Tadano GR-500EXL-3 Service Manual Download Page 123

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IWZ04-5300E02

343-550-22100

344-916-80100

WZ04-5300E

Harness (Upper)

Z-12

2. Harness (slewing table, right)

Z-12

Plug

Plug Plug Plug

Plug

Plug Plug Plug
Plug Plug Plug

CN583

Air pressure detector

N002

N003

N005

N008

To cab hareness

S43-124

S43-123

S43-122

CN584

Pressure sensor (elevating cylinder, boom raising)

S03-021

S03-022

S03-023

CN585

Pressure sensor (elevating cylinder, boom lowering)

S04-024

S04-025

S04-026

CN894

Joint connector to “crane”

470AA

LG/Y

412AA

G/W

411AA

G/L

279AA

BR/R

156AA

R/Y

333AA

B/W

132AA

L/R

S43-122

S43-123

S43-124

S43-AA

100

CN1052

Steering filter clogging detection switch

156AB

R/Y

132AA

L/R

B76AA

COT

CN930

External warning lamp (3 color)

402AA

R/W

401AA

400AA

470AA

LG/Y

B76AJ

330AA

G/B

322AA

G/R

130AA

L/Y

COT

500

450

500

200

CN1331

Joint connector to “crane”

S03-023

S03-021

S04-024

S03-022

S03-AA

SHIELD

SHIELD4

S04-AA

SHIELD

SHIELD43

S43-AA

SHIELD

SHIELD3

S03-AA

B76AA

800

250

1100

300

2800

CN521

Over-front detection switch

333AA

B/W

B76AB

156AA

R/Y

CN890

External indicator lamp (2 color)

B76AC

412AA

G/W

411AA

G/L

300

N006

200

150

300

COT

250AB

295AA

BR/Y

402AA

R/W

401AA

400AA

400

350

COT

CN592

Drum rotation

detection switch (aux. winch)

322AA

G/R

B76AE

250AE

CN596

Over-unwinding

detection switch (aux.) (option)

470AD

LG/Y

279AA

BR/R

CN595

Over-unwinding detection switch (main) (option)

470AC

LG/Y

295AA

BR/Y

CN591

Drum rotation

detection switch (main winch)

330AA

G/B

B76AD

250AB

CN060

Air solenoid valve (air horn) (SL60)

130AA

L/Y

200

COT

800

250

900

800

250

200

N001

N004

N007

B76AH

150

COT

1350

2550

COT

100

850

2600

Yellow tape

White tape

Yellow tape

Ground

E076

Ground

E077

412

G/W

411

G/L

411

G/L

412

G/W

Joint connector

CN890

150

200

100

450

CN829A

External

indicator lamp

(red) 100%

Ground

External

indicator lamp

(yellow) 90%

CN828A

CN828B

CN829B

Summary of Contents for GR-500EXL-3

Page 1: ......

Page 2: ...nd sales units in the parts catalog before replacing them 1 Applicable spec and serial number Spec No Applicable serial number GR 500E 3 00102 541100 Separate service manual Separate Service Manual Pu...

Page 3: ...H type outrigger specification machine Front rear right and left are the directions viewed from a position when operator sits on operator s seat with the boom directed to the front of the frame Those...

Page 4: ...iter AML AML C 7 Auto Stop solenoid valve energizing type Normally energized 8 Anti two block device Fitted 9 External warning lamp AML Fitted 10 Oil cooler Fitted 11 Air conditioner Fitted 12 ICF inf...

Page 5: ...4 9 2903 10 2 9 2903 10 2 1 44 10 2 1 Volume cubic centimeter cm 3 cc cubic meter m 3 cubic inch in 3 cubic foot ft 3 gallon gal cubic inch in 3 liter lit L 1 1 10 6 6 10237 10 2 3 53147 10 5 1 2 31...

Page 6: ...10 1 01972 10 1 7 37562 10 1 8 85074 9 80665 9 80665 10 2 1 1 10 2 7 23301 10 2 8 67961 10 1 9 80665 10 2 9 80665 1 10 2 1 7 23301 8 67961 10 1 35582 10 2 1 35582 1 38255 10 1 38255 10 1 1 1 2 10 1 12...

Page 7: ...the front view and draw the right side view on the right side of the front view Tridimensional shape can generally be drawn with the figures viewed from 3 directions For those which cannot be drawn w...

Page 8: ...7 WA04 4610E 6 Group index System Diagrams Data Adjustment and Checks Y Z Y Z...

Page 9: ...eding Procedure Y 4 Adjusting procedure Electric Y 5 Assembly Adjustment Crane Operation Y 6 Assembly Adjustment Traveling Device Y 7 Operation Check Crane Operation Y 8 Operation Check Traveling Devi...

Page 10: ...lic Parts Location Diagram Lower Z 7 Hydraulic Parts Location Diagram Torque Converter Z 8 Pneumatic Parts Location Diagram Z 9 Electric Parts Location Diagram Upper Z 10 Electric Parts Location Diagr...

Page 11: ...vice 9 6 2 Braking device 9 6 3 Steering device 10 7 Mass table 11 Y 2 Adjusting Pressure Hydraulic Pressure 12 1 Location position of relief valve etc 12 2 Items 13 2 1 Winch 13 2 2 Telescoping 14 2...

Page 12: ...tion detection switch left CN529 32 Y 6 Assembly Adjustment Crane Operation 33 1 Adjusting boom telescoping wire ropes 33 2 Installing and adjusting anti buckling bolts for telescoping cylinders 37 Y...

