Tadano TT-800XXL1 Service Manual Download Page 1

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Publication No.

GT-800XXL-1/S1(U)-1E

Truck Crane

TT-800XXL-

Applicable Serial No. 475326

～

Model

◯

ｃ

2003

PRINTED IN JAPAN
0310 K

Service Manual

GT-800XXL-1/S1(U)-1E

Summary of Contents for TT-800XXL1

Page 1: ...Publication No GT 800XXL 1 S1 U 1E 01 Truck Crane TT 800XXL 1 Applicable Serial No 475326 Model 2003 PRINTED IN JAPAN 0310 K Service Manual GT 800XXL 1 S1 U 1E...

Page 2: ...instructions in this manual are identified as DANGER WARNING CAUTION or NOTICE These terms are defined as follows NOTICE NOTICE indicates an important operational or maintenance procedure or condition...

Page 3: ...low the capacitors to discharge Pull out the ignition key and hang a tag saying Don t start the engine in the cab 6 Don t carry out maintenance while lifting the vehicle with only a jack or a hoist Su...

Page 4: ...fixing it don t apply too much force to it but check the part for the cause Only after relieving the cause proceed disassembling 7 Use lifting slings appropriate for the weight and characteristics of...

Page 5: ...Spill or leak Review fire and explosion hazards before proceeding with clean up Use appropriate personal protective equipment during clean up Dike spill Prevent liquid from entering sewers waterways...

Page 6: ...separate operation and maintenance manual and the parts catalog for repair and maintenance of the crane in conjunction with this manual If the parts needs to be replaced check the disassemble units a...

Page 7: ...Fitted Winch brake Automatic brake Neutral brake Winch Drum rotation indicator Touch type Option Weight Counterweight Removable type Load moment indicator AML AML LK Auto stop solenoid valve energizin...

Page 8: ...cubic meter m 3 cubic inch in 3 cubic foot ft 3 gallon gal cubic inch in 3 liter lit L 1 0 000001 0 0610 0 0000353 1 231 3 785 1000000 1 61024 35 31 0 004329 1 0 01639 16 39 0 0000164 1 0 000579 0 264...

Page 9: ...3 0 1383 1 12 11 3 0 113 1 1525 0 01153 0 08333 1 Centigrade Fahrenheit F F F F F F 90 67 78 40 40 10 12 22 60 15 56 110 43 33 160 71 11 80 62 22 30 34 44 20 6 67 70 21 11 120 48 89 170 76 67 70 56 67...

Page 10: ...m Elevation System Winch System Boom Telescoping System Safety System Cab Control System System Diagrams Data Adjustment and Checks B C D E F G H I J K L M N O P Q R S T U V W X Y Z A GROUP INDEX Hydr...

Page 11: ...Valve B 3 Rotary Joint B 4 Hydraulic Pilot Control Valve Elevating Telescoping Winch B 5 Sequence Valve Pilot Pressure B 6 475348 B 7 Solenoid Valve Pilot Pressure 475349 B 8 Solenoid Control Valve Ji...

Page 12: ...ve Swing D 3 Hydraulic Motor Swing D 4 Swing Speed Reducer D 5 D Select Valve Dolly D 6 Boom Elevation System Elevating System E 1 Elevating Cylinder E 2 Counterbalance Valve Elevating E 3 Select Valv...

Page 13: ...ing G 5 Hose Reel G 6 G Hydraulic Valve G 7 Safety System Safety System H 1 Load Moment Indicator AML Refer to separate manual W301 0232E Boom Length and Angle Detector H 2 Outrigger Extension Length...

Page 14: ...alve Lever Pedal L 5 Solenoid Valve Boom Telescoping Aux Hoist L 6 475348 L 7 L Solenoid Control Relief Valve Elevating Slow Stop 475349 L 8 Data Adjustment and Checks Hydraulic Pressure Setting Table...

Page 15: ...of Hydraulic Parts Z 4 Location of Electrical Parts Upper Z 5 Location of Electrical Parts Lower Z 6 Location of Electrical Parts Outrigger Operation Option Z 7 Hydraulic Electric Carrier Equipment Co...

Page 16: ...ucture 2 1 1 General view 2 1 2 Inside view 3 1 3 Pump Mounting 11 1 4 Gear ass y 12 Flow Control Valve 1 Structure 14 Rotary Joint 1 Structure 15 2 Potentiometer 21 2 1 Adjustment 21 2 2 Soldering 21...

Page 17: ...ooler 1 Structure 49 2 Air bleeding procedure 49 Jib Lock Pin 1 Structure 50 Jib Offset Cylinder 1 Structure 51 Counterweight Cylinder 1 Structure 52 Pilot Check Valve 1 Structure 53 Check Valve Gauge...

Page 18: ...lve 2 The reducing valve regulates the oil pressure below the specified value the sequence valve regulates it above the specified value 1 5 Flow control valve This valve is installed on the A4 pump ci...

Page 19: ...f the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 1 General view Hydraulic Symbols Symbol Name Size A1 A...

Page 20: ...B 2 B 2 Hydraulic Pump 3 W101 0280E 1 2 Inside view Variable displacement piston pump...

Page 21: ...30 Gear pump 35 Name plate Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf T2 212 282 156 4 208 T3 62 82 45 7 60 5 T4 12 15 8 8 11 T5 28 35 20 6 25 8 T6 56 70 41 3 5...

Page 22: ...el pin 18 Parallel pin 19 O ring 20 O ring 21 O ring 22 O ring 23 O ring 24 Hex socket head bolt 25 Hex socket head bolt 26 Nut 27 Plug 28 Hex socket head bolt 29 Orifice 30 Shim 31 Shim 32 Shim Threa...

Page 23: ...l plate 3 Control plate 5 Plug 6 Hex socket head bolt 7 Parallel pin 8 O ring 9 O ring Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf T1 M16 23 28 17 20 6 Apply THRE...

Page 24: ...E B 2 B 2 Hydraulic Pump 1 Piston 2 Cylinder block 4 Retainer 6 Guide 7 Spring 8 Parallel pin 9 Spring seat 10 C retaining ring 1 Piston 2 Cylinder 3 Cylinder 4 Piston 5 Spring Rotary section 4 Piston...

Page 25: ...8 W101 0280E B 2 B 2 Hydraulic Pump 1 Joint control piston 2 Hanger 3 Metal 4 Orifice Hanger section 6 7...

Page 26: ...al case 4 Shim 5 Bearing 6 Bearing 7 Oil seal 8 C retaining ring 9 O ring 1 Shaft 2 Shim 4 Bearing 5 Bearing 7 Apply the qrease equivalent to MORITON GREASE NO 2 Product by SUMICO to the lip of oil se...

Page 27: ...ide plate 10 Side plate 11 Seal ring 12 Coupling 13 Bush 14 Stud bolt 15 Bearing 16 Square ring 17 18 O ring 19 C retaining ring 20 Plain washer 21 Plug 22 Plain washer 23 Nut 24 Parallel pin 25 O rin...

Page 28: ...of propeller shaft Standard 900 mm 35 4 in Maximum allowance 920 mm 36 2 in Minimum allowance 880 mm 34 6 in Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf Bolt 1 M...

