Tadano GR-700N Service Manual

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Page 1

Page 2

Foreword

WA04-4651E

Foreword

This service manual describes the composition of the Model GR-700N-1 rough terrain crane, its adjustment

methods and hydraulic and electric circuit diagrams.

This service manual applies to the cranes with the specification numbers given below. Check the specification

number on the nameplate of your crane.

Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the

crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales

units in the parts catalog before replacing them.

1. Applicable spec. and serial number

Spec. No. Applicable serial number

GR-700N-1-00101

FE0376--

GR-700N-1-00121

GR-700N-1-00122

Separate service manual

Separate Service Manual Publication No.

1 General Cautions WA01-0121E

2 Automatic Moment Limiter (AML-C) W301-0481E

3 Data Transmitter (DCU2 and VCU) W303-0681E

Please note that, for product improvement, some changes which are not

covered in this manual may have been incorporated in the machine.

And please note that this manual may cover the functions and equipment

which are not equipped with your machine.

Please check your actual machine for repair and maintenance.

Page 3

Foreword

WA04-4651E

2. External view

The following is the traveling posture.

Front, rear, right, and left are the directions viewed from a position when operator sits on operator's seat with the

boom directed to the front of the frame. Those directions remain invariant regardless of slewing direction of the

superstructure.

Page 4

Foreword

WA04-4651E

3. Outline of specifications

No. Item

Spec. No.

GR-700N-1

-00101

GR-700N-1

-00121

GR-700N-1

-00122

1 No. of boom sections 6

2 No. of jib stages 3

3 Single top Fitted

4 Winch

Main winch Fitted

Auxiliary winch Fitted

Winch high-speed hoisting down Fitted

Winch brake Automatic brake (Neutral brake)

5 Outrigger H-type

6 Automatic moment limiter (AML) AML-C

7 Auto. stop solenoid valve energizing type Normally energized

8 Anti-two-block device Fitted

9 Oil cooler Fitted

10 Air conditioner Fitted

11 Telematics Fitted

12 Eco mode system, Fuel consumption monitor Fitted

13 Emergency steering system Fitted

14 Engine model Cummins QSL9-4A

15 Tires 385/95 R25

Page 5

Foreword

WA04-4651E

4. Conversion table

Length

millimeter

centimeter

meter

inch

in, ”

foot

ft, ’

mile

kilometer

1 1×10-1 1×10-3 3.93701×10-2 3.28084×10-3

1 1.60934

1×10 1 1×10-2 3.93701×10-1 3.28084×10-2 6.21373×10-1 1

1×103 1×102 1 3.93701×10 3.28084

2.54×10 2.54 2.54×10-2 1 8.33333×10-2

3.048×102 3.048×10 3.048×10-1 1.2×10 1

Speed

km/h mile/h, mph

1 6.21373×10-1

1.60934 1

Area

square millimeter

mm2

square centimeter

cm2

square meter

square inch

in2

square foot

ft2

1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5

1×10

1 1×10-4 1.55×10-1 1.07639×10-3

1×10

1×104 1 1.55×103 1.07639×10

6.4516×102 6.4516 6.4516×10-4 1 6.94444×10-3

9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1

Volume

cubic centimeter

cm3, cc

liter

lit, L

cubic meter

cubic inch

in3

cubic foot

ft3

gallon (US)

gal

1 1×10-3 1×10-6 6.10237×10

-2

3.53147×10-5 2.64172×10-4

1×103 1 1×10-3 6.10237×10 3.53147×10-2 2.64172×10-1

1×106 1×103 1 6.10237×104 3.53147×10 2.64172×102

1.63871×10 1.63870×10-2 1.63871×10

-5

1 5.78704×10-4 4.329004×10-3

2.83168×104 2.83168×10 2.83168×10

-2

1.728×103 1 7.48051

3.78541×103 3.78541 3.78541×10-3 2.31×102 1.33680×10-1 1

Force

N kgf lbf

1 1.01972×10-1 2.24809×10-1

9.80665 1 2.20462

4.44822 4.53592×10-1 1

Page 6

Foreword

WA04-4651E

Mass

gram

kilogram

ounce

pound

metric ton

short ton

s. t

1 1×10-3 3.5274×10-2 2.20462×10-3 1×10-6 1.10231×10-6

1×103 1 3.5274×10 2.20462 1×10-3 1.10231×10-3

2.83495×10 2.8349×10-2 1 6.25×10-2 2.83495×10-5 3.12494×10-5

4.53592×102 4.53592×10-1 1.6×10 1 4.53592×10-4 5×10-4

1×106 1×103 3.5274×104 2.20462×103 1 1.10231

9.07185×105 9.07185×102 3.2×104 2×103 9.07185×10-1 1

Pressure

pascal

kPa MPa kgf/cm2 lbf/in2, psi bar

1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4 1×10-5

1×103 1 1×10-3 1.01972×10-2 1.45038×10-1 1×10-2

1×106 1×103 1 1.01972×10 1.45038×102 10

9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10 9.80665×10-1

6.89476×103 6.89476 6.89476×10-3 7.03072×10-2 1 6.89475×10-2

1×105 1×102 1×10-1 1.01972 1.45038×10 1

Torque

N-cm N-m kgf-cm kgf-m

foot-pound

ft-lbf

inch-pound

in-lbf

1 1×10-2 1.01972×10-1 1.01972×10-3 7.37562×10-3 8.85074×10-2

1×102 1 1.01972×10 1.01972×10-1 7.37562×10-1 8.85074

9.80665 9.80665×10-2 1 1×10-2 7.23301×10-2 8.67961×10-1

9.80665×102 9.80665 1×102 1 7.23301 8.67961×10

1.35582×102 1.35582 1.38255×10 1.38255×10-1 1 1.2×10

1.12985×10 1.12985×10-1 1.152513 1.15213×10-2 8.33333×10-2 1

Power

watt

kW PS

1 1×10-3 1.35962×10-3

1×103 1 1.35962

7.355×102 7.355×10-1 1

Centigrade-Fahrenheit

°F °C °F °C °F °C °F °C °F °C °F °C

-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11

-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67

-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22

-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78

-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33

Conversion equation: t [°C] = 5 (T [°F] -32) / 9, T [°F] = (9 × t [°C] + 160) / 5

Page 7

Foreword

WA04-4651E

5. Drawing method of illustrations in this service manual

The third angle projection method of mechanical drawing is used for the illustrations in this service manual.

The third angle projection method is generally composed of the front view (the figure viewed from the front:

A), top view (the figure viewed from the top: B), and right-side view (the figure viewed from the right: C) as

shown below. Draw the top view immediately above the front view, and draw the right-side view on the right

side of the front view. Tridimensional shape can generally be drawn with the figures viewed from 3 directions.

For those which cannot be drawn with the figures viewed from 3 directions, the additional figures, such as

left-side view (the figure viewed from the left: D), back view (the figure viewed from the back: E), or bottom

view (the figure viewed from the bottom: F) may be used.

For other cases, when individual detailed drawing is required, an arrow view, sectional view, or detail drawing

may be used separately.

A: Front view

B: Top view

C: Right

-side view

D: Left

-side view

E: Back view

F: Bottom view

Page 8

WA04-4651E

6. Group index

System Diagrams

Data, Adjustment and Checks

Y Z

Page 9

Foreword

WA04-4651E

7. Contents

Chapter

Section

Spec. No.

GR-700N-1

-00101

GR-700N-1

-00121

GR-700N-1

-00122

Data, Adjustment and Checks

Service Data

Y-1

Adjusting pressure

Hydraulic Pressure Y-2

Pneumatic Pressure Y-3

Air Bleeding Procedure

Y-4

Adjusting procedure

Electric Y-5

Assembly Adjustment

Crane Operation Y-6

Traveling Device Y-7

Operation Check

Crane Operation Y-8

Traveling Device Y-9

Inspection and Maintenance

Y-10

System Diagrams

Hydraulic Circuit

Z-1

Torque Converter Circuit

Z-2

Pneumatic Circuit

Z-3

Electric Circuit

Upper

Z-4

Lower

Z-5

Hydraulic Parts Location Diagram

Upper

Z-6

Lower

Z-7

Torque Converter

Z-8

Pneumatic Parts Location Diagram

Z-9

Electric Parts Location Diagram

Upper

Z-10

Lower

Z-11

Harness

Upper

Z-12

Lower

Z-13

View System Z-14

Page 10

Data, Adjustment and Checks

Contents

Y-1 Service Data ..................................... 1

1. Amounts of oil and coolant ........................ 1

2. Operating speed ....................................... 1

3. Hydraulic device ....................................... 2

3.1 Hydraulic pump .......................................... 2

3.2 Hydraulic motor .......................................... 2

3.3 Hydraulic cylinder ....................................... 3

4. Slewing section ......................................... 5

5. Boom section ............................................ 5

5.1 Boom slide plate ......................................... 5

5.2 Jib slide plate .............................................. 6

5.3 Boom bending and deformation ................. 7

5.4 Jib bending and deformation ...................... 8

5.5 Wire rope .................................................... 9

5.6 Sheave ..................................................... 10

5.7 Inspection of the hook block ..................... 10

6. Criteria for maintenance and replacement

of vehicle ..................................... 11

6.1 Power transmission device ....................... 11

6.2 Braking device .......................................... 11

6.3 Steering device ......................................... 12

7. Mass table .............................................. 13

Y-2 Adjusting Pressure

(Hydraulic Pressure) .............. 14

1. Location (position of relief valve etc.) ...... 14

2. Items .................................................... 15

2.1 Winch ........................................................ 15

2.2 Telescoping ............................................... 16

2.3 Elevating ................................................... 17

2.4 Slewing...................................................... 18

2.5 Outrigger ................................................... 19

2.6 Remote control pilot pressure ................... 20

2.7 Steering ..................................................... 21

2.8 Torque converter oil pressure ................... 21

2.9 Jib tilt and jib telescoping .......................... 22

2.10 Suspension lock ........................................ 23

Y-3 Adjusting Pressure

(Pneumatic Pressure) ............ 24

Page 11

Y-4 Air Bleeding Procedure ................. 25

1. Hydraulic pump ....................................... 25

1.1 Steering and ACC charging pump

(double gear pump) ............................ 25

1.2 Main pump ................................................ 25

1.3 Main pump (when the tank pressurization

tool is used) ........................................ 26

1.4 Tank pressurization tool ........................... 26

1.5 Other (cylinder) ......................................... 26

2. Winch brake ............................................ 27

3. Service brake .......................................... 28

4. Hydraulic motor assy .............................. 29

4.1 Slewing motor ........................................... 29

4.2 Winch motor ............................................. 29

4.3 Other motor .............................................. 29

5. Winch counterbalance valve

(main and auxiliary) ..................... 30

6. Jib tilt cylinder ......................................... 30

7. Pilot circuit

(hydraulic pilot control valve) ....... 31

8. Positive control circuit ............................. 32

9. Slewing control valve

(back-pressure valve) .................. 32

10. Hydraulic valve (winch brake) ................. 33

Y-5 Adjusting Procedure (Electric) ...... 34

1. Switch adjustment procedure .................. 34

1.1 Over-front detection switch (CN521) ........ 34

1.2 Boom full retraction detection switch

(CN552) .............................................. 34

1.3 Jib lock pin detection switch (CN573) ....... 35

1.4 Jib connection pin detection switch

(CN572) .............................................. 35

1.5 Jib full retraction detection switch

(CN554) .............................................. 36

1.6 Main wire rope length detection

(Phase A: CN525)

(Phase B: CN526) ............................... 37

1.7 Aux. wire rope length detection

(Phase A: CN527)

(Phase B: CN528) ............................... 37

1.8 Straight ahead detection switch

(CN408) .............................................. 38

1.9 Rear steering lock pin IN detection

switch (CN417) ................................... 38

1.10 Rear steering lock pin OUT detection

switch (CN418) ................................... 38

1.11 Vehicle height detection ............................ 39

1.11.1 Assembly adjustment .......................... 39

1.11.2 Switch adjustment

(front left: CN400, CN401)

(rear left: CN404, CN405) ................... 42

1.11.3 Switch adjustment

(front right: CN402, CN403)