Page 13: ...Operation Check Traveling Device 48 1 Exhaust brake 48 2 Automatic transmission 48 3 Steering mode change 49 4 Overshift prevention 49 5 Checking differential lock operation interwheel differential lo...

Page 14: ...1 Engine oil 15 API Service Classification SAE30 class CD or better SAE10W 30 for cold climates Grease 1 Daphne Eponex SR No 2 Idemitsu Grease centralized greasing 1 Nigtight LE 0 Nippon Grease Fuel...

Page 15: ...8 Eng 2860 40 Displacement cm 3 rev 42 7 34 0 Charging pump torque converter Speed reducing ratio 1 066 Idling min 1 629 23 Eng 670 25 Max min 1 2683 38 Eng 2860 40 Displacement cm 3 rev 33 2 Emergenc...

Page 16: ...3 After jack full extension and retraction operation approximately 10 mm set the crane horizontally with the jacks slightly extended 2 If any tire is not raised off the ground while setting the jacks...

Page 17: ...ML display after leaving as it is for 2 hours Check the jib length on the integrated information screen in the AML maintenance mode Displays the value to the second digit after decimal place Suspensio...

Page 18: ...Lower 12 10 Rear Upper on oblique face 49 46 Lower side 12 10 Standard or 15 or 13 3rd boom section Front Upper on upper part of side face 28 26 Lower side 12 10 Lower on oblique face 15 13 Lower 12 1...

Page 19: ...15 B 14 B 1 5 L 1000 L length of each boom section Lateral Base boom 2nd boom section 3rd boom section 4th boom section Top boom section C 10 C 10 C 10 C 10 C 9 5 C 1 0 L 1000 Indentations at boom ov...

Page 20: ...iameter mm 16 Nominal diameter 14 9 Construction P S 19 39 P 7 370 018 09860 Number of broken wire pcs 10 4th boom extension Wire rope diameter mm 16 Nominal diameter 14 9 Construction IWRC 6 P WS 31...

Page 21: ...mooth and correct any sharp corners 2 Check whether or not the sheaves turn lightly If a sheave turns heavily the wire rope will slide against the sheave and the rope may be damaged If a sheave turns...

Page 22: ...40 ON 2150 50 0 Eco mode OFF When torque converter stalls Approx 2240 Reference value Check conditions PTO switch OFF Shift lever 2nd gear Drive selection switch 4WD High Service brake ON 6 2 Braking...

Page 23: ...dard value Remarks Steering cylinder Pin outer diameter mm Cylinder side 35 0 009 0 025 Rod side 35 0 009 0 025 Wheel Camber 0 Caster 0 Kingpin angle 6 Toe in mm 0 Steering angle Inner wheel 26 0 1 Ti...

Page 24: ...t 5850 12870 Slewing bearing 560 1230 Slewing drive unit including hydraulic motor 170 380 Center joint 85 190 Elevating cylinder 400 2 880 2 Winch assembly including hydraulic motor Main 330 730 Auxi...

Page 25: ...12 WY02 1870E Y 2 Y 2 Service Data Y 2 Adjusting Pressure Hydraulic Pressure 1 Location position of relief valve etc...

Page 26: ...and hydraulic valve winch brake 2 Turn the PTO switch ON 3 Move the winch lever that is blocked at its full stroke on the hoisting up side while the elevating lever is moved at its full stroke on the...

Page 27: ...speed min 1 Check procedure MPa kgf cm 2 psi Boom extending V 16 7 0 5 170 5 2420 70 2150 MAX 1 Turn the PTO switch ON 2 Fully extend the boom 3 Move the telescoping lever at its full stroke on the ex...

Page 28: ...e Engine speed min 1 Check procedure MPa kgf cm 2 psi Boom raising D 27 5 0 5 280 5 3980 70 2150 MAX 1 Turn the PTO switch ON 2 Fully extend the elevating cylinder 3 Move the elevating lever at its fu...

Page 29: ...tration of slewing range limit function in AML Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Slewing 1 G 20 6 0 5 210 5 2990 70 Already the pressure is set by the valve ma...

Page 30: ...ing then increase engine speed Item Mark Set pressure Engine speed min 1 Check procedure MPa kgf cm 2 psi Outrigger I 20 6 0 5 210 5 2990 70 2600 1 Connect a pressure gauge to the pressure check port...

Page 31: ...edure MPa kgf cm 2 psi Steering J 19 6 1 0 200 10 2840 140 2600 1 Connect a pressure gauge to the pressure check port J 2 Turn the PTO switch OFF 3 Without jacking up turn the steering to the right si...

Page 32: ...Turn the PTO switch ON 3 Make sure that constant pressure is being produced while engine is running 4 And check the pressure by the pressure gauge Note Adjustment is not possible If the pressure is o...

Page 33: ...speed min 1 Check procedure MPa kgf cm 2 psi Torque converter oil pressure 1 4 or over 14 or over 200 or over 670 IDL 1 Turn the PTO switch OFF with the air conditioner OFF 2 Confirm set pressure on...

Page 34: ...ressure 850 8 7 123 Must be no leakage within pressure regulator operation range 129 Full opening pressure 950 20 9 7 0 2 138 3 Air low pressure switch total air low pressure warning Light on pressure...

Page 35: ...G1 4 on the suction flange of the main pump After bleeding from the suction side tighten the plug again 3 Start the engine with air conditioner OFF and PTO OFF and run it at idle approximately 670 mi...

