Page 1 GT-800XXL-1/S1(U)-1E Publication No. Truck Crane TT-800XXL- Model Applicable Serial No. 475326 ～～～～ ◯ ｃ 2003 PRINTED IN JAPAN 0310...
Page 2 Safety Safety Most accidents that occur during machine operation [NOTICE] and maintenance are caused by failure to observe [NOTICE] indicates an important operational or basic safety rules and precautions. Before operating maintenance procedure or condition, which, if not strictly observed, can result in damage to machine your machine or performing maintenance, read and components or deteriorated machine performance.
Page 3 Safety 1. Fundamental cautions fatal accidents, as there is a possibility that the vehicle loses its balance and falls down on a Servicemen inexperienced in the units of this machine worker in a dismounting process of certain units. should be cautious about safety operations. They 7.
Page 4 Safety 7. Put disassembled parts in order so that parts such In case that the position of the center of gravity is as bolts are not left behind in the machine. And not clear and there is a possibility of swing of load check that no parts run short at assembly.
Page 5 Safety 4.1 Gasoline 2. Battery fluid (dilute sulfuric acid) may cause loss of sight or burn injury. 1.Spill or leak: Review fire and explosion hazards If battery fluid stains an eye, skin, or clothes, before proceeding with clean up. Use appropriate immediately wash down them with a great deal personal protective equipment during clean up.
Page 6 Foreword Foreword This service manual describes the composition of the Model TT-800XXL-1 truck crane, its repair, checks and adjustment methods and other relevant matters. Note that this service manual does not provide the information in the separate service manuals given below. This service manual applies to the cranes with the specification numbers given below.
Page 7 Foreword 3. Outline of specifications Spec. No. Item GT-800-1-90102 2M2D (North America) No. of boom sections No. of jib stages Single top Option Main winch Fitted Auxiliary winch Fitted Winch Winch brake Automatic brake (Neutral brake) Drum rotation indicator Touch-type (Option) Weight Counterweight Removable type...
Page 8 Foreword 4. Conversion table Length millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km 0.001 0.03937 0.00328 1.6093 0.01 0.3937 0.03281 0.6214 1000 39.37 3.281 25.4 2.54 0.0254 0.08333 304.8 30.48 0.3048 Area square millimeter, mm square centimeter, cm square meter, m...
Page 9 Foreword Work, energy foot-pound, inch-pound, N-cm kgf-cm kgf-m ft-lbf in-lbf 1X10 1.01972X10 1.01972X10 0.00737 0.0885 1X10 1.01972X10 1.01972X10 0.7376 8.851 9.80665 9.80665X10 1X10 0.0723 0.868 9.80665X10 9.80665 1X10 7.233 86.8 135.58 1.3558 13.83 0.1383 11.3 0.113 1.1525 0.01153 0.08333 Centigrade-Fahrenheit ゜F ℃...
Page 10 GROUP INDEX Hydraulic Power Generating System Swing System Boom Elevation System Winch System Boom Telescoping System Safety System Control System Data, Adjustment and Checks System Diagrams WA04-1310E...
Page 11 Foreword 5. Contents Spec. No. GT-800-1-90102 Chapter Section 2M2D (North America) General General Cautions Refer to separate manual SA01-01-2E Hydraulic Power Generating System Hydraulic Power Generating System Hydraulic Pump Flow Control Valve Rotary Joint Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch) Sequence Valve (Pilot Pressure) ~#475348 Solenoid Valve...
Page 12 Foreword Spec. No. GT-800-1-90102 Chapter Section 2M2D (North America) Swing System Swing System Swing Ass’y Hydraulic Pilot Control Valve (Swing) Hydraulic Motor (Swing) Swing Speed Reducer Select Valve (Dolly) Boom Elevation System Elevating System Elevating Cylinder Counterbalance Valve (Elevating) Select Valve (Dolly) Winch system Winch System Winch...
Page 13 Foreword Spec. No. GT-800-1-90102 Chapter Section 2M2D (North America) Boom T elescoping system Telescoping System Boom (Five-Section Boom) Telescoping Cylinder Counterbalance Valve (Telescoping) Hose Reel Hydraulic Valve Safety System Safety System Load Moment Indicator (AML) Refer to separate manual W301-0232E Boom Length and Angle Detector Outrigger Extension Length Detector Solenoid Valve (Auto Stop)
Page 14 Foreword Spec. No. GT-800-1-90102 Chapter Section 2M2D (North America) Control System Control System Remote Control Valve (Lever) ~#475341 Remote Control Valve (Pedal) #475342~ Shuttle Valve (Lever, Pedal) Solenoid Valve (Boom Telescoping/Aux. Hoist) ~#475348 Solenoid Control Relief Valve (Elevating Slow Stop) #475349~ Data, Adjustment and Checks Hydraulic Pressure Setting Table...
Page 15 Foreword Spec. No. GT-800-1-90102 Chapter Section 2M2D (North America) System Diagrams Hydraulic Circuit Electric Circuit Electric Circuit (Outrigger Operation, Option) Location of Installation Location of Hydraulic Parts Location of Electrical Parts (Upper) Location of Electrical Parts (Lower) Location of Electrical Parts (Outrigger Operation, Option) Hydraulic, Electric, Carrier Equipment Comparison Table...
Page 16: Table Of Contents
Hydraulic Power Generating System Contents ■ ■ Hydraulic Power Generating System Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch) Functions of units........1 Structure ..........22 Hydraulic pump .......... 1 Rotary joint ..........1 Hydraulic pilot control valve......1 ■ Sequence Valve (Pilot Pressure) Sequence valve ..........
Page 17 ■ Hydraulic Motor (Oil Cooler) Structure ..........49 Air bleeding procedure......49 ■ Jib Lock Pin Structure ..........50 ■ Jib Offset Cylinder Structure ..........51 ■ Counterweight Cylinder Structure ..........52 ■ Pilot Check Valve Structure ..........53 ■ Check Valve (Gauge lsolator) Structure ..........
Page 18: Functions Of Units
B-1 . B-1 . Hydraulic Power Generating System Hydraulic Power Generating 1.6 Solenoid valve (for venting pressure for remote control) System 1. Functions of units It supplies and vents the pilot pressure for the remote control. While the solenoid valve is 1.1 Hydraulic pump deenergized, the oil flow to the remote control valve is shut off, making crane operation...
Page 19: Hydraulic Pump
Hydraulic Pump Hydraulic Pump [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 20: Inside View
Hydraulic Pump 1.2 Inside view Variable displacement piston pump W101-0280E...
Page 21 Hydraulic Pump 1.Control section (C.C.W. rotation) 8.shaft section (front) 16.O-ring 27.Hex. socket head bolt 2.Control section (C.W rotation) 9.shaft section (rear) 18.Hex. socket head bolt 28.Coupling 3.Cover section 11.Adapter ring 19.O-ring 30.Gear pump 4.Rotary section 12.Front housing 20.Plug 35.Name plate 5.Piston section 13.Rear housing 21.O-ring...
Page 22 Hydraulic Pump Control Section 1, 2 (This view shows “Right rotation”) 1.Requlator cover 10.Adjust screw 18.Parallel pin 26.Nut 2.Body 11.Arm 19.O-ring 27.Plug 3.Guide 12.Spring 20.O-ring 28.Hex. socket head bolt 4.Barrel 13.Spring 21.O-ring 29.Orifice 5.Spool 14.Spring 22.O-ring 30.Shim 6.Spring seat 15.Spring 23.O-ring 31.Shim 7.Spring seat...
Page 23 Hydraulic Pump Cover section 3 1.Cover 3.Control plate 6.Hex. socket head bolt 8.O-ring 2.Control plate 5.Plug 7.Parallel pin 9.O-ring Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 23 - 28 17 – 20.6 Apply THREE BOND 1305 to the plug 5 (12 places) W101-0280E...
Page 24 Hydraulic Pump Piston section 5 Rotary section 4 1.Piston 7.Spring 1.Piston 4.Piston 2.Cylinder block 8.Parallel pin 2.Cylinder 5.Spring 4.Retainer 9.Spring seat 3.Cylinder 6.Guide 10.C-retaining ring W101-0280E...
Page 25 Hydraulic Pump Hanger section 6, 7 1.Joint (control piston) 2.Hanger 3.Metal 4.Orifice W101-0280E...
Page 26 Hydraulic Pump Shaft section 8 (front) Shaft section 9 (rear) 1.Shaft 6.Bearing 1.Shaft 4.Bearing 2.Seal case 7.Oil seal 2.Shim 5.Bearing 4.Shim 8.C-retaining ring 5.Bearing 9.O-ring 7. Apply the qrease equivalent to MORITON GREASE NO.2 (Product by “SUMICO”) to the lip of oil seal 7.
Page 27 Hydraulic Pump Gear pump 30 1.Frame 9.Side plate 17. ------ 25.O-ring 2.Body 10.Side plate 18.O-ring 26.Hex. socket head bolt 3.Body 11.Seal ring 19.C-retaining ring 27.Spring washer 4.Case 12.Coupling 20.Plain washer 28.Stud bolt 5.Gear 13.Bush 21.Plug 29.Stud bolt 6.Gear 14.Stud bolt 22.Plain washer 7.Gear 15.Bearing...
Page 28: Pump Mounting
Hydraulic Pump 1.3 Pump Mounting 1. Hydraulic pump is attached to the gear ass’y. [NOTICE] L: Installation dimension of propeller shaft 2. The drive power from P.T.O is transferred to the Standard .......900 mm (35.4 in) hydraulic pump by the propeller shaft and gear Maximum allowance ..920 mm (36.2 in) ass’y.
Page 29: Gear Ass'y
Hydraulic Pump 1.4 Gear ass’y [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 30 B-2 . B-2 . Hydraulic Pump 1. Gear case 7. Collar 13. Ball bearing 19. Elbow 2. Gear case 8. Idle shaft 14. Output shaft 20. Hex. socket plug 3. Ball bearing 9. Ball bearing 15. Hex. socket plug 21. Oil seal 4.
Page 31: Flow Control Valve
B-3 . B-3 . Hydraulic Pump Flow Control Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 32: Rotary Joint
