serial no. m00879 - maeda mini cranesmaedaminicranes.co.uk/pdf/mc104/mc104_service_manual.pdf · 2....

SERIAL NO. M00879 AND UP

MC-104CWMINI CRAWLER CRANE

SERVICE MANUAL

CONTENTS

i

1. GENERAL VIEW ...................................................................................................................1

2. MAIN DATA AND SPECIFICATIONS...................................................................................2

3. WORKING RADIUS AND LIFTING HEIGHT DIAGRAM......................................................3

4. RATED TOTAL LOAD CHART .............................................................................................4

5. STANDARD FUNCTION TIME AND FUNCTION PRESSURE ...........................................6

6. COMMON PARTS LIST ........................................................................................................7

7. HYDRAULIC CIRCUIT DIAGRAM ........................................................................................9

8. POWER TRAIN SYSTEM DIAGRAM ................................................................................ 10

9. HYDRAULIC PIPING ASSEMBLY..................................................................................... 11

9.1 Swivel Joint Line....................................................................................................... 11

9.2 Control Line A........................................................................................................... 12

9.3 Control Line B........................................................................................................... 13

9.4 Travel Line................................................................................................................ 14

9.5 Outrigger Line........................................................................................................... 15

9.6 Pump and Tank Line ................................................................................................ 16

10. HYDRAULIC OIL TANK ASSEMBLY................................................................................. 17

10.1 Air Breather .............................................................................................................. 18

10.2 Oil Filler, OP-V22 ..................................................................................................... 19

10.3 Return Filter, RA-04-10-10....................................................................................... 20

11. ENGINE ASSEMBLY ......................................................................................................... 21

11.1 Specifications ........................................................................................................... 22

11.2 General View............................................................................................................ 23

11.3 Explanation of Main Components............................................................................ 24

11.4 Troubleshooting........................................................................................................ 30

11.5 Inspection and Adjustment....................................................................................... 37

CONTENTS

ii

12. HYDRAULIC PUMP ............................................................................................................41

12.1 General View.............................................................................................................41

12.2 Inside View ................................................................................................................42

12.3 P-Q Characteristic .....................................................................................................43

12.4 Principle of Operation................................................................................................44

12.5 Troubleshooting ........................................................................................................46

13. TRAVEL CONTROL VALVE ...............................................................................................47

13.1 General View.............................................................................................................47

13.2 Specifications ............................................................................................................47

13.3 Inside View ................................................................................................................48

14. TRAVEL MOTOR ................................................................................................................49

14.1 General View.............................................................................................................49

14.2 Specifications ............................................................................................................49

14.3 Inside View ................................................................................................................50

14.4 Principle of Operation................................................................................................51

14.5 Function.....................................................................................................................52

14.6 Precautions When Using ..........................................................................................55


15. REMOTE CONTROL VALVE..............................................................................................58

15.1 General View.............................................................................................................58

15.2 General......................................................................................................................59

15.3 Hydraulic Circuit Diagram .........................................................................................60

15.4 Function.....................................................................................................................61


16. OUTRIGGER SELECTOR VALVE .....................................................................................75

16.1 General View.............................................................................................................75

16.2 Specifications ............................................................................................................76

16.3 Inside View ................................................................................................................77

16.4 Hydraulic Circuit Diagram .........................................................................................78

16.5 General......................................................................................................................78


CONTENTS

iii

17. ROTARY JOINT ................................................................................................................. 81

17.1 General View............................................................................................................ 81

17.2 Inside View ............................................................................................................... 82

17.3 Specifications ........................................................................................................... 82

18. BOOM ASSEMBLY ............................................................................................................ 83

19. TELESCOPIC CYLINDER ................................................................................................. 86

19.1 General View............................................................................................................ 86

19.2 Specifications ........................................................................................................... 87

19.3 Counter-balance Valve............................................................................................. 88

19.3.1 General View ................................................................................................. 88

19.3.2 Specifications................................................................................................. 88

19.3.3 Troubleshooting ............................................................................................. 88

20. DERRICK CYLINDER ........................................................................................................ 89

20.1 General View............................................................................................................ 89

20.2 Specifications ........................................................................................................... 90

20.3 Counter-balance Valve............................................................................................. 91

20.3.1 General View ................................................................................................. 91

20.3.2 Specifications................................................................................................. 91

20.3.3 Troubleshooting ............................................................................................. 91

21. WINCH ASSEMBLY........................................................................................................... 93

21.1 General View............................................................................................................ 93

21.2 Worm Reduction Gear Box...................................................................................... 94

21.3 Winch Hydraulic Motor............................................................................................. 96

21.3.1 General View ................................................................................................. 96

21.3.2 Specifications................................................................................................. 97

22. SWING SYSTEM................................................................................................................ 98

22.1 General View............................................................................................................ 98

22.2 Swing Reduction Gear Box...................................................................................... 99

22.3 Swing Hydraulic Motor ........................................................................................... 100

22.3.1 General View ............................................................................................... 100

22.3.2 Specifications............................................................................................... 100

CONTENTS

iv

23. OUTRIGGER ASSEMBLY ................................................................................................102

23.1 General View...........................................................................................................102

23.1.1 No. 1 and No. 3 Outrigger Assembly............................................................102

23.1.2 No. 2 and No. 4 Outrigger Assembly............................................................104

24 OUTRIGGER CYLINDER .................................................................................................106

24.1 General View...........................................................................................................106

24.2 Specifications ..........................................................................................................108

24.3 Double Pilot Check Valve .......................................................................................109

24.3.1 General View ................................................................................................109

24.3.2 Specifications................................................................................................110

25. ELECTRICAL CIRCUIT DIAGRAM...................................................................................111

26. ELECTRICAL WIRING DIAGRAM....................................................................................112

27. ENGINE STARTING CIRCUIT DIAGRAM........................................................................114

28. ENGINE STOPPING CIRCUIT DIAGRAM .......................................................................115

29. OUTRIGGER OPERATING CIRCUIT DIAGRAM ............................................................116

30. CREEP SPEED OUTPUT CIRCUIT DIAGRAM...............................................................117

31. DISASSEMBLY AND ASSEMBLY OF BOOM..................................................................118

31.1 Disassembly ............................................................................................................118

31.2 Assembly.................................................................................................................126

1. GENERAL VIEW

1

1580(Grounded track length)

1980(Overall length)

(2016.7)

600(Overall width)13

06(O

vera

ll he

ight

)

★ Above sketch represents the machine with the travel lever stowed for Transport Position.

2. MAIN DATA AND SPECIFICATIONS

2

Systems and Items MC-104CW

Crane capacity 0.995 t × 1.1 m

Maximum working radius 5.10 m

Maximum lifting height above ground 5.50 m

Winch system Type Hydraulic motor driven, Worm geared, Worm cell lock

Hook hoist speed 4.0 m/min. (3-layer 4-part reeving)

Hoist wire rope φ6 × 39 m

Telescoping system Type Hydraulic cylinder + Wire rope type telescoping system × 2

Type of boom Fully automatic 4-stage boom with pentagonal section(2 to 4 stages: simultaneous telescoping)

Boom length 1.85 m to 3.00 m to 4.15 m to 5.30 m

Boom telescoping stroke/Telescoping time

3.45 m/16 sec.

Boom hoist system Type Hydraulic double action cylinder, direct acting × 1

Hoist angle and time 0 to 75°/9 sec.

Swing system Type Swing ring support, Hydraulic motor driven, Worm andspur gears

Swing angle and time 360° continuous/1.6 min.−1 (360° continuous/1.6 rpm)

Outrigger Type 1st stage with flexible stay damper, 2nd stage manualpullout, Hydraulic cylinder direct acting

Maximum extended width (Lateral) 3,400 mm × (Rear) 2,785 mm × (Front) 3,300 mm

Overall length (except boom) ×Overall width × Overall height

1,980(1,580) mm × 600 mm × 1,305 mm

Travel system Type Hydraulic motor driven, Stepless speed changer

Travel speed 0 to 2.4 km/h

Grade ability 20°Track length on ground ×Width

1,044 mm × 180 mm

Ground pressure 28.4 ka (0.29 kgf/cm2)

Track tension adjustment Cylinder lubricating type

Engine Type Yanmar GA300SECMS1

Displacement 0.296 liter (296 cc)

Rated output (Continuous) 5.7 kw/1,800 min.−1 (7.8 ps/1,800 rpm)

Starting method Starting motor and coil starter

Type of fuel and tankcapacity

Lead-free gasoline/60 liter

Hydraulic system Pump specification/Tankcapacity

Variable displacement piston pump8.6 cc + 8.6 cc /20 liter

Remote controller Radio control type Specific small power, 40-wave auto scan

Creep speed mode Proportional flow control & Engine throttle control

Outrigger radio control Possible (even starting and stopping the engine)

Total mass 1,050 kg

3. WORKING RADIUS AND LIFTING HEIGHT DIAGRAM

3

Reference Drawing 1: MC-104C Working Radius and Lifting Height Diagram

Working radius (m)

Lifti

ng h

eigh

t abo

ve g

roun

d (m

)Boom

Boom

Boom

Boom

4. RATED TOTAL LOAD CHART

4

MC-104C Rated Total Load Chart

Rated Total Load Chart with Outrigger Extendedto Maximum

Rated Total Load Chart with Outrigger Extendedto other than Maximum

1.85 mBoom

3.00 mBoom

4.15 mBoom

5.30 mBoom

1.85 mBoom

3.00 mBoom

4.15 mBoom

5.30 mBoom

1.1or less

995 1.1or less

995 1.8or less

820 2.4or less

650 1.1or less

735 1.1or less

735 1.8or less

435 2.4or less

295

1.3 980 1.3 980 2.0 750 2.5 620 1.3 620 1.3 620 2.0 405 2.5 280

1.5 890 1.5 890 2.5 620 2.8 550 1.5 540 1.5 540 2.5 280 2.8 210

1.65 790 2.0 750 2.8 550 3.0 500 1.65 490 2.0 405 2.8 210 3.0 185

2.5 620 3.0 500 3.5 380 2.5 280 3.0 185 3.5 140

2.8 550 3.5 380 4.0 300 2.8 210 3.5 140 4.0 100

3.95 300 4.5 250 3.95 110 4.5 75

5.1 200 5.1 60

Rated total load is based on the actual working radius which takes into consideration the bending ofboom due to load. Violent crane operation is extremely dangerous. Always keep the safety in yourmind.

�

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

Rat

ed to

tal l

oad

(kg)

Wor

king

Rad

ius

(m)

4. RATED TOTAL LOAD CHART

5

Crane Operation Prohibited Zone

WARNING

• Sketches below indicate the zones where crane work is prohibited according to thepattern of outrigger placement (Shadowed area in the sketch). Within such zones,tippingover of machine may take place to result in serious personal accident. Neverattempt to perform crane work in such zone.

• Of the 4 outriggers, the pair of either front and rear or right and left should always be set tothe standard placement (Front 60 degrees and rear 45 degrees). Even with the twooutriggers set to standard placement, the work should be performed in accordance withthe value in Total Rated Load Chart with Outriggers Extended to other than Maximum.

• Outrigger placement whereby work is allowed over entire circle, is only in accordance with“Standard Extension” at the center in the sketch below.

Standard Extension

Swing center

XAM02910

�

5. STANDARD FUNCTION TIME AND FUNCTION PRESSURE

6

Engine Speed(980 min.−1 [980 rpm])

Engine Speed(1800 min.−1 [1800 rpm])

Time(sec.)

Pressure(MPa [kgf/cm2])

Time(sec.)

Pressure(MPa [kgf/cm2])

Boom hoisting Hoisting 14 3.4 [35] 8.8 5.9 [60]

Lowering 11 4.9 [50] 9.5 14.7 [150]

Swinging Right 63 3.4 [35] 37 10.3 [105]

Left 63 3.4 [35] 37 10.3 [105]

Telescoping Extending 26 2.9 [30] 16 4.9 [50]

Contracting 15 7.8 [80] 14 15.7 [160]

Up-down motion Up 29 3.9 [40] 16 5.9 [60]

Down 29 3.9 [40] 16 5.9 [60]

Outrigger Pulling out 31 2.0 [20] 14 4.4 [45]

Pushing in 21 2.9 [30] 9 11.3 [115]

6. COMMON PARTS LIST

7

MC-053 SK098 MC-205C MC-275C RemarksHook ○ ○ ○Sheave (hook)Hook nut ○ ○ ○Latch ○ ○ ○Wire rope φ6 × 39 mNo. 3 extension wire rope φ9 × 3920No. 3 contraction wire rope φ6 × 3920No. 4 extension wire rope φ6 × 3920Slide plate for boom downward ○ ○Slide plate for No. 4 boomdownward

○ ○

Slide plate for boom upward(23 t)Slide plate for boom upward(17 t)Side plate ○ ○No. 4 contraction wire rope φ5 × 6170Sheave (at boom end) ○Extension sheave for No. 3 boom ○ ○Extension sheave for No. 4 boom ○ ○Contraction sheave assembly forNo. 3 and 4 booms

○ ○

Snap sheave A ○IdlerDerrick cylinder D. Kanbara usedDrum Sin-ei SeisakushoWinch reduction gear △ The shaft and motor

mounting portions aredifferent.

Winch motor Sumitomo EatonSwing bearing ○Swing reduction gear ○ ○ ○Swing motor ○ ○ ○Telescopic cylinder D. Kanbara usedIdler (travel system) ○Grease cylinder ○Track roller ○Rubber crawler ○Sprocket ○Travel motor △ Interchangeable in general

Rotary joint ○ Nishina

Outrigger cylinder △ Common with W pilotcheck

Stay damper KayabaRemote control valve Nabuko NSS50 12 VDCOutrigger select valve Toyooki

6. COMMON PARTS LIST

8

MC-053 SK098 MC-205C MC-275C RemarksTravel control valve NishinaControl lever of swing ○Control lever of telescopic ○Control lever of winch ○Control lever of derrick ○Protect weight ○ ○ ○Chain (for overwind alarm)Overwind alarm ○Return filter ○Air breather ImaoLevel gauge ○Oil fillerPump ○ Fujikoshi

Flange hub ○Cylindrical hub ○Coupling ○Accelerator lever (F) ○Accelerator cable FM ○Throttle lever △ The length is different.

WakenAccelerator cable FR ○Accelerator change assembly ○Engine ○ Yanmar G300

Push-pull cable (for travel) WakenPanel (travel stand portion) ○Choke knob ○Hour meter ○Engine switch ○Fuse holder ○Horn switch ○Light switch ○Fuse (5 A) ○Fuse (15 A) ○Charge lamp ○Alarm buzzer ○Working lamp ○Battery ○ 32A19R

Alternator ○V belt ○Load meterLevel ○Marker lampTransmitter assembly MCT300Receiver assembly

7. HYDRAULIC CIRCUIT DIAGRAM

9

Trav

el c

ontro

l val

veN

ishi

na K

ogyo

0769

5-00

000

Max

imum

leak

age:

10

Iiter

/min

Rel

ief s

et p

ress

ure:

210

kgf

/cm

2

Outrigger cylinder 4

B (I

n)

A (O

ut)

Tele

scop

e cy

linde

rN

EO

Xφ

60×

45×

1150

st

A (E

xten

d)B

(Con

tract

)

Trav

el m

otor

NA

CH

I: F

ZD-1

00-2

5B-9

-828

3AR

educ

tion

ratio

: 1/

36.9

6C

apac

ity:

8.9

cc/re

vM

axim

um p

ress

ure:

210

kgf

/cm

2

Max

imum

leak

age:

14.