Page 36: ...turn the PTO switch OFF and start the engine After idling the engine for 5 seconds turn the PTO switch ON and OFF repeatedly and quickly and check for any abnormal noise 6 If any abnormality is found...

Page 37: ...ake reduce the winch speed as far as the drum can rotate Once you start bleeding a winch brake you need not move the winch lever to and fro Keep the lever to the position so that the drum rotates at t...

Page 38: ...ep the slewing circuit hydraulic pressure at approximately 4 9 MPa 50 kgf cm 2 710 psi for approximately 30 seconds 4 2 Winch motor NOTICE Do not apply any load to the motor before completing air blee...

Page 39: ...steps by moving the slewing lever to the left slewing side 2 Elevating Pull out the connector CN100 of the AML vent solenoid valve Move the boom elevating lever fully to the boom lowering side Keep t...

Page 40: ...section 7 and the positive control See the section 8 are bled Conditions Engine speed Idling 670 min 1 PTO ON 1 Open the air bleed plug and move the winch lever fully to the end of its stroke in the...

Page 41: ...itch fixing bolt tightening torque 4 to 6 N m 41 to 61 kgf cm 3 to 4 4 ft lbf 2 2nd boom full retraction detection switch CN553 Adjust the switch position so that its contact is shifted opened closed...

Page 42: ...t tightening torque 40 to 50 N m 410 to 510 kgf cm 29 5 to 36 8 ft lbf NOTICE Make sure that the red LED lights up when the switch is activated 4 Jib connection pin detection switch CN572 1 Slewing th...

Page 43: ...locking agent ThreeBond 1401 or the equivalent to the threaded section of the switch Switch fixing nut tightening torque 19 to 20 N m 193 to 204 kgf cm 14 to 14 8 ft lbf NOTICE Make sure that the gree...

Page 44: ...ghtening torque 19 to 20 N m 193 to 204 kgf cm 14 to 14 8 ft lbf NOTICE Make sure that the green LED lights up when the switch is activated 8 Straight ahead detection switch CN408 Set the rear wheels...

Page 45: ...Note Make the head surface of the bolt X flat beforehand Use the bolt X and the nut Y of roller assy 10 Over unwinding detection switch aux winch option CN596 Follow the same procedure as that in ove...

Page 46: ...ng boom telescoping wire ropes 1 With the boom fully retracted tighten the nut A until a tension is placed on the top boom section retraction wire rope to keep the boom fully retracted 2 Tighten the f...

Page 47: ...section extends by 1 to 5 mm 0 04 to 0 2 in from the 4th boom section 4 Tighten the nut A until the top and 4th boom sections are fully retracted 5 Extend the boom by 200 to 300 mm 8 to 12 in by opera...

Page 48: ...third turn equally 7 2 Extend the boom by 200 to 300 mm 8 to 12 in by operating the boom telescoping control lever and then retract it fully Check the boom is fully retracted OK END NG 8 1 Tighten nu...

Page 49: ...two nuts C by approximately a third turn equally 9 When only the 4th boom section is not fully retracted 9 2 Extend the boom by 200 to 300mm 8 to 12 in by operating the boom telescoping control lever...

Page 50: ...inders 1 Connect the boom and telescoping cylinder using the pins A and B 2 Adjust the bolt C locked with nuts D and E so that it can be turned by hand and the clearance S is 0 5 mm 0 02in or less App...

Page 51: ...vel and tighten the cap until it stops at the stopper At this time the position of tank body and cap should be as shown in Fig 1 In addition tighten the cap until the mark is aligned with the mark on...

Page 52: ...2 Move the accelerator sensor lever so that it contacts stopper C Then adjust nut H until there is no pedal play NOTICE Be sure to check that the accelerator switch operates 3 When at Max position ac...

Page 53: ...6 14 5 0 800 100 0 8 0 1 0 116 14 5 0 4 2 Adjusting the steering angle 1 Jack up the vehicle Operate the steering cylinder 2 to 3 times with 4 wheel steering to bleed air out from the cylinder 2 Befor...

Page 54: ...hometer and do not overrun the engine Max 2950 min 1 Drive speed selection must be done with the vehicle at a complete stop and with the brakes not applied The mechanism does not allow 2WD selection i...

Page 55: ...er N position Operate the outrigger extend retract selector switch Icon flashes on the AML display Press all outrigger control switch Outriggers operate Main switch ON Shift lever Not in N position Op...

Page 56: ...in the cab 2 Icon flashes on the AML display 3 Check that the extension width smaller than the detected value can be registered on AML manually 5 Jib side up function 1 Automatic stop by two blocking...

Page 57: ...he limited AML override switch to ON With CN503 1 switch pressed extend the 3rd 4th and top boom by approximately 1m 3 3 ft each With CN503 1 switch pressed retract the 3rd top boom With CN503 2 switc...

Page 58: ...the boom length reaches 18 43 m 60 5 ft With CN503 2 switch pressed retract the 2nd boom With CN503 1 switch pressed extend the 3rd 4th and top boom by approximately 1m 3 3 ft each With CN503 1 switch...

Page 59: ...buzzer Sound Checking procedure AML limit Buzzer CN818 280Hz Continuous low tone Buzzer sounds at 100 when main switch is ON and PTO switch is ON Intermittent low tone sound occurs at 90 and above Tw...