Page 29: ...ence in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations Structure 1...

Page 30: ...ocket plug 16 Snap ring 17 Air bleeder 18 Bushing 19 Elbow 20 Hex socket plug 21 Oil seal 22 Hex socket head bolt 23 Hex socket head bolt 24 Parallel pin Thread size and tightening torque Tightening t...

Page 31: ...ake sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW114 0130E01 PA PB T IW114 0130E03 7 4 2 1 3...

Page 32: ...THREE BOND 4101 Do not apply grease Apply grease EP2 Fill the clearance with grease at assembly Apply thread locking compound equivalent to THREE BOND 1401 Apply waterproof sealant to the whole perip...

Page 33: ...B 4 B 4 Rotary Joint 16 W181 0300E 27 GR2 11 GR1 Tap for slinging 2 places M10 IW181 0300E02 FRONT AC2 P4 P3 AC1 P2 P1 P2 11 DR T2 T1 T T W2 W1 19 A Upper view A Lower view B...

Page 34: ...5 1 M8 23 28 17 20 1 Apply thread locking agent equivalent to THREE BOND 1401 to the threaded sections Hydraulic section Tightening torque Thread Thread size N m ft lbf Upper P1 Winch Lower G1 196 145...

Page 35: ...05 NOTICE On the following serial No the connecting structure of the potentiometer 20 and the shaft 1 and number of brush are partially different from the illustration IW181 0290E03 TT 800XXL 1 475326...

Page 36: ...15 Base 16 Dry lock nut 17 Coned disc spring 18 Guide 19 O ring 20 Potentiometer 21 Cover 22 Packing 23 Lever 24 Pin 25 Guide 26 Air breather 27 Hose joint 28 Hose band 29 Hex socket set screw 30 Mac...

Page 37: ...2 6 5 3 2 3 4 1CC 4 3 1DD 1 2 1AA 2 1 1BB 12 6 12 13 5 13 14 4 614 8 3 8 9 2 9 10 1 10 27 12 627 28 11 628 29 10 629 30 630 20 21 7 21 22 6 22 4 24 5 15 4 615 16 3 16 18 2 618 19 1 19 3 2 1 6 5 4 3 2...

Page 38: ...p mark Slip ring assy 3 Turn the potentiometer shaft using a slotted screwdriver so that the resistance between the upper terminals 1 and 2 is minimum between 1 ohm and 15 ohm Leave the terminals 6 pi...

Page 39: ...inch NOTICE There is a case that the appearance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the seria...

Page 40: ...vating Telescoping Winch 23 W134 0270E C1 C2 Vent down down extending lowering Aux winch up Main winch up Telescoping retracting Elevating raising a3 a4 b3 b4 C3 B1 B2 B3 B4 T2 A1 A2 A3 A4 P2 T1 a1 a2...

Page 41: ...alve Elevating Telescoping Winch 24 W134 0270E Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf C1 C2 C3 a1 a2 a3 a4 b1 b2 b3 b4 Vent G1 4 29 4 22 A3 B3 A4 B4 G3 4 167...

Page 42: ...B 5 B 5 Hydraulic Pilot Control Valve Elevating Telescoping Winch 25 W134 0270E B A B A 14 13 IW134 011012 Aux winch Main winch Telescoping Elevating Cross section of whole body...

Page 43: ...B 5 B 5 Hydraulic Pilot Control Valve Elevating Telescoping Winch 26 W134 0270E C D E F G C D E F G 1 2 3 4 7 16 12 8 12 9 A A Aux winch Main winch Telescoping Elevating IW134 0270E03...

Page 44: ...2 Telescoping selector valve 3 Elevating selector valve 4 End cover 5 O ring 6 O ring 7 Hex socket head bolt 8Main relief valve 9 Main relief valve 12 Hex socket head bolt 13 Plug 14 O ring 15 Plug 1...

Page 45: ...nch 28 W134 0270E IW134 0270E04 29 30 6 2 4 20 19 21 22 1 25 24 23 13 18 17 15 28 27 26 28 14 7 11 10 9 8 12 23 24 25 16 17 Overload relief valve C C Aux winch D D Main winch IW134 0110E07 18 17 15 28...

Page 46: ...k valve 20 Spring check valve 21 Plug check valve 22 O ring 23 Hex socket head bolt 24 Plain washer 25 Spring washer 26 Plug 27 O ring 28 Plug 29 Steel ball 30 Hex socket set screw Thread size and tig...

Page 47: ...uttle valve 16 O ring 17 Orifice 18 Spring flow control valve 19 Plug 20 O ring 21 Check valve 22 Spring check valve 23 Plug check valve 24 O ring 25 Hex socket head bolt 26 Plain washer 27 Spring was...

Page 48: ...Spool end 12 Pilot cover 13 Pilot cover 14 Orifice 15 Spring flow control valve 16 Plug 17 O ring 18 Plug 19 O ring 20 Hex socket head bolt 21 Plain washer 22 Spring washer 23 Plug Thread size and ti...

Page 49: ...O ring 7 Packing 8 Body 9 O ring 10 Cap nut 11 Adjust screw 12 O ring 13 Nut 14 Body 15 Spring 16 Valve 17 Valve seat 18 O ring 19 Seal lead 20 Tie up wire Thread size and tightening torque Tightening...

Page 50: ...6 O ring 7 O ring 8 Body 9 Valve 10 Spring 11 Adjust screw 12 O ring 13 Nut 14 Cap nut 15 Tie up wire 16 Seal lead Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf 1 1...

Page 51: ...is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling o...

Page 52: ...ening torque Tightening torque Thread Thread size N m ft lbf 1 M24 1 5 58 8 68 6 43 4 50 6 1 Body 2 Filter 3 Filter retainer 4 Back pressure regulating valve 5 Pressure reducing valve 6 Hex socket hea...

Page 53: ...7 11 10 8 6 3 5 12 2 13 9 1 4 1 Body 2 Spool 3 O ring 4 Plug 5 Spring seat 6 Spring 7 Adjust screw 8 Body 9 O ring 10 Nut 11 Cap nut 12 O ring 13 O ring Pressure reducing valve illustrated as 5 in the...

Page 54: ...mbly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 T2 4 2 T1 3 T A2 A1 P IW121...

Page 55: ...disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW121 067001 A2 T P A...

Page 56: ...61 801 802 326 324 P A T 311 Spool 312 Sleeve 324 Spring 326 Retaining ring 361 O ring 362 O ring 363 O ring 801 Solenoid valve 802 Seal nut 861 O ring Thread size and tightening torque Tightening tor...

Page 57: ...case that the appearance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machin...

Page 58: ...W112 0240E 18 Name plate 21 Tigh rod 27 Plug 29 Hex socket head bolt 31 Nut 32 Ribbet screw 33 Ball 38 O ring Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf P T G1...

Page 59: ...03 16 6 35 35 28 28 34 19 38 23 27 33 25 44 35 33 33 37 8 9 35 33 16 34 19 38 27 23 20 22 7 8 A A 6 Collar 7 Spring folder 8 Plug 9 Spring 16 Solenoid 19 Body 20 Spring 22 Spring 23 Filter 25 Spool en...