7 lit

er/m

in A

(Rea

r)

B (F

ront

)




B (I

n)

A (O

ut)

Der

rick

cylin

der

B (L

ower

)A

(Ris

e)

Win

chRe

duct

ion

gear

: YT

9813

3X1

Redu

ctio

n ra

tio:

1/30

Hydr

aulic

mot

or:

J-13

EBE-

BCa

pacit

y: 1

2.9

cc/re

vRa

ted

spee

d: 1

562

rpm

Rate

d to

rque

: 2.

4 kg

fmM

axim

um to

rque

: 2.

8 kg

fmRa

ted

pres

sure

: 14

0 kg

/cm

2

Max

imum

pre

ssur

e: 1

65 k

g/cm

2

Retu

rn fi

lter

Yam

ashi

n Ko

gyo

RA-0

4-30

-10

Filte

ring

prec

ision

: 30

m

Engi

neYa

nmar

GA3

00SE

CMSI

Max

imum

out

put:

10.5

ps

Rate

d ou

tput

: 7.8

ps

Hydr

aulic

pum

pNA

CHI

PYD-

08-1

7L3S

-424

2FCa

pacit

y: 8

.6+8

.6 c

c/re

vM

axim

um s

peed

: 20

00 rp

mRa

ted

spee

d: 1

800

rpm

Max

imum

pre

ssur

e

P

1: 2

10 k

gf/c

m2

P2:

210

kgf

/cm

2

Tank

cap

acity

20

liter

Outrigger 4

Outrigger 3

Outrigger 2

Outrigger 1

(Out) Rise (In)Lower

(Out) Up (In)Down

(Out) Contract (In)Extend

(Out) Right

(In)Left

Cont

rol v

alve

Nabu

koXS

S50-

SFA4

T-12

Rate

d pr

essu

re

: 2

10 k

gf/c

m2

Rate

d flo

w

:

50 lit

er/m

inSe

quen

ce V

alve

crac

king

pres

sure

: 1

3 to

17

kgf/c

m2

Pres

sure

redu

cing

valu

e se

t pre

ssur

e

: 1

4.5

kgf/c

m2

Set o

il pre

ssur

e

: 1

0 kg

f/cm

2

Rate

d vo

ltage

:

DC1

2Y

Out

rigge

r sel

ect v

alve

Toyo

oki K

ogyo

H-02

261

Max

imum

pre

ssur

e

:

210

kgf/c

m2

Pilo

t pre

ssur

e :

10.2

to 1

5.3

kgf/c

m2

Allo

wabl

e pr

essu

re

: 7

1.4

kgf/c

m2

Rate

d vo

ltage

: 12Y

E (L

ower

)D

(Ris

e)F

(Dow

n)A

(Up)

C (E

xten

d)B

(Con

tract

)

E (L

ower

)D

(Ris

e)F

(Dow

n)A

(Up)

C (E

xten

d)B

(Con

tract

)

Sw

ivel

join

tN

ishi

na K

ogyo

0774

1-00

000

Rat

ed c

apac

ity :

15 li

ter/m

inM

axim

um p

ress

ure

: 210

kgf

/cm

2

Max

imum

spe

ed :

2 rp

mTo

rque

: 4

kgfm

less

than

A (O

ut)

B (I

n)

B (L

eft)

A (R

ight

)

Sw

ing

syst

emR

educ

tion

gear

: Y

T1-8

701-

X01

Red

uctio

n ra

tio :

1/36

Hyd

raul

ic m

otor

: J-

32E

BE

-BC

apac

ity :

31.6

cc/

rev

Rat

ed s

peed

: 66

1 rp

mR

ated

torq

ue :

4.0

kgfm

Max

imum

torq

ue :

5.0

kgfm

Rat

ed p

ress

ure

: 95

kgf/c

m2

Max

imum

pre

ssur

e : 1

20 k

gf/c

m2

Trav

el m

otor

NA

CH

I : F

ZD-1

00-2

5B-9

-828

3AR

educ

tion

ratio

: 1/

36.9

6C

apac

ity :

8.9

cc/re

vM

axim

um p

ress

ure

: 210

kgf

/cm

2

Max

imum

leak

age

: 14.

7 l/m

in

B (R

ear)

A (F

ront

)

A (O

ut)

B (I

n)

8. POWER TRAIN SYSTEM DIAGRAM

10

Engine

Hydraulic pump

Crane control valve

Double pilotcheck valve

Outrigger1 cylinder

Outrigger2 cylinder

Outrigger3 cylinder

Outrigger4 cylinder

Swingmotor

Reductiongear

Swing ring

Counter-balancevalve

Telescopecylinder

Out

rigge

r se

lect

val

ve

Pressure reducing valve set pressure :

14.5 kgf/cm2+0.5−0

P2 P1

Travel control valve

Relief set pressure : 210 kgf/cm2

Boom telescopingwire rope

Winchmotor

DrumWire rope Reductiongear

Counter-balance valveDerrick cylinder




9. HYDRAULIC PIPING ASSEMBLY

11

9.1 Swivel Joint Line

Low

erR

ise

Pay

atte

ntio

n to

th

e fit

ting

angl

e.

Hoi

stLo

wer

Ext

end

Con

tract

Pay

atte

ntio

n to

th

e fit

ting

angl

e.P

ay a

ttent

ion

to

the

fittin

g an

gle.

Fix

the

four

hos

es a

t the

in

dica

ted

posi

tion.

W motor down

W motor up

Tele

scop

e cy

linde

r co

ntra

ct

Sw

ivel

Joi

nt C

onne

ctio

n D

iagr

am

Telescope cy

linder

extend

Gui

de p

in

Derrick c

ylinder rise

Der

rick

cylin

der

low

er

1. Elbow 6. Hose for derrick cylinder head side

2. Elbow 7. Hose for telescopic cylinder

3. Bushing 8. O-ring

4. Hose for winch 9. Band

5. Hose for derrick cylinder bottom side


12

9.2 Control Line A

Load

met

er

Inse

rt th

e co

pper

pac

king

w

hen

inst

allin

g th

e lo

ad m

eter

Cau

tion

: Whe

n fix

ing

fittin

gs a

nd c

onne

ctin

g pi

pes,

be

sur

e to

tigh

ten

them

sec

urel

y so

that

no

oil

leak

s be

caus

e of

loos

enin

g.

1. Main selector valve 1-6. Main selector pipe 3. Connector

1-1. Main selector pipe 1-7. Main selector pipe 4. Connector

1-2. Main selector pipe 1-8. Main selector pipe 5. Connector

1-3. Main selector pipe 2. Gauge-PP pipe 6. Connector

1-4. Main selector pipe 2-1. Gauge pipe 7. Connector

1-5. Main selector pipe 2-2. PP pipe 8. Connector


13

9.3 Control Line B

Sw

ing

left

Sw

ing

right

Vie

w B

(S=1

/2)

A

B

Vie

w A

To load meter

Win

ch u

pper

por

t

Eng

ine

Sel

ect v

alve

Sw

ivel

join

t

Sw

ing

redu

ctio

n ge

ar

Win

ch lo

wer

Der

rick

cylin

der r

ise

Tele

scop

ic c

ylin

der

cont

ract

Der

rick

cylin

der l

ower

Tele

scop

ic c

ylin

der e

xten

d

Win

ch h

oist

Win

ch lo

wer

Der

rick

cylin

der l

ower

Tele

scop

ic c

ylin

der e

xten

dS

win

g le

ft

Der

rick

cylin

der r

ise

Win

ch h

oist

Sw

ing

right

Tele

scop

ic c

ylin

der c

ontra

ct

Det

aile

d V

iew

of S

elec

t Val

ve C

onne

ctio

n P

ort

1. Connector 7. Tee

2. Elbow 8. Connector

3. Hose for swing 9. Spiral tube

4. Hose for telescopic cylinder and winch down side 10. Band

5. Hose for derrick cylinder and winch up side 11. Elbow

6. Connector


14

9.4 Travel Line

1. Pipe for right travel 1 4. Pipe for left travel 1

2. Pipe for right travel 2 5. Connector

3. Pipe for left travel 2


15

9.5 Outrigger Line

1. Pipe for rear right A 7. Pipe for front left A 13. Connector

2. Pipe for rear right B 8. Pipe for front left B 14. Bolt (M10 × 20)

3. Pipe for rear left A 9. Terminal joint 15 Bolt (M6 × 20)

4. Pipe for rear left B 10. Gall 16. Spring washer (M10)

5. Pipe for front right A 11. Hose for outrigger 17. Spring washer (M6)

6. Pipe for front right B 12. Connector


16

9.6 Pump and Tank Line

For P2 port

Engine

Old tank

Control valve

Select valve

Travel control valve

For P1 port

10. HYDRAULIC OIL TANK ASSEMBLY

17

1. Hydraulic oil tank 6. Oil filler 11. Plain washer (M6) 16. Hose2. Return filter 7. Bolt (M10 X 30) 12. Packing 17. Wire band3. Air breather assembly 8. Spring washer (M10) 13. Liquid packing 18. Band4. Cap 9. Nut (M6) 14. Hydraulic oil 19. Bracket5. Oil level gauge 10. Spring washer (M6) 15. Hose joint 20. Plain washer (M10)


18

10.1 Air Breather

Apply thread tightener.

Ass

embl

e th

e ai

r bre

athe

r so

that

the

pack

ing

6 a

dher

es to

the

hous

ing.

1. Connector 5. Spring

2. Connector 6. Packing

3. Housing 7. Steel ball

4. Plate 8. Screw


19

10.2 Oil Filler, OP-V22

1. Cap

2. Mounting flange

3. Mounting flange

4. Strainer

5. Packing

6. Chain

7. Cap mounting plate

8. Packing

9. Stopper


20

10.3 Return Filter, RA-04-10-10

Tightening torque Apply oil-proof heat resistant adhesive for connection.

Caution : In case of MC 104C, remove the pipe 2 and fix the connector R1/2×φ16.

1. Cover 5. Plate

2. Inlet valve 6. Valve holder

3. Inner tube 7. Valve assembly

4. Element 8. Lock screw

8 7 6 5 4 3 1 2

11. ENGINE ASSEMBLY

21

"No

Fire

"

Stic

k th

e pl

ates

on

the

both

si

des

of th

e "N

o Fi

re" l

abel

.

Oil level gauge, Oil filler port

Fuse 20A for protection of the starter circuit

Engine oil drain

For MC 104C, stick plates for prevention of friction between the machinery cover and the tank.

1. Engine 6. Lock screw (M10 X 45) 11. Drain joint

2. Exhaust pipe 7. Spring washer (M10) 12. Plug

3. Gasket 8. Nut (M10) 13. Packing

4. Bolt (M8 X 20) 9. Engine oil (SD10W-30) 14. Rubber plate

5. Spring washer (M8) 10. Gasoline

11. ENGINE ASSEMBLY

22

11.1 Specifications

Engine name GA300SECMS1

Type 35-deg. Inclined 4-cycle, spark ignition

Number of cylinder, Bore × Stroke 1 − φ78 mm × 62 mm

Total piston displacement 0.296 liter

Dry weight 37 kg

Maximum output 10.5 ps

Rated output/Speed 7.8 ps/1800 rpm

Valve layout Overhead valve

Output shaf Camshaft

Output shaft rotating direction Left (viewed from the output shaft side)

Type of fuel Lead-free regular gasoline equivalent toJIS K2202

Fuel tank capacity 6.0 liter

Lubrication method Forced splash lubrication

Lubricating oil capacity 1.2 liter (Upper limit)/0.63 liter (Lower limit)

Lubricating oil SAE#30

Carburetor Float type butterfly valve, side draft (BV26TH)

Ignition system Contactless magnet ignition

Spark plug BPR5ES (with resistor)

Cooling system Forced air cooling

Starting system Starting motor starter

Stopping system Primary cable short-circuit

Governing system Centrifugal weight type all speed

Air-cleaning system Viscous type urethane element

Exhaust silencing system Expanded silencing type

Lighting and charging system Flywheel magnet type

Since this generator is insufficient foroutput of the crane radio controller, anexternal alternator is connected to thegenerator with belt.

11. ENGINE ASSEMBLY

23

11.2 General View

11. ENGINE ASSEMBLY

24

11.3 Explanation of Main Components

1. Fuel System

The fuel system mixes fuel (gasoline) and air andsends the mixture to the cylinder and is composed ofthe following devices:

2. Carburetor

The carburetor is of the transverse blowing typeand mixes air and fuel (gasoline) with float valve andbutterfly valve. The structure and the componentsare as follows:

Components and Functions:

No. Parts Name System Functions

① Throttle valvelever

Controls flow rate of air passingthrough the venturi.

② Pilot screw Adjust stability of low speedrotation.

③ Pilot jet Low-speedfuel

Measures fuel at the time of low-speed operation.

④ Choke valvelever

Starting fuel Measures fuel at the time of coldstart.

⑤ Main jet Measures fuel at the time ofmedium or high speed operation.

⑥ Main nozzle High-speedfuel

The exhaust nozzle of mixture tobe supplied at the times ofmedium and high-speedoperations.

⑦ Needle valve Fuel flow-in Controls fuel flow to the floatchamber.

⑧ Float Fuel flow-in Keeps fuel oil level constant in thefloat chamber.

⑨ Float chamberbody

Fuel flow-in

(Gasoline)(Air)

Fuel tank

Fuel pipe

(Mixture)

Fuel valve mechanism

Air cleaner Carburetor

Air inlet

Cylinder

Fuel tank

Air cleaner

Fuel pipe

Carburetor

Fuel pipe

Fuel valve

①Throttle valve lever ④Choke valve lever

Throttle adjustmentscrew

Throttle valve

②Pilot screw

③Pilot jet

⑥Main nozzle

Packing

⑧Float

Choke valve

Carburetor body

⑤Main jet

⑦Needle valve

Pin

⑨Float chamber body

PackingBolt

11. ENGINE ASSEMBLY

25

The carburetor mechanism is divided into thefollowing systems from the viewpoint of operation:① Fuel flow-in system from fuel tank to carburetor.② Low speed fuel system through which fuel oil

flows at the time low-seed operation.③ High speed fuel system through which fuel oil

flows at the time of high speed operation.④ Starting fuel system that promotes cold start.

1. Fuel Flow-in System (Float and Needle valve)The float chamber ① is the fuel chamber below

the carburetor and keeps the fuel level constant byopening and closing the needle valve ② at the

entrance as the float lowers and rises.

2. Low-speed Fuel System (Pilot jet, Pilot air jet)

At the time of idling , the throttle valve ① slightly

opens and air flows quickly in the nearby pilot outlet② due to the small clearance between the throttlevalve ① and the venturi. The pilot screw ③ is a

needle value that controls oil flow from the pilot outlet② and also adjust the mixture ratio at the time of

idling.Since the throttle valve ① is mostly closed, air is

sucked slightly and flows slowly around the mainnozzle, and no fuel comes from the main system.