Page 60: ...ocation of the switch refer to Z 10 Electric Parts Location Diagram Upper 1 Inside cab While the PTO is engaged select the Eco mode 1 and Eco mode 2 and depress the accelerator pedal fully Then check...

Page 61: ...t lever into the N position Adjust the engine speed to 1 000 min 1 or higher using the idling adjuster knob Exhaust brake indicator illuminates OFF Not activated 2 Return the engine speed to idling an...

Page 62: ...speed to 22 km h Check that transmission does not downshift display 3 5 Gradually reduce speed Check that transmission downshifts to 2nd gear at 18 km h display 2 6 Maintain a speed of 11 km h Move t...

Page 63: ...n when one is turned Differential lock OFF Check that the differential lock indicator is extinguished and that opposite wheel on the rear axle rotates in opposite direction when one is turned When the...

Page 64: ...pressure 620 Hz Continuous beep high tone Buzzer sounds if the torque converter pressure is 1 0 MPa 10 2 kgf cm 2 145 psi or less while the parking brake is not applied 2WD 4WD select 620 Hz Continuou...

Page 65: ...r at N position 2 Moving the shift lever D make sure that only D of gear position indicator on combination meter flashes When the emergency transmission switch is turned OFF D and 1 flash 3 Depressing...

Page 66: ...sounds Steered a little 2 wheel Lit Continuous beep 4 Select the 4 wheel steering mode and check that the warning buzzer does not sound Steered a little 4 wheel Lit No beep 5 Set the rear wheel strai...

Page 67: ...Aux winch telescoping and slewing pilot valve circuit Clean 1 point 30 7 Top cylinder selection hydraulic valve circuit Clean 1 point 30 8 Top cylinder retracting prevention hydraulic valve circuit C...

Page 68: ...om Connecting Pin and Thread Size Table Note means that more than one spec No are applicable Unit mm 1 mm 0 039 inch Applicable spec No GR 500E 3 Part Name Diameter Thread size Elevating cylinder Rod...

Page 69: ...c circuit 10 4 1 Electric circuit crane 10 4 2 Electric circuit carrier 11 4 3 Electric circuit slewing table right 12 4 4 Electric circuit slewing table left 13 4 5 Electric circuit boom jib single t...

Page 70: ...rake related lower 36 3 Control parts lower 37 Z 10 Electric Parts Location Diagram Upper 38 1 Inside cab 38 2 Relay assy inside cab 39 3 Slewing table boom 40 4 Pressure switch installation diagram 4...

Page 71: ...age and paragraph No 69 2 3 Electric circuit 70 2 3 1 Electric circuit slewing table left 70 2 3 2 Electric circuit boom 71 2 3 3 Electric circuit jib 72 3 General view anemometer 73 4 Harness anemome...

Page 72: ...wing right proportional control valve SL120 Slewing left proportional control valve SL121 Solenoid valve for slewing free lock selection SL161 Slewing relief proportional control valve SL162 39 Hydrau...

Page 73: ...3 05 12 2 13 2 10 2 RR RL RL RL RR RR 02 04 06 03 31 C A C A P A B SL24 SL22 B A P B4 A4 A3 B3 T2 A2 B2 B1 A1 50 85 65 66 A1 A2 01 a5 38 30 3 39 b5 30 4 a1 53 48 6 45 2 48 5 b5 a5 P T O 11 2 T P1 P2 D...

Page 74: ...High SL46 F1 F2 R SL47 Low Front Lock up SL49 Accumulator SL41 P T O Line filter 20 M14 1 5 G1 G3 8 G3 8 Torque converter case M16 1 5 G1 G1 Oil cooler G3 8 G3 8 Torque converter inlet relief valve S...

Page 75: ...lve Check valve Cracking pressure 850 kPa 8 7k gf cm2 123 psi Full opening pressure 950 20 kPa 9 7 0 2 kgf cm2 138 3psi Safety valve Air compressor Turning on pressure 710 20 kPa 7 2 0 2 kgf cm 103 3...

Page 76: ...shown by following block diagram Z 4 4 3 Electric circuit slewing table right Center joint Z 5 Electric circuit lower cab CN894 CN1331 Z 4 4 7 Electric circuit SCT Z 4 4 6 Electric circuit GSMT CN1072...

Page 77: ...e S AA Example S016 AA S016 AB 6 Joint label Same with Wire label J AA Example J001AA J035AA J106AA J1000AA JC01AA JS016AA JB01AA 7 Node name at diverging point N Wire 1 Indication of wire size Indica...

Page 78: ...L G W L Y G B Exhaust brake switch Notice shows the momentary switch 3 6 1 4 1 4 3 6 3 Up Down Switch Lower outrigger operation jack slide selection Middle OFF 3 OFF Outrigger operation box illuminat...

Page 79: ...horn D 2 CN532 Main winch hoisting up detection switch Contact open hoisting up Z 4 4 4 Z 12 3 CN533 Aux winch hoisting up detection switch Contact open hoisting up CN534 Boom extending detection swi...

Page 80: ...GSMT Z 4 4 6 Z 12 6 CN1605 Air conditioner water pump Turn on water pump start M 1 Z 4 4 2 Z 12 1 2 CN No Usage Description Electric circuit coordinate Electric circuit diagram Harness diagram CN1610...

Page 81: ...connector to slewing table left 3 2 1 4 5 6 3 1 4 6 5 2 CN580 Slewing angle detector SHIELD2B 1 2 3 4 5 6 7 8 9 10 11 JC11 JC11 1 12 13 14 15 16 17 18 19 20 21 22 JC11 2 23 24 25 26 27 28 29 30 31 32...