Page 60: ...B 9 B 9 Solenoid Control Valve Jib Set and Counterweight Cylinder 43 W112 0240E B B IW112 0240E03 14 35 14 24 17 43 15 35 14 Spool 15 Housing 17 Housing plunger 24 Housing 35 O ring 43 O ring...

Page 61: ...B 9 B 9 Solenoid Control Valve Jib Set and Counterweight Cylinder 44 W112 0240E IW112 0220E05 P T C C IW112 0220E06 D D C O...

Page 62: ...t Cylinder 45 W112 0240E IW112 0220E07 42 12 2 41 1 40 10 4 30 3 36 5 13 11 39 1 Spring 2 Needle valve 3 Nut 4 Gasket 5 Spring 10 Housing 11 Sleeve 12 Sleeve 13 Poppet 30 Screw 36 O ring 39 O ring 40...

Page 63: ...ke sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure B A D C IW115 027001 B D C A IW115 027002 7 6 5...

Page 64: ...tions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure a e b f P A...

Page 65: ...T2 T1 3 1 Body 2 Plug 3 Spool 7 Spring seat 8 Square ring 9 O ring 11 Spring 12 Solenoid DC24V 15 Hex socket head bolt Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf...

Page 66: ...A B IW102 012001 1 Front case 2 Rear case 3 Shaft 4 Cylinder block 5 Piston retainer 7 Spherical retainer 8 Spherical pin 10 Collar 12 Spring 13 Straight key 14 Plain washer 16 Oil seal 17 Needle bea...

Page 67: ...es unit described in the parts catalog before starting disassembling operations 1 Structure 1 Spring pin 2 plate 3 Plain bearing 4 Ring seal 5 O ring 6 Piston 7 Cylinder 8 Rod 9 Rod cover 10 Plain bea...

Page 68: ...of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 Cylinder 2 Split pin 3 Nut 4 Piston 5 Plain bearing 6 O ring 7 Rod 8 Rod c...

Page 69: ...r of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW180 0040E01 1 2 3 4 5 6 7 8 9 10 1 2 11 15 12 13 14 1 Cylinder 2 Split p...

Page 70: ...ial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 10 9 8 11 C A B D 7 5 6 4 1 2 12 3 IW115 004002 1 Body 2 O ring 3...

Page 71: ...the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure P3 P2 P1 S P IW116 012001 1 P1 P2 P3 S 8 2 5 4 3 6 7 IW11...

Page 72: ...4 Select valve dolly 1 2 Swing slow stop 1 2 1 Condition for slow stop 1 2 2 Control element 1 Swing Ass y 1 Structure 2 2 Swing bearing mounting bolt 3 2 1 Bearing Inner ring bolts 3 2 2 Bearing oute...

Page 73: ...tor be free so that the boom can follow the movements of the dolly while travelling 2 Swing slow stop 2 1 Condition for slow stop Slow stop function is activated when the crane is in the condition mar...

Page 74: ...tions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure NOTICE Apply...

Page 75: ...facing the front of the carrier Apply torque control agent to the threaded sections of the bolts Install the plain washer orienting its chamfer on the internal periphery as shown below Thread size an...

Page 76: ...s of the bolts Install the plain washer orienting its chamfer on the internal periphery as shown below Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf 1 42 points 2 3...

Page 77: ...case that the appearance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machi...

Page 78: ...Control Valve Swing 6 W134 0121E Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf P R G1 200 240 145 174 AM BM G3 4 150 180 108 130 G Pa Pb Pa Pb Pi1 Pi2 G1 4 34 38 25...

Page 79: ...ve Swing 7 W134 0121E A B A B AM RV BM Dr G P RB RA Sol 1 Sol 4 Pi2 Pa Pi1 Pb Sol 3 Sol 2 706 253 263 702 703 351 152 701 701 151 352 353 IW134 012003 AM RV BM Dr G P Sol 1 Sol 4 IW134 012007 Cross se...

Page 80: ...D 3 D 3 Hydraulic Pilot Control Valve Swing 8 W134 0121E C C Dr P R G C2 C1 152 414 413 401 450 412 411 415 151 IW134 012004 A A Cross section along the line A A...

Page 81: ...D 3 D 3 Hydraulic Pilot Control Valve Swing 9 W134 0121E AM RA CA2 152 644 643 642 641 661 IW134 012005 B B Cross section along the line B B...

Page 82: ...BM CB1 CA1 AM Pi1 Pb Sol 2 Sol 3 Pi2 231 211 212 234 235 C C 561 511 521 551 101 251 512 522 562 552 241 251 252 221 252 152 201 243 242 222 261 261 Pa IW134 012006 Pi1 Pb Sol 2 Sol 3 Pi2 Pa IW134 01...

Page 83: ...1 Cap 552 Plug 561 O ring 562 O ring 641 Spring seat 642 Spring 643 Steel ball 644 Seat 661 O ring 701 Relief valve 702 Solenoid relief valve 703 Relief valve 706 Solenoid valve DC24V Thread size and...

Page 84: ...n functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure PB DR...

Page 85: ...401 Hex socket head bolt 432 Stop ring 433 Stop ring 437 Iocking ring 438 Iocking ring 443 Roller bearing 444 Roller bearing 451 Spring pin 464 Plug 471 O ring 472 O ring 485 O ring 491 Oil seal 702 B...

Page 86: ...machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before st...

Page 87: ...US 3 8 L Do not disassemble the king pins 8 27 nor spacer 13 1 Spur gear 2 Retainer 3 Roller bearing 4 Casing 5 Oil seal 6 Ball bearing 7 Plug 8 King pin 9 Carrier 10 Bearing washer 11 Needle bearing...

Page 88: ...ber of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 Valve body 3 Ball 8 Valve seat 10 Valve stem 14 Retainer 21 Pointer 26...

Page 89: ...1 1 2 Counterbalance valve 1 1 3 Select valve dolly 1 Elevating Cylinder 1 Structure 2 Counterbalance Valve Elevating 1 Structure 4 2 Function 6 2 1 When control valve is at the neutral position 6 2...

Page 90: ...n rod from pushed in by the load during boom lowering to maintain the lowering speed at a level determined by the oil entry flow rate to the cylinder 2 It also prevent the retraction of the piston rod...

Page 91: ...Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting...

Page 92: ...asher 18 Bolt 19 Support 20 Fitting 21 O ring 22 Fitiing 23 O ring 24 Pipe 25 Pipe 26 T fitting 27 Pipe 28 Clamp ass y 29 Sleeve 30 Bolt 31 Spring washer 32 Counterbalance valve ass y 33 Fitting 34 O...

Page 93: ...e starting disassembling operations 1 Structure IW119 021001 B A P P B P P A 7 6 5 4 2 6 2 5 2 3 2 4 2 9 2 10 2 11 2 12 2 13 2 14 2 2 2 1 2 16 2 15 1 2 8 3 7 3 8 3 6 3 5 3 4 3 3 3 1 3 2 2 7 IW119 0210...