Rotary Joint Rotary Joint [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 33 Rotary Joint Upper (view A) FRONT Tap for slinging (2 places) (M10) IW181-0300E02 Lower (view B) W181-0300E...
Page 34 Rotary Joint 1.Slip ring ass’y 8.Core 15.Ring seal 22.Clamp 2.Plain bearing 9.Plain bearing 16.Bolt 23.Nut 3.Packing 10.Support 17.Flange bolt 24.Plate 4.Ring seal 11.Grease nipple 18.Plate 25.Hex. socket head bolt 5.Body 12.Plain bearing 19.Plug 26.Ring seal 6.Core 13.Ring seal 20.Plate 27.Plug 7.Shaft 14.Packing 21.Flange bolt...
Page 35 Rotary Joint Slip ring ass’y [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 IW181-0260E03 27 26 IW181-0260E04 16,17 IW181-0260E05 IW181-0290E03...
Page 36 Rotary Joint IW181-0260E09 IW181-0260E07 32,33 IW181-0260E10 IW181-0260E08 1.Shaft 10.BH+CB 19.O-ring 28.Hose band 2.Ring set plate 11.Spacer 20.Potentiometer 29.Hex. socket set screw 3.Bearing 12.Spacer 21.Cover 30.Machine screw 4.Ring 13.BH+CB 22.Packing 31.Bolt 5.Ring 14.Support 23.Lever 32.Bolt 6.Ring set plate 15.Base 24.Pin 33.Spring washer 7.U nut 16.Dry lock nut 25.Guide...
Page 37 Rotary Joint Wiring diagram LOWER (Slip ring) UPPER (Brush holder) Pot2 Pot1 26 1 626 626 1 26 3 2 23 23 2 27 12 627 627 12 27 28 11 628 628 11 28 29 10 629 629 10 29 630 9 30 20 8 20 8 20...
Page 38: Potentiometer
B-4 . B-4 . Rotary Joint 2. Potentiometer 3. Turn the potentiometer shaft using a slotted screwdriver so that the resistance between the 2.1 Adjustment upper terminals 1 and 2 is minimum between 1 ohm and 15 ohm. Leave the terminals (6 pieces) 1.
Page 39: Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch)
Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Hydraulic Pilot Control Valve (Elevating, Telescoping, W 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 serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 40 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Vent Vent (down) (down) (extending) (lowering) b3,b4 a3,a4 Aux. winch Main winch Telescoping Elevating (up) (up) (retracting) (raising) IW134-0270E02 W134-0270E...
Page 41 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Thread size and tightening torque Tightening torque Thread Thread size ft-lbf C1,C2,C3,a1,a2,a3,a4,b1,b2,b3,b4,Vent G1/4 29.4 A3,B3,A4,B4 G3/4 P1,P2,A1,B1,A2,B2 W134-0270E...
Page 42 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Cross section of whole body Aux. winch Main winch Telescoping Elevating IW134-011012 W134-0270E...
Page 43 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) ・ Aux. winch Main winch ・ Telescoping Elevating IW134-0270E03 W134-0270E...
Page 44 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Aux. winch Main winch Telescoping Elevating IW134-011004 1.Winch selector valve 5.O-ring 9.Main relief valve 15.Plug 2.Telescoping selector valve 6.O-ring 12.Hex. socket head bolt 16.Eye bolt 3.Elevating selector valve 7.Hex. socket head bolt 13.Plug 4.End cover 8Main relief valve...
Page 45 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Winch selector valve Overload relief valve 25,24,23,13 9 8 12,23,24,25 16,17 C-C (Aux. winch) , D-D (Main winch) IW134-0270E04 Main relief valve 16,17 IW134-0110E07 W134-0270E...
Page 46 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) 1.Winch selector valve body 8.Return spring 16.Plug 23.Hex. socket head bolt 2.Spool (main,aux. winch) 9.Return spring 17.O-ring 24.Plain washer 3.-------------------------------- 10.Spring seat 18.Spring retainer 25.Spring washer 4.Flow control valve 11.Spool end (flow control valve) 26.Plug (main winch), (aux.
Page 47 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Telescoping selector valve Overload relief valve 27,26,25,13 12,25,26,27 19,20 19,20 F-F (Telescoping) IW134-0270E03 1.Telescoping selector valve 7.Spring seat 15.Plug (shuttle valve) 23.Plug (check valve) body 8.Return spring 16.O-ring 24.O-ring 2.Spool (telescoping) 9.Return spring 17.Orifice 25.Hex.
Page 48 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Elevating selector valve Overload relief valve 22,21,20,13 12,20,21,22 16,17 16,17 G-G (Elevating) IW134-0110E09 1.Elevating selector valve body 7.Spring seat 13.Pilot cover 19.O-ring 2.Spool (elevating) 8.Return spring 14.Orifice 20.Hex. socket head bolt 3.Flow control valve (elevating) 9.Return spring 15.Spring (flow control valve) 21.Plain washer...
Page 49 Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Main relief valve (Main winch, Aux. winch), (Elevating, Telescoping) 14 13 12 11 10 9 IW134-011010 1.Socket 6.O-ring 11.Adjust screw 16.Valve 2.Valve 7.Packing 12.O-ring 17.Valve seat 3.Spring 8.Body 13.Nut 18.O-ring 4.O-ring 9.O-ring 14.Body 19.Seal lead 5.Backup ring...
Page 50 B-5 . B-5 . Hydraulic Pilot Control Valve (Elevating, Telescoping, W inch) Overload relief valve (Main winch), (Aux. winch), (Elevating), (Telescoping) IW134-011011 1.Socket 5.Valve seat 9.Valve 13.Nut 2.Valve 6.O-ring 10.Spring 14.Cap nut 3.O-ring 7.O-ring 11.Adjust screw 15.Tie up wire 4.Spring 8.Body 12.O-ring 16.Seal lead...
Page 51: Sequence Valve (Pilot Pressure)
Sequence Valve (Pilot Pressure) Sequence Valve (Pilot Pressure) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 52 Sequence Valve (Pilot Pressure) Cross section along the line A-A (back pressure regulating valve, pressure reducing valve) 1.Body 2.Filter 3.Filter retainer 4.Back pressure regulating valve 5.Pressure reducing valve 6.Hex. socket head bolt IW122-0112E01 Thread size and tightening torque Tightening torque Thread Thread size ft-lbf...
Page 53 B-6 . B-6 . Sequence Valve (Pilot Pressure) Pressure reducing valve (illustrated as 5 in the cross section along the line A-A) IW122-011005 1.Body 5.Spring seat 9.O-ring 13.O-ring 2.Spool 6.Spring 10.Nut 3.O-ring 7.Adjust screw 11.Cap nut 4.Plug 8.Body 12.O-ring △ 366-038-80000 △...
Page 54: Solenoid Valve (Pilot Pressure) (~#475348)
B-7 . B-7 . Solenoid Valve (Pilot Pressure) (~#475348) Solenoid Valve (Pilot Pressure) (~#475348) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 55: Solenoid Valve (Pilot Pressure) (#475349~)
Solenoid Valve (Pilot Pressure) (#475349~) Solenoid Valve (Pilot Pressure) (#475349~) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 56 B-8 . B-8 . Solenoid Valve (Pilot Pressure) (#475349~) Solenoid Valve ass’y 31 1 312 361 IW121-067003 311.Spool 326.Retaining ring 363.O-ring 861. O-ring 312.Sleeve 361.O-ring 801.Solenoid valve 324.Spring 362.O-ring 802.Seal nut Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 6.9 - 7.9 5.1 - 5.8...
Page 57: Solenoid Control Valve (Jib Set And Counterweight Cylinder)
Solenoid Control Valve (Jib Set and Counterweight Cylinder) Solenoid Control Valve (Jib Set and Counterweight Cylinder) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 58 Solenoid Control Valve (Jib Set and Counterweight Cylinder) 18.Name plate 27.Plug 31.Nut 33.Ball 21.Tigh rod 29.Hex. socket head bolt 32.Ribbet screw 38.O-ring Thread size and tightening torque Tightening torque Thread Thread size ft-lbf P, T G1/2 A1, B1, A2, B2, A3, B3, G3/8 C•O G1/2...
Page 59 Solenoid Control Valve (Jib Set and Counterweight Cylinder) 28 34 19 38 23 27 33 6.Collar 7.Spring folder 8.Plug 9.Spring 16.Solenoid 19.Body 20.Spring 22.Spring 23.Filter 25.Spool end 27.Plug 28.Hex. socket head bolt 33.Ball 34.O-ring 35.O-ring 37.O-ring 38.O-ring 44.O-ring 34 19 38 27 23 20 IW112-0220E03 W112-0240E...
Page 60 Solenoid Control Valve (Jib Set and Counterweight Cylinder) 14.Spool 15.Housing 17.Housing plunger 24.Housing 35.O-ring 43.O-ring IW112-0240E03 W112-0240E...
Page 61 Solenoid Control Valve (Jib Set and Counterweight Cylinder) IW112-0220E05 IW112-0220E06 W112-0240E...
Page 62 B-9 . B-9 . Solenoid Control Valve (Jib Set and Counterweight Cylinder) Relief valve 42 12 40 10 IW112-0220E07 1.Spring 5.Spring 13.Poppet 40.O-ring 2.Needle valve 10.Housing 30.Screw 41.O-ring 3.Nut 11.Sleeve 36.O-ring 42.O-ring 4.Gasket 12.Sleeve 39.O-ring △ 366-404-20000 W112-0240E...
Page 63: Pilot Check Valve (Jib Set)
B-1 0 . B-1 0 . Pilot Check Valve (Jib Set) Pilot Check Valve (Jib Set) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 64: Solenoid Valve (Oil Cooler)
B-1 1 B-1 1 Solenoid Valve (Oil Cooler) Solenoid Valve (Oil Cooler) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 65 B-1 1 . B-1 1 . Solenoid Valve (Oil Cooler) Solenoid valve ass’y IW121-025003 1.Body 7.Spring seat 11.Spring 2.Plug 8.Square ring 12.Solenoid (DC24V) 3.Spool 9.O-ring 15.Hex. socket head bolt Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 44 - 49 32 - 36 39 - 49...
Page 66: Structure
B-1 2 . B-1 2 . Hydraulic Motor (Oil Cooler) Hydraulic Motor (Oil Cooler) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 67: Structure
B-1 3 . B-1 3 . Jib Lock Pin Jib Lock Pin [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 68: Structure
B-1 4 . B-1 4 . Jib Offset Cylinder Jib Offset Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 69: Structure
B-1 5 . B-1 5 . Counterweight Cylinder Counterweight Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 70: Structure