Fuel in the low-speed system flows from the mainjet hole ④ through the oil hole, enters the pilot jet ⑤,

mixes with air from the air breather in front of theventuri and turns into emulsion (liquid with airbubbles). The emulsion flows through the clearanceadjusted with the pilot screw and flows out of the pilotoutlet ②.

(Fuel flow-in system)

(Low-speed fuel system)


Fuel

②Needle valve(Float valve)

Float

①Float chamber

③Pilot screw

②Pilot outlet

①Throttle valve

Bypass Pilot air jet

④Main jetVenturi

⑤Pilot jet③Pilot screw ⑤Pilot jet

②Pilot outlet

11. ENGINE ASSEMBLY

26

At the time of idling, the tip of the throttleadjustment screw beside the pilot screw hits thethrottle valve lever and limits the opening of thethrottle valve. The throttle adjustment screw shouldbe adjusted together with the pilot screw.

3. High-speed Fuel System (Main Nozzle, Main Air Jet)

(To cylinder)

Main air jet

①Throttle valve

④Main nozzle

③Air breather

②Main jet

At the time of high-speed operation, the throttlevalve ① opens almost completely. Air from the air

cleaner flows from the suction port through the venturiand the throttle valve ① and is sucked in the cylinder.

Since this airflow is subjected to negative pressuredue to thin passage of the venturi, fuel in the floatchamber passes through the main jet ②, mixes withair from the air breather hole ③ and turns into

emulsion (liquid with air bubbles). The emulsionflows from the main nozzle ④, flows out of the venturi,

mixes with the main airflow into mixture and flows inthe cylinder.

4. Starting Fuel System (Choke Valve)When the choke valve is closed at the time of cold

start, intake air reduces and the negative pressurerises for smooth starting with high mixture ratio. Ifthe choke is closed at the time of starting, the portionafter the choke (on the combustion chamber side) willbe subjected to a high negative pressure and morefuel than in the normal state will flow out. Therefore,heavy mixture is jetted from the main nozzle to theventuri.


(High-speed fuel system)

(Starting fuel system)

Adjuster

Slow port

Pilot air jet

High-speed system

(To cylinder)

Pilot jet

(To cylinder)

①Throttle valve open

Choke lever open

Venturi④Main nozzle

(To cylinder)

The choke lever opensat the starting time.

Choke valve

11. ENGINE ASSEMBLY

27

5. Change of Fuel Flow by PathThe fuel-jetting path has a main

nozzle and a pilot outlet. Theirfunctions are as explained above.When these functions are combin-ed, fuel is supplied depending onload as shown in the right figure asa whole.

(Specification of Carburetor)

GA90 GA110GA120GA140

GA160GA180GA210

GA220 GA240 GA280 GA300 GA340

Type BV15-10 BV16-11 BV18-11 BV18-11 BV20-15 BV24-16 BV24-16 BV26-18 BV26-18 BV26-2?

Bore (mm) φ15 φ16 φ18 φ18 φ20 φ24 φ24 φ26 φ26 φ26

Venturi (mm) φ10 φ11 φ11 φ13 φ15 φ16 φ17 φ18 φ18 φ20

Main jet #62.5 #66 #63.8 #72.5 #80 #90 #92.5 #95 #95 #102.5

Pilot jet #40 − #42.5 #40 #37.5 #40 #42.5 #45 #45 #50

Throttle valve #150 02801P-1/4H

#170 #170 #110 #170 #160 #170 #170 #170

Pilot screwopening

1-1/2 turns − 1 turn 1-1/2 turns 2-1/2 turns 1-1/4 turns 2 turns 2 turns 2 turns 1 turn

Float chamberoil level (mm)

23 25 28 28 28 31 31 31 31 31

(Fuel flow change by path)F

uel s

uppl

y

Total supply

Main systemBypass

Pilot outlet

(Complete close)Throttle valve opening (Load factor)

(Full open)

11. ENGINE ASSEMBLY

28

3. Governor

When the engine operates at a specified speed,the governor controls supply of mixture depending onload from the outside so that the engine can keep thespeed all the time. The governor system of thismachine has the mechanical structure calledcentrifugal all-speed governor.1. When the engine speed increases, the governor

weight opens outward due to the centrifugal force(opens and closes depending on the enginespeed), and the motion moves the governorspindle right and left.

2. The motion of the governor spindle is transmittedto the governor yoke.

3. The motion is interlocked from the governor yoketo the governor lever, led to the carburetor throttlevalve and adjusts the opening (balanced tensionof the regulator spring) of the throttle valve thefixed engine speed.

4. Mechanical Decompressor

The mechanical type centrifugal weight autodecompressor fitted to the camshaft mechanismopens the exhaust valve at the time of starting theengine and reduces tension of the starter rope to startthe engine easily.

1. When the engine startsThe centrifugal weight pushes the decompressionneedle and tappet to open the exhaust valve, andpulling the recoil releases compression and thecamshaft rotates smoothly.

2. While the engine operatesWhen the engine speed comes to 850 rpm to950 rpm or more, the centrifugal forces moves thecentrifugal weight outward and the decompressionneedle is pulled in. This brings the exhaust valveto the normal working state.

Governor yoke

Side cover

Governor

Crankshaft

Governor spindle

Governor weight

Starting time

Centrifugal force

Cam gear

Camshaft

Needle (Decompressor)

During operation

Return spring

Crank gear

Tappet

Weight

Needle

Camshaft

Needle (Decompressor)

Governor lever

Throttle link mechanism

11. ENGINE ASSEMBLY

29

5. C.D.I. Type Electronic Spark Advance Ignition Circuit (GA280, GA300)

Circuit Diagram

Ignition coil

Spark plug

Ignition capacitor

Diode

Gate

Bia

s ci

rcui

t

Bia

s ci

rcui

t

Analog electronic circuit

Ignition circuit

Pow

ersu

pply

circ

uit

Exciter coil (to be used as pulser coil as well)

Magnet

Flywheel

C.D.I. Unit

1. Principle of OperationAs the flywheel rotates, the exciter coil generates

current, and the current is rectified with the diode andis charged in the ignition capacitor. Then, the sparkplug generates spark.At the time, the thyristor is off.

11. ENGINE ASSEMBLY

30

11.4 Troubleshooting

1. Table of Trouble Causes and Phenomena

Poor compression(Is compression available?)

Wear of valve seat or improper seatcontact

○ ○ ○ ○ ○

Improper valve clearance ○ ○ ○ ○ ○

Wear or sticking of air intake/exhaustvalve guide

○ ○ ○ ○ ○ ○

Wear of piston/cylinder ○ ○ ○ ○

Wear of piston ring ○ ○ ○ ○

Loose cylinder head bolt ○ ○

Broken cylinder head gasket ○ ○

Insufficient tightening of spark plug ○ ○

Improper fuel/fuel system Poor fuel property ○ ○ ○ ○ ○ ○

Water/dust mixed in fuel ○ ○ ○ ○ ○ ○

Closure of fuel valve or insufficientfuel

○ ○ ○

Clogging of air bleed hole on fueltank cover

○ ○ ○ ○

Air in fuel pipe ○ ○ ○ ○

Improper mixture(Is the mixture good?)

Defective operation of carburetorfloat valve

○ ○ ○ ○ ○ ○ ○

Clogging of carburetor oil passage ○ ○ ○ ○

Improper adjustment of carburetor ○ ○ ○ ○ ○ ○ ○

Improper carburetor oil level ○ ○ ○ ○ ○ ○

Defective operation of chokevalve/lever

○ ○ ○ ○ ○ ○

Insufficient airtightness of air intakepipe

○ ○ ○ ○

Improper adjustment of governor ○ ○ ○ ○ ○ ○

Defective ignition system(Is the ignition satisfactory?)

Contamination of spark plug orincorrect spark gap

○ ○ ○ ○ ○ ○

Disconnection of ignition coil ordefective earth

○

Others Clogging of air cleaner/element ○ ○ ○ ○ ○

Carbon deposit in cylinder ○ ○ ○ ○

Seizure or wear of rotating andsliding portions

○ ○

Defective operation of breather valve ○

Overload ○ ○ ○ ○

Bla

ck e

xhau

st

Whi

te e

xhau

st

Mis

fire

Spi

tting

Sta

rt d

iffic

ulty

Insu

ffici

ent o

utpu

t

No

rota

tion

incr

ease

Hig

h-sp

eed

failu

re

Low

-spe

ed fa

ilure

Phenomena

Causes

11. ENGINE ASSEMBLY

31

2. Causes of Troubles and Measures against Troubles

(1) Start Difficulty

Phenomena Probable Causes Measures

• The crankshaftrotates slowly.

• Seizure of crank pin metal/bearing

• Seizure of piston ring or cylinder

• Highly viscous engine oil

Repair or replacement of seized portion.


Inspection and change

• Insufficientcompressedpressure

• Damage or improper contact of airintake/exhaust valve seat

• Wear of piston/cylinder/piston ring

• Breakage of gasket/packing forcylinder head

• Insufficient tightening of spark plug orbreakage of gasket

• Sticking of air intake/exhaust valveguide

• Thrust of valve due to insufficientvalve clearance

Grind or replace the seat.

Replace the piston ring/piston.

Replace the gasket/packing.

Replace the gasket/packing and tightenthe spark plug additionally.

Repair or replace the valve guide.

Adjust the valve clearance.

• Proper fuel gas is notsucked in thecylinder.

• The fuel tank runs out of fuel

• Water/dust in fuel filter/fuel pipe

• Fuel flows only a little or abnormally.

a) Clogging of air bleed hole on fueltank cover

b) Insufficient opening of fuel valvelever

c) Clogging of fuel filter

d) Air in fuel pipe

• Fuel does not flow in the carburetorfloat chamber.

a) Sticking of float valve

b) Improper adjustment (oil level) offloat valve

• Gas fuel is not sucked in the cylinder.

a) Insufficient carburetion due to gasleak

b) Clogging of carburetor oilhole/main jet

c) Insufficient airtightness of airintake pipe, etc.

d) Clogging of air cleaner element

e) Closure of throttle valve due toimproper adjustment of governor

Supply fuel to the tank

Clean the fuel filter/fuel tank.

Clean the air bleed hole.

Open the valve lever fully.

Clean the fuel filter.

Loosen the joint bolt to bleed air.

Clean or replace the float valve.

Adjust the oil level of the float valve.

Clean the carburetor oil hole/main jet.

Replace the packing or tighten the pipeadditionally.

Clean the element.

Adjust the governor again.

11. ENGINE ASSEMBLY

32


• Overflow from carburetor

a) Defective float valve or adhesionof gum substance

b) Damage of float (insufficientbuoyancy due to puncture)

c) Improper oil level


Replace the float and adjust the oillevel.

Adjust the oil level in the float chamber.

• No spark from sparkplug

• Defective electrode or contaminationof spark plug

• Incorrect connection of plugcap/high-tension cable

• Demagnetization of flywheel magnet

Clean the spark plug and adjust thespark gap or replace it.

Connect it correctly or replace it.

Replace the flywheel magnet.

(2) Insufficient Output


• The crankshaftrotates slowly.

• Seizure of crank pin metal/bearing

• Seizure of piston ring or cylinder



• Insufficientcompressedpressure

• Leakage of compression from airintake/exhaust valve seat

a) Damage or improper contact of airintake/exhaust valve seat

b) Thrust of valve due to insufficientvalve clearance

c) Sticking/wear of air intake/exhaustvalve guide

d) Defective operation ofdecompressor

• Wear or sticking of piston ring

• Breakage of gasket/packing forcylinder head

• Insufficient tightening of spark plug orbreakage of gasket

Grind or replace the air intake/exhaustvalve seat.


Repair or replace the valve guide.

Check operation of the decompressor.

Replace the piston ring.

Replace the gasket/packing.

Replace the gasket/packing and tightenthe spark plug additionally.

• Proper fuel gas is notsucked in thecylinder.

• Fuel flows only a little in the pipe.

a) Clogging of fuel filter

b) Insufficient opening of fuel valve

c) Air in fuel pipe

• Fuel does not flow in the carburetorfloat chamber.

a) Sticking of float valve

b) Improper adjustment of float valve

Clean the fuel filter/fuel tank.

Open the fuel valve lever fully.

Loosen the joint bolt to bleed air.


Adjust the oil level of the float valve.

11. ENGINE ASSEMBLY

33


• Gas fuel is not sucked sufficiently inthe cylinder.

a) Insufficient carburetion due to gasleak

b) Clogging of carburetor oilhole/main jet

c) Insufficient airtightness of airintake pipe, etc.

• Improper adjustment of governor

• Clogging of air cleaner element

Clean the carburetor oil hole/main jet.

Replace the packing or tighten the pipeadditionally.

Adjust the governor again.

Clean the element.

• Weak spark fromspark plug

• Contamination/improper adjustmentof spark plug

Clean the spark plug and adjust theelectrode gap.

• Overheat • Contamination of cooling fan/fin orclogging with dusts

• Carbon deposit in cylinder

• Overload

• Improper heat value of spark plug

• The ambient temperature is high.

Clean the fan/fin.

Remove carbon from and clean thecylinder head and the cylinder.

Set the load to the rated one.

Replace the spark plug with thedesignated one.

Ventilate the cooled air inlet and theexhaust outlet.

(3) Poor Exhaust Color (Black smoke)

Probable Causes Measures

• Fuel containing much impurity is used



• Improper opening of choke valve(Isn't the choke half open?)

Change the fuel to the designated new one.

Clean the element.

Check oil tight and adjust the oil level in the floatvalve.

Open the choke valve fully.

(4) Poor Exhaust Color (White smoke)


• Wear of piston ring/oil ring

• Reverse fitting of piston ring/oil ring

• Wear of air intake valve/exhaust valve guide

• Defective operation of breather valve

• Too much supply of engine oil

Replace the ring.

Fit the ring correctly.

Replace the valve guide.

Clean or replace the breather valve.

Reduce the engine oil to the specified amount.

11. ENGINE ASSEMBLY

34

(5) Misfire


• Water mixed in fuel

• Too heavy fuel

• Sticking/wear of air intake valve/exhaust valveguide

• Wear/improper contact of air intake valve/exhaustvalve seat

• Insufficient valve clearance

• Contamination of spark plug or improper sparkgap

Clean the fuel tank and change the fuel.

Adjust the carburetor.(Replace the main jet to a smaller one.)

Correct or replace the valve guide.

Correct or replace the valve seat.


Clean the spark plug or adjust the spark gap.

(6) Backfire (Spitting)


• Improper contact of air intake valve/exhaust valveseat or insufficient valve clearance

• Sticking of air intake valve guide


Grind or replace the valve seat or adjust the valveclearance.

Correct or replace the valve guide.

Clean or replace the carburetor float valve.

(7) No Rotation Increase


• Improper adjustment of governor(Improper opening of throttle valve)

• Insufficient valve clearance(Improper valve open/close time)


• Improper mixture


• Clogging of exhaust port/muffler with carbon

• Overload

Adjust the governor.


