and boom angle detector
△
5
423-563-20000

G-1
G-1
Boom
7
W536-1260E
2. Disassembly
[NOTICE]
The procedure to remove the 2nd--top boom
sections is described below.
Before removing hoses and cables, put marks on
them to facilitate reassembly.
Use waste rugs to prevent damage to the rod of the
leveling cylinder.
2.1 Removing the bucket
1. Set up the aerial platform level.
2. Swing the boom to the over-side or over-rear.
3. Set a workbench which can support the bucket.
Lower the bucket onto the platform, and stop the
machine.
[NOTICE]
Choose a workbench so that the boom becomes
parallel to the ground when the bucket is set on the
workbench.
4. Operate each manual control levers inside the
swing table to its stroke end to release residual
pressure in the hydraulic circuits.
[NOTICE]
When you operate the manual control levers, turn
and hold the emergency switch in the "ON"
position.
5. Remove the covers from the bucket and top
boom section.
6. Disconnect the wiring for the bucket and for the
automatic charging system (on the top boom
section).
7. Disconnect the optical fiber cable from the signal
transmitter on the bucket, and fix it on the head of
the top boom section.
[NOTICE]
If you loop up the optical fiber cable, make the
radius of the loops 60 mm or greater to prevent
damage to the optical fiber cable.

G-1
G-1
Boom
8
W536-1260E
8. Remove the hose which connects the top boom
section and the bucket from the joint on the
boom.
9. Disconnect the bucket from the leveling cylinder
by removing the pin 1, then remove the pin 2.
10.Separate the bucket from the boom.
2.2 Removing the 2nd boom section
1. Pull the optical fiber cable out of the AMC.
Then remove the optical fiber cable from the top
face of the boom, and fix it temporarily on the
head of the 2nd boom section.
[NOTICE]
If you loop up the optical fiber cable, make the
radius of the loops 60 mm or greater to prevent
damage to the optical fiber cable.

G-1
G-1
Boom
9
W536-1260E
2. Remove the nuts (2 pcs.) for the boom extension
wire rope.
[NOTICE]
Before removing the nuts, measure the dimension L
shown in the figure below as the reference for
reassembly.
3. Remove the high-pressure hoses (2 pcs.) which
are connected to the telescoping cylinder.
4. Remove the high-pressure hoses (2 pcs) which
are connected to the telescoping cylinder.
[NOTICE]
When detaching the cord, prevent the cord reel of
the boom length detector from pulling the cord all
the way.
5. Detach the high-pressure hoses (5 pcs.) from the
connecting section.
To prevent each hose from overlapping another,
fix the hoses on the top face of the 2nd boom
section using packaging tapes.
[NOTICE]
Before removing hoses, put marks on them to
facilitate reassembly.
6. Disconnect the wiring for the automatic charging
system (on the base boom section) from the
wiring for the terminal on the base boom section.
(See the figure below.)
7. Detach the wiring for the automatic charging
system (on the base boom section) from the base
boom section, and attach it to the swing table
using a packaging tape, etc.

G-1
G-1
Boom
10
W536-1260E
8. Remove the mounting support and the support on
the base boom section from the head of the base
boom section. (See the above figure.)
Remove the terminal on the base boom section
from the base boom section.
[NOTICE]
The support mounting bolts are very hard to loosen
because thread locking agent (Loctite 262T) is
applied on them.
9. Remove the multi-sheave block from the top face
of the base boom head, and detach the boom
retraction wire ropes (2 pcs.)
Push the detached boom retraction wire ropes
through an elongated hole into the 2nd boom
section.
Then fix the boom retraction wire ropes on the top
face of the 2nd boom section using a packaging
tape, etc.
[NOTICE]
Before removing the wire ropes, measure the
dimension L1 shown in the figure below as the
reference for reassembly.
IW536-065010
L1
10.Remove the slide plates on the top, side and
bottom faces of the base boom section head.
[NOTICE]
The mounting bolts for the upper slide plate Assy
and lower slide plate are very hard to loosen
because thread locking agent (Loctite 262T) is
applied on them.
11. Pull the telescoping cylinder fixing pin out of the
base boom section, and remove the anti-buckling
bolt.
[NOTICE]
The anti-buckling bolt is very hard to loosen
because thread locking agent (Loctite 262T) is
applied on it.

G-1
G-1
Boom
11
W536-1260E
12.Pull the 2nd boom section out of the base boom
section.
[NOTICE]
Prevent the hydraulic hoses, optical fiber cable,
and wire ropes on the top face of the 2nd boom
section from being crushed between the base
boom head and the 2nd boom section.
2.3 Removing the top boom section
1. Remove the connecting pin from the 2nd boom
section, and pull out the telescoping cylinder.
2. Remove the rope guide roller Assy from the tail of
the 2nd boom section.
[NOTICE]
The mounting bolts for the rope guide roller Assy
are very hard to loosen because thread locking
agent (Loctite 262T) is applied on them.

G-1
G-1
Boom
12
W536-1260E
3. Move the hoses and optical fiber cable toward the
rear of the boom. Then remove the pin, and pull
out the multi-sheave block and sheave Assy on
the tail of the 2nd boom section upward.
4. Remove the support 1 (roller Assy) and support 2
(support Assy) inside the 2nd boom section.
5. Remove the covers from the upper face of the
2nd boom section.
Remove the slide plates on the top and side
faces of the boom and the roller Assy on the
bottom face of the boom.
The figure below omits a lower-side slide plate.
[NOTICE]
The mounting bolts for the upper slide plates are
very hard to loosen because thread locking agent
(Loctite 262T) is applied on them.
6. Pull out the top boom section by approx. 0.5 m.
Remove the sheave Assy and button bolt (4 pcs.)
for wire rope guide.
[NOTICE]
The button bolts are very hard to loosen because
thread locking agent (Loctite 262T) is applied on
them.

G-1
G-1
Boom
13
W536-1260E
7. Pull out the boom extension wire rope slightly
forward. Then fix it to the top boom section head
using a cord, etc.
8. Pull the top boom section out of the 2nd boom
section.
9. Separate the top boom section into the frame
(head of the top boom section), the FRP boom,
and the saddle (tail of the top boom section).
10. Remove the terminal for the automatic charging
system from the support on the frame.
11. Remove the rubber cover from the end of the
frame.
Remove the pin from the frame, and pull out the
leveling cylinder.

G-1
G-1
Boom
14
W536-1260E
12.Detach the joint from the head of the frame.
Then separate the joint from the hose.
13.Detach the optical fiber cable from the frame.
3. Inspection
3.1 Boom
Check the boom for torsion, deformation, warp or
cracks.
3.2 Slide plate
Replace cracked or severely worn parts.
3.3 Sheave
Replace damaged, deformed or severely worn
parts.
3.4 Boom telescoping wire rope
[NOTICE]
The following wire ropes must not be reused:
Deformed or corroded.
Kinked.
10% or more wires within one turn of a strand are
broken.
Decrease in the diameter exceeds 7% of the
nominal diameter.
Damaged by heat.

G-1
G-1
Boom
15
W536-1260E
4. Adjusting the clearance around the
FRP boom
[NOTICE]
If the shim does not fit or the remaining clearance
is too large, decrease or increase the shim pieces.
Make the remaining clearance as small as
possible.
4.1 Adjusting the clearance between the frame
and the FRP boom
1. Measurement of the frame outer dimension
(FB) and inner dimension (BBS, BBM, BBL)
of the FRP boom
Measure the frame outer dimension and the inner
dimension of the FRP boom using vernier
calipers.
The numbers in parentheses shown in the figure
represents the standard values.
Frame outer dimension: FB (mm)
Measure the outer dimension at the center points
on the side faces of the frame. (See the figure
below.)
Inner dimension of the FRP boom: BB1, BB2,
BB3 (mm)
Measure the inner dimension at the position of
the frame mounting bolt holes on the side faces
of the FRP boom. (See the figure below.)
The measured values of the inner dimension of
the FRP boom (BB1--BB3) are represented as
below.
Minimum of the inner dimension of the FRP
boom: BBS
Maximum of the inner dimension of the FRP
boom: BBL
Middle of the inner dimension of the FRP boom:
BBM
2. Calculating shim pieces from the minimum of
the inner dimension (BBS) of the FRP boom
Calculate S1 (difference between the minimum
dimension BBS and frame outer dimension FB),
and determine the number of the shim pieces.
S1=BBS-FB
S1/0.8=Na  RemainderA(0 A 0.7)
0A0.4:
Divide Na pieces of shim (t=0.8mm) in two, and
put them in the right and left of the boom.
If Na is an odd number, make the shim pieces of
either side 1 more than the other.
0.4<A 0.7:
Divide Na pieces of shim (t=0.8mm) in two, and
put them in the right and left of the boom.
Then put 1 piece of the shim (t=0.5mm) in either
side.
If Na is an odd number, however, make the piece
of either side of the shim (t=0.8mm) 1 more than
the other. Then put 1 piece of shim (t=0.5mm) in
the side of the less pieces of shim.
Shim (t=0.8mm): 422-025-90051
Shim (t=0.5mm): 422-025-90061