Page 94: ...ce Valve Elevating Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf A G3 4 167 123 P P G3 8 49 36 2 1 177 196 130 145 2 15 127 147 94 108 3 1 108 127 80 94 3 7 59 78 4...

Page 95: ...oil entering through port A of the control valve enters chamber C flows out through port B by opening the check valve and enters the holding side of the actuator 2 At this time since port PP is connec...

Page 96: ...log before starting disassembling operations 1 Structure 1 Valve body 2 Cover 3 Ball 9 Valve seat 10 Valve stem 13 Adapter 21 Pointer 26 Lever 40 Support 46 A Name plate 46 B Name plate 46 C Name plat...

Page 97: ...hoist 1 Winch 1 Structure 2 Hydraulic Motor Winch 1 Structure 4 2 Air bleeding procedure 6 Counterbalance Valve Winch 1 Structure 7 2 Function 8 2 1 Balancing and holding functions 8 2 2 Overload rel...

Page 98: ...e to quick switching of the winch operation selector valve the overload relief valve opens to let the pressure escape to the tank in order to prevent damage 1 3 Hydraulic valve 1 Selects applying or r...

Page 99: ...is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling op...

Page 100: ...1 1 gal 4 L Do not disassemble the sleeve 41 1 Bracket 3 Bolt 4 Spring washer 5 Oil seal 7 Bearing retainer 8 Ball bearing 9 Nut 10 Washer 11 Collar 12 Bolt 13 Spring washer 14 Drum gear 15 Collar 16...

Page 101: ...ce in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure Th...

Page 102: ...4 101 403 443 106 431 113 124 301 444 402 472 703 710 741 742 720 706 404 702 707 471 122 123 121 114 485 464 111 131 697 451 303 401 761 762 463 432 705 701 473 476 IW102 013003 A 720 773 771 772 A I...

Page 103: ...ing 472 O ring 473 O ring 476 O ring 485 O ring 491 Oil seal 697 O ring 701 Brake cover 702 Brake piston 703 Coupling 705 Brake spring 706 O ring 707 O ring 710 Brake shim 720 Brake casing 741 Separat...

Page 104: ...isassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW119 0500E01 B1 A1 B A...

Page 105: ...g torque Tightening torque Thread Thread size N m ft lbf 151 152 G3 8 69 79 51 58 171 M12 64 74 47 54 252 G1 4 34 38 25 28 253 G1 4 34 38 25 28 256 M10 14 18 10 13 271 273 M12 88 108 65 80 551 M33 181...

Page 106: ...alve 3 3 Hoisting down 1 As oil is sent to port B by the control valve it flows to the motor via port B1 2 The return oil from the motor is blocked at port A1 to raise the pressure at port B 3 This pr...

Page 107: ...e and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure IW123 020001 B1 P1 P2 Dr AC B2 T IW123 020002 B1 B2 T 4 10 2 6 7 5 2 3 8 1 P1 P2 Dr AC 9 T...

Page 108: ...plate 11 3 3 Sheave 11 3 4 Boom telescoping wire rope 11 4 Reassembly 11 4 1 Greasing 11 4 2 Install anti buckling bolts for telescoping cylinder 11 4 3 Installing lower slide plates 12 4 4 Installing...

Page 109: ...ol valve is at the neutral position 23 2 2 While actuator is being pushed up 23 2 3 While actuator descends 23 Hose Reel 1 Structure 24 2 Dismounting 25 3 Mounting 25 4 Disassembly 25 5 Reassembly 25...

Page 110: ...to the telescoping cylinder and serves to prevent the cylinder from retracting while the control lever is in NEUTRAL to prevent the cylinder from being driven by the load during retraction and to prev...

Page 111: ...pump to the selector valve 2 The pressurized oil is sent to the No 1 telescoping cylinder making the 2nd boom section extend 3 After the 2nd boom section is fully extended press the next section exten...

Page 112: ...nd top boom sections retract by the wire rope mechanism 4 When the No 2 telescoping cylinder is almost fully retracted the boom full retraction detector switch is activated and disestablishes the sole...

Page 113: ...the appearance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the...

Page 114: ...5 G 2 G 2 Boom Five Section Boom 5 W536 0760E G 2...

Page 115: ...4 Guide 85 Bolt 86 Spring washer 87 Plain washer 88 Support 89 Guide 90 Pin 91 Bolt 92 Pin 93 Pin 94 Sheave ass y 95 Bolt 96 Plate 97 Spacer 98 Spacer 99 Pin 100 Split pin 101 Pin 102 Bolt 103 Bolt 10...

Page 116: ...s 2 pieces and the hose leading to the hose reel from the telescoping cylinder NOTICE To prevent the hose reel from spinning attach a wire to the hose to the pipe sleeve of the hose and secure the wir...

Page 117: ...of the rear end of the 3rd boom section by loosening the bolt 1 and remove the pin and sheave assy by loosening the nut 5 Remove the pin from the rear end of the top boom section by loosening the bolt...

Page 118: ...e rope for 4th boom section extension Hexagon socket head bolt L4 2 Lift up the rear end of the telescoping cylinder slightly using a crane and pull out the connecting pin that connects the 3rd boom s...

Page 119: ...boom section retraction Jig Top boom section IW536 0620E15 4 After removing the retainer on the top of the 4th boom section head and removing the slide plate pull out the top boom section by approx 1...

Page 120: ...e diameter reduction exceeding 7 of the nominal diameter Evidence of any heat damage from any cause 4 Reassembly 4 1 Greasing When installing unplated pins apply grease beforehand Apply TNR 2 Grease s...

Page 121: ...m rear end Place shims so that the total clearance distributed to right and left is 0 5 mm 2 Upper clearance on boom rear end Place shims that the lateral deviation of center is 1 5 mm and vertical de...

Page 122: ...Over right Over left Other conditions Free from solar heat and wind 1 The hook displacement A in sketch under the above test conditions under no load must be brought within 200mm 7 9 in in all boom di...

Page 123: ...4 W537 0101E G 3 Jib 1 Structure 1 1 Location of Jib Model TR 600XL TR 800XXL TT 800XXL Modification No Applicable serial No 1 545430 545419 475327 2 545410 545419 475326 3 545430 545419 475330 4 5454...

Page 124: ...Support ass y 13 Support 14 Plate 15 Bolt 16 Nut 17 Plain washer 18 Support 19 Pin ass y 20 Support 21 Support ass y 22 Support ass y 23 Support ass y 24 Plate 25 End 26 Pin 27 Split pin 28 Plain wash...

Page 125: ...G 3 Jib 16 W537 0101E G 3 1 2 Jib main body Model TR 600XL TR 800XXL TT 800XXL Modification No Applicable serial No 1 545410 545419 475326 2 545410 545419 475326 3 545410 545419 475326 4 545460 545419...

Page 126: ...in ass y 16 Spacer 17 Sheave ass y 18 Plate 19 Pin 20 21 Link 22 Plate 23 Plate 24 Plate 25 Pin 26 Plain washer 27 Split pin 28 Stopper 29 Roller ass y 30 Spacer 31 Pin 32 Bar 33 Pin 34 Split pin 35 P...