Page 82: ...CN1067 1 2 3 4 5 6 CN639 4 6 8 2 5 9 1 3 7 1 2 1 CN588 1 2 3 CN587 2 1 CN548 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 4 2 6 1 3 5 6 5 4 3 2 1 CN586 SHIELD22 1 4 2 5 3 12 13 14 15 16 17 18 19...

Page 83: ...1 W S03 023 R S03 023 R S04 026 R 1 25 S03 AA B 130AA L Y 130AA L Y S43 122 R S43 122 R S43 123 W S43 123 W S04 025 B S04 AA B B76AB B 1 25 B76AA B B76AA B 1 25 B76AD B B76AJ B Output Pressure sensor...

Page 84: ...oportional control valve Slewing relief proportional control valve Slewing relief proportional control valve Boom angle detector Boom length detector Boom length and angle detector 5V Boom length and...

Page 85: ...C06 019 B C06 018 W R G G B S62AB G B C06 019 B C06 018 W C06 019 B C06 018 W 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Working lamp boom option Jib lock pin detection s...

Page 86: ...Instrument_GND 30 1 30 External_Instrument_CS 31 1 31 External_Instrument_RX 7 1 7 NC 2 1 2 GND 34 1 34 BATT_GND 1 1 1 NC 3 1 3 NC 19 1 19 WAKE_UP 4 1 4 NC 5 1 5 NC 6 1 6 NC 28 1 28 ICF_RX 8 1 8 NC 9...

Page 87: ...1 20 RXD1 8 1 21 RS1 7 1 22 TERM_GND 6 1 23 NC 5 1 24 NC 4 1 25 NC 3 1 26 NC 2 1 27 NC 1 1 28 NC 16 1 29 CS1 15 1 30 NC 14 1 31 NC 13 1 32 NC 12 1 33 NC 11 1 34 NC 10 1 35 NC 9 1 36 NC 1 2 1 ANT_GPS 1...

Page 88: ...cuit diagram of this machine is composed of Z 4 Electric Circuit Upper and Z 5 Electric Circuit Lower mainly The electric circuit lower is shown by following block diagram Center joint Z 5 3 1 Electri...

Page 89: ...2 F Contact close more than 50 C 122 F F 7 Z 13 1 2 CN556 Temperature switch 85 C 185 F Contact close more than 85 C 185 F CN568 Air pressure switch stop lamp Contact close depressing brake pedal Z 5...

Page 90: ...For A C water pump I 6 Z 13 1 2 CN1640 Resistance CAN J 15 Z 5 3 2 CN1680 Fuse box 1 J 22 Z 5 3 1 CN1681 CN1682 CN1683 J 21 CN1684 CN1685 CN1690 Fuse box 3 I 22 CN1691 CN1692 I 21 CN1693 CN1720 Return...

Page 91: ...W8 4 CN4 4 RPOW9 7 CN4 7 Do25 8 CN4 8 Do26 9 CN4 9 Do27 3 CN4 3 Do28 10 CN4 10 RPOW10 2 CN4 2 Do29 1 CN4 1 Do30 6 CN4 6 Do31 12 CN4 12 GND 21 CN5 21 RPOW11 20 CN5 20 Do33 19 CN5 19 Do34 18 CN5 18 Do35...

Page 92: ...LER SW 53 B 23 23 NEUTRAL SW 58 B 10 10 IDLE UP CANCEL SW 51 B 12 12 EXH BRAKE SW 49 B 13 13 STARTER SW S 48 B 15 15 STARTER SW M 1 46 B 18 18 STARTER SAFETY RELAY 43 B 20 20 ACCEL SW 61 B 22 22 COLD...

Page 93: ...CN428 Fuel sensor 1 2 CN411 Air pressure detection switch parking brake 2 1 CN051 SL51 Air solenoid valve 2 4 wheel drive shift 2 1 CN568 Air pressure switch stop lamp 2 1 CN064 SL64 Air solenoid valv...

Page 94: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 23 WZ07 3970E Z 6 Hydraulic Parts Location Diagram Upper 1 Winch 2 Telescoping 2 343 466 11000 3 343 466 12000 1 342 116 00000...

Page 95: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 24 WZ07 3970E 3 Elevation 4 Slewing 3 343 550 20000 0 342 411 80000 0 343 009 70000 1 343 466 13500...

Page 96: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 25 WZ07 3970E 5 Return 6 Drain 4 343 466 14000 3 343 466 15000...

Page 97: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 26 WZ07 3970E 7 Gauge 8 Winch brake 1 343 466 16000 2 343 466 16500...

Page 98: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 27 WZ07 3970E 9 Pilot 10 Steering 3 343 466 17000 2 347 226 70000 0 347 223 81000...

Page 99: ...Z 6 Z 6 Hydraulic Parts Location Diagram Upper 28 WZ07 3970E 11 Air conditioner 12 Operation assy operation valve 2 345 115 01000 2 343 234 80000...

Page 100: ...29 WZ07 3970E Z 6 Z 6 Hydraulic Parts Location Diagram Upper 13 Pressure switch 14 Jib side up and down 1 343 638 33000 2 343 466 82000...

Page 101: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 30 WZ07 3950E Z 7 Hydraulic Parts Location Diagram Lower 1 Suction 0 346 418 01000 2 347 337 70000...

Page 102: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 31 WZ07 3950E 2 Steering 2 346 418 02000...

