Tadano TM-2000-1 Service Manual
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Tadano TM-2000-1 Service Manual

Tadano TM-2000-1 Service Manual

Boom truck
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◯ ｃ 2006
PRINTED IN JAPAN
0609
K
01
Boom Truck
TM-2000-
Model
Applicable Serial No.
TM-2000-1/S1(U)-1E
Publication No.
1
EX0069～

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Summary of Contents for Tadano TM-2000-1

  • Page 1 TM-2000-1/S1(U)-1E Publication No. Boom Truck TM-2000- Model Applicable Serial No. EX0069～ ◯ ｃ 2006 PRINTED IN JAPAN 0609...
  • Page 2 Safety Safety [NOTICE] [NOTICE] indicates an important operational or Most accidents that occur during machine operation maintenance procedure or condition, which, if not and maintenance are caused by failure to observe strictly observed, can result in damage to machine components or deteriorated machine performance. basic safety rules and precautions.
  • 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 1.1 Unit No. of the TM-2000-1 series This manual contains information on the systems Boom Frame nameplate Spec. nameplate and components of TM-2000-1 series cranes. unit No. unit No. It also contains repair, inspection, and adjustment procedures for those systems and components.
  • Page 7 Foreword 3. Outline of specifications Spec. No. Item TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 TM-2000-1 -104 -304 -114 -314 -204 -214 -404 -414 No. of boom 5-section sections Winch Hydraulic motor driven, planetary gear speed reduction, provided with automatic brake Outriggers Min.7.15’...
  • 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...
  • Page 9 Foreword Torque inch-pound, N-cm kgf-cm kgf-m foot-pound, ft-lb in-lb 1×10 1.01972×10 1.01972×10 0.00737 0.0885 1×10 1.01972×10 1.01972×10 0.7376 8.851 9.80665 9.80665×10 1×10 0.0723 0.868 9.80665×10 9.80665 1×10 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 °C °F °C...
  • Page 10 GROUP INDEX Hydraulic Power Generating System Outrigger System Swing System Boom Elevating System Winch System Boom Telescoping System Safety System Radio-control System Data, Adjustment and Checks System Diagrams WA04-2140E...
  • Page 11 Foreword 5. Contents TM-2000-1 Spec. No. Chapter Section -104 -304 -114 -314 -204 -214 -404 -414 General Refer to separate manual General Cautions SA01-01-2E Hydraulic Pressure Generating System Manual Control Valve(Boom elevating, telescoping, swing, outrigger, high / low shift) Manual Control Valve (Outrigger)
  • Page 12 Foreword TM-2000-1 Spec. No. Chapter Section -104 -304 -114 -314 -204 -214 -404 -414 Pilot Check Valve (Front and rear – stabilizer) Pilot Check Valve (Outrigger jack and front outrigger jack) Power Slide Cylinder (Outrigger and front outrigger) Power Slide Cylinder (Rear stabilizer) –...
  • Page 13 Foreword TM-2000-1 Spec. No. Chapter Section -104 -304 -114 -314 -204 -214 -404 -414 Boom T elescoping System General description of telescoping system Boom (Five-section boom) Telescoping Cylinder Counterbalance Valve (Telescoping) Safety Devices AMA (Load moment indicator) Boom Length / Angle Detector...
  • Page 14 -104 -304 -114 -314 -204 -214 -404 -414 System Diagrams Hydraulic Circuit (Spec. No.: TM-2000-1-104, 114, 204, 214) Hydraulic Circuit (Spec. No.: TM-2000-1-304, 314, 404, 414) Electric Circuit (Spec. No.: TM-2000-1-104, 204) Electric Circuit (Spec. No.: TM-2000-1-114, 214) Electric Circuit (Spec.

  • Page 15: Table Of Contents

    Hydraulic Power Generating System Contents B-1 Manual Control Valve (Boom B-7 Solenoid Valve (Winch high speed elevating, telescoping, swing, & swing brake) .......19 outrigger, high/low shift)....1 Structure ..........19 Structure ........... 1 B-8 Solenoid Valve B-2 Manual Control Valve (Winch unload).......21 (Outrigger)........

  • Page 16: Manual Control Valve (Boom Elevating, Telescoping, Swing, Outrigger, High/Low Shift)

    Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Manual Control Valve (Boom elevating, telescoping, swing, outrigger, high/low shift) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations.
  • Page 17 Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Cross section Body assy 1. Body assy 5. Valve (Telescoping) 9. O-ring 13. Relief valve (PR1) 2. Valve (Swing) 6. Valve (Confluence) 10. Relief valve (RV1) 14.
  • Page 18 Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Valve (Swing) Body assy 11. Relief valve (RV2) 36. O-ring 43. Hexagon socket bolt 57. Screw 12. Relief valve (RV3) 37. Oil seal 44. Hexagon socket bolt 58.
  • Page 19 Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Valve (Elevation) Valve (Telescoping) Valve (Confluence) 13. Relief valve (PR1) 38. Retainer 44. Hexagon socket bolt 81. Rod end 33. Check valve 39. Retainer 45. Plug 82.
  • Page 20 Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Relief valve (RV1) Relief valve (RV2) 10. Relief valve (RV1) 106.O-ring 112.O-ring 140.Backup ring 11. Relief valve (RV2) 107.O-ring 113.Nut 141.Backup ring 62. O-ring 108.Body 114.Cap nut 142.Backup ring 103.O-ring 109.Regulator valve...
  • Page 21 B-1 . B-1 . Manual Control Valve (Boom eleva ting, tele scoping, s wing, outri gger, high/low shift) Relief valve (RV3) Relief valve (PR1) 12. Relief valve (RV3) 111.Screw 151.Body 157.Body 13. Relief valve (PR1) 113.Nut 154.O-ring 158.O-ring 109.Regulator valve 114.Cap nut 155.Backup ring 159.Backup ring...

  • Page 22: Manual Control Valve

    Manual Control Valve(Outrigger) Manual Control Valve (Outrigger) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the parts sales unit described in the parts catalog before starting disassembling operations.