(rear right: CN406, CN407) ................. 43

Y-6 Assembly Adjustment

(Crane Operation) .................. 44

1. Adjusting boom telescoping wire ropes ... 44

1.1 Adjusting boom telescoping wire ropes .... 44

1.2 Adjusting boom head lower slide plate ..... 46

1.3 Adjusting wire rope

for 5th boom section extension ........... 47

Page 12

iii

2. Boom clearance adjustment .................... 48

2.1 Shim adjustment at lower oblique sides

of the boom bottom ............................ 49

2.2 Shim adjustment at upper part

of the boom bottom ............................ 49

2.3 Shim adjustment at sides

of the boom bottom ............................ 50

2.4 Slide plate adjustment at lower part

of the boom head ............................... 51

2.5 Clearance adjustment at upper part

of the boom head ............................... 52

2.6 Shim adjustment at upper part

of the boom bottom ............................ 53

2.7 Clearance check at upper part

of the boom bottom ............................ 53

2.8 Clearance check at sides

of the boom bottom ............................ 54

3. Installing and adjusting anti-buckling bolts

for telescoping cylinders .............. 54

4. Bubble level adjustment .......................... 55

4.1 Leveling the slewing table plane .............. 55

4.2 Upper and lower bubble level

adjustment .......................................... 57

4.3 Adjustment check ..................................... 57

4.4 Readjustment ........................................... 57

Y-7 Assembly Adjustment

(Traveling Device) .................. 58

1. Service brake adjustment ....................... 58

1.1 Adjusting the brake pedal ......................... 58

1.2 Tightening the cap of reserve tank

of service brake fluid .......................... 58

1.3 Check after replacing brake hose ............ 59

2. Accelerator adjustment ........................... 59

2.1 Accelerator pedal ..................................... 59

2.2 Accelerator sensor assembly

and adjustment ................................... 60

2.3 Engine speed ........................................... 62

2.4 Procedure for checking engine stall

speed .................................................. 62

3. Parking brake adjustment ........................ 63

3.1 Adjusting the clearance

(between brake shoe and drum) ......... 63

3.2 Connecting parking brake

and spring chamber ............................ 63

4. Tire and steering angle adjustment ......... 63

4.1 Tire size and air pressure ......................... 63

4.2 Adjusting the steering angle...................... 63

5. Torque converter and transmission ......... 64

5.1 Maximum allowable speed........................ 64

5.2 Adding oil to the torque converter

and transmission ................................. 64

6. Braking force ........................................... 65

6.1 Parking brake force ................................... 65

6.2 Service brake force ................................... 65

6.3 Auxiliary operating brake (aux. brake)

force .................................................... 65

7. Adjusting headlight light axis ................... 66

7.1 Adjusting low beam ................................... 66

7.2 Adjusting high beam ................................. 66

7.3 Procedure for adjusting light axis .............. 66

8. Hydraulic suspension .............................. 67

8.1 Releasing pressure in the accumulators

for hydraulic suspension ..................... 67

9. Retightening the hub nuts ....................... 67

10. Fuel air bleeding procedure ..................... 67

11. Axle alignment adjustment procedure ..... 68

11.1 Align the axle center with frame center ..... 68

11.2 Align each axle using 1st axle

as datum axle ..................................... 69

12. Wheel alignment adjustment procedure .. 70

12.1 Work preparation ...................................... 70

12.2 Front wheel adjustment ............................. 71

12.3 Rear wheel adjustment ............................. 71

12.4 Checking procedure .................................. 71

12.5 After checking ........................................... 71

Page 13

Y-8 Operation Check

(Crane Operation) .................. 72

1. Outrigger status indicator by operating outrigger inside cab . 72

2. Outrigger status indicator

by lower outrigger control box ...... 72

3. Boom telescoping control ........................ 73

3.1 Extension .................................................. 73

3.2 Retraction ................................................. 73

3.3 Emergency telescoping ............................ 73

4. Hoisting................................................... 74

5. Backward stability control ....................... 74

6. Jib side-up function ................................. 75

7. Warning .................................................. 76

8. Eco mode operation check ..................... 76

Y-9 Operation Check

(Traveling Device) .................. 77

1. Permanent-magnetic retarder .................. 77

2. Automatic transmission ........................... 78

3. Rear steering lock ................................... 79

3.1 Operation check A .................................... 79

3.2 Operation check B .................................... 80

3.3 Operation check C .................................... 80

4. Overshift prevention ................................ 80

5. Warning .................................................. 81

6. Speedometer .......................................... 82

7. Emergency accelerator switch ................. 82

8. Emergency transmission switch .............. 82

9. Hydraulic suspension .............................. 83

9.1 Normal operation ...................................... 83

9.2 Emergency operation ................................ 85

Y-10 Inspection and Maintenance ......... 88

Page 14

Y- 1

Service Data

WY01-2692E

Y-1 Service Data

1. Amounts of oil and coolant

(1L = 2.64172 × 10-1 gal)

Item

Standard value (L)

Remarks

Amount of oil

Hydraulic oil

Total oil capacity 930

TADANO Hydraulic Oil LL (TADANO Genuine)

Tank capacity 620

Speed reducer gear oil

Slewing 3.8 Mobilgear 600XP 320 (Exxon Mobil)

Winch

Main 6.1

Mobilgear 600XP 150 (Exxon Mobil)

Auxiliary 6.1

1st axle Hub section 2.9×2

Apolloil gear HE-S90 (Idemitsu) or Cosmo Gear GL-590 (Cosmo)

2nd and 4th axles

Carrier differential

12×2

Planetary gear 2.6×4

3rd axle

Carrier differential

Planetary gear 2.6×2

Torque converter and transmission (total oil capacity)

38.5

TADANO Genuine Torque Converter Oil

Brake fluid Service brake 2.1

TADANO Genuine Brake Fluid DOT-5.1

Engine oil Engine 27

JASO Standards: DH-2 or higher

SAE15W-40

(SAE10W-30 for cold climates)

Grease 1

Daphne Eponex Grease SR No. 2 (Idemitsu)

Grease (lower centralized lubrication distributor)

1 Nigtight LE-0 (Nippon Grease)

Fuel tank 400 Diesel fuel JIS K2204 #2

Amount of

coolant

Coolant

Total volume 45.3 (*1)

TADANO Genuine Long-life Coolant

Necessary volume of long-life coolant

22.7 (*2)

Coolant additives

3.8

(or equivalent)

Cummins DCA4

(*1): 12.8 L (in engine), 21.8 L (in radiator), 6.0 L (in reservoir tank), 1 L (in pipe), 3 L (in oil cooler),

0.7 L (in hot-water heater) (total amount including long life coolant and coolant additives)

(*2): With mixing ratio of 50%

2. Operating speed

Item Standard value Remarks

Operating

speed

Telescoping

Extending 34.2 m/124 s

Retracting ―

Elevating

Raising 0° to 84°/58 s

Lowering ―

Winch rope (hoisting up) speed

Main 131 m/min On 5th layer

Auxiliary 114 m/min On 3rd layer

Slewing 2.1 min-1

△

346-605-90000

△

344-527-

00001

△

345-808-

11000

△

344-527-

10001

[NOTICE]

Standard values are values at time of vehicle shipment from TADANO. Limit values are the limits at which adjustment or part replacement is necessary.

Page 15

Y- 1

Service Data

WY01-2692E

3. Hydraulic device

3.1 Hydraulic pump

Item Standard value Remarks

Crane pump (double piston pump)

Speed reducing ratio 0.642

Idling (min-1) 1090 ± 31 Eng.700 ± 20 min-1 (PTO-ON)

Max. (min-1)

2414

+78 0

Eng.1550

+50 0

min-1 (PTO-ON)

Displacement (cm3/rev) 82 + 82

Steering pump (double gear pump)

Speed reducing ratio 0.815

Idling (min-1) 859 ± 25 Eng.700 ± 20 min-1

Max. (min-1) 2785 ± 61 Eng.2270 ± 50 min-1

Displacement (cm3/rev) 52.2 + 13.9

Torque converter pump

Speed reducing ratio 0.605

Idling (min-1) 1157 ± 33 Eng.700 ± 20 min-1

Max. (min-1) 3752 ± 83 Eng.2270 ± 50 min-1

Displacement (cm3/rev) 23.7

Emergency steering

pump

Displacement (cm3/rev) 14.56

3.2 Hydraulic motor

(1 L/min = 2.64172 × 10-1 gal/min)

Item Standard value Remarks

Winch (main, auxiliary)

Displacement (cm

/rev) 127 to 195

Variable displacement pump with

auto-brakes

Drain (when running) Maximum drain: 6.5 L/min For reference

Slewing

Displacement (cm

/rev) 169.4

Drain (when running) Maximum drain: 20 L/min For reference

△

345-808-

13000

△

366-535-

20000

△

366-548-60000

△

363-706-70000

△

366-545-30001

△

366-635-

70000

△

366-635-

80000

△

366-635-90000

Page 16

Y- 1

Service Data

WY01-2692E

3.3 Hydraulic cylinder

(1 m = 3.28084 ft)

(1 mm = 3.93701 × 10

-2

in)

Item

Standard

value

Remarks

Condition and method

Safety and notice

Holding

performance

Elevating

1° or less/

2 hours

Inspection conditions

1. Boom angle: 60°±2° (Lowering operation)

2. Boom full retraction

3. Engine stop

4. No load Inspection method Read the variation of boom angle from the AML display after leaving as it is for 2 hours, or 15 hours (one night).

• Due to the holding failure of telescoping, elevating, or jack cylinder during measurement, the engine hood and carrier cab of the vehicle, or surrounding vehicles can be damaged. Therefore, hoist up the hook block near the two-blocking position, and set up the crane paying attention to boom directions.

Telescoping

0.1m or less/

2 hours

Inspection conditions

1. Each boom section extended by approximately 1 m

(*1)

2. Boom angle: 60°±2°

3. Engine stop

4. No load

Inspection method Read the variation of boom length from the AML display after leaving as it is for 2 hours.

• Check the boom length on the integrated information screen in the AML maintenance mode. (Displays the value to the second

digit after decimal place.)

Jack

retracting

1mm or

less/

5 hours

Inspection conditions

1. Boom stowed over-front

2. Slide fully extended

3. After jack full extension and retraction operation (approximately 10 mm), set the crane horizontally with the jacks slightly extended.

(*2)

(If any tire is not raised off the ground while setting the jacks, use blocks to secure the remaining stroke.)

Inspection method Check the displacement by measuring the dimensions again after 5 hours.

• Set the crane considering

the possibility of damaging the vehicle or surrounding vehicles due to the holding failure of the jack cylinder during measurement.

• Do not stick a tape on the cylinder rod while measuring. (If the tape is not removed, it may enter inside the dust seal.)

• Pay attention not to damage the rod when marking the points with a pencil. (Depending on the shape of the outriggers, mark the points on a position where the measurement of jack inner case is easy

and secure.)

Jack

extending

1mm or

less/

5 hours

Inspection conditions

1. Boom stowed over-front

2. Slide fully retracted

3. Jack fully retracted

(*2)

Inspection method Check the displacement by measuring the dimensions again after 5 hours.

(*1): • In the case of ESP boom, extend the 2nd boom section (telescopic section 1) by 1 m.

• When you check the machine which are equipped with telescoping mode I and telescoping mode II, make sure to set the telescoping mode corresponding cylinder 1 or cylinder 2.

(*2): Set under the idling condition.

For models equipped with “automatic accelerate function”, set under the condition that “automatic accelerate function” is not activated.

Page 17

Y- 1

Service Data

WY01-2692E

Item

Standard

value

Remarks

Condition and method Safety and notice

Holding

performance

Jib

tilt

1° or less/

2 hours

Inspection conditions

1. Angle lowered by 5°±2° from jib tilt angle upper limit (minimum offset angle)

2. Boom angle: 60°±2°

3. Engine stop

4. No load

Inspection method Read the variation of the jib tilt angle from the AML display after leaving with no initial retraction for 2 hours.

• Due to the holding failure of telescoping, elevating, or jack cylinder during measurement, the vehicle and surrounding vehicles can be damaged. Therefore, hoist up the hook block near the two-blocking position, and set up the crane paying attention to boom directions.

Jib

telescoping

0.1m or less/

2 hours

Inspection conditions

1. Each jib section extended by approximately 1 m.

(*3)

2. Jib offset angle: 5°±2°

3. Boom angle: 60°±2°

4. Engine stop

5. No load

Inspection method Read the variation (retraction amount) of the jib length from the AML display after leaving as it is for 2 hours.

• Check the boom length on the integrated information screen in the AML maintenance mode. (Displays the value to the second

digit after decimal place.)

Suspension

On-rubber

10 mm or

less/

15 hours

Inspection conditions

1. Boom stowed over-front

2. Suspension locked

3. On-rubber

4. Stop the engine and turn off the power.

5. Oil temperature: normal temperature

Inspection method Check the displacement by measuring the dimensions again after 15 hours.

• Complete the leveling.

• Mark the points for

dimension measurement on the fender end above the tire and on the tire.

Jack-up

30 mm or

less/

15 hours

Inspection conditions

1. Boom stowed over-front

2. Suspension locked and axle held

3. Extend the outriggers and set the machine horizontally. (Raise the tires off the ground.)

4. Stop the engine and turn off the power.

5. Oil temperature: normal temperature

Inspection method Check the displacement by measuring

the dimensions again after 15 hours.