Clean the element.

Adjust the carburetor.

Clean the spark plug, adjust the spark gap or replacethe spark plug.

Remove carbon and clean the exhaust port/muffler.


11. ENGINE ASSEMBLY

35

(8) High-speed Failure



• Weak tension of governor spring

• Too heavy mixture


• Carbon deposit in combustion chamber

• Overload


Replace the governor spring or change the holeposition.

Clean the carburetor.

Use a spark plug of the designated heat value.

Remove carbon.


(9) Low-speed Failure



• Too heavy mixture


• Wear of piston ring

• Wear of piston/cylinder

• Clogging of low-speed air jet


Clean the carburetor.

Clean the spark plug, adjust the spark gap or replacethe spark plug.

Replace the ring.

Replace the piston/cylinder.

Clean the air jet.

(10) Abnormal Noise


• Wear of connecting rod large end

• Loose connecting rod bolt

• Wear of piston pin

• Wear or play of crank bearing

• Wear or play of cam bearing

• Insufficient or too much valve clearance

• Loose flywheel end nut

Replace the connecting rod.

Tighten the connecting rod bolt additionally.

Replace the piston, the piston pin and the connectingrod.

Replace the bearing.

Replace the bearing.

Adjust the valve clearance or replace the valve.

Tighten the end nut additionally.

11. ENGINE ASSEMBLY

36

(11) Run On (Dieseling)


• Overload

• Overheat

• Carbon deposit in combustion chamber


• Defective operation of decompressor


Correct clogging of the air intake port or the cylinderfin.

Remove carbon from the cylinder.

Replace the spark plug with the designated one.

Check operation of the decompressor.

* "Run on" means that the engine continues rotating at low speed even after switched off.

11. ENGINE ASSEMBLY

37

11.5 Inspection and Adjustment

1. Inspection of Engine Oil

1. Check of Oil LevelHold the engine level, remove the cylinder oil filler

port cover and check the oil level with the oil levelgauge fitted to the oil filler port cover. When the oillevel comes down close to the lower limit, supply thedesignated engine oil up to the upper limit scale.

2. Deterioration and Change of OilCheck contamination and viscosity of the engine

oil. If discolored black or is not viscous, the oil hasbeen deteriorated and should be changed. Whenchanging the engine oil, drive the engine for a while,remove the drain plug while the engine is warm anddrain the old engine oil.

[Caution]• In case of gasoline engine, be sure to change the engine oil every 50 working hours

because the engine oil is apt to be diluted (due to clearance leak of mixture from thepiston). We have often heard that, after certain working hours, gasoline ingredientsincreased irrespective of the oil level and the engine oil lost viscosity and, therefore theengine seized during heavy work.

• When the machine is inclined for the sake of conditions of work equipment, make theengine level and check the oil level.

3. Kind of Engine OilUse any engine of Class SE or higher of the New

SAE (A.P.I.) Classification and select viscosity fromthe following table taking the ambient temperature intoaccount:

(Liter)

GA90,110

GA120,140

GA160to 210

GA220,240

GA280to 340

Oil volume 0.4 0.5 0.6 1.0 1.2

Class SE of New SAE (A.P.I.) Classification

Temperature SAE Viscosity Classification

Below 30 °C Class SE Automobile engine oilSAE10W-30

Over 30 °C Class SE Automobile engine oil SAE30

Oil level gauge (Do not screw the oil filler port cover and check the oil level.)

Oil filler port

Oil level

Upper limit (F)

Lower limit (L)

(Supply oil up to right before overflowing.)

11. ENGINE ASSEMBLY

38

2. Inspection of Fuel

Check the fuel level with the level gauge on thefuel tank. When refueling, remove the fuel tank capand refuel slightly below the fuel filler port. When thefuel filter in the fuel filler port is contaminated withdusts, clean it.

Type of fuel oil:Lead-free regular gasoline(equivalent to JIS K2202, Motor gasoline)

3. Inspection of Fuel Pipe

Check if fuel is leaking from the clamp or the jointalong the fuel pipe, and also check the appearance ofthe fuel pipe for crack or any other deterioration.

Fuel tank cap

Fuel filler port filter

Fuel pipe

11. ENGINE ASSEMBLY

39

4. Inspection and Cleaning of Air Cleaner

Remove the inner element periodically and cleanit with gasoline. Then, dip it in the mixed oil (with themixing ratio of gasoline 2 to 4 to engine oil 1) andsqueeze it until no drip comes out, wipe it well and setit in the air cleaner. Never use broken elements.(Multipurpose specification)

[Caution]

Never wash the filter paper element.

5. Inspection of Spark Plug

1. Remove the spark plug periodically and checkburning and wear of the electrode, clean it with awire brush and adjust the spark gap (electrodegap).

2. Replace the electrode, if worn or broken, with anew one. If the plug is used continuously, anengine trouble, waste of fuel or abnormal exhaustgas will occur.

0.8 to 0.9 mmSpark gap adjustment standardvalue :

Resistor spark plug isused to reduce radiocontrol noise. :

Spark plug BPR5ES

Air cleaner

(Special Specification)

Sponge Filter paper element

Spark plug

11. ENGINE ASSEMBLY

40

3. Engine condition can be judged from burnedcondition of the electrode.

Good burn When the electrode and the insulator porcelain are burnt white, light brown or gray,they are considered burnt well and the plug is functioning perfectly.

Burn withcontamination

• Smoky burn (Contamination due to cooling)The igniting portion is completely covered with black dry carbon. Spark becomesweaker and weaker, and the portion comes not to ignite. The engine does not startwell, becomes unstable at low speed and stops at last or is not acceleratedsmoothly.

• Fogging (Contamination due to wetting)Deposit of wet carbon, wetting with gasoline or oil.Smoky burn and fogging occur due to abnormal ignition system other than the plugor abnormal fuel system, improper maintenance of the engine, use in improperconditions or over-cooled spark plug.

Over-burn If the spark plug is burnt excessively, the engine power will reduce and will not rotatefast. The insulator porcelain will become white just like being exposed and bespotted, the center electrode will be worn quickly or the porcelain will be cracked.

The following causes are considered : use of plug being burnt easily, too advancedignition timing, too thin mixture, insufficient cooling of engine, extraneous matters incombustion chamber, use of low-octane gasoline, etc.

12. HYDRAULIC PUMP

41

12.1 General View

Oil filler: PF 1/4 Discharge port : P1

View A

Hydraulic symbol

Discharge port : P1

Discharge port : P2

Discharge port : P1

Product name PVD piston pump

Type PVD-0B-17L3S-4242F

Capacity P1, P2 : 8.6 cc/rev

Pressure P1, P2 : 210 kgf/cm2

Speed Rated speed : 1,800 rpmMaximum speed : 2,000 rpm

Inlet pressure −0.2 to 0.4 kgf/cm2

Hydraulic oil Equivalent to ISO VG 46.

Oil temperature Working temperature range : −20 to 100°CNormal temperature : 60°C

Driving method Engine direct connection : 8.7 ps (at 1,800 rpm)Input torque : 3.46 kg･fm (at 1,800 rpm)

Control characteristic Constant horsepower control

Suction port: S1Suction port: S1

Suctionport: S1

12. HYDRAULIC PUMP

42

12.2 Inside View

1. Body S 14. Spring C 34. Snap ring

2. Body H 15. Spring TI 35. Snap ring

3. Shaft 18. Spring holder 36. Snap ring

4. Cylinder barrel 19. Spring guide 39. O-ring

5. Valve plate 20. Pin 42. Plug

6. Piston 23. Washer 43. O-ring

7. Shoe 24. Retainer 44. Socket head bolt

8. Shoe holder 25. Lock pin A 51. Plug

9. Barrel holder 26. Lock pin B 52. Spring washer

10. Swash plate 30. Ball bearing 56. Spring pin

11. Needle 31. Needle bearing 60. Lock screw

12. Related pin 32. Oil seal 61. Nut

13. Packing 33. Plate spring 62. Seal washer

12. HYDRAULIC PUMP

43

12.3 P-Q CharacteristicD

isch

arge

: q1

= q

2 (c

c/re

v)

Discharge pressure : P1 + P2 (kgf/cm2)

RemarksLegendsTest Conditions

Input torque 3.46 kgf⋅mEquivalent to ISO VG 46

50±5 °C

1,800 rpm

Right

Hydraulic Machine Test

Product name

Test name

Type of oil

Oil temperature

Pump horsepowerconsumption

7.28 PS

Pump absorptiontorque

2.9 kgf⋅m

Speed

Direction ofrotation

Type

Materialorder No.

Serial No.

PVD-0B-17L3S-4242F

(For MC205)

PVD piston pump

P-Q Characteristic

12. HYDRAULIC PUMP

44

12.4 Principle of Operation

(1) Mechanism of Constant Flow Double PumpThis pump looks like a single pump but has the functions of a double pump because the uniquemechanism enables to provide two equal discharges from one piston cylinder barrel kit.Fig. 2 shows principle of operation for double pump.This pump is equipped with an even number of pistons, which reciprocate to suck and dischargehydraulic oil like the usual piston pump. The discharge ports of the cylinder barrel are arrange insideand outside alternately, and the valve plate also has two discharge ports on the inside and the outsideaccordingly. So, the discharge flow is divided in the two ports on the outside and inside and flowsequally through the two ports at the same time.

Suction flow Discharge flow

(a) Valve Plate

(b) Cylinder barrel

Suction flow Discharge flow P1

(a) Valve Plate

(b) Cylinder barrel

Discharge flow P2

Discharge flow P1

and ??? Discharge flow P2

and ???

Fig. 1 Usual Swash Plate Type Piston Pump Fig. 2 Principle of Operation

12. HYDRAULIC PUMP

45

(2) Constant Horsepower Variable MechanismThe pump capacity varies with the swash plate angle, and the swash plate angle allows performingconstant horsepower control with the simple direct-acting variable mechanism.This variable mechanism is available in two ways:

(a) PVD-0B/1B (Fig. 3-a)The center of rotation of the swash plate is at the ball on the rear side of the pump.Load F1 from the piston side is located in the direction shown in the figure and generates a right-turn moment to the swash plate. On the other hand, a spring for setting constant horsepowersis fitted in the opposite direction and is set to a fixed load.As the pressure increases, the above moment incases and bends the spring and reduced theswash plate angle, so that the discharge decreases and the horsepower is maintained constant.

(b) PVD-2B/3B (Fig. 3-b)The center of rotation of the swash plate is almost the same as the center of load on the piston side,and the position of the swash plate angle is determined with the spring fitted in the oppositedirection of the oil pressured added to the control piston. The control piston is subjected to thetotal of pressures of the two systems. As the pressures increase, the spring is bent, the swashplate angle decreases and the discharge also decreases. Therefore, the horsepower ismaintained constant.

Fig. 3-a

Fig. 3-b

Fig. 3-a

Fig. 3-b

12. HYDRAULIC PUMP

46


Causes of Troubles and Measures against Troubles

Phenomena Causes Measures

1. The engine is overloaded. 1) The engine speed is higherthan the specified one.

2) The pressure is higher than thespecified one.

3) Seizure or damage of partsinside the pump

1) Adjust the speed to thespecified one.

2) Adjust the pressure to thespecified one.

3) Repair or replace the pump.

2. The pump oil level lowersextremely and the dischargepressure does not rise.

1) Decrease of engine speed

2) The pump coupling isdefective.

3) Seizure or damage of partsinside the pump.

1) Adjust the engine speed.

2) Repair or replace the pumpcoupling.

3) Repair or replace the pump.

3. Abnormal noise and abnormalvibration (cavitation)

1) Mixing air/water in hydraulic oil.

2) The suction pipe is clogged ornarrowed.

3) Trouble of the accessory pump(when the pump is fitted )

4) Damage of caulked portion ofpiston shoe.

5) Loosening of pump mountedportion.

6) Defective coupling

1) Tighten the circuit, especiallythe suction pipe, additionally.Change the hydraulic oil mixedwith water.

2) Correct the suction pipe.

3) Repair or replace theaccessory pump.

4) Replace the piston assembly.

5) Mount the pump correctly.

6) Replace the coupling.

4. Oil leakage 1) Defective O-ring/seatpacking.

2) Loosening /improper fitting ofcap ring.

3) Oil leaks from the oil seal edge.

1) Replace the O-ring/seatpacking (Set it correctly in theright position.)

2) Fit it again with the specifiedtorque.

3) Repair or replace the oil sealand the shaft.

13. TRAVEL CONTROL VALVE

47

13.1 General View

Stroke

10

(W

idth

acr

oss

flats

)-0

.15

+0M

8×1.

25－

2,

Effe

ctiv

e th

read

dep

th 1

6

Circuit diagram

RearFront

RearFront

Right rearRight front

Left frontLeft rear

Pressure detection portPT1/4

A

A

13.2 Specifications

Maximum flow on machine P1, P2 16 liter/min.

Main relief valve (both P1 and P2) set pressure 20.6±0.5 MPa (210±0.5 kgf/cm2) at 16 liter/min

Hydraulic oil Equivalent to ISO VG 46

Working temperature range 253 to 363 K (−20 to 90°C)

Inner leakage ((at 9.8 MPa(100 kgf/cm2), #46323 to 328 K (50 to 55°C)200 M/min (200 cc/min.) max each spool

Spool operating effort (Spring force) At neutral : 88.2 N approx. (9 kgf approx.)At full stroke : 117.6 N approx. (12 kgf approx.)

T port allowable back pressure (Normal back pressure) 1.47 MPa (15 kgf/cm2) [0.49 MPa (15 kgf/cm2)]

Paint color Red rust

Port size (JIS B2351, O-ring seal) P1, P2, T...............................PF1/2A1, A2, B1, B2, CO...............PF3/8

13. TRAVEL CONTROL VALVE

48

13.3 Inside View

A Detailed view of main relief valve (S=1/1) (2 places)

Section X-X Section Y-Y

1 Compression spring 25 Flange plug2 Valve needle 26 Flange plug3 Lock nut 27 Flange plug4 Ring gasket 28 Flange plug5 Spring holder 29 Sems screw6 Compression spring 30 Lock screw7 Seal holder 30 Nut8 Back-up ring 31 Rivet9 Sleeve 32 O-ring

10 Poppet 33 O-ring11 Compression spring 34 O-ring12 Housing 35 O-ring13 Valve seat 36 O-ring14 Wire 37 O-ring15 Spring cover 38 O-ring16 Tie rod 39 O-ring17 Inlet housing 40 O-ring18 Inlet housing 41 O-ring19 Plug 42 Plug20 Plunger housing21 Open spool22 Body23 Name plate24

14. TRAVEL MOTOR

49

14.1 General View

Oil level

Lubricating oil fillerdrain port

2-G3/8(A,B Port)

JIS Symbol

14.2 Specifications

Type FZD-100-25B-9-8283A

Reduction gear Maximum output 922 N･m (94 kgf･m)

Maximum output speed 43.6 rpm

Reduction ratio 1/36.96

Hydraulic motor Capacity 8.9 cc/rev

Maximum working pressure 20.6 Mpa (210 kgf/cm2)

Maximum output speed 1,610 rpm

Maximum flow 14.7 liter/min

Parking brake Static friction torque 17.6 N･m (18 kgf･m)

Release pressure 1.5 Mpa (15 kgf/cm2)

Left travel motorA : Reverse B : Forward

Right travel motorA : Forward B : Reverse

14. TRAVEL MOTOR

50

14.3 Inside View

14. TRAVEL MOTOR

51

14.4 Principle of Operation

Par

king

bra

ke Cou

nter

bala

nce

valv

eH

ydra

ulic

mot

or

Sim

ple

plan

etar

y re

duct

ion

gear

(2-s

tage

)

Car

rier 2

Fixe

d po

rtion

Rot

atin

g po

rtion

Not

e: b

1 m

eans

4 p

lane

tary

gea

r, an

d b2

mea

ns 3

pla

neta

ry g

ear.