  • Page 23: Manual Control Valve

    Manual Control Valve(Outrigger) Valve (Front stabilizer) Valve(Extension/Retraction) 2. Body assy 25. Retainer 29. Spring 33. Hexagon socket bolt 3. Valve (Swing) 26. O-ring 30. Spool end 34. Hexagon socket bolt 23. O-ring 27. Bracket 31. Cover 35. Check valve 24. Oil seal 28.
  • Page 24 Manual Control Valve(Outrigger) Valve (Outrigger/Right) Valve(Rear Stabilizer & Outrigger/Left) 5. Valve(Outrigger / Right) 25. Retainer 33. Hexagon socket bolt 59. Spring 6. Valve 26. O-ring 56. Retainer 60. Retainer 23. O-ring 31. Cover 57. Spool end 61. Steel ball 24. Oil seal 32.
  • Page 25 B-2 . B-2 . Manual Control Valve(Outrigger) Relief valve(RV5) 9. Relief valve (RV5) 84. O-ring 86. O-ring 94. O-ring 83. Spring 85. O-ring 90. Spring Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf P, V, T G1/2 58.8 –...

  • Page 26: Structure

    Manual Control valve (W inch) Manual Control 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 27 B-3 . B-3 . Manual Control valve (W inch) 1. Body 10. Cover 18. Fork end 25. Nut 2. Body 11. Washer 19. Poppet 26. Spring washer 4. Plug 12. Hexagon socket bolt 20. Spring 29. Flange 5. O-ring 14. Spring 21.

  • Page 28: Structure

    B-4 . B-4 . 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 29: Sequence Valve

    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 30 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 7.Plug 8.O-ring 9.Plug IW122-0112E01 Thread size and tightening torque Tightening torque Sign / port Thread size...
  • Page 31 B-5 . B-5 . 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 32: Solenoid Valve

    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 33 B-6 . B-6 . Solenoid Valve (Auto stop) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf A, B, T G1/4 29.4 G3/8A 30 - 37 22.1 - 27.3 6.9 – 8.9 5 – 6.5 △ 367-402-00000 W121-0910E...

  • Page 34: Solenoid Valve (Winch High Speed & Swing Brake)

    Solenoid Valve (Winch high speed & swing brake) Solenoid Valve (Winch high speed & swing brake) [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 35 B-7 . B-7 . Solenoid Valve (Winch high speed & swing brake) Solenoid valve assy Connector 31 1 IW121-0671E01 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 Sign / Port Thread size...

  • Page 36: (Winch Unload)

    B-8 . B-8 . Solenoid Valve (Winch unload) Solenoid Valve (Winch unload) [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 parts sales unit described in the parts catalog before starting disassembling operations.

  • Page 37: Solenoid Valve

    Solenoid Valve (Outrigger select) Solenoid Valve (Outrigger select) [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 parts sales unit described in the parts catalog before starting disassembling operations.
  • Page 38 B-9 . B-9 . Solenoid Valve (Outrigger select) Solenoid valve assy 31 1 312 361 IW121-0880E03 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 Sign / Port Thread size...

  • Page 39: Pressure Regulator Valve

    B-1 0 . B-1 0 . Pressure Regulator Valve(Outrigger) B-10 Pressure Regulator Valve (Outrigger) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 40: Hydraulic Valve

    B-1 1 . B-1 1 . Hydraulic Valve B-11 Hydraulic Valve [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 41: Shuttle Valve

    B-1 2 . B-1 2 . Shuttle Valve B-12 Shuttle 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 42: Rotary Joint

    Ｂ -1 3. Ｂ -1 3. Ｂ -1 3. Rotary Joint B-13 Rotary Joint 1.Body 2.Core 3.Slip ring assy 4.Plain bearing 5. Plain bearing 6.Plate 7. Plate 8.Packing 9.Ring seal 10.Bolt 11.Bolt 12.Spring washer [NOTICE] 13.Plain washer 14.Bolt 15.Bolt 16. Bolt 17.
  • Page 43 Outrigger System Contents C-1 Jack Cylinder (Front and rear C-7 Relief Valve (Front stabilizer) ..7 stabilizer)........1 Structure ........... 7 Structure ........... 1 Check valve Retaining Bolt Tightening C-8 Pressure Sensor Torques ......... 1 (Front stabilizer).......8 Structure ........... 8 C-2 Jack Cylinder........2 Structure ...........

  • Page 44: Structure

    C-1 . C-1 . Jack Cylinder (Front & rear stabilizer) Jack Cylinder (Front and rear stabilizer) [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 45: Jack Cylinder

    C-2 . C-2 . Jack Cylinder Jack Cylinder [NOTICE] There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations.

  • Page 46: Structure

    C-3 . C-3 . Pilot Check Valve (Front & rear stabilizer) Pilot Check Valve (Front and rear stabilizer) [NOTE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations.
  • Page 47 C-4 . C-4 . Pilot Check Valve (Outrigger jack) Pilot Check Valve (Outrigger jack) [NOTE] 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 48: Structure

    C-5 . C-5 . Power Slide Cylinder (Outrigger) Power Slide Cylinder (Outrigger) [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 49: Structure

    C-6 . C-6 . Power Slide Cylinder (Rear stabilizer) Power Slide Cylinder (Rear stabilizer) [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 50: Structure

    C-7 . C-7 . Relief Valve (Front stabilizer) Relief Valve (Front stabilizer) [NOTE] 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 51: Structure

    C-8 . C-8 . Pressure Sensor (Front stabilizer) Pressure Sensor (Front stabilizer) [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 Swing System Contents D-1 Hydraulic Motor (Swing) ........1 Structure ........... 1 D-2 Swing Speed Reducer ..... 3 Structure ........... 3 Removing of hydraulic motor ....4 Disassembly of reducer ......4 Assembly of reducer ......... 5 Installation of hydraulic motor ....5 D-3 Swing Bearing ........

  • Page 53: 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 54 D-1 . D-1 . Hydraulic Motor (Swing) 1.Housing 8.Plate 16.Spring 35.Retaining Ring 2.Rotary Assy 9.Retaining Ring 17.Distance Piece 41.Cover 3.Shaft Assy 10.Oil Seal 20.Plug Assy 43.Plate 4.Cover Assy 11.Ring 31.Shaft 44.Pin 5.Piston 12.O-ring 32.Bearing 46.Hexagon Socket Bolt 6.Retaining Ring 13.O-ring 33.Bearing 7.Plate 14.O-ring...

  • Page 55: 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 56: Swing Speed Reducer

    Swing Speed Reducer 1. Output shaft 9. Plug 17. Ring 25. Plate 2. Bolt 10. Carrier (B) 18. Plug (G1/2) 26. Planetary gear (B) 3. Spring washer 11. Snap ring 19. Seal washer 27. Needle bearing 4. Retainer (A) 12. Sun gear (B) 20.