(*3): Because the jib of GR-120F is not equipped with emergency telescoping function,

fully extend the 2nd and 3rd jib sections, and extend 4th, 5th, and 6th jib sections by 1 m for each.

Page 18

Y- 1

Service Data

WY01-2692E

4. Slewing section

(1 mm = 3.93701 × 10-2 in)

Item

Standard value

Remarks

Amount of slewing play

Horizontal play

5.0 mm or less

Vertical play

2.5 mm or less

5. Boom section

5.1 Boom slide plate

(1 mm = 3.93701 × 10-2 in)

Location used

Standard

thickness (mm)

Replacement

standard (mm)

Remarks

Limit value

Base boom

section

Front

Upper (on upper part of side face)

Lower (on rounded face)

2-piece

or 16 or 14

2nd boom section

Front

Upper (on upper part of side face)

Lower (on rounded face)

2-piece

or 16 or 14

Rear

Upper (on oblique face)

Side

13 or 19

or 17

Lower (on rounded face)

12 - 14

10 - 12

3rd boom section

Front

Upper (on upper part of side face)

Lower (on rounded face)

2-piece

or 16 or 14

Rear

Upper (on oblique face)

Side

or 19 or 17

Lower (on rounded face)

12 - 14

10 - 12

4th boom section

Front

Upper (on upper part of side face)

Lower (on rounded face)

2-piece

or 16

or 14

Rear

Upper (on oblique face)

Side

or 19 or 17

Lower (on rounded face)

12 - 14

10 - 12

5th boom section

Front

Upper (on upper part of side face)

Lower (on rounded face)

18 - 48 16 - 46

3-piece

or 18 - 46

or 16 - 44

Rear

Upper (on oblique face)

Side

13 or 19

or 17

Lower (on rounded face)

12 - 14

10 - 12

Top boom section

Rear

Upper (on oblique face)

Side

15 13

or 19

or 17

Lower (on rounded face)

15 - 26

13 - 24

Page 19

Y- 1

Service Data

WY01-2692E

5.2 Jib slide plate

(1 mm = 3.93701 × 10-2 in)

Location used

Standard thickness

(mm)

Replacement

standard (mm)

Remarks

Limit value

Jib 1 Front

Lower 12 9

Side - -

Jib 2

Front

Lower 12 9

Side - -

Rear

Upper corner

Upper 30 27

Side 35 33

Side 15 13

Jib 3 Rear

Upper corner

Upper 25 22

Side 35 33

Side 15 13

Page 20

Y- 1

Service Data

WY01-2692E

5.3 Boom bending and deformation

(1 mm = 3.93701 × 10-2 in)

Item

Standard value (mm)

Remarks

Overall boom bending (at full extension, maximum elevation angle, with rated load)

IWY01-001001

No significant vertical or horizontal bends shall be found along the entire boom length.

Set the machine level.

If necessary, adjust the clearance between the boom and the slide plates appropriately.

Bend of individual boom sections

(Lengthwise direction)

IWY01-0010E02

Vertical

Base boom section

2nd boom section

3rd boom section

4th boom section

5th boom section

Top boom section

B ≤ 14

B ≤ 13

B ≤ 14

B ≤ 1.5 × L /1000

L: length of each

boom section

Lateral

Base boom section

2nd boom section

3rd boom section

4th boom section

5th boom section

Top boom section

C ≤ 9

C ≤ 1.0 × L /1000

Indentations at boom overlap sections

(Bending at boom lower plate)

IWY01-001003

2nd boom section

3rd boom section

4th boom section

5th boom section

Top boom section

In vertical direction

D ≤ 4

D ≤ 3

D ≤ 2

In vertical direction

D ≤ t/2

Check for deformation of side plates. There must be no large deformation

particularly on the lower half surface of side plate where pressure

concentrates.

Check for twisting in the lengthwise direction when boom is fully extended.

IWY01-001004

E ≤ 5

Check for dents and other localized indentation.

Depth F

IWY01-0010E05

F ≤ 2

(at L

≥ 50)

Generally dent G on the 4 corners cannot be repaired.

Page 21

Y- 1

Service Data

WY01-2692E

5.4 Jib bending and deformation

(1 mm = 3.93701 × 10-2 in)

Item

Standard value (mm)

Remarks

Overall jib bending (at full extension, minimum tilt angle, with rated load)

IWY01-001001

No significant vertical or horizontal bends shall be found along the entire jib length.

Set the machine level.

If necessary, adjust the clearance between the jib and the slide plates appropriately.

Bend of individual jib sections

(Lengthwise direction)

IWY01-0010E02

Vertical

Jib 1

Jib 2

Jib 3

B ≤ 10

B ≤ 9

B ≤ 1.5 × L /1000

L: length of each jib

section

Lateral

Jib 1

Jib 2

Jib 3

C ≤ 7

C ≤ 6

C ≤ 1.0 × L /1000

Indentations at jib overlap sections

(Bending at jib lower plate)

IWY01-001003

Jib 2

Jib 3

In vertical direction

D ≤ 3

D ≤ 2

In vertical direction

D ≤ t/2

Check for deformation of side plates. There must be no large deformation

particularly on the lower half surface of side plate where pressure

concentrates.

Check for twisting in the lengthwise direction when jib is fully extended.

IWY01-001004

E ≤ 5

Check for dents and other localized indentation.

Depth F

IWY01-0010E05

F ≤ 2

(at L

≥ 50)

Generally dent G on the 4 corners cannot be repaired.

Page 22

Y- 1

Service Data

WY01-2692E

5.5 Wire rope

(1 mm = 3.93701 × 10-2 in)

Item Standard value

Limit

value

Remarks

GR-700N-1-00101, -00121

For main winch

Wire rope diameter (mm)

(Nominal diameter)

16.7

Construction

SeS(48)+6×WS(31) O/O or

IWRC 6×Fi(29) O/O

Number of broken wire (pcs.) –

WS: 15

Fi: 13

For auxiliary winch

Wire rope diameter (mm)

(Nominal diameter)

16.7

Construction

IWRC 6×W S(31) O/O or

IWRC 6×Fi(29) O/O

Number of broken wire (pcs.) –

WS: 15

Fi: 13

For 5th boom extension

Wire rope diameter (mm)

(Nominal diameter)

14.9

Construction IWRC 6×P•Fi(29) O/O

Number of broken wire (pcs.)

–

For 5th boom

retraction/ top boom extension

Wire rope diameter (mm)

(Nominal diameter)

13.1

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

For top boom retraction

Wire rope diameter (mm)

(Nominal diameter)

9.3

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

For jib extension

Wire rope diameter (mm)

(Nominal diameter)

11.2

Construction 7×7+6×Fi(29) O/O

Number of broken wire (pcs.)

–

For jib retraction

Wire rope diameter (mm)

(Nominal diameter)

7.5

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

GR-700N-1-00122

For main winch

Wire rope diameter (mm)

(Nominal diameter)

16.7

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

For auxiliary winch

Wire rope diameter (mm)

(Nominal diameter)

16.7

Construction IWRC 6×WS(31) O/O

Number of broken wire (pcs.) –

For 5th boom extension

Wire rope diameter (mm)

(Nominal diameter)

14.9

Construction

IWRC 6×P•WS(31) O/O or

IWRC 6×P•Fi(29) O/O

Number of broken wire (pcs.) –

WS: 15

Fi: 13

For 5th boom

retraction/ top boom extension

Wire rope diameter (mm)

(Nominal diameter)

13.1

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

For top boom retraction

Wire rope diameter (mm)

(Nominal diameter)

9.3

Construction IWRC 6×P•WS(31) O/O

Number of broken wire (pcs.)

–

For jib extension

Wire rope diameter (mm)

(Nominal diameter)

11.2

Construction 7×7+6×Fi(29) O/O

Number of broken wire (pcs.)

–

For jib retraction

Wire rope diameter (mm)

(Nominal diameter)

7.5

Construction IWRC 6×Fi(29) O/O

Number of broken wire (pcs.)

–

Criteria for wire rope replacement

1. Replace the wire rope if it is deformed or corroded.

2. Replace the wire rope if it is kinked.

3. Replace the wire rope if 10% or more of the wires (except for filler wires) in a lay are broken.

4. Replace the wire rope if the diameter is reduced by more than 7% of the nominal diameter.

5. Replace the wire rope if it has been degraded by heat.

Page 23

Y- 1

Service Data

WY01-2692E

5.6 Sheave

(1 mm = 3.93701 × 10-2 in)

Item

Standard of

minor diameter

(mm)

Limit of minor

diameter

(mm)

(*1)

Remarks

Only sheaves of the hoisting systems are listed here.

• Winch sheave

• Attachment sheave

(heavy-duty lift device)

270 264.6

Determination of limit minor diameter (When rope of nominal diameter less than 25 mm are used) Limit minor dia. = Standard minor dia. - (Nominal rope dia. × 0.3)

Nominal diameter of winch rope:

18 mm

• Upper and lower sheaves

on boom head

• Single top sheave

• Jib head sheave

• Hook block sheave (35 t)

360 354.6

(*1): Wear of sheave groove

5.7 Inspection of the hook block

[NOTICE]

The hook block is an important safety part. Follow the procedure below to inspect it and be sure to use it only under safe conditions.

If any problems are found during inspections, repair or replace the part immediately. A change inspection must be performed when parts are replaced.

Inspect the hook block by the instruction of its manufacture and under the laws and standards of the country where you use the crane.

1. The sheave groove must be smooth to avoid

damaging the wire rope. Use a grinder to smooth

and correct any sharp corners.

2. Check whether or not the sheaves turn lightly. If a

sheave turns heavily, the wire rope will slide

against the sheave, and the rope may be

damaged. If a sheave turns heavily, inspect the

sheave bearings, and lubricate or replace them if

necessary.

3. Check that the sheave split pins and installation

bolts are securely installed.

4. Check that the hook nuts are securely installed. If

necessary, tighten them further or take steps to

prevent their rotation.

5. Replace any worn or damaged hook nuts

immediately.

6. Check that the wire rope latch functions correctly.

If necessary, replace the spring.

7. Perform a magnetic flaw detection test at least

once a year to check for damage in the hook.

Replace the hook immediately if any cracks are

found.

8. As shown in the figure, punch marks are stamped

on each hook. Replace the hook when the

deformation of the dimension (a) between these

marks has increased by 5%.

9. The wear limit of the hook (b) is 3% of the whole

thickness (c).

Hook service limits

(Unit: mm) (1 mm = 3.93701 × 10

-2

in)

Item

Hook capacity

35 t

5 t

Dimension a

(Deformation)

200

(10)

100

(5)

Limit wear: b

3.75

1.68

Thickness: c

125

IWY01-025001E

Punch mark

Page 24

Y- 1

Service Data

WY01-2692E

6. Criteria for maintenance and replacement of vehicle

6.1 Power transmission device

Item Standard value Remarks

Engine speed

Idling (min1)

700 ± 20

MAX

(min

-1

)

PTO OFF

2270 ± 50

PTO ON

1550

+50 0

Eco mode: OFF

Speed limiter ON

1950 ± 20

(With load)

When torque converter stalls Approx. 1,760

(For reference)

Check conditions

• PTO switch : OFF

• Drive mode selection switch

: 6WD/High (*1)

• Emergency transmission switch : ON with 6WD/High state (*2)

• Shift lever : ”2”

• Service brake : ON

(*1) Because the drive mode cannot be changed after the emergency transmission switch is turned ON,

change to "6WD/High" in advance.

(*2) Emergency operation switch inside electrical box in the cab rear

6.2 Braking device

(1 mm = 3.93701 × 10-2 in)

Item Standard value Limit value Remarks

Service

brake

Pad thickness (mm) 20

Including back plate

Disc thickness (mm) 15

(1-mm wear in

single side)

Made of steel

Parking brake

Lining clearance (mm) 0.23

Measure both left and

right at the same time.

Lining thickness (mm) 6.8

Lining center

Drum inner diameter (mm) 304.8

306

Cam roller guide section -

There must be no

deformation.

△

345-808-

13000

△

363-823-

30000

Emergency transmission switch

(Emergency accelerator switch)

(DPF emergency cancel switch)

Page 25

Y- 1

Service Data

WY01-2692E

6.3 Steering device

(1 mm = 3.93701 × 10-2 in)

Item Standard value Remarks

Steering

cylinder

Fixing pin outer diameter (mm)

Cylinder

side

Ø35

–0.025 –0.05

Rod side Ø38

–0.025 –0.05

Knuckle

Vertical clearance to axle (mm)

Upper: 0

Lower: 0.05

Wheel

Camber (°) 0

Caster (°) 0

King pin angle (°) 0

Toe-in (mm)

1st axle +3.0 to +5.0

2nd axle +2.0 to +6.0

3rd axle

0 to +4.0

4th axle

Steering angle (°)

inner wheel (outer wheel)

1st axle

42.0

–1

(34° 31’)

2nd axle

35.0

0 –1

(29° 59’)

3rd axle

20.0

–1

(18° 26’)

4th axle

30.0

0 –1

(26° 23’)

Tire size 385/95 R25 170E

Tire air pressure

900

+100 0

kPa

{9.0

+1.0 0

kgf/cm2}

(130.5

+14.5 0

psi)

△

363-823-30000

△

347-220-

21000

△

347-224-33000

△

345-808-

13000

Page 26

WY01-2692E

Y- 1.