B-1 6 . B-1 6 . Pilot Check Valve Pilot Check Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 71: Structure
B-1 7 . B-1 7 . Check Valve (Gauge lsolator) Check Valve (Gauge lsolator) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 72 Swing System Contents ■ ■ Swing System Select Valve (Dolly) Description of the units ......1 Structure ..........16 Swing drive unit .......... 1 Hydraulic pilot control valve......1 Solenoid valve (swing free/lock selet) ..1 Select valve (dolly) ........1 Swing slow stop ........
Page 73: Description Of The Units
D-1 . D-1 . Swing System Swing System 2. Swing slow stop 2.1 Condition for slow stop 1. Description of the units Slow stop function is activated when the crane is 1.1 Swing drive unit in the condition marked with a circle. Swing stop 1.
Page 74: Swing Ass'y
Swing Ass’y Swing Ass’y [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 75: Swing Bearing Mounting Bolt
Swing Ass’y 2. Swing bearing mounting bolt 2.1 Bearing Inner ring bolts 5 6 7 8 50mm (19.7in) View A "S" mark Front 1.Pain washer 2.Bolt (L=180mm) 3.Plain washer 4.Bolt 5.Support 6.Nut 7.Bolt 8.End 9.Spring washer 10.Pin IW514-0200E01 [NOTICE] Thread size and tightening torque Install the bearing inner ring with the "S"...
Page 76: Bearing Outer Ring Bolts
D-2 . D-2 . Swing Ass’y 2.2 Bearing outer ring bolts 1.Bolt (L=160mm) 2.Bolt (L=190mm) 3.Plain washer (50points) 4.Nut (5points) 5.Reamer bolt (L=185mm) 6.Plain washer (2points) FRONT Swing table IW514-0140E02 [NOTICE] Thread size and tightening torque Apply torque control agent to the threaded sections of the bolts.
Page 77: Hydraulic Pilot Control Valve (Swing)
Hydraulic Pilot Control Valve (Swing) Hydraulic Pilot Control Valve (Swing) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 78 Hydraulic Pilot Control Valve (Swing) Thread size and tightening torque Tightening torque Thread Thread size ft-lbf P, R 200 - 240 145 - 174 AM, BM G3/4 150 - 180 108 - 130 G, Pa, Pb, Pa’, Pb’, Pi1, Pi2 G1/4 34 - 38 25 - 28...
Page 79 Hydraulic Pilot Control Valve (Swing) Cross section Sol.3 Sol.2 Sol.1 Sol.4 152 701 IW134-012003 Enlarged view (Sol.1, Sol.4, RV) Sol.1 Sol.4 IW134-012007 W134-0121E...
Page 80 Hydraulic Pilot Control Valve (Swing) Cross section along the line A-A 414 413 401 450 412 411 415 IW134-012004 W134-0121E...
Page 81 Hydraulic Pilot Control Valve (Swing) Cross section along the line B-B IW134-012005 W134-0121E...
Page 82 Hydraulic Pilot Control Valve (Swing) Cross section along the line C-C 561 511 521 152 201 243 242 222 261 Sol.3 Sol.2 231 211 212 234 235 IW134-012006 Enlarged view (Sol.2, Sol.3) Sol.3 Sol.2 IW134-012008 W134-0121E...
Page 83 D-3 . D-3 . Hydraulic Pilot Control Valve (Swing) 101.Casing 242.O-ring 401.Plug 552.Plug 151.Plug 243.O-ring 411.Plunger 561.O-ring 152.Plug 251.Orifice 412.Spring 562.O-ring 201.Spool 252.Plug 413.O-ring 641.Spring seat 211.Spacer bolt 253.Plug 414.Steel ball 642.Spring 212.Stopper 261.Solenoid 415.Stopper 643.Steel ball 450.Air bleeder screw 644.Seat 221.Cover inverse-proportional...
Page 84: Structure
Hydraulic Motor (Swing) Hydraulic Motor (Swing) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 85 D-4 . D-4 . Hydraulic Motor (Swing) 101.Drive shaft 122.Shoe 433.Stop ring 485.O-ring 106.Spacer 123.Guide plate 437.Iocking ring 491.Oil seal 111.Cylinder 124.Shoe plate 438.Iocking ring 702.Brake piston 113.Spherical bush 131.Valve plate 443.Roller bearing 706.O-ring 114.Cylinder spring 301.Casing 444.Roller bearing 707.O-ring 116.Push rod 303.Valve cover 451.Spring pin...
Page 86: Structure
Swing Speed Reducer Swing Speed Reducer [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 87 D-5 . D-5 . Swing Speed Reducer [NOTICE] Apply THREE BOND 1215 to the mating faces of the hydraulic motor casing and the swing speed reducer bracket (19). Inject lithium based grease to the mating faces of the retainer (2) and the roller bearing (3). After applying THREE BOND 1215 to the outer circumference of oil seal(5), insert the oil seal(5) into casing(4).
Page 88: Structure
D-6 . D-6 . Select Valve (Dolly) Select Valve (Dolly) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 89 Boom Elevation System Contents ■ Elevating System Description of the units ......1 Elevating cylinder ........1 Counterbalance valve......... 1 Select valve (dolly) ........1 ■ Elevating Cylinder Structure ........... 2 ■ Counterbalance Valve (Elevating) Structure ........... 4 Function............ 6 When control valve is at the neutral position......
Page 90: Elevating System
E -1 . E -1 . Elevating System Elevating System 1. Description of the units 1.1 Elevating cylinder 1. The elavating cylinder serve to elevate the boom. 2. A pressure sensor is installed to input the value to the AML for calculating load moment. 1.2 Counterbalance valve 1.
Page 91: Elevating Cylinder
E -2 E -2 Elevating Cylinder Elevating Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 92 E -2 . E -2 . Elevating Cylinder 4,5 4,6 7,40 13,14 15 IW155-0220E02 1.Cylinder 12.Damper ring 23.O-ring 34.O-ring 2.Spring pin 13.Packing 24.Pipe 35.Orifice 3.Plain bearing 14.Backup ring 25.Pipe 36.Grease nipple 4.Packing 15.Dust seal 26.T-fitting 37.Pipe 5.Backup ring 16.Retainer 27.Pipe 38.O-ring 6.Backup ring 17.Spring washer...
Page 93: Counterbalance Valve (Elevating)
E -3 E -3 Counterbalance Valve (Elevating) Counterbalance Valve (Elevating) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 94 E -3 E -3 Counterbalance Valve (Elevating) Thread size and tightening torque Tightening torque Thread Thread size ft-lbf G3/4 G3/8 177 - 196 130 - 145 2-15 127 - 147 94 - 108 108 - 127 80 - 94 59 - 78 43 - 58 Mounting bolt 24 - 27...
Page 95: Function
E -3 . E -3 . Counterbalance Valve (Elevating) 2. Function IW119-021003 This counterbalance valve prevents the actuator 2.3 While actuator descends from being driven by the load and its own weight 1. The hydraulic oil directly flowing from the control faster than the speed corresponding to the oil valve to the actuator also enters through port PP supply rate.
Page 96: Select Valve (Dolly)
E -4 . E -4 . Select Valve (Dolly) Select Valve (Dolly) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 97 Winch System Contents ■ ■ Winch system Hydraulic Valve (Winch Brake Release) Description of the units ......1 Structure ..........10 Hydraulic motor .......... 1 Counterbalance valve......... 1 Hydraulic valve ........... 1 Solenoid valve (telescoping/aux. hoist) ..1 ■ Winch Structure ...........
Page 98: Description Of The Units
F - 1 . F - 1 . Winch System Winch System 2. When the winch lever is returned to neutral, the valve is spring-returned to the neutral position as 1. Description of the units the pilot pressure decreases, and the oil in the winch brake cylinder flows to the tank.
Page 99: Winch
F - 2 F - 2 Winch Winch [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 100 F - 2 . F - 2 . Winch Note: Apply THREE-BOND 1104 to the following 5 places: mating face of the gear case (18) and the gear case cover (37); mating face of the gear case (18) and the bracket (1); mating face of the gear case (18) and the bearing retainer (7);...
Page 101: Hydraulic Motor (Winch)
F - 3 F - 3 Hydraulic Motor (Winch) Hydraulic Motor (Winch) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 102 F - 3 F - 3 Hydraulic Motor (Winch) Cross section of the hydraulic motor IW102-013003 (720) IW102-013004 W102-0131E...
Page 103: Air Bleeding Procedure
F - 3 . F - 3 . Hydraulic Motor (Winch) 121.Piston 301.Casing 471.O-ring 707.O-ring 122.Shoe 304.Front cover 472.O-ring 710.Brake shim 111.Cylinder 401.Hex. socket head bolt 473.O-ring 720.Brake casing 131.Valve plate 402.Hex. socket head bolt 476.O-ring 741.Separater plate 303.Valve cover 403.Bolt 485.O-ring 742.Friction plate...
Page 104: Counterbalance Valve (Winch)
F - 4 F - 4 Counterbalance Valve (W inch) Counterbalance Valve (W 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 serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 105: Function
F - 4 F - 4 Counterbalance Valve (W inch) 101.Casing 201.Cover 272.Square spring washer 355.Orifice 151.Plug 202.Cover 273.Hex. socket head bolt 361.O-ring 152.Plug 203.Spacer 274.Square spring washer 362.O-ring 161.O-ring 204.Spacer 301.Spool 511.Plunger 162.O-ring 252.Air bleeder screw seat 302.Pilot piston 514.Seat 163.O-ring 253.Plug...
Page 106: Principle Of Operation
F - 4 . F - 4 . Counterbalance Valve (W inch) 3. Principle of operation Overload relief valve IW119-0500E03 3. This pressure flows through choke b in the spool, 3.1 When control valve is in neutral enters into chamber c, where it pushes the The holding pressure of the hydraulic motor is plunger to the right by overcoming the spring force, locked by the seat area a of the check valve, the...