G-1
G-1
Boom
16
W536-1260E
3. Calculating shim pieces for the medium
(BBM) and maximum (BBL) of the inner
dimension of the FRP boom
Calculate S2 (difference between the medium
dimension BBM and minimum dimension BBS)
and S3 (difference between the maximum
dimension BBL and minimum dimension BBS)
and determine the number of the shim pieces.
1) Number of shim piece for S2
 S2=BBM--BBS
S2 < 0.5: Shim is not necessary.
S2 0.5:
 S2/0.5=Nb  RemainderB(0 B<0.5)
Divide Nb pieces of shim (t=0.5 mm) in two, and
put them in the right and left of the boom.
Shim (t=0.5mm): 422-025-90330
2) Number of shim piece for S3
 S3=BBL--BBS
S3 < 0.5: Shim is not necessary.
S2 0.5:
 S3/0.5=Nc  RemainderC(0 C<0.5)
Divide Nc pieces of shim (t0.5 mm) in two, and
put them in the right and left of the boom.
Shim (t0.5mm): 422-025-90330
△
1
422-025-90900

G-1
G-1
Boom
17
W536-1260E
4.2 Adjusting clearance in the frame outer
support
[NOTICE]
If the shim does not fit or the remaining clearance
is too large, decrease or increase the shim pieces.
Make the remaining clearance as small as
possible.
1. Measurement of the support (A1--A3) and
outer dimension (R1--R3) of the FRP boom
Measure the frame inner dimension and the outer
dimension of the FRP boom using vernier
calipers.
The numbers in parentheses shown in the figure
represents the standard values.
Inner dimension of the support: A1, A2, A3 (mm)
Measure the inner dimension at the position of
the frame mounting bolt holes on the side faces
of the FRP boom. (See the figure below.)
Outer dimension of the FRP boom: R1, R2, R3
Measure the outer dimension at the position of
the frame mounting bolt holes on the side faces
of the FRP boom. (See the figure below.)
2. Calculating shim pieces for the maximum
clearance
Calculate the "maximum clearance between the
supports and FRP boom", and determine the
number of the shim pieces.
Calculate the clearance on the support mounting
sections.
 ClearanceW1=A1--R1
 ClearanceW2=A2--R2
 ClearanceW3=A3--R3
The maximum value among W1--W3 shall be
called WL.
WL/0.6=Nd  RemainderD
When Nd is an odd number:
Divide "Nd plus 1" pieces of shim (t=0.6mm) in
two, and put them in the right and left of the
boom.
When Nd is an even number:
Divide "Nd plus 2" pieces of shim (t=0.6mm) in
two, and put them in the right and left of the
boom.
Shim (t=0.6mm): 422-027-00111
3. Installing the supports and checking
clearance
1. Insert each shim whose piece number is
determined as described in the previous sections
between the support and FRP boom. Then attach
the supports and frame to the FRP boom.
2. Tighten the frame mounting bolts in the following
sequence.
1) Tighten the front 2 bolts among the tightening
bolts on the top face.
2) Tighten the rear 2 bolts among the tightening
bolts on the top face. Then tighten the mounting
bolts on side faces in the order of position,
uppermost first. Also see the "Assembling the top
boom section" described later.
Tightening torque of the frame mounting bolts:
186--206 N-m {1900--2100 kgf-cm}
Apply torque control agent.

G-1
G-1
Boom
18
W536-1260E
3. After installing the supports, make sure that there
is clearance between the bottom face of the
frame and the inside of the FRP boom bottom
plate.
[NOTICE]
If there is no clearance between the bottom face of
the frame and the inside of the FRP boom bottom
plate, attach the frame and the supports all over
again.
△
1
422-025-90900

G-1
G-1
Boom
19
W536-1260E
4.3 Adjusting clearance between the saddle and
the FRP boom
[NOTICE]
If the shim does not fit or the remaining clearance
is too large, decrease or increase the shim pieces.
Make the remaining clearance as small as
possible.
1. Measurement of the saddle inner dimension
(SB) and outer dimension (BB3) of the FRP
boom
Measure the saddle outer dimension and the
inner dimension of the FRP boom using vernier
calipers.
The numbers in parentheses shown in the figure
represents the standard values.
Saddle inner dimension SB (mm):
Measure the inner dimension at the position of
the mounting bolt holes on the saddle. (See the
figure below.)
Outer dimension of the FRP boom BB3 (mm):
Measure the outer dimension at the position of
the saddle mounting bolt holes on the side faces
of the FRP boom. (See the figure below.)
2. Calculating shim pieces for the side faces of
the boom
Calculate the "clearance between the saddle and
the side face of the FRP boom", and determine
the number of the shim pieces.
Clearance on the side face of the boom S5 =
SB--BB3
 S5/0.8=Ne  RemainderE(0 E 0.7)
0E0.4:
Divide Ne pieces of shim (t=0.8mm) in two, and
put them in the right and left of the boom.
If Ne is an odd number, make the shim pieces of
either side 1 more than the other.
0.4 <E 0.7:
Divide Ne pieces of shim (t=0.8mm) in two, and
put them in the right and left of the boom.
And add 1 piece of the shim (t=0.5mm) to either
side.
If Ne is an odd number, however, make the piece
of either side of the shim (t=0.8mm) 1 more than
the other. Then put 1 piece of shim (t=0.5mm) in
the side of the less pieces of shim.
Shim (t=0.8mm): 422-025-90220
Shim (t=0.5mm): 422-025-90230
3. Calculating shim pieces for the top face of
the boom
Calculate the "clearance between the saddle and
the top face of the FRP boom", and determine the
number of the shim pieces.
Attach the saddle on the FRP boom. Check any
clearance between the saddle and the top face of
the FRP boom at the right and left bolt mounting
positions on the top face of the saddle.
If there is clearance, insert shims (t=0.5mm and
t=1.0mm) between the saddle and the FRP boom
to make clearance as small as possible.
Shim (t=0.5mm): 422-025-90240
Shim (t=1.0mm): 422-025-90250
△
1
422-025-90900

G-1
G-1
Boom
20
W536-1260E
5. Assembly
5.1 Assembling the top boom section
1. Attach hoses to the leveling cylinder.
2. Insert the frame, frame outer support and the
saddle in the FRP boom. Then adjust the
clearance according to the "Adjusting the
clearance around the FRP boom" section.
After adjustment is completed, remove the frame
and frame outer support.
3. Insert the leveling cylinder into the frame, and fix
it with pins.
Then pass the hose for the leveling cylinder and
the optical fiber cable through the frame, out of
the tail of the frame.
[NOTICE]
When installing the leveling cylinder, cover it with
corrugated papers to protect the cylinder.
Pass the hose and the optical fiber cable through
the frame support as shown in the right figure.
Before fixing the optical fiber cable, remove the
spiral tube at the position to be fixed by a clamp.
4. If the joint to be installed on the frame is already
disassembled, reassemble the joint.
Connect the hoses P, Dr, T1, and T2 to the
assembled joint.
Then fix the joint temporarily on the frame.
Connect the hoses T1 and T2 to the rear of the T
(3/8) shown in the figure below.
5. Check the arrangement of the hoses and optical
fiber cable. And bind them in a flat ribbon with a
cord so that the arranged order of the hoses and
cable is maintained. (For the order, see the figure
below.)

G-1
G-1
Boom
21
W536-1260E
6. Measure the inner dimensions at the head and
tail of the 2nd boom section.
[NOTICE]
Record the measured inner dimensions of the
2nd boom section because they are required for
the boom clearance adjustment in the step 9.
7. Attach the saddle on the FRP boom.
Tightening torque of the mounting bolts:
220--250 N-m {2250--2500 kgf-cm}
Apply torque control agent.
Give anticorrosive treatment (painting, etc.) to the
conical spring washers.
8. Attach slide plates to the top and side faces of the
saddle.
9. After installing the slide plates, increase or
decrease the shim according to the dimension
measured in the step 6 to adjust the clearance.
After adjustment, apply thread locking agent
(ThreeBond 1401) to the slide plate mounting
bolts and lock them.
[NOTICE]
The vertical clearance around the boom shall be
1--2 mm in total.
The horizontal clearance around the boom at its tail
shall be 1--2.5 mm in total. The difference of right
and left shim piece number shall be 1 or less.
Increase or decrease the right and left shim pieces
to let the slide plates in even contact with the 2nd
boom section bottom.
Make sure that the lower slide plates and the head
of the FRP boom are free from torsion.

G-1
G-1
Boom
22
W536-1260E
10.If the support has been removed during
disassembly, attach it to the bottom face of the
frame.
Align the end of the support to the section A of the
frame. (See the figure below.)
Tightening torque of the support mounting bolts:
85--103N-m {870--1050 kgf-cm}
B
A
Frame
Bolt (with conical
spring washer)
Support
View B
IW536-126007E
Bolt
(with conical
spring washer)
11. Attach the frame and frame outer support to the
FRP boom.
Tightening torque of the mounting bolts:
186--206 N-m {1900--2100 kgf-cm}
Apply torque control agent.
After fixing the frame and frame outer support,
bend the edges of the plate to prevent the bolts
from loosening.
Give anticorrosive treatment (painting, etc.) to the
conical spring washers.