Page 103: ...Z 7 Z 7 Hydraulic Parts Location Diagram Lower 32 WZ07 3950E 3 Outrigger H type 4 Center joint 5 346 418 04000 1 346 418 03000...

Page 104: ...33 WZ07 3950E Z 7 Z 7 Hydraulic Parts Location Diagram Lower 5 Return 6 Outrigger main body H type 0 346 118 40000 4 346 418 05000...

Page 105: ...34 WZ07 3960E Z 8 Z 8 Hydraulic Parts Location Diagram Torque Converter Z 8 Hydraulic Parts Location Diagram Torque Converter 1 Torque converter related 4 349 317 60000 3 349 232 50000...

Page 106: ...Z 9 Z 9 Pneumatic Parts Location Diagram 35 WZ08 0590E Z 9 Pneumatic Parts Location Diagram 1 Service brake related upper 1 343 466 00000 0 347 226 00000...

Page 107: ...Z 9 Z 9 Pneumatic Parts Location Diagram 36 WZ08 0590E 2 Service brake related lower 7 349 232 70000...

Page 108: ...37 WZ08 0590E Z 9 Z 9 Pneumatic Parts Location Diagram 3 Control parts lower 4 349 232 60000...

Page 109: ...oint connector to slewing table right CN894 CN1331 Joint connector to slewing table left CN887 CN889 CN890 CN891 CN1206 Slewing angle detector CN580 Joint connector to reserve CN921 Joint connector CN...

Page 110: ...n Down Normal state c Emergency accelerator Push Emergency operation Release Normal state Push Emergency operation Release Normal state Up Emergency transmission operation Down Normal state Emergency...

Page 111: ...2 CN102 Top cylinder selection solenoid valve SL230 CN230 AML vent solenoid valve SL100 CN100 Harness slewing table right Drum rotation detection switch main winch CN591 External indicator lamp 2 colo...

Page 112: ...detection switch Boom extending detection switch Aux winch hoisting down detection switch OFF ON ON OFF ON ON OFF ON ON Left detection Right detection Extending detection Hoisting down detection d f...

Page 113: ...to cancel the anti two block function Snap pin View C When not using main hook remove the weight CN862 Two blocking detection switch boom Harness boom head Main two blocking detection switch assy Circ...

Page 114: ...ness single top CN900 Joint connecter Single top stowed state Harness single top FRONT CN901A Joint connecter CN900 Joint connecter Circuit diagram CN902 CN948 CN901B CN1495 CN900 CN901A CN901 CN862 B...

Page 115: ...on switch assy Boom right side CN1778 Sub two blocking detection switch assy Harness jib 2 head Harness jib 1 Harness jib 2 bottom CN859 From cord reel boom length detector When operating jib CN948 Jo...

Page 116: ...4 962 80000 Detail of device connection GPS antenna Main harness GPS antenna GPS antenna Harness GSMT Harness GSMT GSMT GPS antenna cable connection port ICF CN1065 CN1066 CN1072 CN1584 GSMT global sy...

Page 117: ...erminal CN1065 CN1066 CN1068 CN1072 Detail of device connection GPS antenna Detail B View A SCT Antenna cable connection port Main harness Antenna cable Antenna for satellite communications Connector...

Page 118: ...solenoid valve Extending SL21 CN021 Jack FL SL25 CN025 Outrigger jack side selection solenoid valve Outrigger jack side selection solenoid valve Slide FR SL22 CN022 Jack FR SL23 CN023 Outrigger length...

Page 119: ...inal base b contact Normal close type relay a contact Normal open type relay View A 270 3 2 4 5 6 1 6 4 4 L G B 6 4 7 B W CN765 M 644 LG B 647 B W A Controller VCU RF2 connector No RF2 7 M Pole CN No...

Page 120: ...704 CN1004 CN705 DIAG switch CN730 Memory clear switch CN797 S1 B S2 L1 S L2 Head lamp relay G Y Z K E X J I H A B F D C G Y Z K E X J I H A B F D C H G F E D C A B 15A 5A 5A 5A Y X K 1A J 1A I 5A H 5...

Page 121: ...16 CN837 Condenser washer motor J 2 CN838 CN839 CN849 Washer motor roof I 2 CN850 Washer motor front I 3 CN868 Fuse box 2 E 13 CN869 CN870 CN871 E 14 CN872 F 13 CN873 CN874 Fuse box 1 H 13 CN875 CN876...

Page 122: ...p 035BK BR B30DI B CN467 Power window switch 127AA L 128AA L Y B30AM B 218AB Y G B30AN B 157AK R G 157AA R G 157AS R G 122AA R W 122AB R W 122AC R W B30CU B B30CX B B30CY B B30AI B B30CQ B 035AP BR 03...

Page 123: ...W S03 022 B S03 AA B SHIELD SHIELD4 S04 AA B SHIELD SHIELD43 S43 AA B SHIELD SHIELD3 S03 AA B B76AA B 800 250 1100 300 2800 CN521 Over front detection switch 333AA B W B76AB B 156AA R Y CN890 Externa...

Page 124: ...m telescoping aux winch control selection solenoid valve SL143 B75AD B 337AA LG W CN534 Boom extending detection switch 250AJ LG 263AA W G CN144 Boom telescoping aux winch control selection solenoid v...

Page 125: ...etection switch 305AA R 250AB LG B01AC B 750 50 150 CN576 Boom length and angle detector S06 013 G S06 014 W S06 015 R S06 AA Y S06 016 B GR W GR CN858 Cord reel boom length detector 818AA W Y 304AA G...