Page 107 F - 5 . F - 5 . Hydraulic Valve (Winch Brake Release) Hydraulic Valve (Winch Brake Release) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 108 Telescoping System Contents ■ Telescoping System Installing lower slide plates .......12 Installing slide plates onto sides General............. 1 of rear end...........12 Telescoping cylinder ........1 Adjustment ..........12 Counterbalance valve......... 1 Hydraulic valve ........... 1 5.1 Adjusting clearance for the boom ....12 Hose reel ............
Page 109 Function..........23 When control valve is at the neutral position ........23 While actuator is being pushed up ... 23 While actuator descends ......23 ■ Hose Reel Structure ..........24 Dismounting..........25 Mounting..........25 Disassembly ........... 25 Reassembly..........25 ■...
Page 110: Telescoping System
G -1 G -1 Telescoping System Telescoping System 1. General 1.1 Telescoping cylinder 1. The telescoping cylinders are incorporated in the boom, and serve to telescope the boom to witch they are connected by pins. 2. It telescopes the 2nd boom section, and telescopes the 3rd, 4th and top boom sections simultaneously using two double-acting hydraulic cylinders and wire ropes.
Page 111: Description Of Telescoping System
G -1 G -1 Telescoping System 2. Description of telescoping system (Refer to the circuit diagram in Chapter Z.) Fold at the rear end the 3rd boom section. Sheave at the rear end of Adjuster and sheave on the head of the 2nd boom section the 3rd boom section Sheave at the head of the 4th boom section Top boom section retraction wire...
Page 112: Retraction Circuit
G -1 . G -1 . Telescoping System Telescoping mode II 4. After the 3rd through top boom sections are fully (The 3rd through top boom sections extend first.) extended, press the next section extension switch while keeping the boom telescoping lever 1.
Page 113 G -2 G -2 G -2 Boom (Five-Section Boom) Boom (Five-Section Boom) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 114 G -2 G -2 G -2 Boom (Five-Section Boom) W536-0760E...
Page 115: Boom (Five-Section Boom)
G -2 G -2 Boom (Five-Section Boom) 1.Base boom section 47.Hexagon socket head bolt 93.Pin 139.Sheave ass’y 2.Second boom section 48.Slide plate 94.Sheave ass’y 140.Bolt 3.Third boom section 49.Bolt 95.Bolt 141.Split pin 4.Fourth boom section 50.Adjuster ass’y 96.Plate 142.Hexagon socket head bolt 5.Top boom section 51.Bolt 97.Spacer...
Page 116: Disassembly
G -2 G -2 Boom (Five-Section Boom) Telescoping cylinder 2. Disassembly The procedure to remove the 2nd boom section and further sections as an assembly is described below. 2.1 Removing the 2nd boom section 1. Retract the boom fully and set the crane level. 2.
Page 117: Removing The 3Rd Boom Section
G -2 G -2 Boom (Five-Section Boom) 2.2 Removing the 3rd boom section Top boom section 3rd boom section Bolt 1 Pin 1 1 Remove the wire rope for top boom section Support Sheave assy extension/4th boom section retraction located on the top of the 2nd boom head by loosening the nut.
Page 118: Removing The 4Th Boom Section
G -2 G -2 Boom (Five-Section Boom) 2. Lift up the rear end of the telescoping cylinder [NOTICE] slightly using a crane and pull out the connecting Before loosening the nut, measure the length of the pin that connects the 3rd boom section and the wire rope protrusion (L3) as a guide for reassembly.
Page 119 G -2 G -2 Boom (Five-Section Boom) Guide Bolt 1 Support Bolt 2 Wire rope (for top boom section extension / 4th boom section retraction) IW536-0620E14 3. To prevent damage to the wire rope, secure it to the head of the top boom section using a jig. T op boom section Wire rope (for top boom section extension / 4th boom section retraction)
Page 120: Check
G -2 G -2 Boom (Five-Section Boom) 3. Check 4. Reassembly 3.1 Boom 4.1 Greasing Check the boom for twist, deformation, wrap, and • When installing unplated pins, apply grease cracks. beforehand. • Apply TNR-2 Grease sufficienty to the sliding 3.2 Slide plate surfaces of the slide plates, the booms and Check the slide plates for cracks and wear, and...
Page 121: Installing Lower Slide Plates
G -2 G -2 Boom (Five-Section Boom) 4.3 Installing lower slide plates 5. Adjustment 1. Apply thread locking agent to the bolt, tighten it 5.1 Adjusting clearance for the boom lightly and turn it in reverse for a quarter turn. 1.
Page 122: Operation Test
G -2 . G -2 . Boom (Five-Section Boom) 6. Test [NOTICE] ◆Bleed the telescoping cylinders completely and apply grease to the boom sliding surfaces before starting the tests. 6.1 Operation test Telescope the boom several times, and make sure that the telescoping operation is in order.
Page 123: Structure
G -3 G -3 G -3 Model TR-600XL TR-800XXL TT-800XXL Modification No. Applicable serial No. 545430~ 545419~ 475327~ 545410~ 545419~ 475326~ 1. Structure 545430~ 545419~ 475330~ 545460~ 545419~ 475330~ 1.1 Location of Jib W537-0101E...
Page 124 G -3 G -3 1.Support ass’y 11.Slide plate 21.Support ass’y 31.Control cable 2.Plate 12.Support ass’y 22.Support ass’y 32.Support 3.Pin ass’y 13.Support 23.Support ass’y 33.Spring 4.Bolt 14.Plate 24.Plate 34.Plate 5.Spring washer 15.Bolt 25.End 35.Pin ass’y 6.Plain washer 16.Nut 26.Pin 36.Stopper 7.Bolt 17.Plain washer 27.Split pin 37.Stopper...
Page 125: Jib Main Body
G -3 G -3 G -3 Model TR-600XL TR-800XXL TT-800XXL Modification No. Applicable serial No. 545410~ 545419~ 475326~ 1.2 Jib main body 545410~ 545419~ 475326~ 545410~ 545419~ 475326~ 545460~ 545419~ 475330~ W537-0101E...
Page 126 G -3 G -3 1.Jib 2 14.Spring washer 27.Split pin 40.Pin ass’y 2.Jib1 15.Pin ass’y 28.Stopper 41.Pin 3.Support 16.Spacer 29.Roller ass’y 42.Support 4.Snap pin 17.Sheave ass’y 30.Spacer 43.Spacer 5.Pin 18.Plate 31.Pin 44.Pin 32.Bar 45.Bolt 6.Pin 19.Pin 7.Retaining ring 20.---------------------- 33.Pin 46.Spring washer 8.Sheave ass’y 21.Link...
Page 127: Adjustment
G -3 G -3 2. Adjustment 2.1 Adjusting jib 1-2 connecting spring pin 2.2 Adjusting jib inclination Make sure that the clearance between the support In order to facilitate inserting and removing the and spring pin is 5 mm (0.2 in) while the jib 1 elevating pin, adjust the jib inclination by using a supports the jib 2.
Page 128: Adjusting Inclination Of Jib 2
G -3 . G -3 . 2.3 Adjusting inclination of jib 2 Slide plate Shim (t 0.6) Adjust the inclination to facilitate inserting and removing the jib 1-2 connecting pin. 1) If the rear end of the jib 2 is too low for the pin to be inserted and removed easily, apply shims (t0.6 mm (t0.02 in)) to the slide plate on the support on the boom rear end.
Page 129: Telescoping Cylinder
G -4 G -4 Telescoping Cylinder Telescoping Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 130 G -4 . G -4 . Telescoping Cylinder 11 12 31 13 14 15 16 17 18 IW157-0390E03 1.Plug 9.Cylinder 17.Plain bearing 2.Spring pin 10.Rod 18.Dust seal 3.Nut 11.O-ring 31.O-ring 4.Piston 12.Rod cover ass’y 5.Backup ring 13.Support 6.Packing 14.Damper ring 7.Plain bearing 15.Packing 8.O-ring...
Page 131: Counterbalance Valve (Telescoping)
G -5 G -5 Counterbalance Valve (Telescoping) Counterbalance Valve (Telescoping) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 132: Function
G -5 . G -5 . Counterbalance Valve (Telescoping) 2. Function IW119-022003 This counterbalance valve prevents the actuator 2.3 While actuator descends from being driven by the load and its own weight 1. The hydraulic oil directly flowing from the control faster than the speed corresponding to the oil valve to the actuator also enters through port PP supply rate.
Page 133: Hose Reel
G -6 G -6 Hose Reel Hose Reel [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 134: Dismounting
G -6 G -6 Hose Reel 2. Dismounting 1) Remove the protection plate from the case 4 and secure the case 4 in a sufficiently wide [NOTICE] space. When the circuit is suspected to retain high pressure oil, be sure to vent pressure before 2) Tie one end of a wire of a sufficient length to dismounting the hose reel.
Page 135 G -6 . G -6 . Hose Reel 2) With the lower side coated with grease, place spring in case clamped in a vise, and install the protection plates. 3) Fasten spring and pin with special bolt coated with screw locking compound. 4) Remove the vise pliers on the outer end side of spring and attach auxiliary spring.
Page 136: Hydraulic Valve
G -7 G -7 Hydraulic Valve Hydraulic Valve [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 137 G -7 . G -7 . Hydraulic Valve IW123-017003 1.Body 3.Cover 7.Spring 15.Hex. socket head bolt 2.Spool 6.Solenoid valve 10.O-ring 17.Plug 19.Orifice Thread size and tightening torque Tightening torque Thread Thread size ft-lbf Mounting bolt (for solenoid valve.6) △ 366-497-50000 W123-0170E...
Page 138 Safety System Contents ■ ■ Safety System Outrigger Extension Length Detector General............. 1 Structure and function ....... 8 Pressure sensor ......... 1 Disassembly..........9 Boom length and angle detector ....1 Outrigger extension width detector .... 1 Reassembly ..........10 Other detectors and switches.....
Page 139: Safety System
H-1 . H-1 . Safety System Safety System 1.6 Auti-twoblock Device 1. General The anti-twoblock device prevents damage to the crane that would be caused by pulling the hook 1.1 Pressure sensor block into the boom head. When the hook block approaches the boom head, single top or jib, the 1.