G-1
G-1
Boom
23
W536-1260E
12.Pass the hoses and optical fiber cable to the tail
of the top boom section.
[NOTICE]
Pass the hoses and optical fiber cables on the
support (which is covered by a rubber hose and
whose cross section is oval) at the rear end inside
the saddle. See the figure below.
13.Fix the optical fiber cable on the frame using
clamps.
Attach a rubber cover on the frame head.
After attaching the rubber cover, fix the joint to the
frame.
14.Attach the boom extension wire rope and boom
retraction wire rope to the tail of the top boom
section. Then fix them with pins and retaining
rings.
[NOTICE]
Attach each pin so that the retaining ring is located
inside the boom.
Make sure that the retaining rings are inserted and
fixed securely.
15.Pass the boom extension wire rope through the
hole in the slide plate on the side face at the tail
of the tail of the top boom section. Pull its end
until the sheathed section of the wire rope comes
out of the hole.
[NOTICE]
Tie up the curved sections of the boom extension
wire rope with a cord, and fix the cord to the top
boom section.

G-1
G-1
Boom
24
W536-1260E
16.Tie a cord of approx. 5 m long to the threaded
section on the end of the boom extension wire
rope (in order to facilitate subsequent assembly).
17.Apply boom grease (TADANO genuine) to the
surface of the slide plate.
5.2 Assembling the 2nd boom section
1. If the slide plates on the bottom face at the tail of
the 2nd boom section have been removed, attach
them to the original position.
2. To make the height of the lower slide plates on
the 2nd boom section equal, adjust shim based
on the top face of the 2nd boom section.
[NOTICE]
Apply ThreeBond 1401 to the slide plate mounting
screws. Tighten each screw and return it for 1/4
turn (so that the attached slide plate can be moved
slightly by hand.)
Increase or decrease the right and left shim pieces
to let the bottom of the base boom section in even
contact with the slide plates. The difference of right
and left shim piece number shall be 1 or less.
2nd boom section
(The lower side is shown upward in this figure.)

G-1
G-1
Boom
25
W536-1260E
3. Bind the boom retraction wire rope, optical fiber
cable and hoses in a cluster. Pass them into the
2nd boom section, and out of the top face of the
2nd boom section toward the rear of the boom.
[NOTICE]
Prevent the optical fiber cable and hoses from
being smeared with boom grease.
To protect the optical fiber cable and hoses, lay a
cardboard over the area between the hole in the
top face of the 2nd boom section and the boom tail.
4. While pulling the optical fiber cable, hoses, and
wire rope toward the tail of the 2nd boom section,
insert the top boom section into the 2nd boom
section.
5. Insert the top boom section into the 2nd boom
section until the top boom section is exposed
approx. 1 m longer than the fully retracted
condition.
6. Attach a roller Assy on the bottom of the 2nd
boom section.
[NOTICE]
Do not scratch the FRP boom.
7. Attach the sheave Assy to the head of the 2nd
boom section. Reeve the boom extension wire
rope on the grooves on the sheaves.
Tightening torque of the mounting bolts for the
sheave pin:
33--37 N-m {335--375 kgf-cm}
[NOTICE]
When installing the sheaves, make the retaining
rings of the bearing facing toward the outer surface
of the boom.

G-1
G-1
Boom
26
W536-1260E
8. Attach a button bolt (upper) to prevent the boom
extension wire rope from coming off.
Tightening torque for the button bolt: 23--27 N-m
{235--275 kgf-cm}
Apply thread locking agent (Loctite 262T).
9. Pull the boom extension wire rope until it comes
out of the tail of the 2nd boom section.
Then remove the cord which has fixed the boom
extension wire rope to the top boom section.
10.While pulling the optical fiber cable, hoses, and
wire rope toward the tail of the 2nd boom section,
insert the top boom section into the 2nd boom
section all the way.
11. Visually check that the any of the hoses and
optical fiber cable does not overlap another in the
boom.
[NOTICE]
If any of the hoses and optical fiber cable overlaps
another, separate them.
12.Attach slide plate on the sides of the 2nd boom
section head. And adjust clearance using shims.
Then attach a slide plate on the top of the boom
section. And adjust clearance in the same way.
(See the figure below.)
The figure below omits a lower side slide plate.
Tightening torque of the upper slide plate
mounting bolts:
33--37 N-m {335--375 kgf-cm}
Apply thread locking agent (Loctite 262T).
[NOTICE]
The horizontal clearance around the each slide
plate on the side shall be less than 0.2 mm.
The vertical clearance around the boom shall be
1--2 mm in total.

G-1
G-1
Boom
27
W536-1260E
13.Install the support 1 (roller Assy) and support 2
(support Assy) in the tail of the 2nd boom section.
Tightening torque of the support 1 mounting bolts:
20±1N-m{200±10kgf-cm}
[NOTICE]
Apply thread locking agent (ThreeBond 1401) to
the mounting bolts for the support 1 and support 2.
Apply grease to the areas where a hose or optical
fiber cable may contact.
When placing the plates to adjust horizontal
position of the support 1, place the same number of
plates on the right and left side.
14.Apply grease to the areas on the hoses and
optical fiber cable where the multi-sheave block
may contact.
15. Attach the multi-sheave block 2, spacer, and the
sheave Assy (for boom retraction) to the 2nd
boom section.
[NOTICE]
When attaching the multi-sheave block, make the
R-mark side ("R" is painted in red) face the right
side of the boom.
Avoid scratching and damaging the hoses.
Apply sufficient grease to the rotating section and
groove of each sheave.
When installing the sheave Assy (for boom
retraction), make the retaining ring of the bearing
face toward outside of the boom.
Make sure that the retaining rings for the pin are
inserted and fixed securely.

G-1
G-1
Boom
28
W536-1260E
16.Reeve the optical fiber cable and hoses around
the grooves on the multi-sheave block.
Reeve the boom retraction wire rope around the
groove on the sheave Assy (for boom retraction).
[NOTICE]
Reeve the optical fiber and hoses around the
multi-sheave block so that their layout is as shown
in the figure below when viewed from the boom tail.
17.Attach the wire guide roller Assy.
Tightening torque of the wire guide roller Assy
mounting bolts:
35±2N-m{355±20kgf-cm}
Apply locking agent (Loctite 262T).
[NOTICE]
The clearance between the wire guide roller and
the multi-sheave block shall be 1--2 mm. Apply
grease to the both ends of each wire guide roller.
18. While pulling the optical fiber cable, hoses, and
wire rope for boom retraction toward the boom
head, make sure that they are not overlapped
one another in the boom, on the boom, or around
the multi-sheave block.
After the check, remove the cord that holds the
optical fiber cable and hoses in a ribbon.
19.Measure the inner dimensions at the head and
tail of the base boom section.
[NOTICE]
Record the measured inner dimensions of the
base boom section because they are required for
the step 23 and the clearance adjustment in the
"Assembling the boom section".
Measure these
dimensions.
Measure these
dimensions.
Front end of base
boom section
Rear end of base
boom section
IW536-065039E
20. Attach the counterbalance valve to the
telescoping cylinder.
Tightening torque of the mounting bolts:
11.8--13.7 N-m {120--140 kgf-cm}

G-1
G-1
Boom
29
W536-1260E
21. Insert the telescoping cylinder into the 2nd boom
section, then fix the cylinder to the boom using a
pin.
[NOTICE]
Make sure that the retaining rings for the pin are
inserted and fixed securely.
22. Attach the slide plates on the sides and upper
corners at the tail of the 2nd boom sections.
23.After installing the slide plates, increase or
decrease the shim pieces according to the inner
dimension of the base boom section measured in
the step 19 to adjust the clearance based on the
bottom face of the 2nd boom section.
[NOTICE]
In the figure below, the 2nd boom section is
installed in the base boom section.
Increase or decrease the right and left shim pieces
to let the slide plates on the sides and upper corner
in even contact with the sides of the base boom
section.
The vertical clearance around the boom shall be
1--2 mm in total.
The horizontal clearance around the boom at its tail
shall be 1--2.5 mm in total. The difference of right
and left shim piece number shall be 1 or less.
Apply thread locking agent (ThreeBond 1401) to
the mounting screws for the boom side slide plates.
Tighten each screw and return it for 1/4 turn (so
that the attached slide plate can be moved slightly
by hand.)

G-1
G-1
Boom
30
W536-1260E
24. Apply grease to the areas between the tail of the
2nd boom section and the multi-sheave block on
the head of the base boom section (A--B shown in
the figure below) on the hoses and optical fiber
cable.
[When the base boom section has been assembled]
A
BC
Support 1
Multi-sheave
Clamp
IW536-065038E
25.Apply boom grease (TADANO genuine) to the
surface of the slide plate.
26. Insert the 2nd boom section into the base boom
section until the 2nd boom section is exposed
approx. 1 m longer than the fully retracted
condition.
5.3 Assembling the base boom section
1. Pull the boom retraction wire rope to the support
on the top face of the base boom section.
Then fix the boom retraction wire rope to the
support on the top face of the base boom section.
Adjust the dimension L1 to the one measured
before disassembly.
IW536-065010
L1
2. Pass the boom extension wire rope through the
hole in the tail of the base boom section, and
remove the cord on the end of the wire rope.
Then fix the boom extension wire rope to the tail
of the base boom section. Adjust the dimension L
to the one measured before disassembly.
3. Assemble the slide plate Assys to be attached on
the upper area of the base boom section.
4. Attach the slide plates on the top, side and
bottom faces of the base boom section head.