  • Page 57: Assembly Of Reducer

    D-2 . D-2 . Swing Speed Reducer 4. Assembly of reducer 5. Installation of hydraulic motor 1. Press-fit retainer-A (4) and roller bearing (30) to 1. Tighten hydraulic motor by bolt (2). output shaft (1). [NOTICE] [NOTICE] Apply THREE BOND 1104 on the mating surface between the hydraulic motor casing and the swing Apply lithium type grease between retainer-A (4) reducer.

  • Page 58: Swing Bearing

    Swing Bearing Swing Bearing [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 59: Notes For Installation

    D-3 . D-3 . Swing Bearing 2. Notes for installation When installing the inner ring of the swing bearing, face the soft zone (stop plug) to the R position shown in the figure on the previous page. To tighten the bolts•2,4,7, follow the procedures below. Tighten all the bolts temporarily with approximately half the specified tightening torque.
  • Page 60 Boom Elevating System Contents Boom Elevating Cylinder ..1 Structure ........... 1 Pressure detector for AMA ......2 E-2 Counterbalance Valve (Elevating) ........ 3 Structure ........... 3...

  • Page 61: Boom Elevating Cylinder

    E -1 E -1 Boom Elevating Cylinder Boom 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 62: Pressure Detector For Ama

    E -1 . E -1 . Boom Elevating Cylinder 2. Pressure detector for AMA [NOTE] The adjustment of pressure detector is unnecessary. Cylinder side Rod side △ 361-500-70000 △ 361-801-10000 △ 360-275-80000 W155-0310E...

  • Page 63: Counterbalance Valve

    E -2 E -2 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 64 E -2 . E -2 . Counterbalance Valve (Elevating) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf Mounting bolt 34.3 - 39.2 25.3 - 28.9 A-B port G 3/8 44.1 - 53.9 32.5 - 39.8 Plug-3.9 Plug - 7 G 1/2...
  • Page 65 Winch System Contents F-1 Winch ..........1 Structure ........... 1 F-2 Hydraulic Motor(Winch) ....5 Operational explanation ......5 Structural explanation ....... 5 Structure ........... 6 F-3 Counterbalance Valve(Winch) ..7 Structure ........... 7...

  • Page 66: Structure

    F - 1 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 67 F - 1 Winch 1 Winch ASSY 1.Winch ASSY 3.Hydraulic motor 5.Spring washer 7.Plug ASSY 2.Support 4.Bolt 6.O-ring Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf 132-154 97-114 W526-0350E...
  • Page 68 F - 1 Winch 1 Winch ASSY 1.Bracket 14.Needle roller bearing 27.Sun gear(B) 40.Ball bearing 2.Plug ASSY 15.Hexagon socket head plug 28.Carrier(A) 41.Input shaft 3.O-ring 16.O-ring 29.Internal gear 42.Piston 4.Spindol 17.Steel bearing ring 30.Kingpin(B) 43.Lock washer 5.Hexagon socket head plug 18.Kingpin(A) 31.Idle gear 44.O-ring...
  • Page 69 F - 1 . F - 1 . Winch Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf 78.5 37 ※3 108-126 80-93 37 ※4 108-126 80-93 [NOTICE]: ※1：Caulking. ※2：Apply THREE BOND 1373N. ※5：Apply lithium grease or spindle oil. ※6：wrap sealing tape.

  • Page 70: Hydraulic Motor(Winch)

    F - 2 Hydraulic Motor(Winch) F-2 Hydraulic Motor(Winch) 2. Structural explanation 1. Operational explanation Cylinder block-9 is maintained rotatably with the center pin and the control plate. When pressure oil is supplied from the other slit in Cylinder block-9 is pressed against the control the control plate, half of pistons in the cylinder block plate by the corned disc springs at no-load running.
  • Page 71 F - 2 . F - 2 . Hydraulic Motor(Winch) 3. Structure [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: Structure

    F - 3 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 73 F - 3 . F - 3 . Counterbalance Valve(W inch) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf 12-15 9-11 28-35 21-26 55-69 41-51 43-49 32-36 43-49 32-36 △ 366-053-70000 W119-0540E...
  • Page 74 Boom Telescoping System Contents G-1 General description of G-2 Boom (Five-section boom) ....5 telescoping system ....1 Structure ........... 5 Functions of units........1 Dismounting the boom assembly and Telescoping cylinder ........1 preparation of the boom disassembly..7 Counterbalance valve......... 1 Dismounting the boom assembly....7 Wire rope mechanism .......
  • Page 75 Assembling the 3rd boom section .... 25 Assembling the boom telescoping cylinder..28 Assembling the 2nd boom section ... 29 Assembling the base boom section ..34 Mounting the boom assy......37 G-3 Telescoping Cylinder..... 38 1. Structure ............38 G-4 Counterbalance Valve (Telescoping) .......

  • Page 76: General Description Of

    G -1 G -1 General description of telescoping system General description of telescoping system 1. Functions of units 1.1 Telescoping cylinder This cylinder is located inside the boom. It is connected to the base boom section and the 2nd boom section with pins to extend and retract the 2nd boom section.

  • Page 77: Wire Rope Mechanism B (For Retracting The 4Th Boom Section)

    G -1 G -1 General description of telescoping system 2.2 Wire rope mechanism B (for retracting the 4th boom section) This mechanism retracts the 4th boom section at the same time when the 2nd boom section is retracted. The wire rope is passed within the boom in the following order. ・Rear end of the 4th boom section →...

  • Page 78: Wire Rope Mechanism D (For Extending The Top Boom Section)

    G -1 G -1 General description of telescoping system 2.4 Wire rope mechanism D (for extending the top boom section) This mechanism extends the top boom section at the same time when the 4th boom section is extended. The wire ropes are passed within the boom in the following order. ・Front end of the 3rd boom section →...

  • Page 79: Relation Between Boom Extending/Retracting Operations And Wire Rope Mechanisms

    G -1 . G -1 . General description of telescoping system 3. Relation between boom 4. Boom telescoping order extending/retracting operations and wire rope mechanisms 4.1 Extending 1. When the 2nd boom section is extended, the 3rd 3.1 Boom extension boom section is also extended at the same time by the wire rope mechanism A.
  • Page 80 G -2 G -2 G -2 Boom (Five-section boom) Boom (Five-section boom) 1. Structure General View △ 312-049-90100 W536-1040E...