Page 140: Boom Length And Angle Detector
Boom Length and Angle Detector Boom Length and Angle Detector 2. The cord wound on the drum is unwound and [NOTICE] rewound by the recoil spring after the extension There is a case that the appearance and so on and retraction of the boom.The resultant drum differ from the parts for this machine.
Page 141 Boom Length and Angle Detector 1.Plate 16.Spring 31.Pin terminal 46.Cable 2.Case 17.Cover 32.Nut 47.Holder 3.Drum ass’y 18.Clip 33.Washer 48.Terminal 4.Slip ring ass’y 19.Clip 34.Screw 49.Terminal 5.Contact ass’y 20.Support 35.Bolt 50.Angle detector 6.Contact ass’y 21.Cord guide 36.Bolt 51.Plug 7.Bearing case 22.Collar 37.Screw 52.Thrust bearing 8.Bearing...
Page 142: Disassembly And Reassembly
Boom Length and Angle Detector Drum assy 2. Disassembly and reassembly 2.1 Removing the cord 1. Remove the connector and the cord lock from the end of the cord. Wind up the cord on the drum Plate slowly until no tension of the spiral spring is applied on the cord.
Page 143 Boom Length and Angle Detector Core wire original position after it is rotated a quarter turn by Cord finger and released. If it is not returned, loosen the bolt and adjust the position of the bracket. Shield wire [NOTICE] Drum assy If the potentiometer is faulty, replace it referring to Vinyl tube the "Replacing the potentiometer (boom length...
Page 144: Replacing Spiral Spring
Boom Length and Angle Detector 2.4 Disassembling the potentiometer 13. Draw out the cord slightly from the drum and (for boom length detector) make sure that the resistance between the red and white terminals increases smoothly. [NOTICE] If both the cord and spiral spring are faulty, remove 14.
Page 145: Reassembling Potentiometer
H-2 . H-2 . Boom Length and Angle Detector 2.5 Reassembling potentiometer 2.6 Replacing the boom angle detector 1. Install a new potentiometer. Disconnect the lead wires to the boom angle detector from the pin terminal section, and replace [NOTICE] the boom angle detector assy.
Page 146: Outrigger Extension Length Detector
Outrigger Extension Length Detector Outrigger Extension Length Detector [NOTICE] 3. The consequent rotation of the drum drives the There is a case that the appearance and so on potentiometer shaft through gears which reduce differ from the parts for this machine. Although there the speed to 5/6.
Page 147: Disassembly
Outrigger Extension Length Detector 1. Base plate 6. Nut 11. Screw 16. Screw 2. Drum assembly 7. Potentiometer 12. Set screw 17. Clamp 3. Case 8. Cover 13. Screw 18. Connector 4. Packing 9. Shaft 14. Gear•B 19. Cable 5. Gear•A 10.
Page 148: Reassembly
Outrigger Extension Length Detector 3. Reassembly 5. Remove bolt and separate drum assembly and base plate. 1. Put a zero marker on a new wire by winding a yellow tape on it. Then tie an auxiliary string of Drum assembly about 1.0 m (3.3 ft) in length to the terminal of the wire.
Page 149 H-3 . H-3 . Outrigger Extension Length Detector 4. Apply grease (Molyspeed Grease No.0) to the When replacing the potentiometer with a new one, bearing of case and put the case over drum mount it onto the bracket, then solder the cable to assembly.
Page 150: Solenoid Valve (Auto Stop)
Solenoid Valve (Auto Stop) Solenoid Valve (Auto Stop) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 151 H-4 . H-4 . Solenoid Valve (Auto Stop) Solenoid valve ass’y 1.Body 2.Plug 4.Spool 7.Spring seat 8.Square ring 9.O-ring 11.Spring 12.Solenoid (DC24V) IW121-0540E04 Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 44 - 49 32 - 36 39 - 49 29 - 36 4.4 –...
Page 152 Contents ■Crane Cab Glass Condenser Ass’y ........18 Glass replacement procedure ....1 Electric ............ 19 Electric circuit ..........19 Bonding the joint between windshield glass Main harness A .........20 and roof glass........ 2 Main harness B .........21 Important points for assembly (Layout) ... 22 ■Air Conditioner Evacuation ..........22 Charging with refrigerant......22...
Page 153 12.2 Compressor diagnosis chart (1/2) .... 39 13.Troubleshooting ........41 14.Control table ..........47 ■Hydraulic Motor (Air Conditioner) (Option) (~#475327) Structure ..........48 ■Hydraulic Motor (Air Conditioner) (Option) (#475328~) Structure ..........49 ■Solenoid Valve (Air Conditioner) (Option) (~#475354) Structure ..........51 ■Solenoid Valve (Air Conditioner) (Option) (#475355~) Structure ..........
Page 154: Crane Cab Glass
Crane Cab Glass Crane Cab Glass 6. Let the primer C coated surfaces dry for more than 15 minutes. 1. Glass replacement procedure 7. Clean and degrease the bonding surfaces of the Follow the procedure described below to replace new glass with a gauze soaked with white the fixed windshield window glass, roof glass, gasoline or acetone.
Page 155: Bonding The Joint Between Windshield Glass And Roof Glass
K-1 . K-1 . Crane Cab Glass while aligning the marks (masking tape pieces put [NOTICE] in Step 3) on the glass with those on the cab Wipe away any excessive adhesive. body. Rubber dam 11. Fit the molding on the circumference of the new Molding Glass glass and bond its end joint with an instant...
Page 156: Air Conditioner
Air Conditioner Air Conditioner [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 157: Introduction To Air Conditioning
Air Conditioner 2. Introduction to air conditioning (Absorbing heat from surroundings.) Vaporization [NOTICE] Liquid Vapor This section explains the fundamentals of the car air conditioner. Difficult concepts and special mechanisms have been omitted where possible, Condensation and only contents which focus on the basic (Radiating heat of vapor outward.) functions have been included.
Page 158: Basic Refrigeration Cycle
Air Conditioner 3. Basic refrigeration cycle 2. Compressor This component absorbs the gaseous refrigerant 3.1 Construction that was vaporized in the evaporator, and An ordinary air conditioner circulates a volatile compresses it to higher pressure so that it can be liquid (called a refrigerant) that is contained in more easily liquefied in the condenser.
Page 159: Conditions For Air Conditioning Equipment
Air Conditioner 3.2 Conditions for air conditioning equipment The conditions required for a high-performance air conditioner are the following. Refrigerant vaporizes at the lowest temperature possible. Refrigerant liquefies easily. The largest possible quantity of refrigerant vaporizes in the evaporator. 1. When we look at the conditions of the refrigerant 5.
Page 160: Refrigerant
Air Conditioner 3.3 Refrigerant 2. As shown in the figure below, the refrigerant 1. The substance that circulates through the HFC134a remains in liquid form at relatively high refrigeration cycle, and functions to transmit heat, temperatures when it is strongly compressed. is known as the refrigerant.
Page 161: Refrigeration Cycle Of A Car Air Conditioner
Air Conditioner 3.4 Refrigeration cycle of a car air conditioner 2. Compared with the basic refrigeration cycle 1. The refrigeration cycle of a car air conditioner described earlier, this cycle has an expansion comprises a compressor, condenser, receiver, valve with a different construction, and adds a expansion valve, and evaporator.
Page 162: Receiver Functions
Air Conditioner 2. Large variations in compressor speed 3. There are two types of receivers – block joint type The compressor of a household air conditioner is and union type. The difference is the means of maintained at a constant motor speed. The connecting the pipes.
Page 163: Reheat Method (Flow Control Valve)
Air Conditioner 3.7 Reheat method (flow control valve) 2. With this method, the temperature is controlled by 1. The air which cools (or heats) the cab is taken in changing the opening of a water valve that is from outside (or inside) by a blower motor, and attached to the heater unit.
Page 164: Components
Air Conditioner 3.8 Components Air circulation inside cab LCD panel Outside-cab air supply COOL Min. Max. Cool Face Face and foot Foot The current volume The current temperature IW701-0160E14 Switches Sign on the LCD panel 1.Power switch 8.Sign of air supply selection 2.Air conditioner switch 9.Sign of air conditioner operation (Snow-shaped sign) 3.Inside/outside air selector switch...
Page 165 Air Conditioner Air outlet changeover switch WARNING This switch is used to select the air blowing While the engine and the air conditioner are direction. As it is pressed, the direction changes running, be sure not to touch the rotating objects (fan belt, condenser fan, etc).
Page 166: Layout
Air Conditioner 4. Layout 4.1 Overall layout W701-0160E...
Page 167: Overall Layout
Air Conditioner 4.2 Overall layout W701-0160E...
Page 168: Evaporator Section
Air Conditioner 4.3 Evaporator section W701-0160E...
Page 169: Compressor Ass'y
Air Conditioner 5. Compressor ass’y W701-0160E...
Page 170: Evaporator Ass'y
Air Conditioner 6. Evaporator ass’y W701-0160E...