14. TRAVEL MOTOR

52

14.5 Function

Series Travel motor consists of the fixed body mainly composed of a hydraulic motor and a hydraulicvalve and the rotating body mainly composed of a simple planetary reduction gear.

1. Reduction Gear

1) FunctionSeries travel motor reduction gear is composed of 2 stages of simple planets, reduces the speed ofhigh-speed rotary motion from the hydraulic motor, converts it into low-speed large torque and rotatesthe case.

2) OperationAs shown in the right figure, the gear S2 isconnected to the hydraulic motor output shaft withspline, and rotation of the gear S2 is reduced astage among the gears (S2, b2 and a2). The one-stage reduced rotation is reduced two stagesamong the gears (S1, b1 and a1) connected toCarrier 2 with spline, and this rotation istransmitted to the rotating body through theinternal gears a1 and a2 and become the traveldriving force.

The reduction ratio of the 2-stage simple planet isgenerally expressed as follows:

R = ･

where,Zs1, 2: Number of teeth of the gears s1 and s2

Za1, 2: Number of teeth of the gears a1 and a2

Since the body rotates, the reduction ratio of ...Series travel motor is expressed as follows:

R' =

Fixed portion Rotating portion

Carrier 2

Simple planetaryreduction gear (2-stage)

Fig. 3Zs1

Zs1 + Zd1

Zs２

Zs２ + Zd２

1

1 − 1/R

14. TRAVEL MOTOR

53

2. Hydraulic Motor

1) FunctionThe hydraulic motor is of an axial piston motor type (rotating cylinder swash plate type) and convertshydraulic energy from the pump into rotary motion.

2) Structure and Principle of Operation (See the figure below.)

The motor shaft is integrated with the gear S2 or connected to the gear with spline.

Piston ⑥

Cylinder barrel ④

Valve plate ⑤

Shaft ③

Swash plate ⑦ Port A

Port B

Fig. 4

The pressurized oil flown in from the hydraulic valve is supplied to the valve plate ⑤.The pressurized oil, if supplied to Port A, flows in the cylinder port in the cylinder barrel ④ and pushesthe piston ⑥. This press force is converted into torque through the swash plate ⑦ and the torque istaken out to the shaft ③ connected to the cylinder barrel with spline.The return oil in the cylinder port flows out through Port B of the valve plate ⑤.

In case of reverse rotation, the pressurized oil flows in Port B, and the return oil flows out of Port A.

14. TRAVEL MOTOR

54

3. Hydraulic Valve (Counter-balance Valve)

The pressurized oil, when supplied from Port A , pushes to open the check valve ③ and flows in

the inlet side port of the hydraulic motor. The pressurized oil flows through the choke hole C , enters the D chamber, overwhelms the spring ④ and slides the spool valve ② to the right.

Then, the return oil of the hydraulic motor flows in from Port B , returns to Port B through theopening E between the body ① and the spool valve ② and rotates the hydraulic motor.

When the pressurized oil is supplied from Port B , the above parts operate in reverse and the hydraulicmotor rotates in reverse.

When the pressurized oil from Port A is interrupted from the pressurized state, the spool valve ②moved to the right tries to return to the left side due to the spring ④ force.

At the time, the oil in the D chamber tries to flow out to Port A through the choke hole C , but thespool valve ② controls the speed returning to the left side by the throttling effect of the choke hole C .

Even if the pressurized oil in Port A is interrupted, the hydraulic motor tries to rotate by inertia force.At the time, the spool valve ② limits the return oil gradually to stop the hydraulic motor smoothly

depending in the switching speed and the notch shape.

Fig. 5

14. TRAVEL MOTOR

55

14.6 Precautions When Using

1. Mounting Method

(1) Sprocket Engaging Portion A , Body Engaging Portion B

(2) When mount the motor on the machine body and when mounting the sprocket on the motor, do not usehammer and push it in quietly using the mounting bolt.

(3) Use the designated bolt (equivalent to 11T or more) for mounting the motor and the sprocket and applythe following tightening torque:

Thread Size Tightening Torque

M10 5 to 6.5 kgf･m

{49 to 64 N･m}

2. Piping

(1) For piping to the motor, see the mounting dimension diagram. Pay attention to the rotation direction.(2) The piping port is covered at the time of delivery. When piping, use care to prevent dusts from

entering the pipe after cutting the welding scale.(3) The motor is of an internal drain type, the drain pressure (pressure in the hydraulic motor body) rises up

to the motor outlet pressure. In order to protect the internal parts such as oil seal, decide the pipesizes and the connecting method so that the pressures in the pipes A and B do not exceed theallowable pressure in casing.Arrange so that the allowable (normal and surge) pressures do not exceed 5 kgf/cm2 {0.5 Mpa} and10 kgf/cm2 {1 Mpa} respectively.

(4) Good filtering will extend the life of the hydraulic system and raise the reliability. Set a 10 µm filterinside the circuit.

14. TRAVEL MOTOR

56

3. Gear Lubricating Oil

(1) Use diesel engine oil equivalent to SAE-30-CD as the lubricating oil. (At the time of delivery, IdemitsuApollo Diesel Motive S-330 is used.)

(2) Any of the recommended gear oils may be used, but try to use only one oil and not to mix different oils.(3) At the time of delivery, the motor is lubricated. When refilling lubricating oil, follow the procedures

below:a) Remove the plugs from the oil filler port and the oil level check port.b) Supply the lubricating oil up to the LEVEL mark.c) Screw the plugs in the oil filler port and the oil level check port. At the time, be sure to wind seal

tape around the plugs.

Oil level check port

Oil filler port LEVEL

( Rc 1 / 8' )

( Rc 1 / 8' )

( Rc 1 / 8' )Oil filler outlet port

(4) Lubricating Oil Amount for ... Series

Type Capacity

−100 330 cc

(5) Change Timing of Lubricating OilFirst change : 200hr or 2 monthsSecond and later changers : Every 1,000 hr or yearly

4. General Precautions

(1) Be careful of oil leakage and loosening of bolt all the time to find them promptly. Also, we recommendyou to prepare a check sheet.

(2) In case of continuous operation, pay attention to the casing temperature of the reduction gear body.Keep the casing temperature at the normal hydraulic oil temperature + 20°C.

14. TRAVEL MOTOR

57


Trouble Phenomena Main Causes Countermeasures

The motor does notstart.

Defective operation of any hydraulicequipment other than travel motor.

Check the motor inlet temperature andinspect, repair or replace otherequipment.

Defective operation of hydraulic motor

• Breakage of internal parts

• Leakage of pressurized oil frominternal drain check valve

Replace the broken parts (kits)

Remove foreign matters or replace theBody 1 kit

Defective operation of counter-balance

• The spool does not stroke.


Defective operation of reduction gear

• Breakage of internal parts Replace the broken parts (kit)

The machine speeddoes not increase.

Defective operation of any hydraulicequipment other than travel motor

Inspect, repair or replace eachequipment.

Defective hydraulic motor

• Reduction of volumetric efficiency dueto abnormal wear caused by catchingforeign matters .

Replace the worn parts (kit)

The motor does not stopor stops slowly.

Defective operation of counter-balance

• The spool does not return normally.Remove foreign matters or replace theBody 1 kit

The brake does notwork or the brakingforce is weak.

• Abnormal wear of steel plate, diskplate or brake piston

Replace the worn parts

• Breakage of spring Replace the spring

• The back pressure is high and thepressurized oil in the brake line doesnot drain smoothly.

Review the piping

Oil leakage Breakage of O-ring Replace the O-ring

Breakage of oil seal

• The motor outlet pressure is high.

• Defective operation of internal draincheck valve

Replace the oil seal

Review the piping


Abnormal wear of mechanical seal Replace the floating seat and the sealring

15. REMOTE CONTROL VALVE

58

15.1 General View

Remote Control Valve

A1 : Lower-No. 4 outrigger IN

B1 : Rise-No. 4 outrigger OUT

A2 : Down-No. 3 outrigger IN

B2 : Up-No. 3 outrigger OUT

A3 : Extend-No. 2 outrigger IN

B3 : Contract-No. 2 outrigger OUT

A4 : Left-No. 1 outrigger IN

B4 : Right-No. 1 outrigger OUT


59

15.2 General

This valve is an electromagnetic control valve with the functions to change magnetic direction foroperating and stopping the load actuator with solenoid and to maintain the operating speed of the actuatorconstant with the pressure-compensated flow control valve at the time of single operation.

• SpecificationValve Rated Specifications• Maximum working pressure : 210 kgf/cm2

• Rated flow : 50 liter/min• Sequence valve pressure (back pressure) : 13 to 17 kgf/cm2 (cracking)• Pressure reducing valve set pressure : 14.5 to 15 kgf/cm2

• Working oil temperature range : −20 to 80°C• Recommended hydraulic oil viscosity range : 8 to 400 cSt• Recommended hydraulic oil cleanliness : NAS Class 9 max.

(Recommended filter 10 µm max.)

Solenoid Rated Specification• Rated voltage : 12 VDC• Voltage fluctuation range: +20 to −10%V• Current and power consumption (at 20°C)

SOL No Current value, Power consumption Application

1 to 8 0.91 A, 11 W approx. For actuator drive control

11, 12 1.7 A max. (20.4 W approx.) For controlling flow control valve andaccelerator positioner

• Water resistance : Conformity to S2 in JIS D0203• Excitation rating : Continuous.

Continuous excitation heats the solenoid to hightemperature. Do not touch it carelessly, but youwill get your fingers burned.

• Circuit Configuration (The hydraulic circuit is shown on the next page.)Since the electromagnetic selector valve (hoist, winch, telescope and swing) is composed of parallelcircuits, more than one electromagnetic selector valve can be operated at the same time. In case ofsimultaneous operation, the actuator with the lowest load pressure starts operating first.This valve has the center bypass passage through which supplied oil from the pump is released withoutload when the selector valve is set to neutral.

�


60

15.3 Hydraulic Circuit Diagram

Pressure gauge

P (Pump port)

Sequence valve (Back pressure valve)

Pilot pressure reducing valve

Center bypass passage

Parallel passage

T (Tank port)

Supply/exhaust portion

Flow control valve portion

Accelerator positioner portion

Dr. (External drain)

Hoist

Winch

Telescope

Swing

Lower

Down

Rise

Up

Extend Contract

Left Right

Pilot passage

Tank passage

U-turn cover

Electromagnetic selector valve


61

15.4 Function

1. Composition and Function of Supply Portion

The supply portion is composed of the supply port (a) to which pressurized oil is supplied from thepump, the oil passage through which the pressurized oil flows to the controller (selector), the exhaust port(b) through which return oil from the actuator flows to the tank, the sequence valve (1) and the pressurereducing valve (2).

The sequence valve (1) is intended to secure the minimum working pressure of the pilot at the time ofelectromagnetic selecting without load, and the pressure reducing valve (2) keeps the pilot pressure at thespecified value.

When oil is not supplied, both the sequence valve (1) and the pressure reducing valve (2) do notoperate, and the passage from the pump to the center bypass is closed but the passage to the primary sidefrom the pump to the pressure reducing valve (2) is open.

The oil, when supplied from the pump, pushes to open the sequence valve (1), flows to the centerbypass passage and does not operate the downstream selector valve. In that case, the pump pressure atthe supply port (a) becomes the one of the sequence valve (1). (Cracking pressure: 13 to 17 kgf/cm2).At the same time, the pressure reducing valve (2) starts holding the pilot pressure as the set pressure ofthe valve. (Pressure reducing valve set pressure: 14.0 to 14.5 kgf/cm2)

When the oil from the pump operates the downstream selector valve, the pump pressure becomes theload pressure, and when the load pressure reaches the set pressure of the external relief valve, the circuitpressure is held as the relief valve set pressure.

* For the function of the pressure reducing valve, see Page 11.

WARNING

• This selector valve is not fitted with a relief valve. So, the circuit maximum pressuredepends on the relief valve fitted to other than the selector valve.

• Set the relief valve set pressure to lower than the valve rated pressure.If the set pressure is set to over the rated pressure, the relief valve will be degraded, getout of order or be broken.

�


62

Secondary sideTo each pilot control line

Primary side

Pilot passageFilter

Pumppassage

Tank passage Center bypass passage

The figure is simplified to show the circuit configuration.

When oil is not supplied, the circuit is interrupted

Fig. 1


63

2. Function of Flow Control Valve

2-1) When each selector valve is at the neutral position (Fig. 2)Pressurized oil from the pump flows through the center bypass passages of the control valve and ofeach selector valve and the tank passage and returns to the tank from the exhaust port of the supplyportion.

From pump

U-turn cover

Center bypass passage of each selector valve

Each selector valve tank passage Tank passage Center bypass passage

Tank

Fig. 2


64

2-2) When selector valves are operated (when the negative electromagnetic proportional pressurereducing valve solenoid is not energized) (Fig. 3)

When any selector valve is changed over, the center bypass passage is closed, and pressurized oilpushes up the detection valve (1) and flows in the parallel passage. At the time, the pump pressureaffects the primary side chamber (a) of the flow control spool (2) while the load pressure (the detectionvalve downstream pressure) affects the secondary side chamber (b) and the detection valve springchamber (c). Since the primary side piston (3) and the secondary side piston (4) are of the samediameter, the differential pressure between the front and the rear of the detection valve (1) affects theflow control spool (2) in the right direction.On the other hand, the secondary pressure of the negative electromagnetic proportional pressurereducing valve (5) affects the control valve spring chamber (d) and also affects the flow control spool(2) in the left direction together with the spring force.Since the secondary pressure comes to the maximum when the negative electromagnetic proportionalpressure reducing valve solenoid (SOL11) is not energized, the rightward force, which affects the flowcontrol spool (2), exceeds the leftward force, and the flow control spool (2) comes to the left end.Therefore, the control notch (e) portion remains closed, and the all pressurized oil from the pump flowsto the selector valves through the parallel passage.