Service Data

7. Mass table

The dry weights of the major components are shown in the table below.

Refer the weights, and select appropriate hoisting devices when removing and installing the component.

(kg (lb))

Assy name Mass

Slewing table assy

(not including: boom, jib, elevating cylinder, slewing bearing,

counterweight)

5900 (13000)

Slewing bearing 520 (1150)

Slewing drive unit (including: hydraulic motor) 210 (460)

Center joint 85 (190)

Elevating cylinder 480×2 (1060×2)

Winch assy (including: hydraulic motor)

Main winch 430 (950)

Auxiliary winch

410 (900)

Boom assy (including: boom telescoping cylinder) 8400 (18500)

Jib assy (including: jib tilt and jib telescoping cylinder) 1320 (2910)

Counterweight 510 (1120)

H-type outrigger assy (including: slide cylinder, jack cylinder) 820×4 (1810×4)

Engine 710 (1570)

Torque converter 240 (530)

Transmission 430 (950)

Retarder 110 (240)

Axle (not including: steering cylinder)

1st axle 610 (1350)

2nd axle 870 (1920)

3rd axle 950 (2100)

4th axle 870 (1920)

Wheel assy (including: tire) 230×8 (510×8)

Page 27

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

Y-2 Adjusting Pressure (Hydraulic Pressure)

1. Location (position of relief valve etc.)

Detail A

View B

View C

View D

Slewing table section

Vehicle over-front

Hydraulic valve (for winch brake)

Main winch pipe

Hydraulic pilot control valve (for main)

Hydraulic pilot control valve (for slewing)

Solenoid control valve

(for outrigger)

Sequence valve

Priority valve

Slewing center

Lower frame, left center section

Page 28

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2. Items

2.1 Winch

[NOTICE]

Set the AML emergency switch to "Emergency" (after the pressure adjustment, make sure to return the AML

emergency switch to "Normal" position).

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL) Confirm set pressure on the crane information screen in the maintenance mode of AML. Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa

kgf/cm

psi

Winch

hoisting up

(A)

27.5±0.5 280±5 3980±70

1550

(MAX.)

1. Block the joints of the main winch pipe between the hydraulic pilot control valve C2 port and hydraulic valve.

2. Turn the PTO switch ON.

3. Move the main winch lever at its full stroke on the hoisting up side while the elevating lever is moved at its full stroke on the lowering side.

4. In this state, set the engine speed to 1550 min

-1

and check the pressure.

Rear of oil tank

Solenoid control valve

(for outrigger)

Hydraulic pilot control valve (for main)

View D

Main winch pipe

Hydraulic valve

(for winch brake)

Solenoid control valve (for outrigger)

Winch hoisting up (A)

Page 29

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.2 Telescoping

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Confirm set pressure on the crane information screen in the maintenance mode of AML.

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed (min

-1

)

Check procedure

MPa kgf/cm2 psi

Boom

retracting

(B)

23.0±0.5 235±5 3340±70

1550

(MAX.)

1.Turn the PTO switch ON.

2. Fully retract the boom.

3. Move the telescoping lever at its full stroke on the retracting side.

4. In this state, set the engine speed to 1550

min-1 and check the pressure.

Boom

extending

(C)

20.1±0.5 205±5 2920±70

1. Turn the PTO switch ON.

2. Fully extend the 2nd and 3rd boom sections.

3. Move the telescoping lever at its full stroke on the extending side. At this time, do not operate any of the 4th, 5th, and top boom section extending switches.

4. In this state, set the engine speed to 1550

min-1 and check the pressure.

Hydraulic pilot control valve (for main)

Boom extending (C)

Boom retracting (B)

Slewing table right side

Hydraulic pilot control valve (for main)

Page 30

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.3 Elevating

[NOTICE]

Set the AML emergency switch to "Emergency" (after the pressure adjustment, make sure to return the AML

emergency switch to "Normal" position).

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Confirm set pressure on the crane information screen in the maintenance mode of AML.

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa kgf/cm2 psi

Boom

raising

(G)

27.5

+0.5 0

280

+5 0

3980

+70 0

1550

(MAX.)

1.Turn the PTO switch ON.

2. Fully extend the elevating cylinder.

3. Move the elevating lever at its full stroke on the raising side.

4. In this state, set the engine speed to 1550 min

-1

and check the pressure.

Boom

lowering

(E)

4.5

+0.5 0

+5 0

650

+70 0

700

(IDL.)

1.Turn the PTO switch ON.

2. Fully retract the elevating cylinder.

3. Move the elevating lever at its stroke full stroke on the lowering side.

4. In this state, check the pressure.

Boom raising (G)

Boom lowering (E)

Hydraulic pilot control valve (for main)

Slewing table right side

Page 31

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.4 Slewing

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Confirm set pressure on the crane information screen in the maintenance mode of AML.

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa kgf/cm2 psi

Slewing

relief valve

(U)

20.1±0.5 205±5 2920±70

1550

(MAX.)

1.Turn the PTO switch ON.

2. Apply the slewing lock.

3. Move the slewing lever at its full stroke on the right and left side.

4. In this state, set the engine speed to

1550 min-1 and check the pressure.

Slewing

overload

relief valve

(N)

22.6 230 3270 -

Already the pressure is set by the valve

manufacturer. (Adjustment is not necessary.)

Hydraulic pilot control valve (for slewing)

Overload relief valve (N)

Relief valve (U)

Slewing table right side

Hydraulic pilot control valve (for slewing)

Page 32

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.5 Outrigger

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa kgf/cm2 psi

Outrigger

relief valve

(L)

20.6±0.5 210±5 2990±70

1550

(MAX.)

1. Connect a pressure gauge to the

pressure check port (L).

2. Turn the PTO switch ON.

3. Fully extend the outrigger while the

speed is idling.

4. In this state, set the engine speed to

1550 min

-1

and check the pressure by the

pressure gauge.

Rear of oil tank

Solenoid control valve

(for outrigger)

Solenoid control valve (for outrigger)

Relief valve (L)

Pressure check port (L) (G1/4)

Page 33

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.6 Remote control pilot pressure

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa

kgf/cm

psi

Low

pressure

(S)

2.9 or over

30 or

over

420 or

over

700

(IDL.)

1. Connect a pressure gauge to the pressure check port (S).

2. Turn the PTO switch ON.

3. Set the air conditioner switch to OFF.

4. In this state, check the pressure by the pressure gauge.

(Note): Adjustment is not possible.

If the pressure is out of the set pressure

range, replace the sequence valve.

High

pressure

(R)

3.9 or less

40 or

less

560 or

less

700

(IDL.)

1. Connect a pressure gauge to the pressure check port (R) of sequence valve.

2. Turn the PTO switch ON.

3. Set the side up jib to the stowing operation state.

4. In this state, check the pressure by the pressure

gauge.

View A

Pressure check port (R) (S) (G1/4)

Sequence valve

Low pressure (S)

High pressure (R)

Sequence valve

Slewing table (left side)

Page 34

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.7 Steering

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed (min

-1

)

Check procedure

MPa kgf/cm2 psi

Steering

(I)

16.0±1.0 163±10 2320±140 2000

1. Connect a pressure gauge to the pressure check port (I) (G1/4) of front left (between 1st axle and 2nd axle) steering pipe.

2. Without jacking up, turn the steering to the right side. Gently move the steering cylinders to the end of the stroke.

3. In this state, set the engine speed to 2000 min

-1

and check the pressure by the pressure gauge.

(Note): Adjustment is not possible.

If the pressure is out of the set pressure

range, replace the priority valve.

2.8 Torque converter oil pressure

Item

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa

kgf/cm

psi

Torque

converter oil

pressure

1.2 or over

12 or

over

170 or

over

700

(IDL.)

1. Turn the PTO switch OFF with the air conditioner OFF.

2. Confirm set pressure on the vehicle information

screen in the maintenance mode of AML.

2.0 to 2.4 20 to 24 290 to 350 2000

Steering (I) (in priority valve)

Slewing table (inside)

Slewing center

Priority valve

Lower frame (bottom face)

Pressure

check port (I) (G1/4)

Front

Steering cylinder

(front 1st axle left side)

Page 35

Y- 2

Adjusting Pressure (Hydraulic Pressure)

WY02-1720E

2.9 Jib tilt and jib telescoping

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Confirm set pressure on the crane information screen in the maintenance mode of AML.

Item

(Mark)

Set pressure

Engine

speed

(min

-1

)

Check procedure

MPa kgf/cm2 psi

Jib tilt

(raising)

(H)

20.6±0.5 210±5 2990±70

700

(IDL.)

1. Turn the PTO switch ON.

2. Mount the jib, then set the boom/jib operation selector switch to the "Jib tilt" side.

3. Fully raise the jib.

4. Stroke the telescoping lever fully to the jib tilt raising side.

5. In this state, check the pressure.

Jib

telescoping

(retracting)

(H)

1. Turn the PTO switch ON.

2. Mount the jib, then set the boom/jib operation selector switch to the "Jib telescoping" side.

3. Fully retract the jib.

4. Stroke the telescoping lever fully to the jib retracting side.

5. In this state, check the pressure.

Jib tilt

(lowering)

(F)

11.8 ±0.5 120±5 1710±70

700

(IDL.)

1. Turn the PTO switch ON.

2. Mount the jib, then set the boom/jib operation selector switch to the "Jib tilt" side.

3. Fully lower the jib.

4. Stroke the telescoping lever fully to the jib tilt lowering side.

5. In this state, check the pressure.

Jib telescoping (extending)

(F)

1. Turn the PTO switch ON.

2. Mount the jib, then set the boom/jib operation selector switch to the "Jib telescoping" side.

3. Fully extend the jib.

4. Stroke the telescoping lever fully to the jib extending side.

5. In this state, check the pressure.

Hydraulic pilot control valve (for main)

Jib tilt lowering (F)

Jib tilt raising (H)

Slewing table right side

Hydraulic pilot control valve (for main)

Page 36

WY02-1720E

Y- 2.

Adjusting Pressure (Hydraulic Pressure)

2.10 Suspension lock

[NOTICE]

Oil temperature: 50 ± 5°C (113 - 131°F) (hydraulic oil: TADANO Hydraulic Oil LL)

Shift the control lever or switch while the engine is idling, then increase engine speed.

Item

(Mark)

Set pressure

Engine

speed (min

-1

)

Check procedure

MPa

kgf/cm

psi

Suspension lock

relief valve

(K)

20.6±0.5 210±5 2990±70 2000

1. Connect a pressure gauge to the pressure check port (K).

2.Move the suspension lock cylinders to the end of the stroke.

3. In this state, set the engine speed to 2000 min

-1

and check the pressure by the

pressure gauge.

△

345-808-

11500

Rear of oil tank

Solenoid control valve

(for outrigger)

Solenoid control valve (for outrigger)

Relief valve (K)

Pressure check port (K) (G1/4)

Page 37

Y- 3.

Adjusting Pressure (Pneumatic Pressure)

WY03-0351E

Y-3 Adjusting Pressure (Pneumatic Pressure)

Item

Set pressure

Remarks

No. in circuit

diagram

kPa kgf/cm2 psi

Pressure regulator

On-load 740

+29 –20

7.5

+0.3 –0.2

107

+4 –3

Check that the air dryer recovers its

performance

during unloading.

200

Unload 830 ± 20 8.5 ± 0.2 120 ± 3

Safety valve

Cracking pressure 850 8.7 123

Must be no leakage within pressure regulator operation range.

197

Full opening

pressure

950 ± 20 9.7 ± 0.2 138 ± 3

Air low-pressure switch (low air pressure

warning)

Light-on pressure 540

+10 –49

5.5

+0.1 –0.5

+1.5 –7

173

Light-off pressure 540

+59 –49

5.5

+0.6 –0.5

+8.5 –7

Reducing valve

For service brake

of front wheels

None

194

For service brake of rear wheels (al

for brake lock)

440 ± 29 4.5 ± 0.3 64 ± 4 Check upper tank.