Page 171: Condenser Ass'y
Air Conditioner 7. Condenser ass’y W701-0160E...
Page 172: Electric
Air Conditioner 8. Electric 8.1 Electric circuit △ 363-205-60030 W701-0160E...
Page 173: Main Harness A
Air Conditioner 8.2 Main harness A W701-0160E...
Page 174: Main Harness B
Air Conditioner 8.3 Main harness B W701-0160E...
Page 175: Important Points For Assembly (Layout)
Air Conditioner 9. Important points for assembly (Layout) 9.1 Evacuation [NOTICE] If moisture and air are not fully eliminated from the cycle, they will cause problems such as cooling trouble and clogs in the cycle. 1. Evacuate by applying vacuum to the high- and low-pressure service valves.
Page 176: Check For Gas Leakage And Amount Of Refrigerant Charge
Air Conditioner 9.3 Check for gas leakage and amount of 9.5 Run-in operation refrigerant charge Operate the A/C for 5 minutes or more under the [NOTICE] conditions below to perform the initial run-in Never check using a halide-torch type leak detector. operation.
Page 177: How To Charge Air Conditioner Gas
Air Conditioner 10. How to charge air conditioner gas 10.1 Charging gas in automatic operation Gas charging unit (Reference) W701-0160E...
Page 178 Air Conditioner Flow Jigs and Procedure Safety point tools Plug the power supply cord of the main unit. Connect the coupler of the high-pressure side (red hose) and the Be careful to the low-pressure side with the compressor main body sequentially. scaffold Purge residual pressure before connecting because the connection of coupler becomes firm if there is residual pressure in...
Page 179: How To Charge Air Conditioner Gas
Air Conditioner 10.2 How to charge air conditioner gas Flow Jigs and Procedure Safety point tools Plug the power supply cord of the main unit. Connect the coupler of the high-pressure side (red hose) and the Be careful to the low-pressure side with the compressor main body sequentially.
Page 180 Air Conditioner Flow Jigs and Procedure Safety point tools Detach the empty gas can, and 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.
Page 181: How To Check Air Conditioner
Air Conditioner 10.3 How to check air conditioner Jigs Flow Procedure Safety point tools Illumination lamp check (for control panel) 1) The lamp lights with the working lamp switch ON. (Two lamps Lights both 2 lamps. on upper and lower of center in the panel.) 2) The lamp turns off with the working lamp switch OFF.
Page 182: Diagnosis Table
Air Conditioner 11 Diagnosis table 11.1 Car air conditioner system diagnosis table I (Refrigeration circuit) A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure...
Page 183 Air Conditioner A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure repair method) Remove blocked foreign object, or ------------------------------ TXV failure (blocking) replace TXV and R/D.
Page 184 Air Conditioner A/C system Status explanation Measures (specific Phenomenon explanation to Diagnosis result (phenomenon of trouble of A/C system Possible cause part name and consider other factors principal cause) phenomenon pressure repair method) Check that thermo Evaporator is frosting. Thermistor Installation position failure of therms sensor is in is not cold.
Page 185: Car Air Conditioner System Diagnosis Table
Air Conditioner 11.2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure) Trouble Diagnosis result phenomena Phenomenon explanation to Measures (specific part name Disorder section (phenomenon of principal Possible cause other than A/C consider other factors and repair method) cause)
Page 186 Air Conditioner Trouble Diagnosis result phenomena Phenomenon explanation to Measures (specific part name Disorder section (phenomenon of principal Possible cause other than A/C consider other factors and repair method) cause) system Noise sounds. Engine room side Sound is generated when -------------------------------- Vibration or slip by belt Tension belt, replace, or...
Page 187 Air Conditioner 11.3 Car air conditioner system diagnosis table III (Electrical system) Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part phenomenon of check and and confirmation (phenomenon of name and repair method) functional parts confirmation principal cause) 1) Neither...
Page 188 Air Conditioner Operation trouble First operation Second operation check Diagnosis result Possible cause Measures (specific part phenomenon of check and and confirmation (phenomenon of name and repair method) functional parts confirmation principal cause) 6) Compressor Measure clutch -------------------------------- ---------------------------- Clutch suction voltage is low (7V Repair or replace parts.
Page 189 Air Conditioner 11.4 Car air conditioner system diagnosis table IV (Electronic thermo system) Operation Measures Guessing of Diagnosis result trouble Check and confirmation of (Thermistor amplifier trouble functional (Refer to temperature Possible cause phenomenon of operational parts replacement, and connector parts characteristic for thermistor.) functional parts...
Page 190: (Electronic Thermo System)
Air Conditioner Operation Measures Guessing of Diagnosis result trouble Check and confirmation of (Thermistor amplifier trouble functional (Refer to temperature Possible cause phenomenon of operational parts replacement, and connector parts characteristic for thermistor.) functional parts repair.) Insufficient Replaces Insufficient cooling status does -------------------------------- Thermo amp.
Page 191: Compressor
Air Conditioner 12. Compressor 12.1 Compressor abnormal sound diagnosis chart Action Cause Phenomenon Diagnosis Confirm user's comments well, Claimed of abnormal sound When clutch ON. Abnormal sound. Replace main unit. and reproduce the sound. Shaking caused by belt looseness. Adjust belt tension. Looseness of bolts and screws.
Page 192 Air Conditioner 12.2 Compressor diagnosis chart (1/2) Phenomenon and diagnosis result Cause Remedy Compressor does not work. Clutch terminal voltage is normal. 12V or 24V Clutch seizure. Repair Clutch terminal voltage low. Amateur and rotor clearance failure. (airgap failure) Repair Clutch terminal voltage none.
Page 193: Compressor Diagnosis Chart (1/2)
Air Conditioner Compressor diagnosis chart (2/2) Phenomenon and diagnosis result Cause Remedy Engine room side When clutch is disengaged. Clutch bearing failure. (roller) Repair Contact and slipping by airgap failure. Idle pulley bearing failure. Refer to "Car air conditioner Deflection of V-belt. system diagnosis table II".
Page 194: Troubleshooting
Air Conditioner 13.Troubleshooting Blowout temperature does not fall. Is snow mark on panel blinking? ＮｏＹｅｓ When setting temperature is COOL-MAX, • Open or short circuit of eva-sensor. and blowout mode is Vent mode, is air mix • Controller failure. dumper a position of cool-max? Ｎｏ...
Page 195 Air Conditioner Blowout temperature does not rise. When setting temperature is HOT-MAX, and blowout mode is Foot mode, is air mix dumper a position of hot-max? ＹｅｓＮｏ Check warm water piping. • Disconnect or contact failure of air mix M/A connector. •...
Page 196 Air Conditioner Blower motor does not operate. Is there a battery voltage on both blower motor terminals (+) and (-) with air blow HI? (Note 1) ＮｏＹｅｓ Is there battery voltage between Replace blower motor. blower motor (+) red and body? Ｎｏ...
Page 197 Air Conditioner Magnet clutch does not engage. Does snow mark light when A/C switch is pressed? ＮｏＹｅｓ Is there a voltage on clutch? Snow mark is blinking. ＮｏＹｅｓ • Open or short circuit Is there a voltage between pressure Clutch failure, and replace compressor.
Page 198 Air Conditioner Inside and outside air cannot be switched. Is inside and outside air mode indicator in operation panel LCD blinking? ＮｏＹｅｓ Is any foreign object adhering to Inside and outside air M/A M/A lever? connector disconnection or Or, has M/A lever been damaged? contact failure, or M/A failure or main harness failure.
Page 199 Air Conditioner Mode cannot be switched. Is human shape indicator in operation panel LCD blinking? ＮｏＹｅｓ Is rod of M/A installed properly? Inside and outside air M/A connector disconnection or ＮｏＹｅｓ contact failure, or M/A failure or main harness failure. Correct Are levers of dumpers installed properly?
Page 200: Control Table
K-2 . K-2 . K-2 . Air Conditioner 14.Control table Input Output Input from Panel LCD display on panel Blowout mode In/outside air ON/OFF In/outside A/C switch Blowout mode Air blow mode Relay change switch mode Switch air switch INPUT/OUTPU T CONTROL FACE Circulated...
Page 201: Hydraulic Motor (Air Conditioner) (Option) (~#475327)
K-3 . K-3 . Hydraulic Motor (Air Conditioner) (Option) (~#475327) Hydraulic Motor (Air Conditioner) (Option) (~#475327) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 202: Hydraulic Motor (Air Conditioner) (Option) (#475328~)