  • Page 81: Boom (Five-Section Boom)

    G -2 G -2 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 82: Dismounting The Boom Assembly And Preparation Of The Boom Disassembly

    G -2 G -2 Boom (Five-section boom) 2. Dismounting the boom assembly and preparation of the boom disassembly 2.1 Dismounting the boom assembly 1. Extend the outrigger and set the crane level. 2. Confirm all the crane functions. 3. Swing the boom over the rear. 4.
  • Page 83 G -2 G -2 Boom (Five-section boom) 2.2 Preparation of the boom disassembly [NOTICE] ◆Refer to the boom length and angle detector replacement procedures in Chapter H before disassembling the boom. 1. Dismount Winch Assy. 2. Prepare 30’ 6” (9300mm) electric cable. - Dummy cable 3.
  • Page 84 G -2 G -2 Boom (Five-section boom) 7. Disconnect dummy cable from BLD cable. * Leave dummy cable inside boom. 8. Disconnect Hose Joint from tel. cylinder. * Put plug. W536-1040E...

  • Page 85: Disassembling The Boom

    G -2 G -2 Boom (Five-section boom) 3. Disassembling the boom 3. Remove the wire ropes for extending the 3rd [NOTICE] boom section from the rear end of the base boom Follow the disassembling procedure described here section. only after removing the winch and the boom length/angle detector.

  • Page 86: Pulling Out The Boom Telescoping Cylinder

    G -2 G -2 Boom (Five-section boom) 3.2 Pulling out the boom telescoping cylinder 5. Pull out the pin fxing the boom telescoping 1. Remove the sheaves for extending the top boom cylinder to the base boom section. section and the wire rope guide from the front end of the 4th boom section.
  • Page 87 G -2 G -2 Boom (Five-section boom) 4. Pull and extend the 4th boom section about 200 [NOTICE] mm (8 in). When it is attempted to remove the support A, it will hit the wire rope for retracting the 4th boom section. [NOTICE] To avoid this, slacken the wire rope for retracting the 4th boom section as shown in the figure below...

  • Page 88: Detaching The 2Nd Boom Section

    G -2 G -2 Boom (Five-section boom) 3.3 Detaching the 2nd boom section 3.4 Detaching the 3rd boom section 1. Remove the slide plates from the side and lower 1. Remove the sheave (1) for extending the 4th surfaces at the front end of the 2nd boom section. boom section and the wire rope guide from the front end of the 3rd boom section.

  • Page 89: Detaching The 4Th Boom Section And Disassembling The Top Boom Section

    G -2 G -2 Boom (Five-section boom) 3.5 Detaching the 4th boom section and 6. Remove the plates from the upper surface of the disassembling the top boom section 4th boom section. 1. Remove the sheave (2) for extending the 4th boom section from the 4th boom section.

  • Page 90: Inspection

    G -2 G -2 Boom (Five-section boom) 4. Inspection 4.1 Boom Check the boom for torsion, deformation, warp, and/or cracks. 4.2 Slide plate Replace cracked or severely worn parts. 4.3 Sheave Replace damaged, deformed, or severely worn parts. 4.4 Wire rope for boom telescoping If any of the following conditions (1) through (5) are found, replace the wire rope.

  • Page 91: Structure Of The Adjuster Assy

    G -2 G -2 Boom (Five-section boom) 5. Structure of the adjuster assy [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: Tools Needed For

    G -2 G -2 Boom (Five-section boom) 6. Tools needed for boom assembling operation The following tools are needed to assemble the boom. They should be prepared by yourself. 6.1 Tool A [NOTICE] All dimensions in the drawings are in millimeters. The materials, thread sizes and pitches are described based on JIS (Japanese Industrial Standard).

  • Page 93: Tool B

    G -2 G -2 Boom (Five-section boom) - Tool fixing pin and plate Material: SS400 6.2 Tool B [NOTICE] The thread size is based on JIS (Japanese Industrial Standard). Bolt: M12 coarse thread with thread length 50 mm (2 in) or more Nut: M12 coarse thread, height less than 13 mm (1/2 in) W536-1040E...

  • Page 94: Assembling The Boom

    G -2 G -2 Boom (Five-section boom) 7. Assembling the boom 4. Install protective covers on the top boom section. 7.1 Assembling the top boom section 1. To facilitate installaton of the cord of the boom length/angle detector, prepare the following cord or wire (later called as “temporary cord”).
  • Page 95 G -2 G -2 Boom (Five-section boom) 7. Measure the following internal widthwise 10.Adjust the clearances of the slide plates on the dimension of the 4th boom section. side surfaces of the boom based on the - At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end dimension measured at step 7.

  • Page 96: Assembling The 4Th Boom Section

    G -2 G -2 Boom (Five-section boom) 7.2 Assembling the 4th boom section 5. Release the wire ropes for extending the top 1. Install the slide plates to the lower surface at the boom section and place them in the grooves of front end of the 4th boom section.
  • Page 97 G -2 G -2 Boom (Five-section boom) 9. Temporarily fix the ends of the wire ropes for 10. Install the slide plates inside the 4th boom retracting the top boom section at the front end of section. the 4thboom section with a wire etc. Install the wire rope guides at the rear end of the 4th boom section.
  • Page 98 G -2 G -2 Boom (Five-section boom) 13. Adjust the clearances for the sheaves (2) for 14. Fix both ends of the wire ropes for extending the extending the 4th boom section. 4th boom section at the front end of the 4th boom Adjust the clearances to the following by section with a wire etc.
  • Page 99 G -2 G -2 Boom (Five-section boom) 17. Install the slide pates at the rear end of the 4th 19. Apply grease to the surfaces outside the 4th boom section. boom section on which the slide plates of the 3rd boom section slide and the slide plates at the rear 18.

  • Page 100: Assembling The 3Rd Boom Section

    G -2 G -2 Boom (Five-section boom) 7.3 Assembling the 3rd boom section 4. Position the support with the wire rope by 1. Install the slide plates to the lower surface at the pressing it against the stopper at the front end of front end of the 3rd boom section.
  • Page 101 G -2 G -2 Boom (Five-section boom) 7. Retract the 4th boom section to the point about 9. Measure the following internal widthwise 200 mm (8 in) before full retraction. dimension of the 2nd boom section. - At 1.0 to 1.4 m (3.3 to 4.5 ft) from the front end [NOTICE] [NOTICE] If the 4th boom section is fully retracted, it becomes...
  • Page 102 G -2 G -2 Boom (Five-section boom) 12. Adjust the clearances of the slide plates on the 14. Pass the temporary cord through the roller assy side faces of the boom based on the dimension and fix the roller assy at the rear end of the 3rd measured at step 9.

  • Page 103: Assembling The Boom Telescoping Cylinder

    Apply Daphne Eponex SR No. 2 grease to the outer [NOTICE] surface of the boom telescoping cylinder. Apply Tadano genuine grease TNR to the support Turn the wire ropes for extending the 3rd boom at the front end of the cylinder.