Page 127: ...e support and spring pin is 5 mm 0 2 in while the jib 1 supports the jib 2 Jib 1 2 connecting spring pin Jib 1 Jib 2 5mm IW537 0050E04 Support Spring pin 2 2 Adjusting jib inclination In order to faci...

Page 128: ...ove a shim t0 6 mm t0 02 in one by one from the slide plate on the support on the boom rear end until the pin can be inserted and removed easily 3 Add or remove shims t0 6 mm t0 02 in on the support o...

Page 129: ...erence in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structur...

Page 130: ...Plug 2 Spring pin 3 Nut 4 Piston 5 Backup ring 6 Packing 7 Plain bearing 8 O ring 9 Cylinder 10 Rod 11 O ring 12 Rod cover ass y 13 Support 14 Damper ring 15 Packing 16 Backup ring 17 Plain bearing 18...

Page 131: ...scribed in the parts catalog before starting disassembling operations 1 Structure B A C IW119 022001 IW119 022002 6 5 4 10 9 1 8 12 11 3 2 7 20 14 13 15 16 17 19 18 B C A M 1 Body 2 O ring 3 Backup ri...

Page 132: ...d oil entering through port A of the control valve enters chamber C flows out through port B by opening the check valve and enters the holding side of the actuator 2 At this time since port PP is conn...

Page 133: ...machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 1 Drum plate 2 Drum plate 3 Seat packing 4 Spring case 5 Spring 6 Aux spring 7 Spec...

Page 134: ...spring case 3 After attaching protection plates as shown utilizing the case mounting holes to prevent spring from hurtling out unscrew special bolt on the pin side and extract pin 4 To replace spring...

Page 135: ...to spring case with special bolt coated with screw locking compound 6 After installation apply water repllant compound to nut 7 Remove the remaining vice pliers 3 Temporarily install drum plate to spr...

Page 136: ...difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Stru...

Page 137: ...5 3 1 7 10 17 3 15 2 10 1 Body 2 Spool 3 Cover 6 Solenoid valve 7 Spring 10 O ring 15 Hex socket head bolt 17 Plug 19 Orifice Thread size and tightening torque Tightening torque Thread Thread size N m...

Page 138: ...cription of system 1 Boom Length and Angle Detector 1 Structure and function 2 2 Disassembly and reassembly 4 2 1 Removing the cord 4 2 2 Installing the cord 4 2 3 Replacing spiral spring 6 2 4 Disass...

Page 139: ...Moment limiter AML L main body 1 The moment limiter maln body calculates the moment being generated on the crane based on signals from the pressure sensor and the Boom length angle detector 2 The cal...

Page 140: ...turn rotates the shaft of the potentiometer 3 The electric resistance of the potentiometer shaft varies proportional to the reduction of the shaft rotation and the change in electric resistance is tra...

Page 141: ...18 Clip 19 Clip 20 Support 21 Cord guide 22 Collar 23 Packing 24 Packing 25 Packing 26 Connector 27 Connector 28 Cord lock 29 Screw 30 Pin terminal 31 Pin terminal 32 Nut 33 Washer 34 Screw 35 Bolt 3...

Page 142: ...ly NOTICE Put match marks on the case and the plate to identify the direction for removing the sub cord IW305 0230E03 Retaining ring Plate Match marks Sub cord Case Bolt 6 Remove the nut and separate...

Page 143: ...he potentiometer side to allow both gears to idle Check that the gear is spring returned to the original position after it is rotated a quarter turn by finger and released If it is not returned loosen...

Page 144: ...g is broken replace the whole drum assy For removing and installing the spring refer to the Removing the cord and Installing the cord above mentioned 2 4 Disassembling the potentiometer for boom lengt...

Page 145: ...it is rotated a quarter turn by finger and released If it is not returned loosen the bolt and adjust the position of the bracket IW305 0230E15 Bracket Spring Bolt Gear B Gear A 3 Fix the gear in the...

Page 146: ...ction of the spiral spring as the cylinder extends or retracts 3 The consequent rotation of the drum drives the potentiometer shaft through gears which reduce the speed to 5 6 4 The rotation of the sh...

Page 147: ...Move the entangling prevention fitting to the zero point mark of the wire yellow tape position and fix it And wind up the wire to the drum up to the zero point mark position NOTICE If the entire wire...

Page 148: ...ength to the terminal of the wire Drum side IW305 0251E10 L3 L4 Zero marker yellow tape Aux string Approx 1m 3 3ft L3 3 24 m 10 63ft L4 0 08m 0 26ft 2 Wind the wire round drum assembly until the yello...

Page 149: ...placing the potentiometer with a new one mount it onto the bracket then solder the cable to the potentiometer terminal NOTICE Finish soldering the wire to the potentiometer terminal as quick as possib...

Page 150: ...procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure T1 8 1 5 6 3 2 7 4 IW121 0540E03 T...

Page 151: ...P IW121 0540E04 T1 T2 Thread size and tightening torque Tightening torque Thread Thread size N m ft lbf 2 44 49 32 36 T1 39 49 29 36 T2 4 4 5 4 3 4 Solenoid valve ass y 1 366 460 80000 1 Body 2 Plug...

Page 152: ...c circuit 19 8 2 Main harness A 20 8 3 Main harness B 21 9 Important points for assembly Layout 22 9 1 Evacuation 22 9 2 Charging with refrigerant 22 9 3 Check for gas leakage and amount of refrigeran...

Page 153: ...14 Control table 47 Hydraulic Motor Air Conditioner Option 475327 1 Structure 48 Hydraulic Motor Air Conditioner Option 475328 1 Structure 49 Solenoid Valve Air Conditioner Option 475354 1 Structure...

Page 154: ...er than the glass bonding surfaces should be immediately wiped away with a cloth soaked with white gasoline 5 Apply a 5 to 20 m 0 0002 to 0 0008 inch thick coat of primer C to the glass bonding surfac...

Page 155: ...m air bubbles Excess adhesive must be wiped away with a spatula and white gasoline 14 Set and press the new glass against the cab while aligning the marks masking tape pieces put in Step 3 on the glas...

Page 156: ...machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Component parts 1 Air conditioner assembly 2 Box assembly 3 Air distributor 4 Harness 5 Drain...

Page 157: ...eat evaporation heat The substance surrounding the liquid is cooled as heat is absorbed from it 2 This natural phenomenon explains in brief the principle of the air conditioning that is used when we n...

Page 158: ...component absorbs the gaseous refrigerant that was vaporized in the evaporator and compresses it to higher pressure so that it can be more easily liquefied in the condenser 3 Condenser In this compon...

Page 159: ...to create a refrigerant mist This allows the refrigerant to vaporize easily 4 In the evaporator the refrigerant mist absorbs heat from the cab and vaporizes rapidly By the time it reaches the evaporat...

Page 160: ...e pressure is reduced so that the refrigerant evaporates at 5 C 23 F the evaporator is also maintained at 5 C 23 F This results in the formation of frost which inhibits the flow of air through the eva...