Hydraulic Motor (Air Conditioner) (Option) (#475328~) Hydraulic Motor (Air Conditioner) (Option) (#475328~) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 203 K-4 . K-4 . Hydraulic Motor (Air Conditioner) (Option) (#475328~) 25 20 IW102-037003 IW102-037002 1.Casing 8.Tapered roller bearing 15.Spring washer 22.Steel ball 5/16 2.Drive shaft 9.Tapered roller bearing 16.Key (7×7×30) 23.Spring retainer 3.Pintle 10.Timing pin 17…. 24.O-ring 4.Cylinder block 11.Timing ring 18….
Page 204: Solenoid Valve (Air Conditioner) (Option) (~#475354)
Solenoid Valve (Air Conditioner) (Option) (~#475354) Solenoid Valve (Air Conditioner) (Option) (~#475354) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 205 K-5 . K-5 . Solenoid Valve (Air Conditioner) (Option) (~#475354) Solenoid valve ass’y IW121-025003 1.Body 7.Spring seat 11.Spring 2.Plug 8.Square ring 12.Solenoid (DC24V) 3.Spool 9.O-ring 15.Hex. socket head bolt Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 44 - 49 32 - 36 39 - 49...
Page 206: Solenoid Valve (Air Conditioner) (Option) (#475355~)
Solenoid Valve (Air Conditioner) (Option) (#475355~) Solenoid Valve (Air Conditioner) (Option) (#475355~) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 207 K-6 . K-6 . Solenoid Valve (Air Conditioner) (Option) (#475355~) Solenoid valve ass’y 157 156 IW121-076003 1.Body 15.Hex. socket head bolt 71.Spring 157.Solenoid (DC24V) 4.Plug 21.Spool 113.Square ring 159.O-ring 9.O-ring 60.Spring seat 156.O-ring Thread size and tightening torque Tightening torque Thread Thread size ft-lbf...
Page 208 Control System Contents ■ ■ Control System Solenoid Control Relief Valve (Elevating Slow Stop) (~#475348) Crane control devices ....... 1 Structure ..........14 ■ Remote Control Valve (Lever) ■ Solenoid Control Relief Valve (Elevating Slow Structure ........... 3 Stop) (#475349~) Structure ..........
Page 209: Control System
L - 1 L - 1 Control System Control System 1. Crane control devices Counterweight mounting/dismounting position indicator lamp (option) AML cancellation warning lamp Jib lock indicator lamp Hydraulic oil temperature 122°F (50°C) indicator lamp Hydraulic oil temperature 185°F (85°C) warning lamp Outrigger switch non-neutral position lamp (option) Boom telescoping operation indicator lamp Auxiliary hoist operation indicator lamp...
Page 210 L - 1 . L - 1 . Control System Outrigger state emergency register indicator lamp 2nd boom emergency telescoping switch Outrigger state emergency register switch 3rd/top boom emergency telescoping switch Oil cooler switch Jib state switch Drum indicator switch (option) Jib removed indicator lamp Flood lamp switch Air conditioner control panel (option)
Page 211: Remote Control Valve (Lever)
L - 2 L - 2 Remote Control Valve (Lever) Remote Control Valve (Lever) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 212 L - 2 L - 2 Remote Control Valve (Lever) Cross section along the line A-A PORTS 1&• 3 PORTS 2&• 4 IW135-0130E03 101.Casing 171.Bolt 216.Spring seat 445.Hex. socket head bolt 103.Casing 172.Nut 217.Washer 452.Disc 111.Port plate 201.Spool 221.Spring 453.Cam shaft 122.O-ring 211.Plug 241.Spring...
Page 213 L - 2 . L - 2 . Remote Control Valve (Lever) Thread size and tightening torque Tightening torque Thread Thread size ft-lbf P, T G1/4 34 - 38 25 - 28 PORTS 1, 2, 3, 4 G1/4 34 - 38 25 - 28 27 - 31 20 - 23...
Page 214: Remote Control Valve (Pedal) (~#475341)
L - 3 L - 3 Remote Control Valve (Pedal) (~#475341) Remote Control Valve (Pedal) (~#475341) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 215 L - 3 . L - 3 . Remote Control Valve (Pedal) (~#475341) Cross section along the line A-A P1 (P3) P2 (P4) IW135-014002 1.Valve body 8.Valve 15.Retainer 22.Collar 2.Valve body 9.Filter 16.Boot 23.Seal 3.Spacer 10.Spring 17.Plate 24.Lever 4.Bolt 11.Plug 18.Bolt 25.Ring 5.Nut...
Page 216: Remote Control Valve (Pedal) (#475342~)
L - 4 L - 4 Remote Control Valve (Pedal) (#475342~) Remote Control Valve (Pedal) (#475342~) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 217 L - 4 L - 4 Remote Control Valve (Pedal) (#475342~) Section A-A 2,4,6 1,3,5 IW135-015003 273.Nut 413.Cam shaft 101.Casing 214.Push rod 301.Spool 414.Bush 102.Casing 217.Shim 311.Spring seat 420.Cam 103.Casing 251.RO plug 313.Washer 431.Block 115.Plate 261.O-ring 315.Iock nut 471.Ball 201.Cover 262.O-ring 323.Iever 472.Set screw...
Page 218 L - 4 . L - 4 . Remote Control Valve (Pedal) (#475342~) Thread size and tightening torque Tightening torque Thread Thread size ft-lbf 19.1 - 22.1 14.1 - 16.3 8.7 - 8.9 6.4 - 6.6 G1/4 27.4 - 31.4 20.2 - 23.2 56.3 - 61.3 41.5 - 45.2...
Page 219: Shuttle Valve (Lever / Pedal)
L - 5 . L - 5 . Shuttle Valve (Lever/Pedal) Shuttle Valve (Lever / Pedal) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 220: Solenoid Valve
L - 6 L - 6 Solenoid Valve (Boom Telescoping/Aux. Hoist) Solenoid Valve (Boom Telescoping / Aux. Hoist) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 221 L - 6 . L - 6 . Solenoid Valve (Boom Telescoping/Aux. Hoist) Cross section along the line X-X B (F) D (H) C (G) A (E) IW121-031003 Note: Apply LOCTITE 262 (thread locking agent) to the threaded section of the seat (1). 1.Seat 5.Solenoid (DC24V) 11.Plain washer...
Page 222: Solenoid Control Relief Valve (Elevating Slow Stop) (~#475348)
L - 7 . L - 7 . Solenoid Control Relief Valve (Elevating Slow Stop) (~#475348) Solenoid Control Relief Valve (Elevating Slow Stop) (~#475348) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 223 L - 8 L - 8 Solenoid Control Relief Valve (Elevating Slow Stop) (#475349~) Solenoid Control Relief Valve (Elevating Slow Stop) (#475349~) [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.
Page 224 L - 8 . L - 8 . Solenoid Control Relief Valve (Elevating Slow Stop) (#475349~) Proportional Reducing Value 326 324 312 361 IW136-0250E02 311.Spool 326.Retaining ring 362.O-ring 861.O-ring 312.Sleeve 331.Spring seat 363.O-ring 324.Spring 351.Orifice 801.Proportional reducing valve 325.C-ring 361.O-ring 802.Seal nut Thread size and tightening torque Tightening torque...
Page 225 Data, Adjustment and Checks Contents ■ Hydraulic Pressure Setting Table ....1 2nd boom full retraction detection limit switch (L8) ........6 ■ Jib stowed detection proximity Air Bleeding Procedure switch (CS10) ........ 6 Hydraulic pump......... 2 Jib lock pin retraction detection limit Accelerator circuit ........
Page 226 ■ 12. Counterweight stowing position detection Boom Connecting Pin and Thread Size Table switch•1 (CS24) and switch•2 (CS25) ............ 23 ............9 13. Front jack full retraction detection switch (S087) ......... 10 ■ Check (Crane Operation) Hoisting............11 .............11 Detection of contact of the front jack with ground ....11 Setup the outrigger emergency....11 Upper outrigger operation (option): It...
Page 227: Hydraulic Pressure Setting Table
Y-1 . Y-1 . Y-1 . Hydraulic Pressure Setting Table Hydraulic Pressure Setting Table △ 345-801-01500 WY02-0320E...
Page 228: Air Bleeding Procedure
Air Bleeding Procedure Air Bleeding Procedure 1. Hydraulic pump [NOTICE] After replacing hydraulic pump or hydraulic oil, be sure to bleed the circuit as follows. Without bleeding the circuit, the hydraulic pump will be broken. Hydraulic pump FRONT Air bleeding plug G1/4 ( O-ring) Hydraulic oil tank...
Page 229: Accelerator Circuit
Air Bleeding Procedure 2. Accelerator circuit 3. Swing circuit 1. Bleed the accelerator circuit by depressing the 3.1 Swing motor accelerator pedal in the crane operator’s cab Bleed the swing motor by following either (1), (2) or repeatedly with the carrier engine stopped. (there (3).
Page 230: Winch Circuit (Main And Aux.)
Air Bleeding Procedure 4. Winch circuit (main and aux.) 5. Jib lock pin and jib offset cylinder [NOTICE] [NOTICE] Bleed the main and auxiliary winch circuits by Bleed the jib lock pin, jib offset cylinder by following following the procedures below. The procedures are either (1), (2), or (3).
Page 231: Hydraulic Pilot Circuit
Y-2 . Y-2 . Air Bleeding Procedure 6. Hydraulic pilot circuit 7. Oil cooler motor Pour the hydraulic oil through the drain port into the 6.1 Swing casing until the oil flows out. Set the hydraulic oil temperature to 50 C (122 F) or higher, set the PTO switch and the swing brake...
Page 232: Electric Switch Adjustment
Electric Switch Adjustment Tightening torque : Electric Switch Adjustment 33in-lbf (3.7N-m) (*1) 1. 3rd / top boom full retraction detection limit switch (L7) Adjust the switch position so that its contact is shifted (opened/closed) when the top boom section is extended/retracted beyond the position where it is 5-8 mm (0.2-0.31 in) longer than its fully retracted length.
Page 233: Switch (L8)
Electric Switch Adjustment 4. Jib lock pin retraction detection limit switch (L1) Adjust the switch position so that the dimension A becomes 30.5 –31.5mm (1.2 –1.24 in) with the switch in free position. (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent).
Page 234: Swing Brake Holding Detection
Electric Switch Adjustment 8. Swing brake holding detection switch (CS23) Adjust the switch position so that the dimension A bocomes 2-2.5 mm (0.08-0.1 in) (*1): Apply the screw locking agent (Three-Bond 1401 or the equivalent). (*1) Tightening torque 8.7 in•lbf (1 N•m) or less IWY04-0490E01 9.