  • Page 104: Assembling The 2Nd Boom Section

    G -2 G -2 Boom (Five-section boom) 7.5 Assembling the 2nd boom section 9. Install the support A around the wire ropes for 1. Install the slide plates to the lower surface at the extending the 3rd boom section. front end of the 2nd boom section. 2.
  • Page 105 G -2 G -2 Boom (Five-section boom) 3. Fully retract the 3rd boom section. 6. Pass the wire rope for retracting the 4th boom section through the adjuster assy. 4. Fix an end of the wire rope for retracting the 4th Then pass the wire rope for retracting the 4th boom section to the rear end of the 4th boom boom section through the equalizer sheave and...
  • Page 106 G -2 G -2 Boom (Five-section boom) 9. Pull the adjuster assy to the front end of the 2nd 12. Fix the support A to the rear end of the 3rd boom boom section and place it on the 2nd boom section.
  • Page 107 G -2 G -2 Boom (Five-section boom) 14. Put an electric lamp in at the front end of the top 16. Pass the wire ropes for extending top boom boom section to illuminate the inside of the boom. section through the openings at the upper surface Look into the boom from the rear end of the boom of the 3rd boom section.
  • Page 108 G -2 G -2 Boom (Five-section boom) 20. Pass the temporary cord through the roller assy 23. Install the slide pates at the rear end of the 2nd and fix the roller assy at the rear end of the 2nd boom section.

  • Page 109: Assembling The Base Boom Section

    G -2 G -2 Boom (Five-section boom) 7.6 Assembling the base boom section 5. Fix the adjuster assy to the front end of the base 1. Install the slide plates to the lower surface at the boom section. front end of the base boom section. [NOTICE] 2.
  • Page 110 G -2 G -2 Boom (Five-section boom) 8. Fix the boom telescoping cylinder to the base boom section with a pin. Put a retaining ring to the pin. [NOTICE] Make sure the retaining rings are securely put in place and the pins are secured. 10.
  • Page 111 G -2 G -2 Boom (Five-section boom) 14. Remove the tool B. 12.Screw a nut on the wire rope for extending the Screw a locknut to lock the wire rope for 3rd boom section. extending the 3rd boom section. Then screw the tool B on the wire rope end. [NOTICE] [NOTICE] The dimension La that was measured during...

  • Page 112: Mounting The Boom Assy

    G -2 . G -2 . Boom (Five-section boom) 16. Adjust the wire ropes for boom telescoping according to Chapter Y “Adjustment procedure of boom telescoping wire ropes”. 17. Install the boom length/angle detector according to Chapter H “Boom length/angle detector replacement procedure”.

  • Page 113: Telescoping Cylinder

    G -3 G -3 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 114 G -3 . G -3 . Telescoping Cylinder Thread size and tightening torque Tightening torque Thread Thread size ft-lbf – 515 – 721 380– 531 13.2 – 16.2 9.7 – 11.9 – 1030 – 1442 760 – 1063 34.3 – 39.2 25.3 –...

  • Page 115: Structure

    G -4 G -4 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 116: (Telescoping)

    G -4 . G -4 . Counterbalance Valve (Telescoping) Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf Mounting bolt 34.3 - 39.2 25.3 - 28.9 A-B port G 3/8 44.1 - 53.9 32.5 - 39.8 Plug-3.9 Plug - 7 G 1/2...
  • Page 117 Safety System Contents H-1 AMA (Load Moment Indicator) ..1 H-2 Boom Length/Angle Detector..17 Structure ........... 1 Construction and function......17 Function of Components......2 Disassembly and reassembly....18 Disassembly of cord........18 Caution About Installing Reassembly of cord ........19 Length Detector......3 Replacing spiral spring......20 Disassembly of potentiometer AMA adjustment........

  • Page 118: Structure

    AMA (Load Moment Indicator) AMA (Load Moment Indicator) 1. Structure W301-0270E...

  • Page 119: Function Of Components

    AMA (Load Moment Indicator) 2. Function of Components 1. Outrigger state indicator lamp 4. Display alteration Lighting condition of these lamps indicates the Only the display on the AMA main body can be extension width of right and left outriggers. altered.

  • Page 120: Caution About Installing

    AMA (Load Moment Indicator) 3. Caution About Installing Length 2. A stopper is attached to the cord. Do not remove the stopper from the cord when installing the Detector detector on the boom, other wise the cord will be 1. Adjust the cord for length detector assy so that the reeled in all the way, leading to damage to the yellow tape on the cord is located as shown in the potentiometer.

  • Page 121: Ama Adjustment

    AMA (Load Moment Indicator) 4. AMA adjustment 3. Run the engine at an idling speed when performing adjustment. AMA stores capacity data for plural models of cranes. After mounting of a crane is completed, 4. Shift the Dip switches and the Rotary switch using you must select the capacity data that correspond an extra thin screwdriver.

  • Page 122: Selecting The Crane Model And Capacity Data

    AMA (Load Moment Indicator) 4.3 Selecting the crane model and capacity data 4.4 Zero-point and span adjustments of length detector . Select the data according to the flowchart below. Swing the boom to over-front before adjustment. ( Exclude the case where the direction of the boom has been decided by the inspection system etc.) START START Set the Dip switches according to the actual crane model and capacity type.

  • Page 123: Zero-Point And Span Adjustments Of Angle Detector

    AMA (Load Moment Indicator) 4.5 Zero-point and span adjustments of angle detector. 4.6 Confirming Accuracy Swing the boom to over-right and make sure that the over-front indication lamp is not lit. Retract the boom fully and swing it to over-right before adjustment. ( Exclude the case where the direction of the boom has been decided by the inspection system etc.) ( Exclude the case where the direction of the boom has been decided by the inspection system etc.) START...

  • Page 124: List Of Error Nos. Related To Ama

    AMA (Load Moment Indicator) 5. List of Error Nos. Related to AMA Description Cause Measures An error among E21-27, E29, E65 Refer to canceling method and E66 occurring in other-side corresponding to each error code. Error in other-side AMA An error among E14-18 and E28 Refer to canceling method occurring in other-side AMA corresponding to each error code.
  • Page 125 AMA (Load Moment Indicator) Description Cause Measures Faulty CPU Faulty AMA main body Replace the AMA main body. Faulty hardware Connector (CN3) disconnected Connect. Make sure that the error occurs on the occasions that the boom is almost fully extended or almost fully retracted. Maladjusted cord of the boom Adjust the cord so that the yellow tape on the cord is located close to the...