Air pressure switch

(stop lamp)

Operating pressure 29

+20 –10

0.3

+0.2 –0.1

4.2

+3 –1.5

187

Air low-pressure switch

(parking brake)

Operating pressure 372 ± 20 3.8 ± 0.2 54 ± 3 163

△

345-804-

22000

Page 38

Y- 4

Air Bleeding Procedure

WY05-3900E

Y-4 Air Bleeding Procedure

1. Hydraulic pump

[NOTICE]

Be sure that the following conditions are met before

starting the engine.

• PTO : OFF

• Air conditioner : OFF

The following is also possible:

After performing step 3 under 1.1, perform step 2 under 1.2. Start the engine, then turn ON the PTO, and run-in the pump for 10 minutes.

1.1 Steering and ACC charging pump (double gear pump)

1. Fill the hydraulic oil tank with the hydraulic oil.

2. With the engine stopped, loosen the air-bleed plug

(G1/4) on the suction flange of the main pump.

After bleeding from the suction side, tighten the

plug again.

3. Start the engine (with air conditioner OFF and

PTO OFF), and run it at idle (approximately 700

min

-1

) for 1 minute to bleed the circuit.

4. Start the engine, and run-in the pump for 10

minutes at idle.

1.2 Main pump

1. Fill the hydraulic oil tank with the hydraulic oil. (If

the suction section is disassembled due to repair

or other reasons, bleed from the air-bleed plug on

the suction side as described above.)

2. Bleed the pump case. Remove the drain plug or

the drain hose.

Pour the hydraulic oil from this drain port until the

oil overflows, then tighten the plug.

3. Start the engine with PTO ON, and run-in the

pump at idle for 5 minutes.

Steering, ACC charging pump

Main pump

Drain plug

Suction flange

Air-bleed plug

G1/4 (O-ring)

Steering, ACC charging pump

Main pump

Drain plug

Suction flange

Air-bleed plug

G1/4 (O-ring)

Page 39

Y- 4

Air Bleeding Procedure

WY05-3900E

1.3 Main pump (when the tank pressurization tool is used)

[NOTICE]

Adjust the pressure setting of the tank

pressurization tool to 15 kPa {0.15 kgf/cm²} (2.2 psi). During work, check the pressure gauge so that the pressure is within 15 kPa {0.15 kgf/cm²} (2.2 psi).

Never actuate the hydraulic cylinder with the tank

pressurization tool attached.

1. After replacing the hydraulic pump or the hydraulic

oil, check that the oil level is at the specified level.

2. Remove the air breather on the top of the

hydraulic oil tank and attach the tank

pressurization tool.

3. Slowly loosen the air-bleed plug on the suction

flange of the main pump and let the oil with

bubbles flow out.

4. After making sure that flowing oil contains no

more bubbles, tighten the air-bleed plug while the

hydraulic oil is flowing out.

5. While the tank is pressurized, turn the PTO switch

OFF and start the engine. After idling the engine

for 5 seconds, turn the PTO switch ON and OFF

repeatedly and quickly and check for any

abnormal noise.

6. If any abnormality is found, bleed the hydraulic

pump again.

7. If there is no abnormal noise, turn ON the PTO

switch and idle the engine for 5 minutes with no

load.

8. During the operation, check for any abnormal

noise or heat of the hydraulic pump and oil leaks

from the whole system.

9. After checking that there is no abnormality,

remove the tank pressurization tool on the top of

the hydraulic oil tank and attach the air breather to

the original position.

10. Now the bleeding is complete.

If the hydraulic pump has been replaced, run-in

the pump.

1.4 Tank pressurization tool

1. Valve assy (A)(Part number：329-806-59100)

1.5 Other (cylinder)

1. When bleeding the cylinder thereafter, make the

engine speed medium (1000 min

-1

or less).

2. When the oil temperature needs to be increased

for adjusting pressure, perform the work after

eliminating air bubbles inside the oil tank by air

bleeding.

△

345-808-

10500

△

346-416-

61000

Steering, ACC charging pump

Main pump

Drain plug

Suction flange

Air-bleed plug

G1/4 (O-ring)

Page 40

Y- 4

Air Bleeding Procedure

WY05-3900E

2. Winch brake

[NOTICE] To avoid damage to the friction plates of the winch

brakes, bleed the winch brakes following the procedures below.

1. When assembling piping, plug the piping between

the hoisting down port of each main and auxiliary

winch motor and the corresponding hydraulic pilot

control valve (main). (For plugging, attach plugs to

the pipe end closer to the hoisting down port of

each motor and the one closer to the

corresponding hydraulic pilot control valve port.)

[NOTICE]

After assembly, do not perform hoisting operation. Hereafter, hoisting up operation by the main and

auxiliary winches is prohibited until bleeding of the winch brakes is completed.

2. Perform hoisting down operation of each main

and auxiliary winch using the corresponding

air-bleed plug of the winch brake.

• Engine: idling

• Corresponding control lever moved fully to the

hoisting down side

(You don’t need move the winch lever to and

fro.)

• When no more bubbles come out of the plug,

bleeding is completed.

3. After bleeding of the winch brakes is completed,

remove the plugs from the piping and connection

sections, and reassemble the piping.

Page 41

Y- 4

Air Bleeding Procedure

WY05-3900E

3. Service brake

[NOTICE]

The vehicle has two boosters; one for the front

wheel brakes and the other for the rear wheel brakes.

Take care of spattering the brake fluid and the fluid

level in the fluid reservoir while bleeding.

1. With the sufficient compressed air in the air

reservoir, depress the brake pedal and loosen the

air-bleed plug on the booster to bleed the circuit.

2. Then tighten the air-bleed plug before releasing

the brake pedal.

3. Repeat the above steps until the flowing brake

fluid contains no air bubbles. After the air bubbles

go out, tighten the air-bleed plug while letting the

fluid flow out.

Booster

[NOTICE]

There are two wheel cylinder air-bleed plugs each

with each axle.

4. Bleed the wheel cylinders in the calipers of the

axles in the steps same as above.

Caliper

Page 42

Y- 4

Air Bleeding Procedure

WY05-3900E

4. Hydraulic motor assy

4.1 Slewing motor

[NOTICE] Do not apply any load to the motor before

completing air bleeding.

Bleed the slewing motor by following either (1), (2)

or (3).

(1) Pour the hydraulic oil from the drain port until the

oil flows out.

(2) Perform the right or the left slewing operation

slowly for approximately one minute.

(3) With the slewing brake being actuated, perform

the right or the left slewing operation and keep the

slewing circuit hydraulic pressure at approximately

4.9 MPa {50 kgf/cm

} (710 psi) for approximately

30 seconds.

4.2 Winch motor

[NOTICE] Do not apply any load to the motor before

completing air bleeding.

1. Pour the hydraulic oil from the drain port until the

oil flows out. (After connecting all pipes, pour oil

just before starting the motor.)

4.3 Other motor

With each hydraulic motor, before operating the

motor, pour the hydraulic oil from the drain port

until the oil flows out.

Page 43

Y- 4

Air Bleeding Procedure

WY05-3900E

5. Winch counterbalance valve

(main and auxiliary)

[NOTICE]

With both the main and auxiliary winches, bleed the

counterbalance valve according to the procedure below.

Conditions

Engine speed : Max PTO : ON

With the air-bleed plug loosened, repeat the

hoisting up and hoisting down operations to

gradually increase the engine speed to the

maximum. When flowing oil contains no more air

bubbles, tighten the air-bleed plug while hydraulic

oil is flowing out.

6. Jib tilt cylinder

1. Mount the jib, and then lower the jib head onto the

ground by the jib tilt lowering operation.

2. Loosen the air-bleed plugs in two positions, then

repeat the jib tilt raising and tilt lowering

operations until the bubbles no longer come out

from either of the two air-bleed plugs.

3. Tighten the air-bleed plugs in two positions, and

raise the boom. Fully extend and fully retract the

jib tilt cylinder repeatedly by jib tilt operation.

Page 44

Y- 4

Air Bleeding Procedure

WY05-3900E

7. Pilot circuit

(hydraulic pilot control valve)

[NOTICE] Conditions

Engine speed : idling PTO : ON Oil temperature : 50°C (122°F) or higher

1 Slewing

With the slewing brake being actuated, move the

slewing lever fully to the right slewing side. Keep

the above conditions for 30 seconds or more for

bleeding. Proceed on the same steps by moving

the slewing lever to the left slewing side.

2 Jib

(Jib tilt)

Mount the jib, then set the boom/jib operation

selector switch to the "Jib tilt" side.

Pull out the connector (CN100) of the AML vent

solenoid valve.

Move the telescoping lever fully to the jib tilt

lowering side. Keep the above conditions for 30

seconds or more for bleeding. Proceed on the

same steps by moving the telescoping lever to the

jib tilt raising side.

(Jib telescoping)

Mount the jib, then set the boom/jib operation

selector switch to the "Jib telescoping" side.

Pull out the connector (CN100) of the AML vent

solenoid valve.

Move the telescoping lever fully to the jib

retracting side. Keep the above conditions for 30

seconds or more for bleeding. Proceed on the

same steps by moving the telescoping lever to the

jib extending side.

3 Elevating

Pull out the connector (CN100) sof the AML vent

solenoid valve.

Move the elevating lever fully to the boom

lowering side. Keep the above conditions for 30

seconds or more for bleeding. Proceed on the

same steps by moving the elevating lever to the

boom raising side.

4 Telescoping

Set the boom/jib operation selector switch to the

"Boom telescoping" side.

Pull out the connector (CN100) of the AML vent

solenoid valve.

Move the telescoping lever fully to the retraction

side. Keep the above conditions for 30 seconds or

more for bleeding. Proceed on the same steps by

moving the telescoping lever to the boom

extension side.

5 Winch (main and auxiliary)

Pull out the connector (CN100) of the AML vent

solenoid valve.

Move the winch lever fully to the hoisting up side.

Keep the above conditions for 30 seconds or

more for bleeding. Proceed on the same steps by

moving the winch lever to the hoisting down side.

Detail A

Solenoid valve (for AML vent) (CN100)

Page 45

Y- 4

Air Bleeding Procedure

WY05-3900E

8. Positive control circuit

While any of the crane operations described in

"7. Pilot circuit (hydraulic pilot control valve)". is

performed, loosen the air-bleed plug near the

lower pump to bleed the positive control circuit.

You can bleed the circuit at the same time with

pilot circuit bleeding.

9. Slewing control valve (back-pressure valve)

[NOTICE] Conditions

Engine speed : Max PTO : ON Slewing brake : ON

1. Open the air-bleed plug and rapidly move the

slewing lever repeatedly between left slewing and

right slewing.

2. When there are no more bubbles in the oil that

flows out, tighten the plug while the oil continues

to f l o w.

エア抜きプラグ

IWY05-044007

Hydraulic pilot control valve (for slewing)

Air-bleed plug

Main pump

Hydraulic pilot control valve (for slewing)

Mounted to right of slewing table

Air-bleed plug (for back-pressure valve)

Page 46

WY05-3900E

Y- 4.

Air Bleeding Procedure

10. Hydraulic valve (winch brake)

[NOTICE] Bleed this valve after the pilot circuit (hydraulic pilot

control valve) (See the section 7.) and the positive control (See the section 8.) are bled.

Conditions

Engine speed : Idling PTO : ON

1. Open the air-bleed plug and move the winch lever

fully to the end of its stroke in the direction

corresponding to the plug.

2. When there are no more bubbles in the oil that

flows out, tighten the plug while the oil continues

to f l o w.

△

345-808-

12500

Hydraulic valve for winch brake

Mounted to right of slewing table

Page 47

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

Y-5 Adjusting Procedure

(Electric)

1. Switch adjustment procedure

1.1 Over-front detection switch (CN521)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch beforehand.

2. Slew the boom to the over-front and set the boom

angle 60° or higher. Then engage the slewing lock

pin.

3. Adjust the clearance between the detection face

of the switch and the cam. Then fix the switch

using a nut. (Make sure that the green LED lights

up at this time.)

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

1.2 Boom full retraction detection switch (CN552)

Adjust the switch position so that its contact is

shifted (opened/closed) when the top boom

section is extended/retracted. The position is 5 to

8 mm (0.2 to 0.31 in) longer than its fully retracted

length.

• Switch fixing bolt tightening torque:

4.9 to 5.9 N-m {50 to 60 kgf-cm} (3.6 to 4.4 ft-lbf)

△

349-503-

30000

△

343-633-

72000

5th boom section

Top boom section

Detail A

Upper face of slewing table

View A

2–2.5 mm (0.08–0.1 in)

Upper face of lower frame

Cutout end of

lower frame

Front

Slewing center

Cam

Page 48

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.3 Jib lock pin detection switch (CN573)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch.

2. Slew the jib from the side of the boom, and secure

it on the bottom face of the boom (by securing it

by the jib lock mechanism).