Page 161: ...this cycle has an expansion valve with a different construction and adds a receiver 3 To increase the cooling capacity of an air conditioner the largest possible amount of refrigerant must be vaporiz...

Page 162: ...refrigerant can be supplied as needed to the evaporator according to the cooling load 2 Inside the receiver is a strainer and a desiccant which remove dust and moisture from the cooling cycle If mois...

Page 163: ...s time is the reheat method IW701 0110E10 Reheating type Flow regulator Evaporator Heater core 2 With this method the temperature is controlled by changing the opening of a water valve that is attache...

Page 164: ...ply 8 11 12 Hot Cool 10 IW701 0160E14 Switches 1 Power switch 2 Air conditioner switch 3 Inside outside air selector switch 4 Air flow switches 5 Temperature control switches 6 Air outlet changeover s...

Page 165: ...pply changes between outside cab air supply and air circulation inside cab repeatedly The current air supply is shown on the display Air flow switches These switches are used to select air flow volume...

Page 166: ...13 13 W701 0160E K 2 K 2 Air Conditioner K 2 4 Layout 4 1 Overall layout...

Page 167: ...14 14 W701 0160E K 2 K 2 Air Conditioner K 2 4 2 Overall layout...

Page 168: ...15 15 W701 0160E K 2 K 2 Air Conditioner K 2 4 3 Evaporator section...

Page 169: ...16 W701 0160E K 2 K 2 Air Conditioner 5 Compressor ass y...

Page 170: ...17 17 W701 0160E K 2 K 2 Air Conditioner K 2 6 Evaporator ass y...

Page 171: ...18 18 W701 0160E K 2 K 2 Air Conditioner K 2 7 Condenser ass y...

Page 172: ...19 19 W701 0160E K 2 K 2 Air Conditioner K 2 8 Electric 8 1 Electric circuit 0 363 205 60030...

Page 173: ...20 20 W701 0160E K 2 K 2 Air Conditioner K 2 8 2 Main harness A...

Page 174: ...21 21 W701 0160E K 2 K 2 Air Conditioner K 2 8 3 Main harness B...

Page 175: ...s or longer and then check that there are no abnormal gauge readings pressure increases 9 2 Charging with refrigerant NOTICE Never inject liquid refrigerant from the low pressure side regardless of wh...

Page 176: ...en connecting the heated water piping be careful not to incorrectly assemble the IN and OUT piping 2 In order to prevent damage resulting from freezing of the water inside the heated water circuit in...

Page 177: ...K 2 K 2 Air Conditioner 24 W701 0160E 10 How to charge air conditioner gas 10 1 Charging gas in automatic operation Gas charging unit Reference...

Page 178: ...SO Make sure to check surroundings 9 Turn OFF the power switch when the gas disappears from the remainder gas sight glass of the main unit 10 Check the air conditioning capability Temperature control...

Page 179: ...h when the gas disappears from the remainder gas sight glass of the main unit Be careful to the scaffold 9 Detach the empty gas can and attach another gas can Be careful that gas liquor does not splas...

Page 180: ...d purge pressure in the hose 1 Set the timer knob to the vacuum side 2 Set the power switch to the automatic or manual 3 Turn OFF the power switch when the high low pressure gauge indicates approx 0 p...

Page 181: ...aximum 2 The heater stops by setting to OFF Must be a warm blow Must be a natural blow 4 1 The blower stops by setting to OFF 2 LO Low ME Medium and HI High There must be a change in three levels 5 Mo...

Page 182: ...its Much air contaminates in refrigeration circuit Deflate from circuit and fill refrigerant Replace receiver drier R D Dirt or blocking in condenser fin Wash condenser Insufficient cooling Pressure a...

Page 183: ...ower electric circuit or blower motor failure Check and repair circuit or replace No cooling High pressure is low and low pressure is high High pressure side and low pressure side will be balanced aft...

Page 184: ...porator case Seal with repair tape or packing agent Air volume is small from the beginning Evaporator frost formation Gas leakage from joint of heater unit and evaporator unit Affix packing again Insu...

Page 185: ...one with large sound Something is heard from blower motor fan relation Foreign object intrusion in fan case Remove foreign object Refrigerant gas sound sound Goooo is heard Gas vibration sound flow s...

Page 186: ...place condenser fan motor Vehicle overheats easily Condenser unit Condenser is set in front of radiator High pressure is high High pressure is high at idling Same cause as refrigeration circuit system...

Page 187: ...tch does not suck Check voltage of clutch relay connector Approx 12V Either of clutch relay or clutch power circuit disconnection is failure Check parts and repair or replace parts Clutch does not suc...

Page 188: ...and confirmation Diagnosis result phenomenon of principal cause Possible cause Measures specific part name and repair method Measure clutch suction voltage Clutch suction voltage is low 7V or less Re...

Page 189: ...stor failure Replace thermistor Check thermo volume Measure resistance of thermo volume terminal Resistance is infinity Thermo volume is disconnected Replace thermo volume Compressor clutch stayed OFF...

Page 190: ...ement and connector repair Replaces thermistor with new one Insufficient cooling status does not change Thermo amp internal failure Replace thermo amp Positioned correctly Thermistor failure Replace t...

Page 191: ...s of bolts and screws Too much belt tension D hose pulsation or shaking When clutch OFF Clutch bearing failure Contact and slippage by airgap failure Idle pulley bearing failure Deflection or too much...

Page 192: ...of blower motor is few Appearance dirt Clutch seizure Amateur and rotor clearance failure airgap failure Core disconnection or short circuit Shaft does not rotate internal lock Compressor cylinder doe...

Page 193: ...ystem diagnosis table II Repair Note 1 Do not judge dirt around the clutch and gasket to be a leakage Some blot of oil will be seen due to the sealing mechanism Oil blot will not cause any problem in...

Page 194: ...re When setting temperature is COOL MAX and blowout mode is Vent mode is air mix dumper a position of cool max When operation of M A stops halfway correct foreign object caught etc of the link Turn ON...

Page 195: ...troubles Check and repair or replace When operation of M A stops halfway correct foreign object caught etc of the link Check warm water piping Replace Check and repair M A lever link section or replac...

Page 196: ...wire and red wire of blower motor relay are connected directly Note 2 Is there a voltage of approx 10V between blue black wire and ground line Replace controller Is there a conduct between blue black...

Page 197: ...Clutch failure and replace compressor Is there voltage between ground wire black and blue red wire of air conditioner harness connector connected with vehicle Pressure switch failure or refrigerant h...

Page 198: ...outside air mode indicator in operation panel LCD blinking Is any foreign object adhering to M A lever Or has M A lever been damaged Inside and outside air M A connector disconnection or contact fail...

Page 199: ...onnection or contact failure or M A failure or main harness failure Correct Are levers of dumpers installed properly Check or replace Correct After removing rod is it heavy to move cam manually Replac...

Page 200: ...perature 6 10 42 8 50 F Timer cancellation temperature 6 12 42 8 53 6 F Count up time 10 1 minutes Timer reset temperature 7 13 44 6 55 4 F Note 3 When compressor clutch is never turned ON after power...