Page 235: Counterweight Equipped Detection Switch•1
Electric Switch Adjustment 11. Counterweight equipped detection 12. Counterweight stowing position switch•1 (CS18), switch•2 detection switch•1 (CS24) and (CS19) and switch•3 (CS20) switch•2 (CS25) [Condition] Adjust the switch position so that the dimension G becomes 2 mm (0.08 in) - 6 mm (0.24 in) or less, •...
Page 236: Front Jack Full Retraction Detection Switch (S087)
Y-3 . Y-3 . Electric Switch Adjustment 13. Front jack full retraction detection Adjust the switch position so that the dimension A switch (S087) becomes 4-5 mm (0.16-0.2 in) (It is possible to adjust it by placing an acrylic 1. Adjust the switch position so that the dimension A board or vinyl chloride board.) becomes 1.5~2 mm (0.06~0.08 in) (*1): Apply the screw locking agent (Three-Bond...
Page 237: Check (Crane Operation)
Check (Crane Operation) Check (Crane Operation) seconds after the jack float touches the ground. Make sure that the front jack indicative symbol on 1. Hoisting the AML is hightlighted in this situation. [Condition] 4. Setup the outrigger emergency • Load :None •...
Page 238: Alarms
Check (Crane Operation) 6. Alarms Type of Item Sound Checking procedure alarm • Buzzer sounds ten seconds later if either Ext./Ret. • 2300Hz O/R switch selection switch or Jack/Slide selection switch is actuated Electric non-neutral position • continous and none of O/R button is operated. buzzer alarm Piiii...
Page 239: Adjustment Procedure Of Front Jack Overload
Y-4 . Y-4 . Check (Crane Operation) 7. Adjustment procedure of front jack overload detector switch (S660) 1. Remove the cap of front jack overload detector switch installed to the front jack head, and loosen the lock nut. 2. Tighten the adjusting screw one turn clockwise. 3.
Page 240: Adjustment And Checks
Adjustment and Checks △ Adjustment and Checks Applicable serial No. ：475338 ~ 1. Engine speed adjustment procedure (MAX. use length at operating) Engine idling Engine MAX 101mm(4.0in) E1=0.15～0.25V Bolt 130mm(5.1in) Potentiometer Lever [20mm(0.79in)] Bolt Cylinder rod Bolt Bolt [23mm(0.91in)] [20mm(0.79in)] Link ASSY IWY05-0730E01 1.1 Speed control...
Page 241 Adjustment and Checks +22.5 Electrical travel （゜） Potentiometer output characteristics IWY05-0730E03 4. Adjust the rod length with nut D so that the gap C of the cylinder rod and the pin may have the play of 2-3 mm (0.08-0.12 in) at all retracting the cylinder rod manually.
Page 242: Accelerator Pedal
Adjustment and Checks 1.2 Accelerator pedal Bolt Knob Lever Spring Accelerator pedal Cylinder rod Bolt IWY05-0730E04 1. Remove the spring. 9. Depress the pedal unit the maximum engine speed (whith no-load) can be secured, apply the 2. Adjust height H of the padal with the end D and bolt C to the pedal, screw in the bolt one turn from cylinder rod to 175-185 mm (6.9-7.3 in) that state, and lock the bolt with nut.
Page 243: Adjusting Boom Telescoping Wire Ropes
Adjustment and Checks 2. Adjusting 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). [NOTICE] Loosen the sway stopper bolt on the bottom of each boom section until it is out of contact with the support.
Page 244 Adjustment and Checks 4. Tighten the nut-A until the top and 4th boom sections are fully retracted. 5. 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. 6.
Page 245 Adjustment and Checks 8. When the wire rope is tense: 8.1 Tighten nut-A by approx. a third turn. 8.2 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. 9.
Page 246 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. WY05-0730E...
Page 247: Oils And Grease Table
Y-6 . Oils and Grease Table Oils and Grease Table Item Quantity : L (gal) Remarks Hydraulic oil 920 (243) TADANO Hydraulic Oil LL Swing ass’y 3.8 (1.0) Mobil Gear 632 Main 4.0 (1.1) ISO VG 320 Winch ass’y Gear oil API Service Class GL-3 Aux.
Page 248: Mass Table
Y-7 . Y-7 . Mass Table Mass Table Spec. No. Part Name GT-800-1-90102 2M2D (North America) Boom ass’y (including telescoping 11470kg (25290lbf) cylinder, jib-1 and jib-2) Telescoping cylinder (No.1) 790kg (1740lbf) Boom Telescoping cylinder (No.2) 880kg (1940lbf) Jib-1 560kg (1230lbf) Jib-2 280kg (620lbf) Elevating cylinder...
Page 249 Y-8 . Y-8 . Boom Connecting Pin and Thread Size Table Boom Connecting Pin and Thread Size Table Applicable model: TR-450XL-4, TR-500XL-4 (mm) Part Name Diameter Thread size Rod end pin Φ100 M30×3.5 Elevating cylinder Base pin Φ90 M30×3.5 M16×2.0 Boom base pin Φ90 (Qty:4)
Page 250 System Diagrams Contents ■ ■ Hydraulic Circuit ........... 1 Harness (Boom) ......... 12 ■ ■ Electric Circuit ..........2 Harness (AML, Upper)........ 13 ■ ■ Electric Circuit (Outrigger Operation, Option) 3 Harness (Lower)......... 14 ■ ■ Location of Hydraulic Parts ......4 Harness (Outrigger Operation, Option) ..
Page 251: Hydraulic Circuit
Z - 1 . Z - 1 . Z - 1 . Hydraulic Circuit △ Applicable serial No. ：475328 ~ △ ：475326 ~ △ ：475355 ~ Hydraulic Circuit △ 344-018-10000 WZ01-1140E...
Page 252: Electric Circuit
Z - 2 . Z - 2 . Model TT-800XXL TT-600XL Z - 2 . Modification No. Applicable serial No. Electric Circuit 475332~ 475334~ 475355~ 437382~ Electric Circuit △ 344-118-80001 WZ03-1830E...
Page 253: Electric Circuit (Outrigger Operation, Option)
Z - 3 . Z-3. Z-3. Electric Circuit (Outrigger operation, option) Electric Circuit (Outrigger Operation, Option) △ 333-316-60010 WZ03-1841E...
Page 254: Location Of Hydraulic Parts
Z - 4 . Z - 4 . Z - 4 . Location of Hydraulic Parts Location of Hydraulic Parts WZ07-0780E...
Page 255: Location Of Electric Parts (Upper)
Z - 5 . Z - 5 . Z - 5 . Location of Electric Parts (Upper) △ Applicable serial No. ：475338 ~ Location of Electric Parts (Upper) WZ02-1380E...
Page 256 Z - 6 . Z - 6 . Z - 6 . Location of Electric Parts (Lower) △ Applicable serial No. ：475334 ~ Location of Electric Parts (Lower) [NOTICE] For error of transmitter refer to Table 1,2,3,4. Table 1 Light emitting diode display Content of error LED1 LED2...
Page 257: Location Of Electrical Parts
Z - 7 . Z - 7 . Z - 7 . Location of Electrical Parts (Outrigger Operation, Option) Location of Electrical Parts (Outrigger Operation, Option) △ 333-316-60300 △ 333-316-60000 WZ02-1400E...
Page 258 Z - 8 . Z - 8 . Z - 8 . Hydraulic, Electric, Carrier Equipment Comparison Table Hydraulic, Electric, Carrier Equipment Comparison Table Parts Name Parts Name Parts Name Parts Name Oil tank Pressure switch (PS10) Bubble level (Illumination) 2nd boom section emergency telescoping switch (S2) Oil filter Remote control valve (pedal)
Page 259 Z - 8 . Z - 8 . Z - 8 . Hydraulic, Electric, Carrier Equipment Comparison Table WZ09-0130E...
Page 260: Harness (Inside Cab)
Z - 9 . Z - 9 . Z - 9 . Model TT-800XXL TT-600XL Harness (Inside Cab) Modification No. Applicable serial No. (*1) In case of TT-800XXL Head-end boom extension switch 475355~ 437382~ Harness (Inside Cab) △ 343-530-31010 WZ04-1290E...
Page 261: Harness (Swing Table Left)
Z -1 0 . Z - 1 0 . Z -1 0 . Harness (Swing Table Left) Model TR-600XL TR-800XXL GR-700EXL TT-800XXL TT-600XL Modification No. Applicable serial No. Harness (Swing Table, Left) 475326~ 545430~ 545430~ 475329~ 545473~ 545473~ 475342~ 437295~ 545485~ 545485~ 545485~...
Page 262: Harness (Swing Table, Right)
Z -1 1 . Z - 1 1 . Z -1 1 . Harness (Swing Table, Right) Harness (Swing Table, Right) △ 343-530-32010 WZ04-1300E...
Page 263: Harness (Boom)
Z -1 2 . Z - 1 2 . Z -1 2 . Harness (Boom) Harness (Boom) △ 343-530-22030 △ 343-530-32040 WZ04-1310E...
Page 264: Harness (Aml, Upper)
Z -1 3 . Z - 1 3 . Z -1 3 . Harness (AML, Upper) Harness (AML, Upper) Model TR-600XL TR-800XXL TT-800XXL Modification No. Applicable serial No. 545419~ 545419~ 475327~ 545410~ 545419~ 475326~ 545410~ 545419~ 475326~ △ 343-625-71100 WZ04-1320E...
Page 265: Harness (Lower)
Z -1 4 . Z - 1 4 . Z -1 4 . Harness (Lower) △ Applicable serial No. ：475334 ~ Harness (Lower) △ 336-500-30021 WZ04-1320E...
Page 266: Harness (Outrigger Operation, Option)
Z -1 5 . Z - 1 5 . Z -1 5 . Harness (Outrigger Operation, Option) Harness (Outrigger Operation, Option) △ 333-316-60020 WZ04-1330E...
Page 267 Head Office 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-R001...

Tadano TT-800XXL1 Service Manual

B Hydraulic Power Generating System

Functions of Units

Structure

Structure

Structure

Potentiometer

Structure

Structure

Structure

Structure

Structure

Structure

Structure

Hydraulic Motor (Oil Cooler)

Jib Lock Pin

Jib Offset Cylinder

Counterweight Cylinder

Pilot Check Valve

D Swing System

Structure

Swing Slow Stop

Structure

Swing Bearing Mounting Bolt

Structure

Structure

Structure

Boom Elevation System

Structure

Structure

Function

Structure

Winch System

Structure

Air Bleeding Procedure

1 Structure

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Principle of Operation

Telescoping System

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Summary of Contents for Tadano TT-800XXL1