Interruption of center bypass passage

Actuator

Parallel passage

1. Detection valve

2. Flow control spool

3. Primary side piston

4. Secondary side piston

5. Negative electromagnetic proportional pressure reducing valve

Fig. 3


65

2-3) When the selector valves are operated (when the negative electromagnetic proportional pressurereducing valve solenoid is energized) (Fig. 4)

When a current is applied to the negative electromagnetic proportional pressure reducing valve (5)solenoid (SOL11), the secondary pressure changes (drops) according to the current value and theleftward force, which affects the flow control spool (2), also reduces. As a result, the flow control spoolmoves to the right and opens the control notch (e) portion to release excessive oil to the tank. Sincethe oil flow from the detection valve (1) to the parallel passage decreases by that, the differentialpressure between the front and the rear of the detection valve (1) reduces and the rightward force,which affects the flow control spool (2), reduces as well. Then, the flow control spool (2) moves to theposition where the rightward force balances with the leftward force.These motions occur continuously, and the oil flow is controlled according to the applied current value.When the load pressure changes in the state, the flow control spool (2) changes the opening of thecontrol notch (e) portion so as to keep the differential pressure between the front and the rear of thedetection valve (1) constant. Also, the spool makes the oil flow to the actuator constant irrespective ofload pressure.

Interruption of center bypass passage

Actuator

From pilot line

To tank line

Excessive oil

Fig. 4

Pilot secondary pressure(Control valve spring chamber pressure)

Coil current

Coil current vs. Pilot secondary pressure

Parallel passage flow

Coil current

Coil current vs. Parallel passage flow

1. Detection valve

2. Flow control spool

5. Negative electromagneticproportional pressurereducing valve


66

3. Function of Accelerator Positioner

When a current is applied to the solenoid (SOL12), the final controlling element moves the spool (2) bythe input current, changes the engine speed with the connected accelerator wire and controls thedischarge flow from the pump.

3-1) When the electromagnetic proportional pressure reducing valve solenoid is not energized (Fig. 5)For the pilot pressure (primary pressure) from the pilot line, the pressure reducing valve spool (1)closes the passage to the secondary side pilot chamber (a). On the other hand, the pilot chamber (a)is connected to the spring chamber (b) through the internal passage of the pressure reducing valvespool (1) and also to the drain port (c).So, the pressures in the pilot chamber (a) and in the spring chamber (b) becomes equal (the drainpressure), and the return spring (3) pushes the spool (2) to the left.

1. Pressure reducing valve spool2. Spool3. Return spring

Engine

Accelerator wire

Primary pressure

From pilot line.

1. Pressure reducing valve spool2. Spool3. Return spring

Fig. 5


67

3-2) When the electromagnetic proportional pressure reducing valve solenoid was energized (Fig. 6)When a current is applied to the electromagnetic proportional pressure reducing valve (4) solenoid(SOL12), the push pin (5) pushes down the pressure reducing valve spool (1) proportionally to thecurrent value and the secondary pressure to the pilot chamber (a) is controlled.When the pressure reducing valve spool (1) is pushed down, the passage between the pilot chamber(a) and the spring chamber (b) is closed. And the pressurized oil entered the pilot chamber (a) affectsthe piston (6) and moves the spool (2) connected to the piston (6) rightward to the position where itbalances with the force of the return spring (3) .The input current is proportional to the spool (2) stroke, it is possible to get the engine speedproportional to the input current and to control discharge flow from the pump.

Primary pressure

From pilot line.

1. Pressure reducing valve spool

2. Spool

3. Return spring

4. Electromagnetic proportional pressure reducing valve

5. Push pin

6. Piston

Fig. 6


68

4. Function of Electromagnetic Selector Valve (Hoist, Winch, Telescope and Swing)

4-1) When the solenoid is not energized (Fig. 7)The return spring (2) retains the spool (1) at the neutral position.The pilot valve spring (4) has pushed up the pilot valve (3) to the solenoid side. In the state, the pilotpassage is interrupted with the pilot valve (3), but the pilot chambers (a) and (b) are connected to thedrain passage with the socket (5).So, the pressures in the pilot chambers (a) and (b) become equal (the drain pressure), and no pressureoccurs that moves the spool (1).Since the spool is of the all-port block type, the passages between the parallel passage (c) and theactuator passages (d1) and (d2) and the passages between the actuator passages (d1) and (d2) andthe tank passage (f) are closed when the spool is at the neutral position. Therefore, all passages tothe actuator are interrupted, and the actuator is at a halt.On the other hand, when other selector valves are at the neutral position, oil from the pump returns tothe tank through the center bypass passage (e) of each selector valve, the U-turn cover and the tankpassage (f).

Actuator

From pumpPilot pressure(through pressure reducing valve)

To drain passage

Oil passage when the pilot portion is at the neutral position

Fig. 7

1. Spool

2. Return spring

3. Pilot valve

4. Pilot valve spring

5. Socket


69

4-2) When the solenoids (SOL1 to 8) were energized (Fig. 8)The following explanation is based on the state that the right solenoid was energized.The push pin (6) pushes down the right pilot valve (3), and the pilot chamber (b) is connected to thepilot passage through the filter (8) and the pilot pressure is supplied to the chamber. At the time, theleft pilot chamber (a) remains connected to the drain passage.Therefore, the differential pressure between the pilot pressure and the drain pressure affects the pilotpiston (7) and moves the spool (1) to the left.As the spool moves, the center bypass passage (e) is closed, but the pump passage (c) is connectedto the actuator passage (d1) and the left actuator passage (d2) is connected to the tank passage (f).Then, the actuator starts moving.When the left solenoid is energized, the passage configuration becomes contrary to the above, and thespool (1) moves to the right but the actuator moves in the reverse direction.When the solenoid is demagnetized, the return spring (2) returns the spool (1) to the neutral position(the state in 4-1), and the actuator return to the neutral position and stops there.

12 VDC is applied

Actuator

Tank

From pump Pilot pressure

To drain passage

Oil passage when pilot portion is changed over

Fig. 8

1. Spool

2. Return spring

3. Pilot valve

4. Pilot valve spring

5. Socket

6. Push pin

7. Pilot piston

8. Filter


70

5. Function of Pressure Reducing Valve

5-1) When the secondary pressure is below the set value (Fig. 9)Since the pressure reducing valve spool (1) pressed with the pressure reducing valve spring (2), thepressurized oil of the primary pressure flows to the secondary side of the pressure reducing valve spool(1) passage (a).

Secondary pressure

Fig. 9Primary pressure

Fig. 9

5-2) When the primary pressure is higher than the set pressure of the secondary pressure (Fig. 10)The pressure reducing valve spool (1) moves until the secondary pressure balance with the pressurereducing valve spring (2) and throttles the passage (a) of the pressure reducing valve spool (1) to retainthe secondary pressure at the set value.

Secondary pressure

Fig. 10Primary pressure

Fig. 10


71

5-3) When the secondary pressure is higher than the set value (Fig. 11)The pressure reducing valve spool (1) moves until the secondary pressure balanced with the pressurereducing valve spring, closes the passage (a) of the pressure reducing valve spool (1) and opens thepassage (b) at the same time to connect it to the tank and reduces the secondary pressure to the setpressure.

Secondary pressure

Fig. 11

Tank Primary pressure

Fig. 11


72


Causes of Troubles and Measures against Troubles

TroublePhenomena

InspectionSystem Inspection Point Causes Measures Remarks

1 The pressuredoes not reachthe specifiedpressure.

Assembly bolt * The assembly bolts havenot been assembled withthe specified torque.

• Check the torquevalue

* Being unloaded withoutfull stroke.

See Paragraph 2

2 Theelectromagneticselector valvedoes not changeover eventhoughenergized.

Electromag-netic selectorvalve

Energizedvoltage

Pilot valve

Spool

Pressurereducing valve

Sequence valve

* Too low voltage ordisconnection

* Foreign matters beingcaught


* Drop below set pressure

* Drop below set pressure

• Inspect and repair theelectric system

• Disassemble, repairor replace the valve

• Disassemble, repairor replace the spool



• Replace thecoil if broken.

3 Theelectromagneticselector valvedoes not returnto the neutralposition eventhoughenergized.


Pilot valve

Spool



• Disassemble, repairor replace it

• Disassemble, repairor replace it

4 Theelectromagneticselector valvechanges overthough notenergized.


Pilot valve * Foreign matters beingcaught or deformed seat


5 Oil leakage fromspool sealsection


Spool seal * Damage of seal parts,wear of seal lip

* Dent or scratch on sealsliding section of spool

* Improper setting of sealparts and slip-on cover

* Adhesion of paint on sealsliding section of spool

• Replace the seal

• Repair or replace thespool

• Check irregular wearof seal lip and correctit

• Remove the paint bythinner


73

TroublePhenomena


6 The spool doesnot slidesmoothly.


Spool * Foreign matters beingcaught

* Breakage of oil filmbetween spool and bodydue to abnormal rise ofoil temperature.

* Wear of spool

* Lubrication failure due tooil deterioration.

* Bent spool

* Distortion of the wholevalve due to defectivemounting face.

* Defective external finalcontrolling element

* Oil remaining on coveropposite to spool

• Disassemble, inspect,correct or replace thespool

• Lower the oiltemperature orreplace the spool

• Replace the spool

• Change the oil(overhaul the circuit)

• Check straightness ofthe spool, repair orreplace the spool

• Loosen the mountingbolts and check themounting face

• Check and correct thelink, lever, etc.

• When the spool ismoved, oil comes outof the air vent hole onthe cover due to oilleakage from thespool sea. Makesure that thisphenomenon occurs,then replace thespool.

7 Flow cannot becontrolledsmoothly.

Electromag-netic flowcontroller

Spool andpiston

Spool chokeplug


Negativeproportionalpressurereducing valve

Restriction ofdetection valve

* Defective operation dueto foreign matters beingcaught.

* Clogging of restrictionwith foreign matters

* Drop of set value due toforeign matters beingcaught.

* Defective operation dueto foreign matters beingcaught.

* Clogging of restrictiondue to foreign matters

• Disassemble, inspect,correct or replace thecontroller


74

TroublePhenomena


8 The acceleratorcannot becontrolledsmoothly.

Acceleratorpositioner

Spool andpiston

Proportionalpressurereducing valve


Wire connectionpoint

* Defective operation dueto foreign matters beingcaught

* Defective operation dueto foreign matters beingcaught

* Drop of set value due toforeign matters beingcaught

* Defective external finalcontrolling element

• Disassemble, inspect,correct or replace thecontroller

• Check and correct thelink, lever, etc.

16. OUTRIGGER SELECTOR VALVE

75

16.1 General View

4-M6 Depth 12

4-M6 Depth 12

Lead wire color: Black and WhiteLead wire length: 50 mm

Maker: AMPPlug terminal: 170020-2Sleeve: 170887-3

OR (Outrigger) Selecter Valve

A1: Right-OR1 OUT A2: Right A8: Up

B1: Left-OR1 IN B2: Left B8: Down

A4: Contract-OR2 IN A3: OR1 OUT A9: OR3 IN

B4: Extend-OR2 IN B3: OR1 IN B9: OR3 OUT

A7: Up-OR3 OUT A5: Contract A11: Rise

B7: Down-OR3 IN B5: Extend B11: Lower

A10: Rise-OR4 OUT A6: OR2 OUT A12: OR4 IN

B10: Lower-OR4 IN B6: OR2 IN B12: OR4 OUT


76

16.2 Specifications

Maximum working pressure 21 MPa

Maximum flow 30 liter/min

Pilot pressure 1.0 to 1.5 MPa

R port permissible back pressure 7 MPa

Protective structure class IEC 529 IP67 (JEM 1030 IP67)

Vibration resistance Step 7 in JIS D1601

Voltage fluctuation allowable range ±10% of rated voltage

Mass 12 kg approx.

Material Aluminum (A2017-T4)

Solenoid Type D-SOL-019 (Plug terminal)

Rated voltage 12 VDC

Holding current 0.6 A

Power consumption 7.2 W


77

16.3 Inside View

1. Manifold block 11. Plunger block 21. Spool

2. Pipe plug 12. Coil block 22. Plug

3. Pipe plug 13. Push rod 23. Pin

4. Nozzle 14. Nut 24. Spring

5. Body 15. O-ring 25. Set screw

6. Piston 16. Terminal 26. Socket head bolt

7. Spring 17. Sleeve 27. O-ring

8. O-ring 18. Terminal 28. O-ring

9. O-ring 19. Sleeve 29. O-ring

10. Bolt 20. Body 30. O-ring


78

16.4 Hydraulic Circuit Diagram

Hydraulic Circuit Diagram

16.5 General

1. Function

6-port Direction Selector Valve (D-HD-01067)

1) Pilot Selector Valve:When the solenoid of D-HD-0106 is energized, a pilot pressure is applied from the PLT X port of thepilot selector valve to the PLT X port of the 6-port direction selector valve, D-HD-01067 and the spool ofthe 6-port direction selector valve is pushed to the right. Then, the flows A1-A3 and B1-B3 occur andoperate the actuator. When the solenoid is demagnetized, the 6-port direction selector valve spool ispushed to the left by the spring, and the flows A1-A2 and B1-B2 occur.

2) When the electric check is impossible, press the manual operation pin of the 6-port direction selectorvalve, and you can check the function.

Manual operation pin

6-port direction selector valveD-HD-01067

Pilot selector valveD-HD-01068



79

2. Precautions of Using

1) Over-tightening of the mounting bolt distorts the body and may result in defective operation. Limit thetightening torque of the mounting bolt to the range from 6 to 8 N･m (0.6 to 0.8 kgf･m).

2) When tightening the mounting bolt, pay attention to extrusion or drop of the O-ring and to theconnecting direction of the valve.

3) This valve has been machined precisely. If dusts enter the valve, the spool will come not to move andthe valve will not function. To operate the valve normally, brush the piping section well. For thestrainer and the filer, use a brush of 100µ or more.

3. Precautions of Hydraulic Oil

1) We recommend you to use any oil equivalent to ISO VG32 or VG46 as the hydraulic oil.

2) Be careful to oil temperature to maintain the specified viscosity. Use the hydraulic oil in the followingtemperature range (our recommended values).

Type of Oil Oil Temperature Viscosity

ISO VG32 0 to 60°C 15 to 340 cSt (mm2/s)

ISO VG46 6 to 65°C 18 to 340 cSt (mm2/s)


80


When the valve comes not to operate well, check the valve according to the following method:

Note 1 : Numbers in ○ are Index Nos. in the Inside View.

2 : To remove the plunger block ⑪, a special tool is necessary. Prepare it beforehand.

Type of Special Tool: D-H0012.

The actuator does not operate even though a changeover signal was sent.Trouble

Check the supply voltage. (The voltage fluctuation allowable range ±10%V)

Press the manual pin 23 of the 6-port direction selector valve : D-HD-01067 to check if the valve operates.

Check the pilot pressure. (The minimum working pilot pressure : 1.0 MPa)

Replace the solenoid plunger block ⑪ and the coil block ⑫.

Clean and reassemble the piston ⑥.

NG Regulate the voltage.

Replace the valve.

Clean and reassemble the valve.

OK

NG Disassemble and inspect the 6-port direction selector valve, visually check wear of the spool 21 to make sure that it is in order.

OKNG

OK

Disassemble and inspect the pilot selector valve : D-HD-01068, check motion and wear of the piston ⑥ and spring ⑦ to make sure that it is in order.