3. Adjust the horizontal position of the switch so that

the clearance B is 4 to 4.5 mm, and fix the switch

using a nut. (At this time, check that the

embedded LED lights up in green (--FE0435) and

red (FE0436--).)

• Nut tightening torque:

40 to 50 N-m {410 to 510 kgf-cm}

(29.5 to 36.8 ft-lbf)

1.4 Jib connection pin detection switch (CN572)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch fixing bolt.

2. Slew the jib from the side of the boom, and secure

it on the bottom face of the boom (by securing it

by the jib lock mechanism).

3. Adjust the lever angle so that the switch contact is

closed when the lever is at the position A shown in

the figure.

• Switch fixing bolt tightening torque:

4.9 to 5.9 N-m {50 to 60 kgf-cm} (3.6 to 4.4 ft-lbf)

△

343-546-

82000

Front

Jib lock pin detection switch

Front

Jib connection pin detection switch

Page 49

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.5 Jib full retraction detection switch (CN554)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch.

2. Install the support so that the switch contact is

closed when the jib is retracted to the position

where it is 5 to 8 mm (0.2 to 0.31 in) longer than

its fully retracted length.

•Switch fixing bolt tightening torque:

4.9 to 5.9 N-m {50 to 60 kgf-cm} (3.6 to 4.4 ft-lbf)

△

343-547-

04000

△

343-547-

04001

Jib full retraction detection switch

Support

Detail A

Page 50

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.6 Main wire rope length detection (Phase A: CN525) (Phase B: CN526)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch beforehand.

2. Adjust the position of the switch so that the

clearance A is 3.5

+0.2 –0.3

mm (0.14

+0.008 –0.012

in) and the

clearance B is 7

0 –1

mm (0.28

0 –0.04

in), and fix the

switch using a nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

3. Make sure that the green LED lights up when the

switch is activated.

1.7 Aux. wire rope length detection (Phase A: CN527) (Phase B: CN528)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch beforehand.

2. Adjust the position of the switch so that the

clearance A is 3.5

+0.2 –0.3

mm (0.14

+0.008 –0.012

in) and the

clearance B is 7

0 –1

mm (0.28

0 –0.04

in), and fix the

switch using a nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

3. Make sure that the green LED lights up when the

switch is activated.

△

349-503-

30000

Page 51

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.8 Straight ahead detection switch (CN408)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded section of the

switch beforehand.

2. Set the rear wheels so that they face straight

ahead.

3. Adjust the vertical position of the switch so that

the clearance A is 2.5 to 3 mm, and then fix by

using the nut. (Tire on-ground state)

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

4. Check that the green LED lights up when the

switch is operated.

1.9 Rear steering lock pin IN detection switch

(CN417)

1.10 Rear steering lock pin OUT detection switch

(CN418)

Adjust the vertical position of the lock pin IN

detection switch and lock pin OUT detection

switch, and fix so that the dimension becomes as

described below.

• Switch fixing screw tightening torque

0.5 to 0.7 N-m {5 to 7 kgf-cm} (0.37 to 0.52 ft-lbf)

* Apply locking adhesive.

△

360-634-

30000

△

347-224-

33000

Mount so that the indicator lamp (convex-shape notch) is directed toward inside the vehicle.

When connecting the harness,

check that the base section does not get bent forcibly. Also, make sure to establish a

clearance with the cam.

Convex-shape notch

Vehicle inside

View B

Lock pin OUT detection switch

Lock pin IN de

tection switch

* Switch fixing screw

5.5 mm (0.22 in)

Lock pin IN detection switch

Lock pin OUT detection switch

Straight-ahead detection switch

View from vehicle rear (4th axle)

Page 52

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.11 Vehicle height detection

1.11.1 Assembly adjustment

[NOTICE]

Before making this adjustment, complete the adjustments in 1.11.2 and 1.11.3.

1. Adjust the vehicle height to the normal traveling state.

(1) Direct the boom to the front or rear.

(2) Press the suspension up/down switch so that the dimension H becomes 145 ± 4 mm (5.7 ± 0.16 in).

(When the switch is released, the suspension becomes locked.)

2. Adjust the length of rod assy so that the support slot and lever hole B become aligned.

 Front left

Front

Axle center

Frame bottom face

Rod assy

Slot

Right switch

Hole C

Hole B

Hole A

Left switch

Front

Vehicle height detection (front left)

Axle (4th axle)

Vehicle height detection (rear right)

(CN406) (CN407)

Vehicle height detection (front right)

Axle (1st axle)

Vehicle height detection (rear left) (CN404) (CN405)

Page 53

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

 Rear left

 Front right

 Rear right

Front

Right switch

Hole C

Hole B

Hole A

Left switch

Axle center

Frame bottom face

Rod assy

Slot

Front

Axle center

Frame bottom face

Slot

Right switch

Hole C

Hole B

Hole A

Left switch

Rod assy

Front

Axle center

Frame bottom face

Slot

Right switch

Hole C

Hole B

Hole A

Left switch

Rod assy

Page 54

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

3. Check that the switch satisfies the operating conditions in the table below.

(When the switch is turned ON, the LED lights up in green.)

Suspension

cylinder

Front left or rear left front right or rear right

Left switch

(CN401)

(CN404)

Right switch

(CN400)

(CN405)

Left switch

(CN403)

(CN406)

Right switch

(CN402)

(CN407)

Retracted OFF ON ON OFF

Normal traveling

state

(H = 145 ± 4 mm

(5.7 ± 0.16 in))

ON ON ON ON

Extended ON OFF OFF ON

△

347-907-

65000

Page 55

Y- 5

Adjusting Procedure (Electric)

WY04-2071E

1.11.2 Switch adjustment (front left: CN400, CN401) (rear left: CN404, CN405)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded sections of the left

and right switches beforehand.

2. Adjusting left switch (CN401, CN404)

Adjust the clearance M between the left switch

detection face and lever (2.5 mm (0.1 in)) so that

the green LED of left switch becomes

extinguished when the support slot and lever hole

A are aligned by the clockwise turning of

adjustment lever. Then, fix by using the nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

3. Adjusting right switch (CN400, CN405)

Adjust the clearance M between the right switch

detection face and lever (2.5 mm (0.1 in)) so that

the green LED of right switch becomes

extinguished when the support slot and lever hole

C are aligned by the counterclockwise turning of

adjustment lever. Then, fix by using the nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

4. Align the support slot with the lever hole B, and

check that the LED is lit in green with both the left

switch and right switch.

△

347-907-

67000

LED lit in green

Slot

Right switch

Left switch

Hole C

LED extinguished

Slot

Hole A

Right switch

Left switch

LED lit in green

LED extinguished

Right switch

Hole C

Hole B

Hole A

Left switch

Lever

Support

Grease sealed-in

LED lit in green

Slot

LED lit in green

Page 56

WY04-2071E

Y- 5.

Adjusting Procedure (Electric)

1.11.3 Switch adjustment (front right: CN402, CN403) (rear right: CN406, CN407)

1. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded sections of the left

and right switches beforehand.

2. Adjusting left switch (CN403, CN406)

Adjust the clearance M between the left switch

detection face and lever (2.5 mm (0.1 in)) so that

the green LED of left switch becomes

extinguished when the support slot and lever hole

A are aligned by the clockwise turning of

adjustment lever. Then, fix by using the nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

3. Adjusting right switch (CN402, CN407)

Adjust the clearance M between the right switch

detection face and lever (2.5 mm (0.1 in)) so that

the green LED of right switch becomes

extinguished when the support slot and lever hole

C are aligned by the counterclockwise turning of

adjustment lever. Then, fix by using the nut.

• Nut tightening torque:

19 to 20 N-m {193 to 204 kgf-cm} (14 to 14.8 ft-lbf)

4. Align the support slot with the lever hole B, and

check that the LED is lit in green with both the left

switch and right switch.

△

347-907-

66000

Right switch

Hole C

Hole B

Hole A

Left switch

Lever

Support

Grease sealed-in

LED lit in green

Slot

LED lit in green

Slot

Hole A

Right switch

Left switch

LED lit in green

Slot

Right switch

Left switch

Hole C

LED extinguished

Page 57

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

Y-6 Assembly Adjustment

(Crane Operation)

1. Adjusting boom telescoping wire ropes

1.1 Adjusting boom telescoping wire ropes

1. Lower the fully retracted boom to horizontal.

2. Evenly tighten the adjustment nuts A (2 points) of

the 5th boom section extension wire rope, so that

the 5th boom section is slightly (1 to 5 mm (0.04

to 0.2 in)) away from the 4th boom section.

3. Evenly tighten the adjustment nuts B (2 points) of

the top boom section extension wire rope until the

top boom section is slightly (1 to 5 mm (0.04 to

0.2 in)) away from the 5th boom section.

Page 58

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

4. Tighten adjustment nut C of the top boom section

retraction wire rope until the top and 5th boom

sections are blocked by their respective stoppers

(the boom sections are fully retracted).

5. Extend the boom by 200 to 300 mm (0.656 to

0.984 ft). Then retract it slowly and check that the

stoppers on the 4th, 5th and top boom sections

contact at the same time. If any stoppers fail to

contact, follow the below procedure to check and

adjust it.

Slack Tense

Check the tension of the 5th boom section extension wire rope.

Evenly tighten adjustment nuts A (2 points) of the 5th boom section extension

wire rope by approx. 1/4 turn.

Evenly loosen adjustment nut C (2 points) for the top boom section

retraction wire rope by approx. 1/2 turn.

Extend and fully retract

the boom to check.

End

Only the 5th boom section extends.

Evenly tighten the right and left adjustment nuts B (2 points) of the top boom section extension wire rope by approx. 1/2 turn each.

Extend and fully retract

the boom to check.

Extend and fully retract

the boom to check.

Without interruption, continue with "Adjusting top end upper slide plate (3rd boom section to 5th boom section)".

Page 59

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

Adjusting top end upper slide plate (3rd boom section to 5th boom section)

1. Make adjustments with each of the boom sections from 4th through top boom fully retracted by the No.3

boom telescoping cylinder.

2. After making the above adjustment, retighten the each of the adjustment bolts in the upper section and in the

side by 1/4 turns, and then fix by using the nuts (both left and right).

3. Lastly, tighten the fixing bolt to the tightening torque of 36 to 40 N-m {370 to 410 kgf-cm} (27 to 30 ft-lbf),

then bend the washer plate to stop the bolt from turning. (If the washer plate does not come to the

appropriate position at the specified torque, position the washer plate to the tightening direction.)

1.2 Adjusting boom head lower slide plate

Refer to the descriptions in "2.4 Shim adjustment at lower part of boom head" of "2. Adjusting clearance for

the boom".

Nut

Adjustment bolt (upper)

Fixing bolt

Washer plate

Adjustment bolt

(side)

Retainer

Slide plate

Nut

Page 60

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

1.3 Adjusting wire rope for 5th boom section extension

After completing the adjustments of "1.1 Adjusting boom telescoping wire rope" and "1.2 Adjusting boom

head lower slide plate", make adjustments below.

△

345-804-

23500

Clear of the ground under conditions below.

 Boom length: 30.3 m; Elevating angle: 80°; Lifted load: 12.5 t

Lower the lifted load, then fully extend the boom only with the hook block (44.0 m).

Fully retract the boom, then enter the clearance of 4th boom section stopper into the record sheet.

End

Tighten the adjustment nuts A for 5th boom extension (2 points) evenly on the left and right until each of the 4th and 3rd boom sections contacts with the stopper (full retraction) (clearance with stopper: less than 0.5 mm). Enter the tightening length of adjustment nuts A for 5th boom extension into the record sheet.

Lower the lifted load, then fully extend the boom only with the hook block (44.0 m).

Clear of the ground under conditions below.

 Boom length: 30.3 m; Elevating angle: 80°; Lifted load: 12.5 t

After the boom is fully retracted, check that the clearance with stopper is 0.5 mm or less.

Page 61

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2. Boom clearance adjustment

[NOTICE]

The part numbers and figures in this manual are shown while using the 2nd boom as an example.

All adjustment procedures are the same from the top to 2nd boom sections (except for the upper part of the boom bottom).

The term "minimum clearance" means the clearance to which the thinnest provided shim cannot be inserted.

With the adjustment work, perform the work in a sequential order with the items listed below. (Refer to Figure 1.)