  • Page 126: When Parts Are Exchanged

    AMA (Load Moment Indicator) Description Cause Measures When the power is turned ON, the boom high angle restriction switch or Boom high/low angle restriction Make sure that the boom high angle boom low angle restriction switch is restriction switch and boom low angle switch position inconsistent with in ON position though the position of restriction switch are turned off.

  • Page 127: Pulling Out Cord From Boom

    AMA (Load Moment Indicator) 7. Boom length/angle detector replacement procedure When it is needed to replace the boom length/angle detector, refer to the following steps as a guide. This replacement procedure describes the following steps. ・Pulling out cord from boom ・Passing cord through boom ・Tools and materials needed - Pipe...
  • Page 128 AMA (Load Moment Indicator) 2) Removing the sheave inside of the boom front end 1. Remove the bolts. (2 pieces) 2. Remove the plate (1 piece) 3. Pull out the pin. Pull out the pin from the side opposite to where the bolts are removed.
  • Page 129 AMA (Load Moment Indicator) 5) Pulling out the cord along the rollers at the boom If the terminals are not detached from the cord end, the cord cannot be pulled out through the rollers C and D. Then, the following steps will be needed. If the cord is cut halfway and the portion of the cord with the terminals can be pulled out from the side of the boom front end, the following steps 1,...
  • Page 130 AMA (Load Moment Indicator) 7.2 Passing cord through boom 1) Removing the rollers etc. Pass the cord only when no roller or pin is installed. If they are in position, remove them according to the following steps. 1. Remove the split pin from the pin for the roller. 2.
  • Page 131 AMA (Load Moment Indicator) 2) Passing a pipe from the boom rear end 1. Pass a pipe from the rear end of the base boom section to the rear end of the top boom section. Pass the pipe from the rear end of the base boom section, via the roller C and the shaded areas of the rollers B and A, to the support at the rear end of the top boom section.
  • Page 132 AMA (Load Moment Indicator) 5) Pass the cord from the rear end of the base boom section. 1. Pass the cord from the cord reel over the roller D and install the roller D in the reverse order of the steps 1 to 3 of 1) above.
  • Page 133 H-1 . H-1 . AMA (Load Moment Indicator) 6) Securing the cord on the boom front end 1. Pull out the wire from the support at the top surface of the top boom section. Once the cord is pulled into the boom for about 400 mm (1.3ft) from the grommet, temporarily fix the cord to the support.

  • Page 134: Boom Length/Angle Detector

    Boom Length/Angle Detector Boom Length/Angle Detector 2. The cord wound on the drum is unwound and rewound by the spiral spring as the boom extends [NOTICE] and retracts. The resultant drum rotation is There is a case that the appearance and so on reduced by the reduction gear, which in turn differ from the parts for this machine.

  • Page 135: Disassembly And Reassembly

    Boom Length/Angle Detector 1. Plate 16. Spring 31. Terminal 46. Cable 2. Case 17. Cover 32. Nut 47. Holder 3. Drum assembly 18. Clip 33. Washer 48. Terminal 4. Slip ring assembly 19. Clip 34. Screw 49. Terminal 5. Contact assembly 20.

  • Page 136: Reassembly Of Cord

    Boom Length/Angle Detector 7. Remove the slip ring assembly from the drum 4. Wind new cord arround drum assembly while assembly. Then, remove the connection preventing slack. After zero marker (at 7.0 m) (soldered) of the slip ring and cord. {22.97 ft} from the end of cord appears on drum, wind cord 1 turn additionally and fix it with Slip ring assembly...

  • Page 137: Replacing Spiral Spring

    Boom Length/Angle Detector Completely insulate soldered connections. 11. Take out new cord through the guide hole of the cord reel, and pull out new cord to the end 9700 mm (31.82ft) 50 mm (0.16ft) completely. Then allow cord to be wound slowly on drum until the zero marker appears at the edge of guide hole.

  • Page 138: Reassembling Of Potentiometer

    H-2 . H-2 . Boom Length/Angle Detector original position by spring. If not, loosen bolts and Gear adjust the position of bracket. Gear B Spring Gear A Bracket Bracket Spring Lead wire Bolt Black Potentiometer To boom angle detector Terminal IW305-0130E15 IW305-0130E13 3.

  • Page 139: Outrigger Extension Detector

    Outrigger Extension Detector Outrigger Extension Detector 2. Retract the outriggers, and check the switch 1. Check of Outrigger Extension indicator to confirm that there is no detection error. Detector When shipped, the proximity switch is secured so that the switch tip is recessed loosened from the Check if the outrigger extension detector switch frame internal surface by one turn 1/16 inches detects the extended condition of the outrigger...

  • Page 140: Rear Stabilizer Extension Detector

    H-3 . H-3 . H-3 . Outrigger Extension Detector 3. Rear stabilizer Extension Detector △ 314-803-36200 W313-0210E...
  • Page 141 Remote Control System Contents V-1 Configurations of Radio-control V-4 Measures for Emergency Case ..12 System........1 When radio-control operation is Structure ........... 1 impossible........12 If the LED of the transmitter flashes ..12 1.1 Names and functions of each part..... 2 1.2 When the mode indicator lamp of the controlunit displays an error number ...13 Safety Functions of...

  • Page 142: System

    V -1 V -1 Configurations of Radio-control System Configurations of Radio-control System [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 143: Names And Functions Of Each Part

    V -1 V -1 Configurations of Radio-control System 1.1 Names and functions of each part ＷV02-0021E...

  • Page 144: Auto Power-Off Function

    V -1 V -1 Configurations of Radio-control System 2. Safety Functions of Radio-control System The radio-control system has the following functions to realize safety operations. 2.1 Auto power-off function When the motion selection switch is not operated for approximately one hour, the power of the transmitter is automatically turned off to save battery consumption.

  • Page 145: Continual Operation Restriction Function

    V -1 V -1 Configurations of Radio-control System 2.3 Continual operation restriction function Error is displayed when any of the motion selection switches is kept in the operation state for approximately five minutes due to a failure, trapped dirt or the like. ! Four LEDs on the transmitter flash to show the failure condition.

  • Page 146: Alarm Function

    V -1 . V -1 . Configurations of Radio-control System 2.5 Alarm function The following alarms sound when the system has a problem, when a wrong operation is made, or to call attention for proper operations. (1) At the time of abnormal stop of the radio-control system: Warning sound Beep (Three times) Warning timing...

  • Page 147: Radio-Control Valve

    V -2 V -2 Radio-control Valve Radio-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 148: Electric Circuit

    V -2 V -2 Radio-control Valve 1.2 Electric circuit W135-0180E...