NG Increase the pilot pressure.OK

NG

OK Use the piston as it is.OK

NG Check if defectives are found, and send them back to us.

An overall inspection of the whole valve is necessary. Consult with us for the overall inspection as well asreplacement of the valve.

OK

17. ROTARY JOINT

81

17.1 General View

Der

rick

cylin

der R

ise (D

)

Tele

scop

e cy

linde

r Ext

end

(C)

Der

rick

cylin

der L

ower

(E)

Win

ch D

own

(F)

Win

ch U

p (A

)

Tele

scop

e cy

linde

r Con

tract

(B)

Win

ch D

own

(F)

Der

rick

cylin

der R

ise (D

)

Tele

scop

e cy

linde

r Con

tract

(B)

Der

rick

cylin

der L

ower

(E)

Tele

scop

e cy

linde

r Ext

end

(C)

Win

ch U

p (A

)

Not

e: A

pply

the

thre

ad ti

ghte

ner (

Lock

tite

262)

to th

e he

xago

n he

ad b

olt ②

.

1. Rotary joint assembly 2. Bolt 3. Spring washer

17. ROTARY JOINT

82

17.2 Inside View

B.D

. F p

ort

A.C

. E p

ort

1. Flange 5. Back-up ring 10. Rivet screw 14. O-ring

2. Hub 6. Pin 11. Snap ring 15. Plug

3. Shaft 7. Name plate 12. Dust seal 16. Plug

4. Thrust washer 9. Socket head bolt 13. O-ring

17.3 Specifications

Rated flow 15 liter/min

Maximum working pressure (A to F) 20.6 MPa (210 kgf/cm2)

Working temperature range −20 to 90°C

Maximum speed 2 rpm

Torque Ports A and F 17.2 MPa (175 kgf/cm2),39.2 N･m (4 kgf･m) max.

Hydraulic oil Equivalent to ISO VG32 to 56

Port ConnectionA: Up B: Contract C: ExtendD: Rise E: Lower F: Down

4-φ9 through

17. ROTARY JOINT

83

18. BOOM ASSEMBLY

84

Sec

tion

A (

s:1/

3)

Sec

tion

B (

s:1/

3)S

ectio

n D

-D (

s:1/

3)S

ectio

n E

(s:

1/3)

Sec

tion

F (

s:1/

2)

Sec

tion

H (

s:1/

2)

V

iew

J (

s:1/

2)

Sec

tion

C (

s:1/

3)S

ectio

n G

(s:

1/2)

Sec

tion

I (s:

1/3)

Det

ail f

or lo

wer

sur

face

of s

lide

plat

e (s

:1/3

)

Sec

tion

K (

s:1/

2)

18. BOOM ASSEMBLY

85

1. No.1 boom 43. Stopper plate

2. No.2 boom 44. Arrow

3. No.3 boom 45. End plate

4. No.4 boom 46. Stopper

5. Wire rope 47. Roller

6. No.3 boom extended wire rope 48. Guide roller

7. No.3 boom retracted wire rope 49. Boom head cover

No.4 boom extended wire rope 50. Boom tail cover

8. No.3 boom retracted wire rope 51. Lock bracket

9. Wire clip assembly 52. Guide shaft

10. Slide plate for boom downward 53. Nut

11. Slide plate for No.4 boom downward 54. Nut

12. Slide plate for boom upward (23t) 55. Wedge socket

13. Slide plate for boom upward (17t) 56. Wedge

14. Side plate 57. End plate

15. Sheave 58. Bolt (M6 × 12)

16. Sheave for No.3 boom extended 59. Bolt (M8 × 15)

17. Sheave for No.4 boom extended 60. Bolt (M8 × 20)

18. Sheave for No.3, 4 boom retracted 61. Bolt (M8 × 30)

19. Snap sheave 62. Bolt (M10 × 15)

20. Idler 63. Bolt (M10 × 15)

21. Telescopic guide roller 64. Bolt (M10 × 20)

22. Foot pin 65. Bolt (M10 × 20)

23. Pin 66. Bolt (M6 × 15)

24. Derrick cylinder rod pin 67. Set screw (M10 × 30)

25. No.3 boom extended sheave pin 68. Nut (M8)

26. No.3 boom stopper 69. Nut (M10)

27. Side stopper plate 70. Nut (M16)

28. Shim 71. Plain washer (M8)

29. No.3 trunnion pin 72. Plain washer (M10)

30. Pin 73. Spring washer (M6)

31. Extended sheave pin 74. Spring washer (M8)

32. Pin 75. Spring washer (M10)

33. Point pin 76. Bushing

34. Pin 77. Snap ring

35. Pin 78. Snap ring

36. Idler shaft 79. Snap ring

37. Collar 80. Snap ring

38. No.4 boom extended sheave collar 81. Snap ring

39. No.3 boom collar 82. Grease nipple

40. No.5 boom retracted sheave collar 83. Snap pin

41. Sheave collar 84. Cotter pin

42. Collar

19. TELESCOPIC CYLINDER

86

19.1 General View

Det

ail f

or S

ectio

n P

(s:

1/1

)

1. Cylinder 5. Stopper 10. Wear ring 14. Set screw

2. Piston rod 6. Rod packing 11. Piston packing 15. Plug

3. Cylinder head 7. Dust seal 12. O-ring 16. Counter-balance valve


87

19.2 Specifications

Cylinder bore × Rod diameter − Stroke φ60 × φ45 − 1150 st

Normal load At the time of extension 58.2 kN (20.6 MPa)

5.9 t (210 kgf/cm2)

At the time of contraction 25.4 kN (20.6 MPa)

5.9 t (210 kgf/cm2)

Pressure for pressure Extension side 26.4 MPa (270 kgf/cm2)

tightness test Contraction side 26.4 MPa (270 kgf/cm2)

Hydraulic oil temperature −20 to 80°C

Hydraulic CircuitHydraulic System Diagram

Telescopic cylinder,Extension/Contraction, A: Extend B: Contract


88

19.3 Counter-balance Valve

19.3.1 General View

Width across flats 32

Check seat portion (1)

Check seat portion (2)O-ring (1)

O-ring (4)

Identification mark "D"

Width across flats 38,Tightening torque 9 to 10 kg･m

Spool O-ring (2)

O-ring (3) Pilot hole (φ0.3)

19.3.2 Specifications

Maximum working pressure 20.6 MPa (210 kgf/cm2)

Withstand pressure 30.9 MPa (315 kgf/cm2)

Maximum flow 50 litermin


Allowable leak 0.05 cc/min. max.(when 210 kgf/cm2 is applied to Port B)

Pilot pressure 1.18+0.3 MPa (12+3 kgf/cm2) when the valveis open.

Spool throttle area Equivalent to φ2.6(at the time of spool stroke)

Check cracking pressure 0.098 MPa (1 kgf/cm2) 0

Working temperature range −10 to +80°C

19.3.3 Troubleshooting

Phenomena Causes Countermeasures

At the time of operation, thetelescopic cylinder contracts(lowers).

1. The check seat portion (1) or (2) isdefective or has caught dusts.

2. Breakage of O-ring (1), (2), (3) or(4).

3. The pilot hole (φ0.3) is cloggedwith dusts, and the spool remainstransferred and the check seatportion (2) remains open,

• Remove the dusts or replacethe seat portion

• Replace the O-ring

• Remove dusts from the pilothole

The telescopic cylinder does notcontract (lower) or the contractingspeed is very slow.

4. The pilot hole (φ0.3) is cloggedwith dusts,


20. DERRICK CYLINDER

89

20.1 General View

Pun

chin

g m

ark:

$ ,

Yea

r, M

onth

YS mark

The last figure of year

ABC・・・

She

el k

it

Tig

hten

ing

torq

ue: 4

4.1

N.m

(45?

kgf

.m (

M33

x 1

5)

Loct

ite c

oatin

g

Det

ail f

or p

isto

nD

etai

l for

cyl

inde

r he

ad

Tig

hten

ing

torq

ue: 8

9 to

98

N.m

(9

to 1

0 N

.m)

Str

oke

Max

. len

gth

2-A

type

(R

1/8

)

Tig

hten

the

pist

on a

t sam

e tim

e.

Lock

tite

coat

ing

1. Cylinder 6. Back-up ring 11. Back-up ring 16. Counter-balance valve

2. Piston rod 7. Bushing 12. Piston 17. Grease nipple

3. Piston rod head 8. Wiper ring 13. Packing 18. Plug

4. Cylinder head 9. O-ring 14. Slide ring 19. Cap

5. U-ring 10. O-ring 15. Bushing 20. O-ring


90

20.2 Specifications



8.08 t (210 kgf/cm2)


4.74 t (210 kgf/cm2)



Hydraulic oil temperature −20 to 80°C

Hydraulic Circuit DiagramHydraulic Circuit Diagram

Derrick cylinder,Rise/Lower A: Rise

B: Lower


91

20.3 Counter-balance Valve

20.3.1 General View


Check seat portion (1)

Check seat portion (2)O-ring (1)

O-ring (4)

Identification mark "D"

Width across flats 38,Tightening torque 9 to 10 kg･m

Spool O-ring (2)

O-ring (3) Pilot hole (φ0.3)


Maximum working pressure 20.6 MPa (210 kgf/cm2)


Maximum flow 50 litermin


Allowable leak 0.05 cc/min. max.(when 210 kgf/cm2 is applied to Port B)

Pilot pressure 1.18+0.3 MPa (12+3 kgf/cm2) when the valveis open.

Spool throttle area Equivalent to φ2.6(at the time of spool stroke)

Check cracking pressure 0.098 MPa (1 kgf/cm2) 0

Working temperature range −10 to +80°C

20.3.3 Troubleshooting

Phenomena Causes Countermeasures

At the time of operation, thederrick cylinder contracts (lowers).

1. The check seat portion (1) or (2) isdefective or has caught dusts.

2. Breakage of O-ring (1), (2), (3) or(4).

3. The pilot hole (φ0.3) is cloggedwith dusts, and the spool remainstransferred and the check seatportion (2) remains open,

• Remove the dusts or replacethe seat portion

• Replace the O-ring


The derrick cylinder does notcontract (lower) or the contractingspeed is very slow.

4. The pilot hole (φ0.3) is cloggedwith dusts,



92

Load

Load

Load

At the neutral position

When the derrick cylinder extends,

Pressurized oil Return oil

When the derrick cylinder contracts,

Return oil Pressurized oil

21. WINCH ASSEMBLY

93

21.1 General View

Sec

tion

A

Hoi

st p

ort

Low

erin

g po

rt

Tig

hten

ing

torq

ue:

2.3

to 3

.1 k

gf.m

Lock

tite

262

coat

ing

Tig

hten

ing

torq

ue:

2.3

to 3

.1 k

gf.m

Lock

tite

262

coat

ing

Lubr

icat

ing

oil:

ISO

320

App

rox.

0.7

L

1. Drum 6. Stud bolt 11. Nut (M10)

2. Wedge 7. Bearing 12. Spring washer (M8)

3. Worm reduction gear box 8. Bolt (M8 × 12) 13. Spring washer (M10)

4. Hydraulic motor 9. Bolt (M10 × 25) 14. Snap ring

5. Cover 10. Socket head bolt (M8 × 16)

21. WINCH ASSEMBLY

94

21.2 Worm Reduction Gear Box

21. WINCH ASSEMBLY

95

1. Case

2. Cover

3. Cover

4. Flange

5 Worm shaft

6. Worm gear

7. Caller

8. Output shaft

P1. Roller bearing

P2. Roller bearing

P3. Ball bearing

P4. Ball bearing

P5. Oil seal

P6. Oil seal

P7. Ring nut

P8. Washer

P9. Key

P10. Bolt (M6 × 20)

P11. Socket head bolt (M8 × 16)

P12. Socket head bolt (M6 × 16)

P13. Spring washer (M6)

P14. O-ring

P15. Packing

P16. Packing

P17. Plug

P18. Plug

21. WINCH ASSEMBLY

96

21.3 Winch Hydraulic Motor

21.3.1 General View

1. Maximum allowable inlet pressure is 220 kgf/cm2.2. The rated speed, the rated flow capacity, the rated torque and the rated pressure show when without a break codition.3. Maximum torque and high pressure

The intermittent operating condition show availability 10%/minute.4. Hydraulic oil 24 to 50 cSt

(100 to 200SSU)5. Allowable temperature range

−30 to 80°C

key: 5 5 18 ××(Straight portion length)

Maximum radius 0.9

Port connector T40243Width across flats 23

Port B

Port A

M6 Depth 13

(Drain port position)

Note 1: Motor rotating direction (viewed from the motor output shaft side)Port A hydraulic Right turnPort B hydraulic Left turn

2: PipingCoat the liquid gasket to the drain plug (PF 1/8).

21. WINCH ASSEMBLY

97

WinchUp/Down A: Down

B: Up


Type J-13EBE-B

Displacement 12.9 cc/rev

Rated speed 1,562 rpm

Rated torque 2.4 kgf･m

Maximum torque 2.8 kgf･m

Rated pressure 140 kgf/cm2

Maximum pressure 165 kgf/cm2

Allo

wabl

e ca

se p

ress

ure

(kgf

/cm

2)

In case of intermittentoperation only,10% max. each minute

Speed (rpm)

Hydraulic SymbolHydraulic symbol

22. SWING SYSTEM

98

22.1 General View

221.75

(Adjust the backlash to 0.05 to 0.1.)

Grease the tooth surface.

Tightening torque 9.44 to 12.8 kgf ･m, Apply Loctite 262.

Tightening torque 9.44 to 12.8 kgf ･m, Apply Loctite 262.

Tightening torque 5.44 to 7.35 kgf･m,

Apply Loctite 262.

1. Swing bearing 6. Swing hydraulic motor 11. Socket head bolt

2. 7. Bolt 12. Spring washer

3. Bolt 8. Spring washer 13. Bolt

4. Bolt 9. 14. Spring washer

5. Swing reduction gear box 10. 15. Plain washer

z Precautions on Mounting• Apply the thread tightener (Loctite) to the thread portions of the bolts ③, ④ and ⑪.• Make the backlashes of the swing reduction gear drive gear and the swing bearing bear 0.

z Maintenance StandardMaintenance Items Maintenance Standard

Bolt tightening torque Check the tightening torque periodically.

Greasing Grease the bearing and the gear tooth surface periodically (monthly).