Page 126: ...ss boom head Two blocking detection switch boom Joint connector CN901 Connector CN901 1 2 3 0 5B Vinyl 04 05 Green tape 3rd top boom full retraction detection switch 320 Vinyl 05 07 0 75W 0 75B M F F...

Page 127: ...Harness Upper WZ04 5300E Z 12 Z 12 1 345 006 82100 56 5 2 Harness single top IWZ04 5280E06 C06 018 W C06 019 B CN901A 800 C06 018 W C06 019 B CN900 M F Joint connector Joint connector COT 07...

Page 128: ...1495 W B R G G B R G G B M M M C06 019 S62 147 S62 148 S62 147 S62AA S62AD S62 148 C06 018 W B C06 019 C06 018 Joint connector Joint connector Joint connector 550 COT 10 500 COT 07 8400 COT 10 SHIELD...

Page 129: ...8 IWZ04 5280E08 5260 50 40 N001 COT 10 330 COT 10 CN948A F Joint connector CN1778 B Plug W B R G G B F 50 180 C06 019 W C06 018 R S62 147 G S62 148 G B S62AB Joint connector Yellow tape SHIELD SHIELD6...

Page 130: ...1700 5 5 Harness jib 2 head 59 IWZ04 5280E09 Joint connector Joint connector Joint connector Yellow tape COT 10 COT 07 30 390 COT 10 330 CN1778 F F CN902 B C06 019 W B Plug Plug Plug Plug M W C06 018...

Page 131: ...006AC O B51AE B 826AA W L 821AA W B 822AA W R B51AF B 822AA W R 016AC Y L 006AC O 826AA W L B51AH B 821AA W B B51AG B GSMT M 28 7 8 20 12 9 23 25 27 2 18 5 4 29 10 24 19 3 21 22 26 6 1 11 13 16 15 17...

Page 132: ...344 941 00101 7 Harness SCT 61 IWZ04 5190E10 F M 150 N005 CN1068 821AA W B 006AC O 016AC Y L 822AA W R 826AA W L B51AH B B51AG B B51AF B CN1072 016AC Y L 006AC O B51AE B 826AA W L 821AA W B 822AA W R...

Page 133: ...ordinate CN720 Rear combination lamp R N 21 CN721A Backup lamp M 19 CN721B CN723 License lamp option L 19 CN730 DIAG switch C 21 CN731 DIAG lamp red D 20 CN732 CN733 DIAG lamp orange E 20 CN734 CN747...

Page 134: ...CC B B08CD B B08CE B SHIELD SHIELD16 S16 AA B SHIELD SHIELD48 S48 AA B Combination lamp L CN1008 B10AT B Combination lamp R CN1009 B10AC B CN793 Engine harness B 653AA Y G 699AD B Y 693AB R W 641AA LG...

Page 135: ...low tape F F Plug SHIELD SHIELD61 S61 AA B COT 07 760 N001 CN408 Straight ahead detection switch S61 143 Y S61 146 B S61 142 R 30 220 COT 05 CN1600 Joint connector rear axle S61 142 R S61 143 Y S61 14...

Page 136: ...tial lock SL64 B20AE B 137AA R B 270 110 100 30 CN745 Air dryer heater B20AB B 556AA R W 250 250 50 70 450 COT 10 COT 05 COT 10 COT 07 COT 05 COT 05 COT 10 COT 05 CN054 Air solenoid valve exhaust brak...

Page 137: ...CN1809 Circut diagram Detail E Harness slewing table left Harness boom Cap To cord reel To anemometer CN1635 CN634 Current voltage converter Detail A Harness crane and carrier Relay assy Harness slewi...

Page 138: ...CN901B Joint connector CN1495 Joint connector CN901B Joint connector CN901B Joint connector CN1495 Joint connector JIB 2 JIB 1 JIB 1 CN948A Joint connector CN948A Joint connector JIB 1 JIB 1 JIB 2 An...

Page 139: ...circuit diagram The electric circuit anemometer is shown by following block diagram CN1425 CN1635 Z 14 2 3 2 Electric circuit boom Z 4 4 1 Electric circuit crane Z 14 2 3 1 Electric circuit slewing t...

Page 140: ...N948B Z 14 4 4 CN1425 Joint connector to boom Z 14 2 3 1 Z 14 4 1 Joint connector to slewing table left Z 14 2 3 2 Z 14 4 2 CN1426 Joint connector to jib Joint connector to boom Z 14 2 3 3 CN1495 Join...

Page 141: ...ND1 9 CN1 10 AGND2 10 CN1 11 AGND3 11 CN1 12 AGND4 12 CN1 13 N C 13 CN1 14 Ao1 14 CN1 15 Ao2 15 CN1 16 Ao3 16 CN1 17 Ao4 17 CN1 18 Ao5 18 CN1 19 Ao6 19 CN1 20 Ao7 20 CN1 21 Ao8 21 CN1 22 AGND5 22 CN1...

Page 142: ...e is AVS and wire size is 0 5mm2 2 2 1 2 3 4 5 6 CN1425 1 2 3 4 5 6 CN1426 E001 M6_1 25 2_Water proof Ground S66 147 S66 147 S66 148 B S66 148 B S66 171 R S66 171 R S66 172 G S66 172 G 1 25 S66AB B Y...