G-1
G-1
Boom
31
W536-1260E
5. Increase or decrease the shim according to the
dimension measure in the step 23 in the
"Assembling the 2nd boom section" section to
adjust the clearance on the slide plates.
[NOTICE]
The vertical clearance around the boom shall be
1--2 mm in total.
The horizontal clearance on the each side of the
boom shall be less than 1mm difference of right
and left shim piece number shall be 1 or less.
If you use a shim piece 0.2 mm thick, insert it
between thicker shim pieces before installing the
shim.
Tightening torque of the lower slide plate
mounting bolts:
36--40 N-m {370--410 kgf-cm}
Apply Loctite 262T or equivalent.
Tightening torque of the side slide plate mounting
bolts:
19--21 N-m {190--210 kgf-cm}
Apply Loctite 1401 or equivalent.
Tightening torque of the upper slide plate
mounting bolts:
23--27 N-m {235--275 kgf-cm}
Apply Loctite 262T or equivalent.
Apply thread locking agent (ThreeBond 1401) to
the mounting screws for the upper slide plates.
Tighten each screw and return it for 1/4 turn.
6. Attach the multi-sheave block on the base boom
section head. Connect the hose to the hose
connection joint on the top face of the boom.
Temporarily fix the optical fibers at tension of
approx. 50 N {5 kgf} to the clamps on the base
boom section.
[NOTICE]
When attaching the multi-sheave block, make the
R-mark side ("R" is painted in red) face the right
side of the boom.
7. Adjust the tension on the hoses and optical fiber
hose.
See the "Tension adjustment of hoses and optical
fibers (during boom assembling)" section later.

G-1
G-1
Boom
32
W536-1260E
8. Attach a button bolt (lower) to prevent the boom
extension wire rope from coming off.
Tightening torque for the button bolt: 23--27 N-m
{235--275 kgf-cm}
Apply Loctite 262T or equivalent.
After installing the bolt, make sure that each
sheave turns in the direction shown in the figure
below when the boom extends.
9. Insert the 2nd boom section into the base boom
section all the way.
Then insert the fixing pin into the telescoping
cylinder, and attach the anti-buckling bolt.
Apply thread locking agent (Loctite 262T or
equivalent) to the anti-buckling bolt.
[NOTICE]
Tighten the bolt until its head touches the A area.
Then lock it using the lock nut.
10.Loosen temporary fixing on the optical fiber.
Adjust the tension on the boom retraction wire
rope.
For details, see the "Adjusting the wire rope"
section later.
After tension adjustment, attach a vinyl hose to
the end of the boom extension wire rope.
[NOTICE]
Do not pull the hoses beyond the basic dimension
(70 mm) as shown below.
IW536-065046E
(
70mm
)
Multi-sheave
Adjusting nut
Wire rope for
boom retraction
Basic dimension

G-1
G-1
Boom
33
W536-1260E
11. After adjustment of the wire rope, attach the
optical fiber rope and adjust tension on the hoses
and optical fiber ropes.
For adjustment procedure, refer to "Tension
adjustment of hoses and optical fibers (after wire
rope adjustment)
12.Attach the cord for the boom length detector to
the 2nd boom section.
Apply thread locking agent (ThreeBond 1401) to
the threaded section of the rollers and cord fixing
bolt.
13.Reeve the wiring for the automatic charging
system which has been detached during
disassembly.
14.Fix the optical fiber cable and wiring for the
automatic charging system on the boom using a
clamp.
15.Connect the hose from the swing table to the
telescoping cylinder.
Connect the optical fiber cable to the AMC on the
swing table.
16.Attach the support on the top face of the base
boom section, and fix the terminals on the base
boom section temporarily.
[NOTICE]
Attach the support parallel to the top face of the
base boom section to facilitate adjustment of
terminal position.

G-1
G-1
Boom
34
W536-1260E
17.Fix the terminals for the top boom section on the
top face of the base boom section temporarily.
18.Connect the wiring for the terminal with the
wiring for the automatic charging.
19.Adjust the position of the terminals for the base
boom section and top boom section, and fix the
terminals.
(For details, see the "Adjusting Procedures
(Electric)" in the "Service Manual (circuit
diagrams and data)".
5.4 Installing the bucket
1. Attach the bucket to the boom and fix it with the
pin 2. Then connect the bucket with the leveling
cylinder using the pin 1.
2. Connect the hose from the bucket with the one
from the boom. Then fix them using a clamp.
3. Connect the optical fiber cable to the transmitter
on the bucket.

G-1
G-1
Boom
35
W536-1260E
4. Connect the wiring for the bucket with the one for
the automatic charging system (on the top boom
section). Connect the wiring using a clamp.
5. Check the function of the terminal for automatic
charging.
(For details, see the "Adjusting Procedures
(Electric)" in the "Service Manual (circuit
diagrams and data)".
6. Attach the covers to the boom and bucket.
6. Adjustment
6.1 Tension adjustment of hoses and optical
fibers (during boom assembling)
1. Install the multi-sheave at the head of the base
boom section at the minimum-clearance position
(so that the pivot of the sheave is 50 mm away
from the support on the base boom section).
IW536-065045E
Multi-sheave
Adjusting nut
Wire rope for
boom retraction
Minimum dimension: 50 mm
Maximum dimension: 100 mm
2. Install the hydraulic hoses and optical fibers in
their place and reeve them on the corresponding
grooves in the multi-sheave.
[NOTICE]
Temporarily fix the optical fibers at tension of
approx. 50 N {5 kgf} to the clamps on the base
boom section.
3. After installing the optical fibers, visually check
from the rear of the boom that they do not touch
the boom telescoping cylinder.
△
7
424-006-50100

G-1
G-1
Boom
36
W536-1260E
6.2 Tension adjustment of hoses and optical
fibers (during wire rope adjustment)
1. Loosen the temporary fixing for the optical fiber
cable.
2. Adjust the tension on and position of the boom
retraction wire rope. (See the "Adjusting Wire
Ropes" section.)
[NOTICE]
Do not pull the hoses beyond the basic dimension
(70 mm) as shown below.
IW536-065046E
(
70mm
)
Multi-sheave
Adjusting nut
Wire rope for
boom retraction
Basic dimension
6.3 Tension adjustment of hoses and optical
fibers (after wire rope adjustment)
1. Loosen the temporary fixing for the optical fiber
cable.
2. Move the multi-sheave with the adjusting nuts to
the basic dimension (so that the pivot of the
sheave is 70 mm away from the support on the
base boom section), and then fix it.
IW536-065046E
(70mm)
Multi-sheave
Adjusting nut
Wire rope for
boom retraction
Basic dimension
3. Pull the optical fiber cable under the tension of
approx. 100 N {10 kgf} and fix it with the clamp at
the head of the base boom section or top boom
section.
[NOTICE]
Do not excessively tighten the optical fiber cable, or
it will be damaged.
Pay attention to the tension value.
3. Make sure that the boom lowered to horizontal or
raised to maximum can operate by repeated
telescoping through the upper controls without
any problem.
At this time, check the following:
Sag in the hoses or optical fiber cable inside the
boom
Whether the hoses and optical fiber cable are
reeved around the specified grooves
△
7
424-006-50100
△
7
424-006-50100

G-1.
G-1.
Boom
37
W536-1260E
6.4 Adjusting wire ropes
1. Retract the boom fully, and set it horizontal.
2. Tighten the adjuster nuts for the boom extension
wire rope and boom retraction wire rope so that
the following dimensions become as described
below:
From the center of the top boom pivot pin to the
front end of the 2nd boom section: 201 mm
From the head of the 2nd boom section to the
head of the base boom section (A in the figure
below): 264 mm
Clearance between saddle and stopper (B in the
figure below): 0 mm
3. Tighten the fixing nut on the end of each boom
retraction wire ropes by the tightening torque
listed below, and lock it.
Then tighten and lock the fixing nuts on the end
of the boom extension wire ropes in the same
way.
[NOTICE]
◆There is 1 wire rope at each right and left sides.
Tighten the adjusting nuts evenly, alternating from
one to the other in order to keep balance between
right and left.
Thread size and tightening torque
Tightening torque
Nut
Thread size
N-m
kgf-m
For retraction
M12
9.8
1.0
For extension
M16
15.7
1.6
△
8
422-016-30000
△
20
422-025-90000

G-2
G-2
Counterbalance Valve (for Telescoping Cylinder)
38
W119-0171E
G-2 Counterbalance Valve (for Telescoping Cylinder)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
0.5
0.8
B
A
X
Y
C
C
D
D
C
B
X
Y
21
23
22
IW119-0170E01
A
B
D
C
D
A
0.5
0.8
A
20
15
19
18
17
15
14
16
123456
1
0
71
1
1
3
91
2
8
A
D
C
X-X
Y-Y
1. Plug
2. O-ring
3. Body
4. Plug
5. O-ring
6. Spring
7 O-ring
8. Poppet
9. Check valve
10. Spring
11. O-ring
12. Guide
13. Cover
14. Plug
15. O-ring
16. Spring
17. Poppet
18. Piston
19. O-ring
20. Plug
21. O-ring
22. Hexagon socket head bolt
23. Plug

39
W119-0171E
G-2.
G-2.
Counterbalance Valve (for Telescoping Cylinder)
Thread size and tightening torque
Tightening torque
Sign/Port
Thread size
N-m
kgf-m
A,B
G3/8
49.0
5
1
G1/2
98.0
10
4
G1/8
20.0
2
14
G3/8
49.0
5
20
G3/8
49.0
5
22
M8
25.0--29.0
2.5--2.9
23
R1/8
8.8--11.8
0.9--1.2
Mounting bolt
M8
13--15.0
1.3--1.5
△
1
366-055-10001
△
0
366-063-30000