4th - top booms

2nd and 3rd booms

[1]: 2.1 Shim adjustment at lower oblique sides of the

boom bottom

[2]: 2.3 Shim adjustment at sides of the boom bottom

[3]: 2.4 Slide plate adjustment at lower part of the

boom head

[4]: 2.5 Clearance adjustment at upper part of the

boom head

[5]: 2.6 Shim adjustment at upper part of the boom

bottom

[2]: 2.8 Clearance check at sides of the boom bottom

[1]: 2.1 Shim adjustment at lower oblique sides of the

boom bottom

[5]: 2.2 Shim adjustment at upper part of the boom

bottom

[2]: 2.3 Shim adjustment at sides of the boom bottom

[3]: 2.4 Slide plate adjustment at lower part of the

boom head

[4]: 2.5 Clearance adjustment at upper part of the

boom head

[5]: 2.7 Clearance check at upper part of the boom

bottom

[2]: 2.8 Clearance check at sides of the boom bottom

Figure 1

(Example: 2nd boom section)

Page 62

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.1 Shim adjustment at lower oblique sides of the boom bottom

(section [1] indicated in Figure 1)

1. Assemble the boom with standard number of

shims inserted to both in the left and right.

[NOTICE]

Only when the boom telescoping cylinder joining pin cannot be inserted, adjust by removing the shim.

Standard number

of shims

0.6-mm thick

2nd boom 2

3rd boom 2

4th boom 2

5th boom Without shim

Top boom Without shim

2. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the threaded sections of support

(35). Lightly tighten the nut (36), and then

untighten 1/4 turns.

2.2 Shim adjustment at upper part of the boom bottom

(section [5] indicated in Figure 1)

1. Assemble the boom with standard number of

shims inserted to both in the left and right.

Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the shim fixing bolt.

Standard number of shims

1.2-mm thick 2.3-mm thick

2nd boom 2 2

3rd boom 2 2

[NOTICE]

When using the 1.2-mm thick shims (31), always

put them under the 2.3-mm thick shims (30).

Left Right

Page 63

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.3 Shim adjustment at sides of the boom bottom

(section [2] indicated in Figure 1)

1. Measure the inner dimension of the outer boom

box at the sliding position of the slide plates at

approximately 1.5 m (4.92 ft) from the boom

bottom.

2. Then, divide the dimension evenly between right

and left sides, and insert shims so that the gaps

become the minimum clearance.

[NOTICE]

If the boom cannot be inserted, measure the inner dimension of the outer boom box at the boom bottom.

3. Apply a thread locking agent (ThreeBond 1401 or

the equivalent) to the fixing bolt. Lightly tighten it

and then untighten it for 1/4 turns.

Standard number of shims

Remarks

1.0-mm thick 0.6-mm thick

2nd boom 2 0

If the total thickness of shims in a single side is 4 mm (0.16 in) or more, make sure to use the slide plate with the thickness of 19 mm (0.75 in) (standard: 15 mm (0.59 in)).

3rd boom 3 0

4th boom 3 0

5th boom 2 1

Top boom 3 1

Left Right

Page 64

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.4 Slide plate adjustment at lower part of the boom head

(section [3] indicated in Figure 1)

1. Perform this adjustment with each boom section

retracted almost fully.

2. Before inserting the slide plates, insert the stopper

plate (19).

3. As a rule, use the slide plates of standard

thickness "0".

[NOTICE]

Only when the plates of standard thickness "0" cannot be inserted, use those of thickness "-2".

4. For the heads of the base, 2nd, 3rd, and 4th boom

sections, select and use the slide plates of the

same thickness for both upper and lower slides for

assembling.

5. For the 5th boom section head, it is allowed to use

the slide plates of different thickness in the upper

and middle parts.

(For the lower part, use the slide plates with

thickness "0" only.)

6. It is allowed to use the slide plates with different

thicknesses between the left and right sides.

[NOTICE]

However, the difference of the clearance between the boxes (dimension X) shall be 2 mm (0.08 in) or less between the left and right sides.

7. Insert the shims to the position shown in the figure

so that the horizontal clearance on the upper slide

plates is adjusted to be minimum (0.6 mm (0.024

in) or less). (The total thickness of shims shall be

1.8 mm (0.071 in) or less (0.6 mm (0.024 in) × 3

pieces or less.)

Details of slide plate assy

(Unit: mm) (1 mm = 3.93701×10-2 in)

Shim

Slide plate

Slide plate assy

LH”0”

RH”-2”

LH"-2"

RH”0”

Dimension (mm)

Part

name

(UP)

(Mid)

(Down)

Stopper plate

2nd boom head

Base boom head

4th boom head

3rd boom head

5th boom head

(Base-4th head

adjusting shim)

(5th head adjusting

shim)

Detail A (1/2)

Detail B

△

342-022-60100

△

342-022-60200

△

342-022-60300

△

342-022-

60500

△

342-022-

60400

Page 65

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.5 Clearance adjustment at upper part of the boom head

(section [4] indicated in Figure 1)

1. Extend the inner boom section for approximately

0.5 m (1.64 ft). Next, lift the boom head slightly to

an extent that the inner case to be adjusted does

not rise up, and then adjust the clearance.

[NOTICE]

If the boom section is not lifted for the work, the tilt cannot be followed to the boom bottom side, and the bottom becomes twisted against the head, and the adjustment of section [5] cannot be performed correctly.

2. Set the slide plates along the curve of the inner

boom section without inclination, and then turn the

upper-side adjustment bolts to let the slide plate to

touch the retainer.

[NOTICE]

If the boom is assembled without correcting the tilting of the slide plates, a load can move the slide plates, and the fixing of the retainer may become loose.

3. Adjust the dimension A using the side adjustment

bolts so that the left-side dimension becomes 1

mm (0.04 in) greater than that in the right side.

[Example: Dimension (left) = 21 mm (0.83 in),

Dimension (right) = 20 mm (0.79 in)]

The above completes the adjustments of 3rd - 5th

boom sections.

For the base boom and 2nd boom sections only,

perform the adjustment described in 4 and 5 below.

4. After the above adjustment, retighten the upper

and side adjusting bolts for 1/4 turns, and then fix

them using nuts (in both sides).

5. Lastly, tighten the fixing bolt to the tightening

torque of 36 to 40 N-m {370 to 410 kgf-cm} (27 to

30 ft-lbf), then bend the washer plate to stop the

bolt from turning. (If the washer plate does not

come to the appropriate position at the specified

torque, position the washer plate to the tightening

direction.)

Adjustment bolt (upper)

Fixing bolt

Washer plate

Adjustment bolt

(side)

Retainer

Slide plate

Nut

Page 66

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.6 Shim adjustment at upper part of the boom bottom

(section [5] indicated in Figure 1)

1. After the adjustment of boom head side (sections

[3] and [4] shown in Figure 1), make the

adjustment below.

2. Check that the difference of the upper clearance

of boom bottom (dimension B) between the right

and left sides is 3 mm (0.12 in) or less.

[NOTICE]

If it exceeds 3 mm (0.12 in), go back to the step "2.5 Clearance adjustment at upper part of boom head" and adjust again.

3. Insert shims until the clearance (dimension C) on

the upper slide plate of boom bottom is minimum.

[NOTICE]

When using the 1.2-mm thick shims (24), always put them under the 2.3-mm thick shims (23).

4. Apply a thread locking agent (ThreeBond 1305 or

the equivalent) to the retainer fixing bolt (27), and

tighten the bolt.

• Tightening torque:

74 to 82 N-m {7.6 to 8.4 kgf-cm} (55 to 60 ft-lbf)

2.7 Clearance check at upper part of the boom bottom

(section [5] indicated in Figure 1)

1. After the adjustment of boom head side (sections

[3] and [4] shown in Figure 1), make the

adjustment below.

2. Check that the difference of the upper clearance

of boom bottom (dimension B) between the right

and left sides is 3 mm (0.12 in) or less.

Also, check that the clearance on the upper slide

plate of boom bottom (dimension C) is from 0 to 5

mm (0 to 0.2 in).

[NOTICE]

If the dimension B and dimension C are not satisfied, pull out the boom, and then go back to the step "2.2 Shim adjustment at upper part of boom bottom" and "2.4 Shim adjustment at lower part of boom head" and adjust again.

Retainer fixing bolt (Example: 4th boom section)

Page 67

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

2.8 Clearance check at sides of the boom bottom

(Section [2] shown in Figure 1)

• 2nd, 3rd, 5th, and top boom sections:

Check that the minimum clearance in the rear end

lateral side (dimension D) is 5 mm (0.2 in) or

more.

• 4th boom section:

Check that the minimum clearance in the rear end

lateral side (dimension D) is 8 mm (0.31 in) or

more.

[NOTICE]

If the dimension D is not satisfied, go back to the step "2.5 Clearance adjustment at upper part of boom head" and adjust again thereafter.

3. Installing and adjusting anti-buckling bolts for telescoping cylinders

ブーム側

シリンダ側

IW536-064008

E D

1. Connect the boom and each boom telescoping

cylinder using the pins A and B.

Set the boom horizontal and fully retracted.

2. With the base, 2nd, and 3rd boom sections, adjust

the bolt C locked with the nuts D and E so that it

can be turned by hand and the axial clearance (S)

from the head of the bolt C is 0.5 mm (0.02 in) or

less. (Apply a thread locking agent.)

With the No.3 boom telescoping cylinder on the

left (viewed from rear), its vertical direction differs

from the above figure.

△

342-014-

10300

2nd, 3rd boom sections

4th-top boom

sections

Boom side

Cylinder side

△

342-022-60000

△

342-022-60071

Page 68

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

4. Bubble level adjustment

The upper bubble level in the cab and the lower bubble level on the outrigger control panel must be adjusted

so that they are parallel to the slewing table plane (*1).

The following shows the general adjustment procedure for bubble levels of large cranes (AC, RC and TC

cranes). (*2)

4.1 Leveling the slewing table plane

First set the machine so that the slewing table plane is horizontal.

Prepare bubble levels other than the ones provided with the machine and set the machine in either of the

methods A and B.

Conditions

Location: On firm and level ground

Outrigger configuration: Maximum extension

Boom configuration: Fully retracted; at elevation angle of 50°; no load on the hook block

○Method A (Case where the machining surface on the slewing bearing can be used)

In case that the machining surface on the slewing bearing is exposed from the base plate of the slewing

table, place bubble levels directly on the machining surface on the slewing bearing with the boom directed

to over-front. (See Fig. 2.) Then extend the jacks to set the machine level in lateral and longitudinal

directions. (*3)

After leveling the machine, make sure that the jack floats are not shaky.

Page 69

Y- 6

Assembly Adjustment (Crane Operation)

WY05-3911E

○Method B (Case where the machining surface on the slewing bearing cannot be used)

1. If the machining surface on the slewing bearing is not exposed, place bubble levels on the base plate

on the slewing table with the boom directed to over-front. Then extend the jacks to set the machine

level in lateral and longitudinal directions. (*3) After leveling the machine, make sure that the jack floats

are not shaky.

2. In this condition, slew the boom by 360° and check the movement of bubbles in the levels. If the

slewing table plane is level, bubbles hardly move during slewing of the boom. If the bubbles move

during slewing of the boom, estimate the inclination of the slewing table plane from the movement of

the bubbles and operate the jacks for fine adjustments.

3. Repeat the above-mentioned check and fine adjustments until the bubbles in the levels hardly move

during slewing of the boom. After final fine adjustment, reset the bubble levels (*4) and slew the boom

by 360° again to check the movement of the bubbles.

*1: "Slewing table plane" refers to the virtual surface on which the upper structure of the crane slews.

In mechanical structure, it corresponds to the machining surface on the slewing bearing.

*2: Apply this procedure when readjusting.

*3: Level the machine by extending the jacks. If jacks are retracted for adjustment, the jack floats may

become clear of the ground.

*4: If the place where bubble levels are placed is not parallel to the slewing table plane when performing the

method B, resettable bubble levels are required.

Page 70

WY05-3911E

Y- 6.

Assembly Adjustment (Crane Operation)

4.2 Upper and lower bubble level adjustment

After leveling the slewing table plane, adjust so that the bubble in each upper and lower bubble level is

center-aligned to the mark using the adjuster screw of each bubble level with the boom directed to over-front

and boom angle of 50°.

4.3 Adjustment check

Finally check if the "Inspection standard of bubble levels' bubble position" is satisfied.

Conditions: Outriggers at full extension; boom fully retracted and no load on the hook block.

• Standard for the upper bubble level: Slew the boom with the boom angle of 50°.

Check that the bubbles are within the marked range when the boom

is directed to front, rear, right and left.

• Standard for the lower bubble level: While the boom is directed to over-front and stowed, check that each

bubble is within the marked range.

4.4 Readjustment

If the standard is not satisfied, check whether the jacks are shaky and make adjustment again.

△

345-804-

17000

Page 71

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

Y-7 Assembly Adjustment

(Traveling Device)

1. Service brake adjustment

1.1 Adjusting the brake pedal

With the pedal weight causing the roller to contact

the plunger, adjust the bolt until it contacts the

stopper, then use the nut to lock it in place.