Page 143: ...019 B C06 018 W R G G B S62AB G B 1 2 3 1 2 3 1 2 3 4 5 1 2 3 4 5 6 7 6 7 G G B R CN948A SHIELD62B SHIELD62A 1 2 3 4 5 1 2 3 4 5 6 7 6 7 1 2 3 4 5 6 C06 019 B S62 147 R S62 148 G S62AA G B S62AB G B C...

Page 144: ...Anemometer Option WZ02 6810E Z 14 Z 14 3 344 961 21200 73 IWZ02 6540E07a 3 General view anemometer 1 W SHIELD G Harness 2 3 5 4 2 1 M 7 6 CN1495 or CN1497...

Page 145: ...r to crane B02AA B S64AB B Y 50 COT 10 COT 07 4200 250 SHIELD SHIELD64A S64AA B Y CN634 S64 147 W 1419AA Y S64 171 R S64 172 G CN1425 Joint connector to boom S64 171 R S64 147 W S64 148 B S64 172 G S6...

Page 146: ...41307 2 2 2 CN1425 S66 171 R S66 147 S66 148 B S66 172 G S66 151 Y S66AB B Y CN1426 S66 171 R S66 147 S66 148 B S66 172 G S66 151 Y S64AA B Y SHIELD SHIELD66 S66AB B Y Ground E001 S64AA B Y N001 7700...

Page 147: ...CN1495 W B R G G B R G G B M M M C06 019 S62 147 S62 148 S62 147 S62AA S62AD S62 148 C06 018 W B C06 019 C09 018 Joint connector Joint connector Joint connector 550 COT 10 500 COT 07 8400 COT 10 SHIEL...

Page 148: ...ter Option Z 14 Z 14 5300 50 N001 COT 10 330 COT 10 CN948A F Joint connector CN1778 B Plug W B R G G B F 50 180 06 019 W 06 018 R S62 147 G S62 148 G B S62AB Joint connector Yellow tape SHIELD SHIELD6...

Page 149: ...B 30 M Plug S62 147 R S62 148 G S62AD G B CN902 Joint connector anemometer SHIELD SHIELD62B S62AB G B SHIELD SHIELD62C S62AC G B SHIELD SHIELD62E S62AE G B SHIELD SHIELD62D S62AD G B SHIELD SHIELD62F...

Page 150: ...justment main menu 3 To terminate the adjustment mode press the key while the adjustment main menu is being displayed Note In detail refer to Chapter D Adjustment Mode in the separate service manual A...

Page 151: ...p Option Z 15 Z 15 1 Structure beacon lamp Z 15 Beacon Lamp Option Z 15 Joint connector CN1796 Harness beacon lamp When not using beacon lamp connect plug connectors together Beacon lamp Plug connecto...

Page 152: ...0 344 450 10100 IWZ02 6790E02 WZ02 6820E Z 15 Z 15 81 Beacon Lamp Option 2 Lamp beacon Beacon lamp Vinyl tape Plug connector 700 F W W Plug M W GR Plug GR 100 100 CN1795...

Page 153: ...456 80200 IWZ02 6820E02 WZ02 6820E Z 15 Z 15 82 Beacon Lamp Option 3 Harness beacon lamp R B Plug R F Plug W W M B M 2200 100 CN1796 Joint connector CN1795 Plug connector 100 COT 07 30 Beacon lamp op...

Page 154: ...ump The centralized greasing supply unit automatically supplies grease to the necessary points of the carrier by switch operation Detail A 4 FR King pin upper 6 FR Steering cylinder 2 FR Steering rod...

Page 155: ...Centralized greasing switch CN431 CN432 CN433 Centralized greasing indicator CN735 CN1042 Grease pump CN744 Harness main and engine Harness main and engine Joint connector CN1798 CN744 Distributor wit...

Page 156: ...box 2 CN770 1 2 3 4 CN768 2 3 1 2 3 1 CN743 Distributor with switch CN735 CN1042 Centralized greasing indicator CN432 CN431 1 2 CN433 Centralized greasing switch 2 3 1 CN1799 Haness main and engine 1...

Page 157: ...acement 13cm 3 min or more Discharge pressure MAX 14 7MPa 150kgf cm 2 Tank capacity 400cm 3 Effective 300cm 3 Grease Grease used at shipment Equivalent Manufacturer Brand Manufacturer Brand Nippon Gre...

Page 158: ...Item Specification Model U 8MT Displacement Switching pressure 0 9MPa 10kgf cm 2 or less Working pressure MAX 14 7MPa 150kgf cm 2 Thread size and tightening torque Sign Port Thread size Tightening tor...

Page 159: ...N744 B01AC B 119AC L R CN1042 006AB O 139AB L Y B01AB B CN433 140AB L G 50 50 150 COT 07 1150 50 50 50 50 Centralized greasing indicator Grease pump Centralized greasing indicator Centralized gresing...

Page 160: ...d Lubrication System Option WZ02 6800E Z 16 Z 16 89 5 2 Harness distributor M F 50 50 350 COT 07 CN1799 Joint connector centralized lubrication option 140AA L G 119AB L R 139AC L Y CN743 Distributor w...

Page 161: ...on March 2015 History of revision 1 2 3 4 5 Head Office Ko 34 Sinden cho Takamatsu Japan Overseas Service Group Tadano Ryogoku Bldg 4 12 Kamezawa 2 chome Sumida ku Tokyo Japan Tel 81 3 3621 7765 Tel f...

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Tadano GR-500EXL-3, Service Manual

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