G-3.
G-3.
Pilot Check Valve (for Telescoping Circuit)
40
W115-0640E
G-3 Pilot Check Valve (for Telescoping Circuit)
[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. Valve body
2. Valve seat
3. Poppet
4. Spring
5. Plug
6. O-ring
7. Piston
8. O-ring
9. Plug
Thread size and tightening torque
Tightening torque
Sign/Port Thread size
N-m
kgf-m
A
G3/8
49.0±5
5.0 ± 0.5
B
G3/8
49.0±5
5.0 ± 0.5
C,D
G1/4
29.4±3
3.0 ± 0.3
Mounting bolt
M10
25±2
2.5 ± 0.2
△
0
366-257-60000
General view
Hydraulic symbol

i
H
Safety System
Contents
H-1 Length Detector (for Boom) ............ 1
1. Structure and function ................................ 1
2. Disassembly .............................................. 2
3. Reassembly ............................................... 3
4. Replacing the potentiometer ...................... 6

1
W305-0680E
H-1
H-1
Length Detector (for Boom)
H-1 Length Detector (for Boom)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure and function
1. This detector consists of major parts such as a
spiral spring, a cord, and a potentiometer.
2. The cord wound on the drum is unwound or
rewound by the spiral spring.
The rotational speed of the drum is reduced by a
gear train, and the rotation is transmitted to the
potentiometer to make the shaft of the
potentiometer turn.
The electric resistance of the potentiometer varies
in proportion to the shaft rotation, and the length
can be detected.
Connection diagram
Potentiometer
Total resistance: 2000 ± 100 Ω
Mechanical turning angle: 3600° ± 10°

2
W305-0680E
H-1
H-1
Length Detector (for Boom)
1. Base plate
2. Case
3. Drum assy
4. Cover
5. Packing
6. Packing
7. Seal connector
8. Bracket
9. Cable assy
10. Potentiometer
11. Nylon clamp
12. Nylon clamp
13. Gear (A)
14. Gear (B)
15. Pin terminal
16. Pin terminal
17. Collar
18. Cord guide
19. Wire assy
2. Disassembly
1. Detach the length detector and the cord end from
the positions they are fixed.
[NOTICE]
When detaching the cord end, prevent the cord reel
of the boom length detector from pulling the cord all
the way.
If the cord is wound up to the point where only
approx. 5 cm of the cord remains outside the
detector with the potentiometer on its end, the
potentiometer may be damaged.
2. While preventing the drum from winding up the
cord, wind the portion of the cord remaining
outside the detector around the case, and fix the
cord using a packaging tape.
[NOTICE]
Fix the cord firmly to prevent it from slackening
during disassembly.
3. Loosen the cord clamp, and open the cover.
4. Disconnect the connection between the cables
and potentiometer at terminals, and remove the
cover together with the cable from the case.
[NOTICE]
To facilitate reassembly, put matchmarks on the
cover and case.
5. Remove the potentiometer and gear (B) together
with the bracket.
IW305-0390E04
Gear (A)
Potentiometer
Gear (B)
Bracket
6. Loosen the setscrew and remove the gear (A).
7. Release the cord that is fixed around the case,
and let the drum wind up the cord slowly until the
spiral spring does not work any more.Then
remove the nuts, and separate the case from the
base plate.
[NOTICE]
To facilitate reassembly, put matchmarks under the
cord outlet on the cover and case.
When releasing the spiral spring tension in the
drum Assy, prevent the cord end from hitting the
cord outlet.

H-1
H-1
Length Detector (for Boom)
3
W305-0680E
8. Remove the bolt, and separate the drum Assy
from the base plate.
Drum assy
Base plate
Bolt
IW305-0390E06
9. If it is necessary to replace the cord, remove the
entire portion of the old cord from the drum Assy.
[NOTICE]
If the spiral spring in the drum Assy is broken,
replace the whole drum Assy.
3. Reassembly
1. Put a marker for the zero point on a new cord with
yellow tape. Then attach an auxiliary cord to the
looped cord end.
2. Pass the new cord through the hole of the drum
Assy.
Then crimp a sleeve-type terminal on the cord end
to prevent the cord from coming off.
IW305-0390E08
Drum assy
Crimp terminal (sleeve type)
3. Wind the new cord around the drum Assy to the
zero point indicated by yellow tape, and
additionally wind the cord further 4 turns around
the drum Assy.
Then fix the cord end using a packaging tape to
prevent it from loosening.
[NOTICE]
Wind the cord clockwise as viewed from the side of
gear mounting.
IW305-0390E09
Gummed tape
Wire
Shaft to
support gear

H-1
H-1
Length Detector (for Boom)
4
W305-0680E
4. Align the yellow tape (zero point) on the drum with
the matchmark (indicating the cord outlet position
of the drum) which has been put on the base plate
during disassembly operation.
Then fix the drum Assy to the base plate using a
bolt.
Drum assy
Base plate
Bolt
IW305-0390E06
5. Apply grease (Moly Speed Grease No. 0) to the
gearing portion of the case.
6. Take the end of the cord (auxiliary cord) out of the
cord outlet of the case.
Then remove the packaging tape that fixes the
cord, and place the case over the drum.
[NOTICE]
When removing a packaging tape, avoid slackening
of the cord. After the packaging tape is removed,
keep avoiding slackening of the cord.
7. Align the matchmarks that have been put during
disassembly on the base plate and case, and fix
the case and base plate using nuts.
8. Attach the gear (A) and fix it using a setscrew (1
point). Apply thread locking agent to the setscrew.
・Recommended thread locking agent: Anaerobic
high-strength sealant ThreeBond 1324N (made by
ThreeBond)
9. Pull the cord all the way out of the cord outlet on
the case. Then make the drum slowly rewind the
cord.
When the yellow tape (zero point) comes to the
edge of the cord outlet, stop the drum from further
rotating. Wind the cord around the case and fix it
with a packaging tape.
[NOTICE]
Keep the cord tense until the disassembly is
completed.
To prevent the drum from winding up the cord after
the potentiometer is installed, fix the cord firmly.
If the cord is wound up to the point where only
approx. 5 cm of the cord remains outside the
detector with the potentiometer on its end, the
potentiometer may be damaged.
IW305-0390E11
Yellow tape
Gummed tape

H-1
H-1
Length Detector (for Boom)
5
W305-0680E
10.While applying 5-V DC between the black and
white terminals (connector terminals 1 and 3) of
the potentiometer, adjust the output voltage
between the red and black terminals 1 and 2) to
the value described below by turning the gear (B)
by hand.
Output voltage: 0.5 ± 0.05 V
・ If it is not possible to apply 5-V DC, adjust the
resistance between the red and black terminals (3
and 2) to the value described below by turning the
gear (B) by hand.
Resistance: 200 ± 20 Ω
11. After the adjustment of the potentiometer is
completed, attach the potentiometer and the gear
(B) together with the bracket while engaging the
gear (B) with the gear (A).
After attaching the bracket, measure either the
output voltage or the resistance between the red
and black terminals of the potentiometer
(connector terminals 1 and 2) again to make sure
that the value is within the allowable range.
[NOTICE]
If the meshing condition of the gears is too strong,
the gears may scratch each other. If it is weak, the
gears may be disengaged.
When attaching the bracket, check the measuring
instrument to keep the output voltage within the
allowable range.
IW305-0390E04
Gear (A)
Potentiometer
Gear (B)
Bracket
12. Pull the cord out of the drum slightly. Make sure
that the measured resistance between the red and
black potentiometer terminals (connector
terminals 3 and 2) increases smoothly when the
cord is pulled.
13. Connect the terminals of the potentiometer to the
ones of the cable.
14. Attach the cover, aligning the matchmarks that
have been put during disassembly.
Pay attention to the orientation of the cord clamp.
15.Pull the cable to remove the slack, and tighten
the cord clamp.
16.Release the cord fixed around the case, and
attach the length detector to the original position.
[NOTICE]
Install the length detector so that the portion of the
yellow tape (zero point) comes to the center of the
cord outlet.
When attaching the length detector, prevent the
drum from winding up the cord.
If the cord is wound up to the point where only
approx.5 cm of the cord remains outside the
detector with the potentiometer on its end, the
potentiometer may be damaged.