  • Page 149: General View

    V -2 V -2 Radio-control Valve 1.3 General View Thread size and tightening torque Tightening torque Sign / Port Thread size ft-lbf – G 1/4 24.5 - 29.4 18 - 22 P, T port G 1/2 53.9 - 63.7 40 - 47 W135-0180E...

  • Page 150: Cross Section

    V -2 V -2 Radio-control Valve 1.4 Cross section W135-0180E...

  • Page 151: Unloading Valve

    V -2 . V -2 . Radio Control Valve 1.5 Unloading valve Relif valve :C 19.61- 20.10 Mpa (2843.45- 2914.45 psi) at 60L/min Relif valve :F 2.06 - 2.65 Mpa ( 298.70 - 384.30 psi) at 1.5L/min Reducing valve :E 1.86 - 1.96 Mpa (270 - 284.5 psi) P : at 5L/min Pilot : at 0.4L/min W135-0180E...

  • Page 152: Accelerator Cylinder

    V -3 . V -3 . Accelerator Cylinder Accelerator 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 153: Measures For Emergency Case

    V -4 V -4 Measures for Emergency Case Measures for Emergency Case 1. When radio-control operation is impossible 1.1 If the LED of the transmitter flashes 1. If the power of the transmitter is turned on while the motion selection switch is operated, indications (2) as shown in the table are displayed.

  • Page 154: When The Mode Indicator Lamp Of The Controlunit Displays An Error Number

    V -4 V -4 Measures for Emergency Case 1.2 When the mode indicator lamp of the control unit displays an error number The mode indicator lamp of the control unit displays indications as are shown in the figure to the right according to the operational conditions. If the mode indicator lamp displays the indications not listed in the figure to the right, the radio-control system has a problem.

  • Page 155: If The Radio-Control Is Not Possible

    V -4 V -4 Measures for Emergency Case 45-49 The part that has a problem cannot be operated with the radio-control operation. Change to the manual operation and then operate the crane. WARNING It is dangerous to make other operations when the operation lever of the part that has a problem cannot be returned to the neutral position, since this would cause the part that has a problem to move at the same time.

  • Page 156: Troubleshooting Guide

    V -4 V -4 Measures for Emergency Case 3. Troubleshooting Guide First check the following when a problem occurs during the radio-control operation. Trouble Checkpoints Measures Power LED does not light • Are batteries inserted? • Insert batteries. • Are batteries inserted in the •...
  • Page 157 V -4 . V -4 . Measures for Emergency Case Radio wave transmission is hindered under the following conditions, which may stop the crane operation. Take an appropriate measure according to the operational condition. !If the appropriate measure does not improve the situation, use the manual operation. Operation example Appropriate measures Distance between the transmitter and reception...
  • Page 158 Data, Adjustment and Checks Contents Y-1 Service Data ........1 Hydraulic Pressure Setting Table ....1 Manual Control Valve(Boom elevating, telescoping, swing, outrigger high/low shift)..........1 Manual Control Valve(Outrigger)....2 Manual Control Valve(Winch)..... 3 Hydraulic Units.......... 4 Swing Motor..........4 Swing Speed Reducer........

  • Page 159: Service Data

    1. Hydraulic Pressure Setting Table 1.1 Manual Control Valve(Boom elevating, telescoping, swing, outrigger high/low shift) [NOTE] Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG1, PG2 ports. Engine Set pressure Item...

  • Page 160: Manual Control Valve(Outrigger)

    Service Data 1.2 Manual Control Valve(Outrigger) [NOTE] Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG port. Engine Set pressure Item Note speed (min 1.Connect a pressure gauge to the PG port.

  • Page 161: Manual Control Valve(Winch)

    Service Data 1.3 Manual Control Valve(Winch) [NOTE] Oil temperature: 45 - 55 C (113 - 131 F) (TADANO Hydraulic oil LL) Connect a pressure gauge to the PG port. Engine Set pressure Item Note speed (min 1.Plug the hoses connected to the hoist-up and hoist-down ports.

  • Page 162: Hydraulic Units

    Y-1 . Y-1 . Service Data 2. Hydraulic Units 2.1 Swing Motor ・Displacement : 43.0cm / rev(2.6in / rev) 2.2 Swing Speed Reducer ・Reduction ratio : 34.98:1 2.3 Winch Motor ・Displacement : 90cm / rev(5.5in / rev) 2.4 Winch Speed Reducer ・Reduction ratio : 29.25:1 2.5 Winch Motor ・Displacement : 125cm...

  • Page 163: Adjustment And Checks

    Y-2 . Y-2 . Y-2 . Adjustment and Checks Adjustment and Checks 1. Adjustment procedure of boom telescoping wire ropes △ 312-049-90970 WY05-1510E...
  • Page 164 System Diagrams Contents Z-1 Hydraulic Circuit : Z-6 Electric Circuit : Spec.TM-2000-1-104,114,204,214 Spec.TM-2000-1-314, 414 (Manual spec.)......1 (Continuous rotation, Radio-controls spec.) ....6a Z-2 Hydraulic Circuit : Applicable serial No. --EX0309....6a Spec.TM-2000-1-304,314,404,414 Applicable serial No. EX0310--....6b ( Radio-controls spec.)....2 Z-7 Location of Hydraulic Parts.....7...
  • Page 165 Frame ............. 15 Operation box .......... 16 Radio-control system ....... 17 Main harness ..........17 Sub harness ..........18 Frame (Rear) ........... 19 Vehicle ............. 20 Angle limit alarm ........21 Z-9 Harness........... 22 Harness (Post and Boom-point) ....22 Harness (Operation box) ......

  • Page 166: Hydraulic Circuit

    Z - 1 . Z - 1 . Z - 1 . Hydraulic Circuit Hydraulic Circuit : Spec.TM-2000-1-104,114,204,214 (Manual spec.) △ 314-022-60200 WZ01-1351E...

  • Page 167: Hydraulic Circuit

    Z - 2 . Z - 2 . Z - 2 . Hydraulic Circuit Hydraulic Circuit : Spec.TM-2000-1-304,314,404,414 ( Radio-controls spec.) △ 314-022-90200 WZ01-1501E...
  • Page 168 Z-3. Z-3. Z-3. Electric Circuit Z-3 Electric Circuit : Spec.TM-2000-1-104, 204 (Non-continuous 375°rotation, Manual spec.) No CN No.,Metal L400 361−323−20000 F CN63 M CN4,AMP L100 316−533−03300 Shield F CN4 M Shield Length detector Power supply Angle display switch Out put CN30,AMP L125∼200 313−612−22302...