Page 201: ...d the part sales unit described in the parts catalog before starting disassembling operations 1 Structure 2 23 24 IW102 026001 18 26 19 3 1 7 6 25 13 14 11 16 22 17 15 20 4 5 8 9 10 12 1 Housing 2 End...

Page 202: ...earance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sa...

Page 203: ...rive shaft 3 Pintle 4 Cylinder block 5 Piston 6 Piston ring 7 Pistonring retainer 8 Tapered roller bearing 9 Tapered roller bearing 10 Timing pin 11 Timing ring 12 Oil seal 13 O ring 14 Hex socket hea...

Page 204: ...difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Stru...

Page 205: ...8 7 11 2 T2 T1 3 1 Body 2 Plug 3 Spool 7 Spring seat 8 Square ring 9 O ring 11 Spring 12 Solenoid DC24V 15 Hex socket head bolt Thread size and tightening torque Tightening torque Thread Thread size N...

Page 206: ...so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operatio...

Page 207: ...4 T2 T1 21 1 Body 4 Plug 9 O ring 15 Hex socket head bolt 21 Spool 60 Spring seat 71 Spring 113 Square ring 156 O ring 157 Solenoid DC24V 159 O ring Thread size and tightening torque Tightening torque...

Page 208: ...alve Pedal 475341 1 Structure 6 Remote Control Valve Pedal 475342 1 Structure 8 Shuttle Valve Lever Pedal 1 Structure 11 Solenoid Valve Boom Telescoping Aux Hoist 1 Structure 12 Solenoid Control Relie...

Page 209: ...witch Front washer switch Swing free lock selector switch Boom telescoping auxiliary hoist control selector switch Telescoping mode I II switch Oil reservoir Load moment indicator AML LK Winch selecto...

Page 210: ...tch Roof washer switch Roof wiper switch Flood lamp switch Drum indicator switch option Oil cooler switch Outrigger state emergency register switch Outrigger state emergency register indicator lamp Ji...

Page 211: ...or this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog b...

Page 212: ...ng 111 Port plate 122 O ring 123 O ring 125 Hex socket head bolt 131 Bush 161 Plug 171 Bolt 172 Nut 201 Spool 211 Plug 212 Push rod 213 Seal 214 O ring 215 Washer 216 Spring seat 217 Washer 221 Spring...

Page 213: ...Thread Thread size N m ft lbf P T G1 4 34 38 25 28 PORTS 1 2 3 4 G1 4 34 38 25 28 125 M8 27 31 20 23 161 R1 4 20 24 14 17 172 M8 16 18 12 13 411 M12 27 31 20 23 445 M8 27 31 20 23 454 1 M8 16 18 12 1...

Page 214: ...ce and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and the part sales u...

Page 215: ...lve 9 Filter 10 Spring 11 Plug 12 O ring 13 Shim 14 Spring 15 Retainer 16 Boot 17 Plate 18 Bolt 19 Piston 20 O ring 21 Plate 22 Collar 23 Seal 24 Lever 25 Ring 26 Plate Thread size and tightening torq...

Page 216: ...unctions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure T P 1 2 I...

Page 217: ...Casing 103 Casing 115 Plate 201 Cover 202 Plug 210 Seal 212 O ring 214 Push rod 217 Shim 251 RO plug 261 O ring 262 O ring 263 O ring 271 Hex Socket head bolt 272 Hex Socket head bolt 273 Nut 301 Spoo...

Page 218: ...Thread Thread size N m ft lbf 272 M8 19 1 22 1 14 1 16 3 271 M6 8 7 8 9 6 4 6 6 251 G1 4 27 4 31 4 20 2 23 2 315 M12 56 3 61 3 41 5 45 2 5 9 7 9 4 4 5 8 472 M6 Apply LOCTITE 241 473 M8 15 2 18 2 11 2...

Page 219: ...sembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure c d a b e f IW128 011001 c...

Page 220: ...t the appearance and so on differ from the parts for this machine Although there is not so much difference in functions and disassembly procedures make sure of the serial number of this machine and th...

Page 221: ...the threaded section of the seat 1 1 Seat 2 Spring 3 Body 4 Spool 5 Solenoid DC24V 7 Sleeve 8 Stopper 10 Hex socket head bolt 11 Plain washer 13 Steel ball 14 Steel ball 15 O ring 16 Plug Thread size...

Page 222: ...and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure A2 P2 P1 A1 T T1...

Page 223: ...tions and disassembly procedures make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations 1 Structure T1 IW136 025...

Page 224: ...11 Spool 312 Sleeve 324 Spring 325 C ring 326 Retaining ring 331 Spring seat 351 Orifice 361 O ring 362 O ring 363 O ring 801 Proportional reducing valve 802 Seal nut 861 O ring Thread size and tighte...

Page 225: ...witch Adjustment 1 3rd top boom full retraction detection limit switch L7 6 2 2nd boom full retraction detection limit switch L8 6 3 Jib stowed detection proximity switch CS10 6 4 Jib lock pin retract...

Page 226: ...ergency 11 5 Upper outrigger operation option It becomes possible when connecting PTO and becoming the crane work possible 11 6 Alarms 12 7 Adjustment procedure of front jack overload detector switch...

Page 227: ...Hydraulic Pressure Setting Table 1 WY02 0320E 1 Y 1 Y 1 Y 1 Hydraulic Pressure Setting Table 1 345 801 01500...

Page 228: ...eeder plug and remove the hose joint of L1 shown above with the engine stopped When oil begins to flow through the air bleeder plug hole tighten the air bleeder plug and the hose joint of L1 3 Before...

Page 229: ...ss y accelerator on the carrier frame AC2 Bleeding plug Bleeding plug Top view of rotary joint AC1 Bleeding plug IWY05 0740E02 3 Swing circuit 3 1 Swing motor Bleed the swing motor by following either...

Page 230: ...he air bleeder screw 4 3 Winch brake release circuit Repeat the slow hoist up and slow hoist down operations with the engine idling until no more air bubbles come out of the air bleeder screw 5 Jib lo...

Page 231: ...raulic oil temperature to 50 o C 122 o F or higher set the PTO switch to ON let the engine idle and move the boom telescoping control lever fully to the retraction side Keep the above conditions for 2...

Page 232: ...2 2nd boom full retraction detection limit switch L8 Adjust the switch position so that its contact is shifted opened closed when the 2nd boom section is extended retracted beyond theposition where it...

Page 233: ...nch drum rotation proximity switch CS13 option Adjust the switch position so that the dimension A becomes 2 3 mm 0 08 0 12 in 1 Apply the screw locking agent Three Bond 1401 or the equivalent 6 Aux wi...

Page 234: ...ow tilt the lever stand by the angle of 16 Squeeze the switch upward and secure it temporarily where its contact is shifted opened closed Then lower the switch by 1 mm 0 039 in from the temporary secu...

Page 235: ...on G is within 8 mm 0 32 in when inserting the counterweight mounting pin extending the counterweight cylinder and lowering the counterweight Also confirm the switch is turned ON Apply thread locking...