6
W305-0680E
H-1.
H-1.
Length Detector (for Boom)
4. Replacing the potentiometer
1. Attach a new potentiometer to the bracket, and
solder leads to the potentiometer terminals.
[NOTICE]
Solder the potentiometer and leads as quickly as
possible to guard the potentiometer from
unnecessary heat.
Fix the potentiometer terminals and leads using
insulating sealant.
The following 2 sealant brands are recommended.
・One-part silicon ThreeBond 1208C or equivalent
one-part silicone sealant (ThreeBond)
・ Shin-Etsu Silicone KE45RTV (Shin-Etsu
Chemical Co., Ltd.)
Orient the terminals of the potentiometer as shown
in the figure below.
IW305-0390E12
Potentiometer
Insulating sealant
2. Attach the gear (B) to the potentiometer shaft, and
fix it with a setscrew (1 point). Apply thread locker
to the setscrew.
・Recommended thread locking agent: Anaerobic
high-strength sealant ThreeBond 1324N (made by
ThreeBond)
3. Assemble the length detector according to the
steps 10. and after in "3. Reassembly" section.
△
1
361-324-20000

i
J
Platform (Bucket)
Contents
J-1 Bucket ............................................... 1
1. Structure .................................................... 1
1.1 Bucket main unit ......................................... 1
1.2 Swing speed reducer.................................. 4
2. Adjusting slide plates for the bucket
elevation frame............................... 5
2.1 Adjustment before
installing elevating frame...................... 5
2.2 Adjustment during installing
the elevating frame ............................. 5
2.3 Operational check of the bucket elevation
(after installing the bucket) ................... 5
J-2 Hydraulic Motor
(for Bucket Swing)................... 7
1. Structure .................................................... 7
2. Function ..................................................... 9
2.1 Function of the pin brake ............................ 9
2.2 Releasing the pin brake
in an emergency................................... 9
3. Geroler set ............................................... 10
3.1 Assembling the Geroler set ......................... 10
3.2 How to insert a roller of the Geroler set
(if it comes off the Geroler)................. 10
J-3 Pilot Check Valve (for Bucket
Elevating Cylinder) ................11
1. Structure ...................................................11

J-1
J-1
Bucket
1
W546-0290E
J-1 Bucket
[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
1.1 Bucket main unit

J-1
J-1
Bucket
2
W546-0290E
1. Hydraulic motor Assy
2. Hexagon socket head bolt
3. Conical spring washer
4. Swing speed reducer
5. Cam follower
6. ―――
7. Plate
8. Spring washer
9. Bolt
10. Nut
11. Retaining ring
12. Spacer
13. Pin
14. Plate
15. Plate
16. Button bolt
17. Spring washer
18. Spacer
19. Pin
20. Grease nipple
21. Cap
22. Split pin
23. Bolt
24. Plain washer
25. ―――
26. ―――
27. Plate
28. ―――
29. Button bolt
30. Nut
31. Bolt
32. ―――
33. Pin
34. Bolt
35. Spring washer
36. Cylinder Assy
37. Fastener
38. Spacer
39. ―――
40. Guide
41. Slide plate
42. Plate
43. Frame Assy
44. Post Assy
45. Slide plate
46. Frame

J-1
J-1
Bucket
3
W546-0290E
Note
1. Apply grease (TADANO Genuine grease TNF) to
the sliding surfaces (guide rail, slide plates, cam
follower) of the bucket elevation frame.
2. Apply molybdenum grease (Never Seez or
equivalent) to the areas of the post Assy which
are in contact with the frame Assy or swing speed
reducer.
Apply grease scrupulously to the splines on the
shaft.
3. Strike a grease nipple which is one of the cam
follower [5] into the end face of the bolt for the
cam follower beforehand.
4. Attach the plate [14] at a correct angle.
Thread size and tightening torque
Tightening torque
Part number Thread size
N-m
kgf-m
2
M12
55--61
5.6--6.2
5 (Provided nut) ------
106--118
10.8--12.0
23
M12
74--82
7.6--8.4
31
M12
74--82
7.6--8.4
△
15
422-671-20000

J-1
J-1
Bucket
4
W546-0290E
1.2 Swing speed reducer
1. Taper roller
2. Worm
3. Taper roller
4. Shim set
5. Spacer
6. Retaining ring
7. Oil seal
8. Gear case
9. Bolt
10. Thrust plate
11. Worm wheel
12. Gear case
13. Ball bearing
14. Oil seal
15. Shaft
16. Plug
17. Dipstick
△
0
366-403-80000

J-1
J-1
Bucket
5
W546-0290E
2. Adjusting slide plates for the bucket
elevation frame
2.1 Adjustment before installing elevating frame
Before installing the bucket elevating frame onto
the bucket swing frame, adjust the slide plate.
1. Refer to the figure in the next page and measure
the dimension of the elevating frame (*A)
2. Adjust the shim to make the clearance between
the inner faces of the outer slide plates (*B) as
described below.
See the "Detail of E" in the figure on the next
page.
 *B (clearance between the inner faces of the outer
slide plates)... no greater than [*A (dimension of
the elevating frame) + 0.5 mm]
2.2 Adjustment during installing the elevating
frame
Requirement for adjustment
・Bucket elevating unit stowed (with bucket
elevating cylinder fully retracted)
・Bucket not installed
1. Make sure that the outer slide plates are at the
location described in "Adjustment before installing
the elevating frame".
2. Install the bucket elevating frame onto the bucket
swing frame while holding the elevating to prevent
it from leaning.
[NOTICE]
◆If the bucket elevating frame leans due to the mass
of the bucket elevating cylinder, remove the cylinder
before installing the elevating frame.
◆Before installing the bucket elevating frame, apply
grease (TADANO Genuine TNF) to the slide plates,
cam floor bearing, and guide rails for the bearing.
3. Turn the adjuster bolts C and D shown in the
figure by hand and tighten them until they turn no
longer. (The clearance between the slide plate
and the elevating frame becomes 0 mm.)
[NOTICE]
◆If the turning extent of the adjuster bolts differ, turn
both bolt to the smaller extent.
4. Adjust the adjuster bolts A and B in the same
manner as the adjuster bolts C and D.
5. Tighten the lock nuts for the adjuster bolts A--D to
fix the adjuster bolts.
Apply Loctite 262T to the adjuster bolts and lock
nuts beforehand.
2.3 Operational check of the bucket elevation
(after installing the bucket)
1. After installing the bucket, repeat elevation of the
bucket, and make sure that the bucket moves
smoothly.
2.If the bucket does not elevate smoothly, remove
the upper control panel and the bucket, and adjust
the adjuster bolts slightly.
If the bucket fails to elevate smoothly even after
re-adjustment of the adjuster bolts, start all over
again from the adjustment of the shim for the
outer slide plates.
3. If re-adjustment is performed, apply thread locking
agent (Loctite 262T) to the adjuster bolts and fix
them.

6
W546-0290E
J-1.
J-1.
Bucket
△
1
422-671-20010
△
15
422-671-20000

J-2
J-2
Hydraulic Motor (for Bucket Swing)
7
W102-0112E
J-2 Hydraulic Motor (for Bucket Swing)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
Hydraulic symbol
General view

J-2
J-2
Hydraulic Motor (for Bucket Swing)
8
W102-0112E
1. Screw
2. Geroler set
3. Drive
4. End cap
5. Seal washer
6. Key
7. Spacer plate
8. Flange
9. Thrust bearing race
10. Output shaft
11. Housing
12. Backup ring
13. Needle bearing
14. Screw
15. Piston pin
16. Oil seal
17. Dust seal
18. O-ring
19. Nameplate
20. Rivet
21. O-ring
22. O-ring
23. Check ball Assy
24. Ball
25. Body
26. Spring
27. Washer
28. Piston cover
29. Screw
30. O-ring
31. Spring
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
Screw [1]
--
20.0--22.6
2.0--2.3
Screw [14]
5/16-2UNF
25.5--31.4
2.6--3.2
Screw [29]
M8
20.0--22.6
2.0--2.3
Port A
G 1/2
98.0
10.0
Port B
G 1/2
98.0
10.0
Pilot port
G 1/4
29.4
3.0
Drain port
G 1/4

J-2
J-2
Hydraulic Motor (for Bucket Swing)
9
W102-0112E
2. Function
2.1 Function of the pin brake
When the pressure on the pilot port increases, the
piston moves to the right as the pressure exceeds
the spring force.
While the motor runs, the drive revolves and
rotates.
When the pressure on the pilot port decreases,
the piston moves to the left due to the spring force
and becomes engaged with the pin hole on the
end of the drive.
The motor is braked as the drive is engaged with
the piston and the revolution of the drive is
stopped.
2.2 Releasing the pin brake in an emergency
(that is, the pressure on the pilot port cannot be
increased)
Screw a bolt for approx. 10 turns through the drain
plug into the threaded hole in the piston to
compress the spring and to move the piston pin to
the right by 7 mm.
The drive will be disengaged from the piston, and
its revolution and rotation becomes possible, thus
releasing the brake on the motor.
[NOTICE]
◆Before releasing the pin brake, make sure that there
is no load torque on the motor shaft.
Pin brake applied
Pin brake released

10
W102-0112E
J-2.
J-2.
Hydraulic Motor (for Bucket Swing)
3. Geroler set
3.1 Assembling the Geroler set
[NOTICE]
◆Pay attention to the arrangement of the output shaft,
drive and the star of the Geroler set.
◆If the arrangement is incorrect, the motor will turn in
the reverse direction.
1. Insert the output shaft in the motor housing with
the key groove on the output shaft facing toward
you.
2.When the drive is inserted in the output shaft, the
valley of a spline will face toward you.
3. Place a spacer plate on the motor housing.
4. Face the side with chamfered splines of star for
the Geroler set toward the output shaft.
Then engage the star with the splines of the drive
with one of its star points 15° counterclockwise
away from the center of the key groove.
5. Direction of motor rotation (viewed from the motor
output shaft)
Pressure port
Direction viewed from
motor output shaft
A
Clockwise
B
Counterclockwise
For the position of the ports, see the figure in the
"1. Structure" section.
3.2 How to insert a roller of the Geroler set (if it
comes off the Geroler)
[NOTICE]
ÆDuring assembly, do not hit a roller with a hammer,
etc.
A Geroler has 7 rollers.
The rollers may come off during
disassembly/assembly of the Geroler set because
they are easy to come off.
If a roller has come off, pay special attention to
reassemble the Geroler set.
Reassemble as follows:
1. Install the star with the ring onto the drive.
Make sure that arrangement of the star and ring is
as shown in the figure in the "3.1 Assembling the
Geroler set" section.
2. Insert rollers around the star.
3. If you cannot insert all the 7 rollers, insert 6 rollers
first.
Then turn the output shaft gradually holding it with
pliers in order to make clearance between the star
and ring.
[NOTICE]
ÆBefore holding the shaft with pliers, cover it with a
rag to protect the shaft.
4. When sufficient clearance is available between
the star and ring, insert the remaining 1 roller.
△
0
366-634-70000
△
0
366-634-10000