  • Page 169: Electric Circuit

    Z-4. Z-4. Z-4. Electric Circuit Z-4 Electric Circuit : Spec.TM-2000-1-114, 214 (Continuous rotation, Manual spec.) F CN62 M F CN63 M No CN No.,Metal L400 361−323−20000 Shield Shield F CN4 M CN4,AMP L100 316−533−03300 Shield F CN70 Length detector Power supply...

  • Page 170: Electric Circuit

    Electric Circuit Z-5 Electric Circuit : Spec.TM-2000-1-304, 404 (Non-continuous 375°rotation, Radio-controls spec.) 1. Applicable serial No. --EX0309 No CN No.,Metal L400 3６1－323－20000 F CN63 M Shield F CN4 M CN4,AMP L100 31６－533－03300 Radio control valve (STD、SANWA) Shield Length detector Power supply...

  • Page 171: Applicable Serial No. Ex0310

    Electric Circuit : TM-2000-1-304, 404 Z-5. Z-5. Z-5. 2. Applicable serial No. EX0310-- No CN, Metal L400 361-323-20000 F CN63 M Shield Shield Length detector Power Output No CN, Metal L3150 313-612-24200 CN62,AMP Shield CN4,AMP L100 316-533-03300 F CN4 M...

  • Page 172: Electric Circuit

    Electric Circuit Z-6 Electric Circuit : Spec.TM-2000-1-314, 414 (Continuous rotation, Radio-controls spec.) 1. Applicable serial No. --EX0309 F CN62 M No CN No.,Metal L400 361－323－20000 F CN63 M Shield Shield CN4,AMP L100 316－533－03300 Shield F CN4 M Radio control valve (STD、SANWA)

  • Page 173: Applicable Serial No. Ex0310

    Electric Circuit : TM-2000-1-314, 414 Z-6. Z-6. Z-6. 2. Applicable serial No. EX0310-- F CN62 M F CN63 M No CN, Metal L400 361-323-20000 Shield Shield Shield F CN70 Length detector Power Output Relay for AMA buzzer CN4,AMP L100 316-533-03300...
  • Page 174 Z - 7 Location of Hydraulic Parts Location of Hydraulic Parts 1. Frame △ 316-484-20000 WZ07-1810E...

  • Page 175: Location Of Hydraulic Parts

    Z - 7 Location of Hydraulic Parts 2. Boom 2.1 With 375° non-continuous swing Connect the 7 hoses from the hose assembled section of the swing frame, and the winch drain hoses. Connect the hoses with the same marks. Arrange clearance of at least 1/2 inch between clamps or bolts and high-pressure hoses. △...

  • Page 176: With 360° Continuous Swing

    Z - 7 Location of Hydraulic Parts 2.2 With 360° continuous swing Notice 1. Connect the hose between same marks. 2. Cover the hoses with spiral tube wraps on the position shown in figure at the passage part of the post side face, and secure both ends with fasteners.

  • Page 177: Outrigger

    Z - 7 Location of Hydraulic Parts 3. Outrigger △ 316-481-21001 WZ07-1810E...

  • Page 178: Lower

    Z - 7 . Z - 7 . Z - 7 . Location of Hydraulic Parts 4. Lower △ 319-233-61000 △ 316-134-30300 △ 319-233-63000 WZ07-1810E...

  • Page 179: Location Of Electrical Parts

    Z - 8 Location of Electrical Parts Location of Electrical Parts Note: 1. Boom 1. Reduce size X as much as possible within the range where the switch can be smoothly rotated. 2. Never apply grease to pins 1 and 2. 3.

  • Page 180: Post And Boom-Point

    Z - 8 Location of Electrical Parts 2. Post and Boom-point 2.1 Non-continuous 375° rotation spec. △ 316-558-14000 WZ02-3270E...

  • Page 181: Continuous Rotation Spec

    Z - 8 Location of Electrical Parts 2.2 Continuous rotation spec. △ 316-558-04000 WZ02-3270E...

  • Page 182: Frame

    Z - 8 Location of Electrical Parts Adjustment Procedure of Outrigger Extension Detector 3. Frame 1. Maximum extension detection switch adjustment procedure (upper surface of frame) 1-1.With the outrigger beams fully extended and jack cylinders fully retracted, screw the proximity switch in until it contacts the upper surface of the outrigger box.

  • Page 183: Operation Box

    Z - 8 Location of Electrical Parts 4. Operation box △ 316-558-02000 WZ02-3270E...

  • Page 184: Radio-Control System

    Z - 8 Location of Electrical Parts 5. Radio-control system 5.1 Main harness △ 316-558-03000 WZ02-3270E...

  • Page 185: Sub Harness

    Z - 8 Location of Electrical Parts 5.2 Sub harness △ 316-557-30000 WZ02-3270E...

  • Page 186: Frame (Rear)

    Z - 8 Location of Electrical Parts 6. Frame (Rear) △ 314-803-36000 WZ02-3270E...

  • Page 187: Vehicle

    Z - 8 Location of Electrical Parts 7. Vehicle △ 319-329-00000 WZ02-3270E...

  • Page 188: Angle Limit Alarm

    Z - 8 . Z - 8 . Z - 8 . Location of Electrical Parts 8. Angle limit alarm △ 314-803-40000 WZ02-3270E...

  • Page 189: Harness

    Z - 9 Harness Harness 1. Harness (Post and Boom-point) △ 313-612-24100 △ 313-612-24200 △ 316-558-14300 △ 316-558-14400 △ 313-613-74200 △ 316-558-04300 △ 316-558-04400 △ 316-558-04500 WZ04-2600E...

  • Page 190: Harness 2

    Z - 9 Harness 2. Harness (Operation box) 2.1 Harness 1 △ 316-558-02300 WZ04-2600E...
  • Page 191 Z - 9 Harness 2.2 Harness 2 △ 316-558-02100 WZ04-2600E...
  • Page 192 Z - 9 Harness 2.3 Switch △ 313-612-23400 WZ04-2600E...
  • Page 193 Z - 9 . Z - 9 . Z - 9 . Harness 3. Harness (Radio-controls) △ 316-558-03600 WZ04-2600E...
  • Page 194 Head Office Ko-34,Sinden-cho, Takamatsu, Japan Overseas Service Group Tadano Ryogoku Bldg. 4-12, Kamezawa 2-chome, Sumida-ku, Tokyo, Japan Tel. 81 (3) 3621-7765 Tel fax 81 (3) 3621-7785 History of revision...

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