Page 236: ...24 Plate 1 Switch 2 CS25 Carrier frame IWY04 0490E05 13 Front jack full retraction detection switch S087 1 Adjust the switch position so that the dimension A becomes 1 5 2 mm 0 06 0 08 in Apply the sc...

Page 237: ...cative symbol on the AML is not hightlight in this situation 3 Extended the front jack again Continue extending operation for more than 4 seconds after the jack float touches the ground Make sure that...

Page 238: ...arm is not necessary because it is output only when the front jack is overloaded A Swing brake lever position detection buzzer Actuate the P T O and turn OFF the swing brake switch on right side of AM...

Page 239: ...the lock nut so that the adjusting screw should not turn 4 Mark the adjusting screw with while point for identification Remove a cap Front jack overload detector switch Lock nut Adjustment screw FRONT...

Page 240: ...er as shown in the above detail drawing Pull the return spring about 10 mm 0 394 in and fix the link to the idling position Connect the connector of potentiometer and measure the voltage E1 between wh...

Page 241: ...in 15 17 mm 0 59 0 67 in longer compared with the free length The free length is 78 mm 3 1 in 65 mm 2 59 in in the drawing value Confirm the lever E completely returns to the idling position by operat...

Page 242: ...te the air bleeding To facilitate the air bleeding by increasing the discharge volume from the master cylinder when air is bled 7 Execute the air bleeding surely 8 Adjust IDL and MAX with the lower op...

Page 243: ...wire rope to keep the boom fully retracted 2 Tighten the four nut B s equally until the 4th boom section extends by 1 5 mm 0 04 0 2 in from the 3rd boom section 3 Tighten the two nut C s equally unti...

Page 244: ...hen retract it fully Check the boom is fully retracted 6 Check the tension of the two 4th boom section extension wire ropes END 7 When the wire rope is slack 8 When the wire rope is tense 7 1 Tighten...

Page 245: ...Extend the boom by 200 300 mm 8 12 in by operating the boom telescoping control lever and then retract it fully Check the boom is fully retracted NG 9 When only the 4th boom section is not fully retra...

Page 246: ...20 WY05 0730E Y 5 Y 5 Adjustment and Checks 10 Adjust the sway stopper bolt for the each boom section NOTICE Refer to Adjusting the bolt on the bottom of each boom section head in chapter G...

Page 247: ...0 Light Oil JIS K 2204 2 Applicable to machine equipped with an air conditioner inside its crane operator s cab 1 After the engine started turn the P T O switch to ON Then Crane Carrier operation sele...

Page 248: ...1230lbf Boom Jib 2 280kg 620lbf Elevating cylinder 960kg 2120lbf Swing table ass y excluding boom and elevating cylinder swing bearing counter weight 5150kg 11360lbf Swing bearing 630kg 1390lbf Swing...

Page 249: ...mm Part Name Diameter Thread size Rod end pin 100 M30 3 5 Elevating cylinder Base pin 90 M30 3 5 Boom base pin 90 M16 2 0 Qty 4 Applicable model GT 550E 1 TR 600XL 4 TR 800XXL 4 TT 600XL 1 TT 800XXL 1...

Page 250: ...on of Electric Parts Upper 5 Location of Electric Parts Lower 6 Location of Electrical Parts Outrigger Operation Option 7 Hydraulic Electric Carrier Equipment Comparison Table 8 Harness Inside Cab 9 H...

Page 251: ...Hydraulic Circuit 1 WZ01 1140E 1 Z 1 Z 1 Z 1 Hydraulic Circuit Applicable serial No 475328 1 475326 2 475355 3 3 344 018 10000...

Page 252: ...Electric Circuit 2 WZ03 1830E 2 Z 2 Z 2 Z 2 Electric Circuit 3 344 118 80001 Model TT 800XXL TT 600XL Modification No Applicable serial No 1 475332 2 475334 3 475355 437382...

Page 253: ...Electric Circuit Outrigger operation option 3 WZ03 1841E 3 Z 3 Z 3 Z 3 Electric Circuit Outrigger Operation Option 0 333 316 60010...

Page 254: ...Location of Hydraulic Parts 4 WZ07 0780E 4 Z 4 Z 4 Z 4 Location of Hydraulic Parts...

Page 255: ...Location of Electric Parts Upper 5 WZ02 1380E 5 Z 5 Z 5 Z 5 Location of Electric Parts Upper Applicable serial No 475338 6...

Page 256: ...RAM check R W check of specific area RAM When power supply is turned on At each cycle processing OFF Voltage watch The power supply voltage and the reference voltage are checked At each cycle process...

Page 257: ...Location of Electrical Parts Outrigger Operation Option Z 7 Z 7 Z 7 7 WZ02 1400E 7 Location of Electrical Parts Outrigger Operation Option 0 333 316 60000 0 333 316 60300...

Page 258: ...ch CS13 Main 23 Pilot check valve 74 Counterbalance valve 126 Room lamp 10W Side of relay box 176 Drum rotation detector switch CS14 Aux 24 Pilot check valve 75 Hydraulic pilot control valve Elevating...

Page 259: ...Hydraulic Electric Carrier Equipment Comparison Table Z 8 Z 8 Z 8 9 WZ09 0130E 9...

Page 260: ...9 Harness Inside Cab Z 9 9 WZ04 1290E 9 Harness Inside Cab Model TT 800XXL TT 600XL Modification No Applicable serial No 7 475355 437382 7 343 530 31010 1 In case of TT 800XXL Head end boom extension...

Page 261: ...Swing Table Left 7 343 529 92020 Model TR 600XL TR 800XXL GR 700EXL TT 800XXL TT 600XL Modification No Applicable serial No 1 2 3 475326 4 545430 545430 475329 5 545473 545473 475342 437295 6 545485...

Page 262: ...Z 11 Z 11 Harness Swing Table Right Z 11 11 WZ04 1300E 11 Harness Swing Table Right 5 343 530 32010...

Page 263: ...Z 12 Z 12 Harness Boom Z 12 12 WZ04 1310E 12 Harness Boom 1 2 2 343 530 32040 1 343 530 22030...

Page 264: ...rness AML Upper Z 13 13 WZ04 1320E 13 Harness AML Upper Model TR 600XL TR 800XXL TT 800XXL Modification No Applicable serial No 1 545419 545419 475327 2 545410 545419 475326 3 545410 545419 475326 3 3...

Page 265: ...14 WZ04 1320E 14 Z 14 Z 14 Harness Lower Z 14 Harness Lower Applicable serial No 475334 1 1 336 500 30021...

Page 266: ...Z 15 Z 15 Harness Outrigger Operation Option Z 15 15 WZ04 1330E 15 Harness Outrigger Operation Option 0 333 316 60020...

Page 267: ...Ko 34 Sinden cho Takamatsu Japan Overseas Service Dept Tadano Ryogoku Bldg 4 12 Kamezawa 2 chome Sumida ku Tokyo Japan Tel 81 3 3621 7765 Tel fax 81 3 3621 7785 History of revision 1 2005 01 27 R 05 R...

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Tadano TT-800XXL1, Service Manual

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