J-3.
J-3.
Pilot Check Valve (for Bucket Elevating Cylinder)
11
W115-0061E
J-3 Pilot Check Valve (for Bucket 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
AB
CD
IW115-023001
1. Plug
2. O-ring
3. Spring
4. Poppet
5. Piston
6. O-ring
7. Body
Thread size and tightening torque
Tightening torque
Sign/port
Thread size
N-m
kgf-m
PortAandB
G1/4
26.4--32.4
2.7--3.3
Plug [1]
G3/8
44.0--54.0
4.5--5.5
Valve mounting
bolt
M10
43--49
4.4--5.0
Hydraulic symbol
△
1
366-239-30000

i
N
Electric System
Contents
N-1 Control Unit
(Accelerator Controller) .......... 1
1. Function ..................................................... 1
2. System configuration ................................. 2
3. Outline of accelerator control ..................... 3
3.1 Operation of accelerator motor................... 3
3.2 Change in engine speed ............................ 3
3.3 Stopping accelerator motor ........................ 3
3.4 Input voltage from potentiometer to detect
accelerator motor position .................... 3
4. Adjustment ................................................. 4
5. Conditions of LED indicator on accelerator
controller and measures when accelerator
cannot work ............................................. 5

N-1
N-1
Control Unit (Accelerator Controller)
1
W316-0121E
N-1 Control Unit (Accelerator Controller)
1. Function
The accelerator controller has the following controlling functions.
- Drives the accelerator motor to make the engine idle when the power is turned on.
- Stores the reference voltage for adjustment operations.
- Compares the reference voltage with the input voltage from the potentiometer to detect the position of the
accelerator motor.
- Turns off the output to the accelerator motor once the input voltage reaches the reference voltage.

N-1
N-1
Control Unit (Accelerator Controller)
2
W316-0121E
2. System configuration
[NOTICE]
This is the case of trucks made by Isuzu utilizing an electronic governor.
In some cases the connector numbers do not reflect the actual condition. Refer to the electrical diagram for
the actual connector numbers etc.

N-1
N-1
Control Unit (Accelerator Controller)
3
W316-0121E
3. Outline of accelerator control
- The accelerator controller controls the engine
speed by rotating the accelerator motor in the
direction to increase/decrease the engine speed
depending on the accelerator 1 and accelerator 2
outputs (Do7 and Do8) from AMC3.
- The following explanation is for the case described
in the previous section "2. System configuration".
(case of trucks utilizing an electronic governor)
3.1 Operation of accelerator motor
1. When increasing the engine speed, the terminal
voltages become:
・CN156[6] = 24V
・CN156[3] = 0V
This makes the accelerator motor rotate in the
direction to increase the speed, and the electronic
engine control lever is moved to the "pull"
direction.
2. When decreasing the engine speed, the terminal
voltages become:
- CN156[6] = 0V
- CN156[3] = 24V
This makes the accelerator motor rotate in the
direction to decrease the speed and the electronic
engine control lever is moved to the "return"
direction.
3.2 Change in engine speed
1.When the electronic engine control lever is moved,
the potentiometer for the accelerator that is
connected with the lever is rotated.
2. This rotation of the potentiometer causes the input
voltage to the electronic governor to change and
the engine speed is increased or decreased.
3.3 Stopping accelerator motor
In this explanation, the accelerator change from "1st
(idling)" or "4th (high)" to "2nd (low)" is used as an
example.
1. When the engine speed is increased (decreased),
the accelerator motor rotates in the direction of
increasing (decreasing) until the input voltage
from the potentiometer to detect the accelerator
motor position coincides with the reference
voltage for the 2nd speed.
2. Once the input voltage from the potentiometer
coincides with the reference voltage for the 2nd
speed, the accelerator motor stops. At this
moment, the accelerator motor mechanism is
automatically locked and the motor stop position
is retained.
3.4 Input voltage from potentiometer to detect
accelerator motor position
1. When the accelerator motor rotates in the
direction to increase the engine speed:
- The input voltage from the potentiometer to detect
the accelerator motor position increases.
2. When the accelerator motor rotates in the
direction to decrease the engine speed:
- The input voltage from the potentiometer to detect
the accelerator motor position decreases.
55
49
4
0
0.73
4.55
4.27
0.31
Cable stroke (mm)
Usable range of cable
Input voltage from the potentiometer
to detect the accelerator motor position
IW316-012003E

N-1
N-1
Control Unit (Accelerator Controller)
4
W316-0121E
4. Adjustment
[NOTICE]
For the adjustment method of the accelerator, refer to Chapter Y "Adjustment of pump revolution speed
(accelerator)".

5
W316-0121E
N-1.
N-1.
Control Unit (Accelerator Controller)
5. Conditions of LED indicator on accelerator controller and measures when
accelerator cannot work
Measure to be taken when the accelerator cannot work
Accelerator
condition
LED
condition
Condition of
accelerator controller
Cause (*3)
Reset
operation
Normal
After power on,
lit on for about 1
second then
turned off
－
－
－
Always lit on
(*1)
The potentiometer to detect accelerator motor
position is broken. (CN157 1-5 or 2-5)
Refer to the following conditions 1 and 2.
Condition 1: Wire breakage CN157 1-5
The supply voltage to the
potentiometer is not within
4.668 V -- 4.928 V
(continuously 50 msec or more)
Condition 2: Wire breakage CN157 2-5
The input voltage to the
potentiometer is 0.293 V or less.
(continuously 50 msec or more)
Repeats two
blinks (*1)
An electric current over 2A flows in the accelerator
motor 2 seconds or more. (*4)
(Motor rotation is stopped while the motor is being
energized.)
Repeats three
blinks (*2)
The accelerator motor operates 10 seconds or
more running.
Repeats four
blinks (*2)
Stops the
accelerator motor
at a place where
an error occurs.
Wrong positional information for the data written in
two places in the memory. (Discrepancy in data)
Repeats five
blinks (*2)
Returns the
accelerator motor
to the idling (1st)
position, then stops
the accelerator
motor.
The input voltage from the potentiometer to detect
accelerator motor position is not within:
"1st speed reference voltage minus 0.23V" -- "4th
speed reference voltage plus 0.23V" (continuous
more than 100 msec)
(The cable of the accelerator motor moves beyond
"4th reference position minus 3mm" -- "1st
reference position plus 3mm")
When
accelerator
cannot
work
(abnormal)
Turned off
Stops the
accelerator motor
at a place where
an error occurs.
Either the output circuit short-circuits or the
internal circuit is broken. (Protected by a
PolySwitch.)
Power
off/on the
unit
When switch
box for
adjustment
is connected
After power on,
lit on for about 1
second then
blinks
-
-
-
（*1）Applicable to during normal operation and memory operation (adjustment)
（*2）Applicable to only during normal operation
（*3）When the accelerator cannot work because the wire between CN157 3 and 6 is broken, the conditions of
the LED and the accelerator controller indicate the "normal" condition.
(This is because the breaking of the wire between 3 and 6 cannot be detected.)
（*4）Maximum output to drive accelerator motor: rating 0.9A
△
0
426-521-31301

i
W
Option
Contents
W-1 Overview of Booster ........................ 1
1. Overview and Function .............................. 1
1.1 Booster specification .................................. 1
1.2 Principle of boosting ................................... 1
1.3 Operating cycle .......................................... 2
1.4 Pressure switch on the booster .................. 3
2. Pneumatic control switch and
air pressure switch ......................... 4
2.1 Overview..................................................... 4
2.2 Pneumatic control switch operation and
booster movement ............................... 4
2.3 Hose on the air pressure switch ................. 4
3. Piping for the booster................................. 5
4. Wiring for the booster ................................ 6
W-2 Hydraulic Booster (with Temporary
Hold Function) ......................... 7
1. Structure .................................................... 7
1.1 General view............................................... 7
1.2 Booster main unit ....................................... 8
1.3 Joint assy.................................................... 9
1.4 Pressure detection switch ........................ 10
W-3 Solenoid Valve
(for Final Tightening and
Release).................................. 11
1. Structure .................................................. 11
W-4 Solenoid Valve
(for Temporary Hold) .............12
1. Structure .................................................. 12

W-1
W-1
Overview of Booster
1
WW02-0070E
W-1 Overview of Booster
1. Overview and Function
Booster increases hydraulic pressure supplied from the hydraulic power takeout circuit on the upper controls to
the suitable pressure for operation of a hydraulic compressor and cutter.
The hydraulic pressure in the power takeout circuit for the upper controls is 14.2---14.7 MPa {145---150 kgf/cm
2
}
Operation of a hydraulic compressor requires pressure of approx. 70 MPa {700 kgf/cm
2
}. Thus a booster is
provided to increase the pressure supplied from the power takeout circuit.
1.1 Booster specification
Temporary hold
function
Operating method
Control signal
Discharge
Standard spec.
(temporary hold
function available)
Squeeze frequency
method
Pulse signal
0.160 L
{160 cc}
1.2 Principle of boosting
Hydraulic oil discharged from the pump goes
through (a) into the primary pressure chamber
(ahead of the piston), and compresses the
hydraulic oil in the secondary pressure chamber
by pushing the boosting piston. (See the figure
"Final tightening" below.)
The hydraulic pressure in the secondary pressure
chamber rises up to approx. 5 times of the one in
the primary pressure chamber, due to the
difference of the primary pressure chamber's
cross sectional area and the secondary
chamber's.