22. SWING SYSTEM

99

22.2 Swing Reduction Gear Box

M10

Dep

th 1

5

2-M

8 D

epth

10

4-M

10 D

epth

12

2-5

Dril

l

1. Gear box 6. Retainer P5. Bolt (M8 × 16) P10. Plug

2. Pinion shaft P1. Roller bearing P6. Bolt (M6 × 16) P11. Snap ring

3. Worm wheel P2. Ball bearing P7. Spring washer (M8) P12. Key

4. Worm shaft P3. Ball bearing P8. Spring washer (M6) P13. Packing

5. Cover P4. Oil seal P9. Oil level gauge

22. SWING SYSTEM

100

22.3 Swing Hydraulic Motor

22.3.1 General View

key: 5 5 18 ××

×

Maximum radius 0.9

M6 Thread depth 9

O-ringType of O-ring AS568-037(ID63.22 W1.78)

(Right) Port B

(Left) Port A

(Drain port position)

Port connector T40243


Drain port 1/88SPF Thread depth 8

Note 1: Motor rotating direction (viewed from the motor output shaft side)Port A hydraulic Right turnPort B hydraulic Left turn

2: Coat the liquid gasket to the drain plug (PF 1/8)


Type J-32EBE-B

Displacement 31.6 cc/rev

Rated speed 661 rpm

Rated torque 4.0 kgf･m

Maximum torque 5.0 kgf･m

Rated pressure 95 kgf/cm2

Maximum pressure 120 kgf/cm2

Swing motorRight, Left A : Right

B : Left

Hydraulic SymbolHydraulic symbol

22. SWING SYSTEM

101

23. OUTRIGGER ASSEMBLY

102

23.1 General View

23.1.1 No. 1 and No. 3 Outrigger Assembly

Whe

n th

e ou

trigg

er is

exte

nded

mos

t, (S

= 1

: 30

)

Whe

n co

nnec

ting

the

outri

gger

hos

e, ?

??

Outri

gger

ass

embly

mou

nting

pos

ition

(S=

1 : 5

0)

Deta

iled

view

of A

por

tion

(S=

1 : 1

)

Deta

iled

view

of B

por

tion

(S=

1 : 1

)


103

1. Rigger adapter

2. Inner box

3. Outrigger top

4. Outrigger base

5 Rotary joint

6. Outrigger pin

7. Rotary shaft

8. Position pin

9. Position pin

10. Position pin

11. Pin

12. Damper pin

13. Stopper plate

14. End plate

15. End plate

16. Outrigger spacer washer

17. Stay damper

18. Rubber support

19. Ball chain

20. Ball chain

21. Ring

22. Snap pin

23. Snap pin

24. Bolt (M8 × 15)

25. Spring washer (M8)

26. Plain washer (M8)

27. Bolt (M8 × 18)


29. Plug

30. Grease nipple


104

23.1.2 No. 2 and No. 4 Outrigger Assembly

Whe

n th

e ou

trigg

er is

exte

nded

mos

t, (S

= 1

: 30

)

Whe

n co

nnec

ting

the

outri

gger

hos

e, ?

??

Outri

gger

ass

embly

mou

nting

pos

ition

(S=

1 : 5

0)

Deta

iled

view

of A

por

tion

(S=

1 : 1

)

Deta

iled

view

of B

por

tion

(S=

1 : 1

)


105

1. Rigger adapter

2. Inner box

3. Outrigger top

4. Outrigger base

5 Rotary joint

6. Outrigger pin

7. Rotary shaft

8. Position pin

9. Position pin

10. Position pin

11. Pin

12. Damper pin

13. Stopper plate

14. End plate

15. End plate

16. Outrigger spacer washer

17. Stay damper

18. Rubber support

19. Ball chain

20. Ball chain

21. Ring

22. Snap pin

23. Snap pin

24. Bolt (M8 × 15)

25. Spring washer (M8)


27. Bolt (M8 × 18)


29. Plug

30. Grease nipple

24. OUTRIGGER CYLINDER

106

24.1 General ViewTi

ghte

ning

torq

ue 3

3.3

N･m

Sea

l kit

Det

aile

d vi

ew o

f pis

ton

Det

aile

d vi

ew o

f cyl

inde

r hea

d po

rtion

Sec

tion

Z-Z

Orif

ice

Orif

ice

Tigh

teni

ng to

rque

9.8

N･m

Type

2-A

(R1/

8)

Stro

ke 2

45 ±

2.0

438

± 2

.0

Pun

chin

g m

ark:

$ ,

Yea

r, M

onth

YS mark


ABC・・・


107

1. Cylinder tube assembly

2. Piston rod assembly

3. Cylinder head

4. U-ring

5 Back-up ring

6. Wiper ring

7. Bushing

8. O-ring

9. O-ring

10. Back-up ring

11. Piston

12. Seal

13. Slide ring

14. Steel ball

15. Set screw

16. Bushing

17. Double pilot check valve

18. Grease nipple

19. Plug

20. Cap

21. Orifice plug

22. Orifice plug

23. Plug


108

24.2 Specifications



6.96 t (210 kgf/cm2)


4.32 t (210 kgf/cm2)



Hydraulic oil temperature −20 to 80 °C


OrificeOrifice


Outrigger Cylinder 1 In/Out, A: Out

B: In


B: In


B: In


B: In


109

24.3 Double Pilot Check Valve

24.3.1 General View

Tigh

teni

ng to

rque

5 to

6 k

gf･m

Free

leng

th 2

9 m

m a

ppro

x.(J

IS O

-ring

type

)

Free

leng

th 3

4 m

m a

ppro

x.

Sect

ion

X-X

Punc

hing

mar

k:

, Y

ear,

Mon

th, L

YS YS mark


ABC JKL・・・

Not

es: 1.

Mou

ntin

g bo

lt (M

6 × 1

.0)

Tigh

teni

ng to

rque

5.9

to 7

.8 N･m

{0.6

to 0

.8 k

gf･m

}2.

This

val

ve is

diff

eren

t fro

m 6

5000

-020

00 in

the

port

scre

w a

nd th

e bo

dy d

imen

sion

s.

1. Body 6. Spring 11. Spring washer

2. Valve seat 7. O-ring 12. Spring

3. Check valve 8. O-ring 13. O-ring

4. Piston 9. O-ring

5. Plug 10. Socket head bolt


110



Rated pressure 17.2 MPa (175 kgf/cm2)


Cracking pressure A1 → A2 0.59 MPa (6 kgf/cm2)B1 → B2 0.2 MPa (2 kgf/cm2)

Pilot area ratio 1 : 2.8

Allowable leak 0.05 cm3/min

25. ELECTRICAL CIRCUIT DIAGRAM

111

Eng

ine

switc

h

Eng

ine

switc

h

Tra

ve

l sid

e p

an

el

lam

pFu

se 5

A

Fuse

15

A

Hou

r met

er

Ligh

t sw

itch

Hor

n sw

itch

Fuse

5 A

Hor

n

Ligh

t

Alte

rnat

or

Ligh

t on

and

off

Bat

tery

12

VD

C

Sta

rter

Spa

rk p

lug

Igni

tion

coil

En

gin

e a

rea

Rel

ay

Prin

ted

circ

uit b

oard

Rel

ay B

X:

4φ

Rel

ay C

X:

Saf

ety

rela

yR

elay

DX

: R

eset

Rel

ay E

X:

Ligh

t

Ho

use

d in

bo

x

Rel

ay G

2R

Sw

itch

pa

ne

l sid

eTr

avel

sta

nd

Out

rigge

r sel

ecto

rva

lve

Acc

eler

ator

Pos

itionTe

rmin

al

Aut

ore

stor

eS

tart

In Out In Out

Out

rigge

r 4

In Out In Out

Out

rigge

r 3

In Out In Out

Out

rigge

r 2

In Out In Out

Out

rigge

r 1

Hor

n sw

itch

Rad

io c

ontro

lho

rn s

witc

h

Rad

io c

ontro

lpow

er s

uppl

y

Em

erge

ncy

stop

Res

et

Rad

io c

ontro

l boa

rdR

ad

io c

on

tro

ller

co

ntr

ol b

ox

Cra

ne

sid

e

26. ELECTRICAL WIRING DIAGRAM

112

(Applicable to Serial No. M00879 to M00888)

Gro

undi

ngte

rmin

al lo

ck

Rec

eive

con

trolle

r

* Th

ese

wire

col

ors

are

diffe

rent

from

Ser

ial N

o. M

0088

9 an

d on

.

Outrig

ger se

lector

valve

8P G

ray

6P Y

ello

w

6P B

lue

Sw

itch

pane

l

Ligh

t12

V, 1

.5 A

UB

-2F

(Mits

uba)

Hor

n

Alte

rnat

or

Fuse

5 A

Trav

el s

ide

pane

l

Trav

el s

tand

pos

ition

dete

ctio

n lim

it sw

itch

Eng

ine

area

8P B

lue

Rel

ay b

ox

Ligh

t on

and

off

6P G

reen

Bat

tery

Buz

zer

26. ELECTRICAL WIRING DIAGRAM

113

(Applicable to Serial No. M00889 and up)

Gro

undi

ngte

rmin

al lo

ck

Rec

eive

con

trolle

r

Outrig

ger se

lector

valve

8P G

ray

6P Y

ello

w

6P B

lue

6P G

reen

Sw

itch

pane

l

Ligh

t12

V, 1

.5 A

UB

-2F

(Mits

uba)

Hor

n

Alte

rnat

or

Fuse

5 A

Trav

el s

ide

pane

l

Trav

el s

tand

pos

ition

dete

ctio

n lim

it sw

itch

Eng

ine

area

Bat

tery

Buz

zer

8P B

lue

Rel

ay b

ox

Ligh

t on

and

off

27. ENGINE STARTING CIRCUIT DIAGRAM

114

Eng

ine

switc

h

Pos

itionTer

min

al

Aut

ore

stor

eS

tart B

atte

ry

Sta

rter

Eng

ine

switc

h

Sta

rt r

elay

L ou

tput

s 12

V w

hen

the

engi

ne s

tops

and

stop

out

putti

ng w

hen

the

engi

ne r

each

esa

cert

ain

spee

d (6

00 to

700

rpm

).

Alte

rnat

or

Saf

ety

rela

y

Cha

rge

lam

p

Res

et r

elay

Sta

rtS

top

Eng

ine

switc

h on

the

cran

e st

and

side

pan

el

Rad

io c

ontr

ol r

ecei

ver

Eng

ine

star

t rel

ay

28. ENGINE STOPPING CIRCUIT DIAGRAM

115

Eng

ine

switc

h

CD

I uni

t

Spa

rk p

lug

Igni

tion

coil

Sta

rtS

top

Rad

io c

ontr

ol r

ecei

ver

Em

erge

ncy

stop

rel

ay

Sto

p re

lay

29. OUTRIGGER OPERATING CIRCUIT DIAGRAM

116

Eng

ine

switc

h

Ligh

t on

and

off

Buz

zer

Ligh

t flic

ker

rela

y

Flic

ker

circ

uit

Out

rigge

r op

erat

ion

switc

h (R

ise/

Low

er)

In Out In Out

Out

rigge

r se

lect

or v

alve

SO

L1Lo

wer

(O

utrig

ger

4 In

)

SO

L2R

ise

(Out

rigge

r 4

Out

)

Rad

io c

ontr

ol r

ecei

ver

30. CREEP SPEED OUTPUT CIRCUIT DIAGRAM

117

Tra

vel L

S

Rad

io c

ontr

ol r

ecei

ver

31. DISASSEMBLY AND ASSEMBLY OF BOOM

118

31.1 Disassembly

1. Removing of Boom from Post

(1) Remove the wire rope "5."Note: Before removing the wire rope "5," lower the hook block with the winch to prevent the hook

block from falling down.


119

(2) Disconnect the T hose "87."(3) Lift the boom with the overhead crane and pull out the foot pin "22" and the DC rod pin "24."

Note: • Since the foot pin "22" is fixed with the hexagon head bolt "59" (M8 × 15L), the end plate"45," remove the foot pin from them.

• Try to lift the boom at the center of gravity with the overhead crane.The boom's center of gravity is about 970 mm from the center of the foot pin.

(4) Remove the boom from the post.(5) Remove the male 90° elbow "85" (PT1/4-PF1/4) and the bushing "86" (PT1/4-PF1/4).


120

No.1 boom

2. Removing of No. 1 Boom

(1) Remove the hexagon nut (M16) "70" and the spherical nut B2 "53" from the edge of No. 3 extensionwire rope "6" and remove the No. 3 extension wire rope "6" from No. 1 boom wire rest.Note: Since No. 3 extension wire rope "6" edge is designed to accept a wrench suitable for the width

across flats 13 mm, fix the wire rope with a wrench so that the wire rope does not turn when thenut is turned.


121

(2) Remove the hexagon nut (M10) "69" from the edge of No. 3 wire rope "7."Note: Since No. 3 extension wire rope "7" edge is designed to accept a wrench suitable for the width


(3) Remove the hexagon nut (M8 × 20) "60" and also remove the fixing bracket "51."(4) Remove the snap ring "79" (Type C 25 for hole) and also remove the pin (25-158) "23."

Note: After removing 2 pieces of the snap ring "79," hit the pin "23" with a round bar or any thingsimilar to that from any side, and you can remove the pin.

(5) Remove the slide plate "10."Note: Remove the hexagon head bolt (M10 × 15L) "63" and the SP stopper plate "43" in this order,

and you can remove the slide plate "10."(6) Fix No. 1 boom and pull out No. 2 to No. 4 booms, and you can remove No. 1 boom.


122


(1) Remove the hexagon head bolt (M8 × 30L) "61" and then remove the latch "46."(2) Remove No. 3 contraction wire rope "7."


123

No.2 boom

(3) Remove the hexagon nut (M10) "69" and the spherical nut B3 "54" from the edge of No. 4 extensionwire rope "7." Then, remove No. 4 extension wire rope "7" from the wire rest of No. 2 boom.Note: Since No. 4 extension wire rope "7" edge is designed to accept a wrench suitable for the width



124

(4) Remove the snap ring (Type C 35 for hole) "81" and also remove the pin (35-132) "32."Note: After removing 2 pieces of the snap ring "81," hit the pin "32" with a round bar or any thing

similar to that from any side, and you can remove the pin.(5) Remove the snap ring (Type C 30 for hole) "80" and also remove No. 3 trunnion pin "29."(6) Remove the slide plate "10."

Note: Remove the hexagon head bolt (M10 × 15L) "63" and the SP stopper plate "43" in this order,and you can remove the slide plate "10."

(7) Loosen the hexagon nut (M10) "69" and remove the hexagon socket head set screw (M10 × 30L, flatpoint) "67."

(8) Fix No. 2 boom and pull out No. 3 and No. 4 booms, and you can remove No. 2 boom.


125


(1) Remove the hexagon nut (M8) "68" from the edge of No. 4 contraction wire rope "8."

(2) Remove the snap ring (Type C 30 for hole) "80" and also remove the pin (30-130) "30."Note: After removing 2 pieces of the snap ring "80," hit the pin "30" with a round bar or any thing

similar to that from any side, and you can remove the pin.(3) Remove the slide plate "11."

Note: Remove the hexagon head bolt (M10 × 15L) "63" and the SP stopper plate "43" in this order,and you can remove the slide plate "11."

(4) Loosen the hexagon nut (M8) "69" and remove the hexagon socket head set screw (M10 × 30L, flatpoint) "67."


126

Telescopic cylinder

No.3 boom

(5) Pull out the telescopic cylinder.(6) Fix No. 3 boom and pull out No. 4 boom, and you can remove No. 3 boom.

31.2 Assembly

For assembly, reverse the disassembly procedures.

* When setting No. 3 contraction wire, be careful not to tangle it with other wires.

serial no. m00879 - maeda mini cranesmaedaminicranes.co.uk/pdf/mc104/mc104_service_manual.pdf · 2....

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