W-1
W-1
Overview of Booster
2
WW02-0070E
1.3 Operating cycle
Hydraulic circuit of booster
1. Operating cycle of booster
The operations of the booster rotate in the order:
releasing → temporary hold → final tightening →
releasing.
2. Releasing (See the figures in the previous
page and above.)
When SOL.C of the solenoid valve for final
tightening is energized, hydraulic oil goes via P,
through the booster port (b), and into the primary
pressure chamber (along the rod), and returns the
boosting piston.
When the boosting piston returns all the way, the
steel ball in the boosting piston is pushed by the
rod and the check valve opens.
Hydraulic oil returning from the HP port goes
through the check valve and the port (t), and goes
back to the hydraulic oil tank via Dr (drain port).
3. Temporary hold (See the above figure.)
When SOL.A of the solenoid valve for temporary
hold is energized, hydraulic oil goes via P, through
t of the solenoid valve for final tightening and p' of
the solenoid valve for temporary hold, and into the
port (t).
Because the check valve in the booster piston
remains open, the hydraulic oil goes through the
secondary pressure chamber and HP port, into
the compressor.
The compressor works with a low pressure
because of the relief valve for temporary hold,
thus it keeps temporary hold condition.
During temporary hold, the relief valve for
temporary hold controls the maximum pressure in
the booster circuit.
As the pressure in the booster circuit is low due to
the relief valve for temporary hold, the pressure of
the compressor is also low.
Opening pressure of the relief valve for
temporary hold:
1--2 MPa {10--20 kgf/cm
2
}

W-1
W-1
Overview of Booster
3
WW02-0070E
4. Final tightening (See the figures in the
previous page and above.)
When SOL.B of the solenoid valve for final
tightening is energized, hydraulic oil goes via P,
through the booster port (a), and into the primary
pressure chamber (ahead of the piston), and
pushes the boosting piston.
When the boosting piston moves, the oil in the
secondary pressure chamber is compressed and
supplied through the port HP into the compressor.
Due to load resistance of the compressor, the
hydraulic pressure in the secondary pressure
chamber goes up to the specified level.
If the hydraulic oil in the secondary pressure
chamber is insufficient, oil is supplied to the
secondary pressure chamber through the port (t).
1.4 Pressure switch on the booster
The pressure switch installed on the main body of
the booster is operated by the oil from the booster,
and converts hydraulic pressure into electric
signals.
It turns ON when the hydraulic pressure in the
booster goes up to the specified level, and
changes the booster operation from final
tightening into releasing.
The structure of the switch is shown below.
Principle of operation
When the hydraulic pressure in the booster
reaches the specified level, the oil pushes the rod
and the switch turns ON.
[NOTICE]
For the adjusting procedures of the switch, see the
"Adjusting Procedures (Electric)" in the separate
"Service Manual (circuit diagrams and data)".
△
1
360-538-41200

W-1
W-1
Overview of Booster
4
WW02-0070E
2. Pneumatic control switch and air
pressure switch
2.1 Overview
1. A pneumatic control switch (air balloon switch) is
provided with the compressor (or the cutter).
To use the switch, connect the air balloon to the
connector for the balloon on the upper controls.
When the air balloon is squeezed, the air sent to
the air pressure switch and the booster works.
2. The air pressure switch is located inside the
bucket.
The switch is operated by the air sent from the air
balloon switch and converts the air balloon
operation into electric signals.
The operation of the booster changes depending
on the electric signal from the air pressure switch.
For details, see the next section.
For the position of the air pressure switch, see the
"Wiring for the booster" later.
2.2 Pneumatic control switch operation and
booster movement
Relation between the operation frequency on the
pneumatic control switch (balloon switch) and the
booster operation is listed below.
Operation on balloon
Booster operation
1st squeeze
Temporary hold
2nd squeeze
Final tightening
3rd squeeze
Release
*1
*1: When the hydraulic pressure reaches the specified
level during final tightening, the booster operation
automatically changes into releasing.
2.3 Hose on the air pressure switch
[NOTICE]
Do not remove the plug at the end of the hose for
the air pressure switch.
Do not detach or replace the hose for the air
pressure switch.
When the ambient temperature rises, the air in the
pneumatic control switch (the balloon) will inflate
and may cause malfunction of the air pressure
switch.
To prevent such malfunction, a hose is attached to
the air pressure switch.
If the air in the balloon inflates, the air in the hose
also inflates, thus the air pressure inside the air
pressure switch keeps balanced. In this way, the
malfunction of the air pressure switch is
prevented.
△
0
821-099-03010

W-1
W-1
Overview of Booster
5
WW02-0070E
3. Piping for the booster
・The figure below shows the booster with squeeze frequency method.
△
3
425-027-52000
△
9
425-027-81000

6
WW02-0070E
6
W-1.
W-1.
Overview of Booster
W-1.
4. Wiring for the booster
・The figure shows the wiring for the booster on AT-146-3-xxx98.
△
2
425-066-41000

W-2
W-2
Hydraulic Booster (with Temporary Hold Function)
7
W185-0150E
W-2 Hydraulic Booster (with Temporary Hold Function)
[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
1.1 General view
Thread size and tightening torque
Tightening torque
Mounting bolt
Thread size
N-m
kgf-m
SOL (for Temporary hold)
M6
122.5 ± 4.9 12.5 ± 0.5
SOL (for final tightening and release) M6
122.5 ± 4.9 12.5 ± 0.5
Sub plate
M8
25±2
2.6 ± 0.2

W-2
W-2
Hydraulic Booster (with Temporary Hold Function)
8
W185-0150E
1.2 Booster main unit
1. Side cover A
2. O-ring
3. Backup ring
4. Tube
5. Head
6. Spring
7. Steel ball
8. Packing assy
9. Tube
10. O-ring
11. Backup ring
12. O-ring
13. O-ring
14. Push rod
15. Rod
16. Tube
17. Piston
18. O-ring
19. Backup ring
20. O-ring
21. O-ring
22. Bush
23. O-ring
24. Backup ring
25. Backup ring
26. O-ring
27. O-ring
28. Nut
29. Screw
30. Side cover C
31. Nut
32. Stud bolt
33. Plain washer
34. Nut
35. Hexagon socket head bolt
36. Switch assy
Thread size and tightening torque
Tightening torque
Sign/Port Thread size
N-m
kgf-m
34
M14
122.5 ± 4.9
12.5 ± 0.5

W-2
W-2
Hydraulic Booster (with Temporary Hold Function)
9
W185-0150E
1.3 Joint assy
1. Sub plate
2. Steel ball
3. Spring seat
4. Spring
5. Plug
6. Poppet
7. Pin
8. Spring
9. Bolt
10. Nut
11. O-ring
12. Plug
13. Orifice

10
W185-0150E
W-2.
W-2.
Hydraulic Booster (with Temporary Hold Function)
1.4 Pressure detection switch
1. Guide
2. Adapter
3. Sleeve
4. Rod
5. Adjuster
6. Lock nut
7. O-ring fixing screw
8. Spring
9. Ram
10. Bracket
11. Switch assy
12. O-ring
13. Backup ring
14. O-ring
15. Backup ring
16. Hexagon socket head bolt
17. Spring washer
18. Grease nipple
19. Plain washer
20. Spring washer
21. Screw
22. Cover
23. Seal
24. Retaining ring
Thread size and tightening torque
Tightening torque
Sign/Port
Thread size
N-m
kgf-m
6
M22×1
25--30
2.55--3.06
△
0
360-538-41200

W-3.
W-3.
Solenoid Valve (for Final Tightening and Release)
11
W121-1100E
W-3 Solenoid Valve (for Final Tightening and Release)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
1. Spring
2. Spring pin
3. O-ring
4. Spool
5. Pin retainer
6. O-ring
7. Armature
8. Kicker spring
9. Kicker pin
10. O-ring
11. Manual override assy
12. Washer
13. Core assy
14. Coil assy
15. Pin
16 Body
17. Spring retainer
Thread size and tightening torque
Tightening torque
Bolt
Thread size
N-m
kgf-m
Mounting bolt
M6
8--10
0.8--1.0
△
0
366-403-50000
Hydraulic symbol
Electric symbol

W-4.
W-4.
Solenoid Valve (for Temporary Hold)
12
W121-1110E
W-4 Solenoid Valve (for Temporary Hold)
[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. Coil assy
2. Kicker pin
3. Kicker spring
4. Armature
5. O-ring
6. Spool pin
7. Spring pin
8. Spool
9. O-ring
10. Manual override assy
11. Body
12. Spring retainer
13. Spring
14. Pin retainer
15. Core assy
16. O-ring
17. Washer
18. Nut
Thread size and tightening torque
Tightening torque
Thread
Thread size
N-m
kgf-m
Mounting bolt
M6
8--10
0.8--1.0
△
0
366-403-60000
Electric symbol
Hydraulic symbol

Head Office
Ko-34,Sinden-cho, Takamatsu, Japan
Overseas Service Group
Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785
History of revision
1
2
3
4
5