1.2 Tightening the cap of reserve tank of service brake fluid

After bleeding air, pour the brake fluid up to a

required level.

[NOTICE] Tightening the cap excessively may break the

stopper.

1. Tighten the cap until it stops at the stopper.

2. Check that the position of the tank body and cap

is as shown in the figure below.

Page 72

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

1.3 Check after replacing brake hose

After you replace the brake hoses and so on,

make sure that any contact does not occur

between the hoses and the structures in any

situation. Check it with moving suspension (up

and down) and steering (right and left.)

In addition, make sure that any hose is not

twisted forcibly.

2. Accelerator adjustment

2.1 Accelerator pedal

Switch

(Idle volume)

Idling

Accelerator sensor

View A

Page 73

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

2.2 Accelerator sensor assembly and adjustment

[NOTICE]

Do not touch the terminal directly because the static electricity tolerance of the sensor is weak. (Execute it after removing static electricity as it touches other metal parts when it is necessary to touch the terminal.)

Force must not be applied to the sensor internal stopper when you adjust the nut for the sensor shaft fixation. (Do not apply turning force to the stopper when the nut is turned toward the stopper from the condition that the sensor shaft is halted by the stopper.)

1. Installation of lever D

Press-fit it in the thrust at the time of tightening

the nut for the lever fixation so that the load is not

applied in the direction of thrust of the sensor

axis.

2. Installation of spring

Before installing the spring, secure the lever A

using the bolt B. Otherwise, the sensor may go to

the stroke end while the spring is installed and

excessive force may be applied to the stopper

inside the sensor. (When installing the bolt, make

the bolt head protrude further than the regular

position, that is, to allow the accelerator pedal to

be depressed further.)

3. Positioning of lever A

Adjust with bolt B and lock with the nut so that

lever A becomes vertical.

4. Positioning of idle side

Adjust the position of the sensor so that each

sensor output (Out1 (white-black) and Out2

(blue-green)) becomes 0.5 ± 0.1 V when 5 ± 0.1

V is impressed to +V1 (red-black) and +V2

(yellow-green).

5. Positioning of accelerator switch

Adjust the installation position of the accelerator

switch so that accelerator switch change at the

position in which each sensor output (Out1

(white-black) and Out2 (blue-green)) becomes

0.82 ± 0.05 V when 5 ± 0.1 V is impressed to +V1

(red-black) and +V2 (yellow-green).

6. Positioning of full stroke side stopper

Adjust the position of the sensor with bolt C and

lock with the nut so that each sensor output (Out1

(white-black) and Out2 (blue-green)) becomes

4.5 ± 0.1 V when 5 ± 0.1 V is impressed to +V1

(red-black) and +V2 (yellow-green).

[NOTICE]

Adjust the bolt so that excessive force should not act on the sensor internal stopper when the sensor reaches the stroke end.

7. Lock six places shown in figure with paint after

adjustment is finished.

View B

Page 74

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

Accelerator sensor output diagram

For positioning procedures 4., 5. and 6. mentioned

as above, check the voltage at the connector

terminals shown below.

△

347-113 -

32000

△

347-113 -

30000

△

347-112 -

62600

Page 75

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

2.3 Engine speed

[NOTICE] Before checking the engine speed, run the engine

to warm it up. (Temperature of the torque converter oil should reach approximately 50°C (122°F).)

1. No-load Max. speed

• PTO OFF : 2270 ± 50 min

-1

• PTO ON : 1550

+50 0

min-1 (Eco mode: OFF)

• Speed limiter ON: 1950 ± 20 min

-1

2. Idling speed : 700 ± 20 min-1

2.4 Procedure for checking engine stall speed

If engine output power decreases or torque

converter oil is heated significantly, check the

engine stall speed as follows:

1. Set the switches and controls as described below.

• PTO switch : OFF

• Shift lever :”2” (High 2nd)

• Drive mode selection switch : 6WD/High (*1)

• Service brake : ON

• Emergency transmission switch:

"ON" with "6WD/High" state (*2)

(*1) Because the drive mode cannot be changed after

the emergency transmission switch is turned ON,

change to "6WD/High" in advance.

(*2) Emergency operation switch inside electrical box

in the cab rear

2. While depressing the brake pedal, depress the

accelerator pedal all the way. Check the engine

speed.

Max. speed standard when stalled:

Approximately 1760 min

-1

(for reference)

When the engine is stalled, heat is generated inside the torque converter. Therefore, never run the engine for 30 seconds or longer, and never run the engine if the oil temperature is 90°C (194°F) or above.

The torque converter generates maximum torque at this time. Therefore, be careful to avoid

sudden movement of the vehicle.

CAUTION

Emergency transmission switch

(Emergency accelerator switch)

(DPF emergency cancel switch)

Page 76

WY05-3920E

-7 Y-7

Assembly Adjustment (Traveling Device)

3. Parking brake adjustment

3.1 Adjusting the clearance (between brake shoe and drum)

1. Jack up the crane and release the parking brake.

2. Rotate the brake drum. Align the adjustment hole

in the drum with the adjuster wheel for the

lining-drum clearance adjustment.

3. Insert the screwdriver through the adjustment hole

and rotate the adjuster wheel to expand the shoes

until the lining fits the drum (resistance is

encountered).

4. Then return the adjuster wheel by 8 notches. The

clearance between the lining and brake drum is

now adjusted to the standard clearance of 0.23

mm (0.009 in).

3.2 Connecting parking brake and spring chamber

1. Place the parking brake lever in the zero-point

position (middle of lever play).

2. While the parking brake is released, the spring

chamber is expanded to its stroke end by the

pressurized air, connect the chamber and brake

lever using material X (end).

3. After connecting, check for any friction between

the drum and lining. Then lock the rod with

material Y (nut).

Lever stroke: approximately 20 mm (0.8 in)

(for reference)

4. Tire and steering angle adjustment

4.1 Tire size and air pressure

• Tire size: 385/95 R25 170E

• Air pressure: 900

+100 0

kPa

+1.0 0

kgf/cm2} (130.5

+14.5 0

psi)

4.2 Adjusting the steering angle

1. Jack up the vehicle and select 8-wheel steering

mode. Turn the steering wheel 2 to 3 times to

bleed the steering cylinders.

2. Before adjusting the steering angle, use a

side-slip tester to check that the amount of tire

side-slip is 3 mm (0.12 in) or less for both the front

and rear tires.

3. If it is more than 3 mm (0.12 in), loosen the bolts

that fasten the left and right tie-rod ends. Then

rotate the tie-rod and adjust the toe-in.

4. Jack up the vehicle on the level surface (so that

the height of the left and right tires is the same).

Use the steering angle measuring jig to adjust the

steering angle in direction A to θ

0 –1

using stopper

bolt A, and the one in direction B to θ

0 –1

using

stopper bolt B.

5. Perform the same adjustment for the wheels on

each axle in the procedure described in the step

6. On only 4th axle, check that the stopper bolts A

and B are not in contact with the housing and the

steering cylinders become stroke end. (The angle

shown in the table above is the reference value of

steering angle at stroke end).

Revised Oct. 2017

Page 77

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

5. Torque converter and transmission

5.1 Maximum allowable speed

Units: km/h (MPH)

Shift position High position Low position

1 14.8 (10.9) 7.0 (5.3)

2 24.6 (16.8) 10.7 (7.7)

(Emergency

transmission: ON)

37.9 (24.5) 14.8 (10.9)

D 52.0 (35.0) 24.6 (16.8)

R 24.6 (16.8) 7.0 (5.3)

[NOTICE] Engine speed: 2000 min

-1

Check the meter indication. Pay attention to the tachometer indication and do

not overrun the engine. (Max. 2360 min

-1

)

Drive selection must be done with the vehicle at a

complete stop and with the brakes not applied.

The mechanism does not allow 4WD selection in

Low-speed drive.

5.2 Adding oil to the torque converter and transmission

[NOTICE] When checking the oil level, turn OFF the PTO and

air conditioner. Check at an oil temperature of 50°C (122°F) when the oil level settles after the engine is started.

Do not add too much or too little oil.

Prevent dust and water from entering when adding oil.

1. With the engine stopped, add oil through the oil

filler port on the top of the torque converter to the

prescribed level on the transmission oil level

gauge.

2. Put the transmission in neutral and start the

engine. While idling (700 min

-1

), continue to add

oil. Check that the oil level settles within the range

indicated by the

mark on the transmission oil

level gauge.

Total oil amount: approximately 38.5 L (10.2 gal)

Page 78

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

6. Braking force

[NOTICE] Detach the connector of the inter-axle differential

lock solenoid valve inside the pneumatic unit in the right center of the vehicle beforehand.

The braking force to be checked is the difference

between the measured value when the brake pedal is depressed and the one when the pedal is not depressed.

After adjustment, return the connector for the

inter-axle differential lock solenoid valve to the original position.

6.1 Parking brake force

1. Must be 20% of the vehicle weight (including 1

person aboard) at least.

Check that the front and rear braking forces are

80.9 kN {8259 kgf} (18208 lbf) or more.

6.2 Service brake force

1. The difference in the braking force between the

right and left wheels must be 6% of the axle load

or less.

Check that it is not greater than 5.9 kN {608 kgf}

(1340 lbf) (according to the type approval testing

standard).

2. Check that the sum of the braking force is 40% of

the vehicle weight at least.

Check that the front (1st and 2nd axles) braking

force is 112.6 kN { 11 487 kgf} (25324 lbf) or more.

Check that the rear (3rd and 4th axles) braking

force is 54.6 kN {5563 kgf} (12264 lbf) or more.

6.3 Auxiliary operating brake (aux. brake) force

1. Check that the sum of the braking force of the

auxiliary operating brake (aux. brake) is 35% of

the vehicle weight at least.

Front + rear = 141.6 kN {14453 kgf} (31863 lbf)

Page 79

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

7. Adjusting headlight light axis

[NOTICE]

Before adjusting the light axis, make sure to perform

the suspension leveling operation.

Headlight type (Hella)

 Standard

Halogen headlight (for high/low beam):

-112R-002485

 Option

Discharge headlight

(for high/low beam): E

-98R-002485

With 10-m beam aiming type headlight tester

(Measure with air conditioner OFF)

7.1 Adjusting low beam

1. Set the switch to the low beam side.

[NOTICE]

Select "With cut" for the measurement mode.

2. Apply masking to the lights of clearance lamp and

turn signal lamp.

3. Check that the cutoff line is directed to upper left

(for traveling on left side of the road) as shown in

Figure 1. If it is directed to upper right (for

traveling on right side of the road), replace the

headlight.

4. Make adjustment so that the elbow point is inside

the range below, and that the luminous intensity

satisfies the value below.

 When illumination center is at 1 m or more

(For reference) GR-700N-1: 1,050 mm (41.3 in)

Up/down: Range between 70 mm (2.8 in) and 200

mm (7.9 in) downward from illumination center

Left/right: Range at 270 mm (10.6 in) each to left

and right from illumination center

6,400 cd or more

(For reference) luminous intensity measurement

point:

Point at 160 mm (6.3 in) downward and 230 mm

(9.1 in) left from illumination center

Figure 1

(Units: mm)

5. Individually for left and right, make adjustments

above.

7.2 Adjusting high beam

Because the headlight serves both for high and low

beam, any adjustment of high beam is not needed.

7.3 Procedure for adjusting light axis

(Units: mm)

1. Adjust the light axis by adjusting the set height of

adjustment screw (with holder) 20 mm (0.8 in)

within the range of ±3 mm (0.12 in).

(Also acceptable by adjusting distance from light

cover outside surface to headlight with 0 ± 3 mm

(0.12 in)).

2. After the adjustment of the light axis, install the

cover.

Support

Holder

Cover

(Spare parts)

Adjustment screw

(6 points in total)

Cutoff line

Illumination center

Elbow point

Luminous intensity measurement point

Page 80

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

8. Hydraulic suspension

8.1 Releasing pressure in the accumulators for hydraulic suspension

When disassembling the components and pipings

in the hydraulic suspension, release pressure in

the accumulators beforehand in the method

described below.

1. Perform vehicle height increasing operation of the

crane in on-rubber operation configuration. After

the suspension is extended to its stroke end, lock

the suspension.

2. Extend the outrigger jacks to make the 8 wheels

clear of the ground.

3. After setting the outrigger extension/retraction

selector to the neutral, press the suspension free

switch.

[NOTICE] Before proceeding to the next step, wait at least 20

seconds after you press the switch.

4. Loosen the pipes connected to the retraction port

of each of 4 suspension cylinders carefully and

slowly. If no pressure remains, you can remove

the clasps. If pressure remains, repeat the step. 3.

9. Retightening the hub nuts

• Retighten the hub nut with the tightening torque

of 640 ± 30 N-m {6500 ± 300 kgf-cm} (472 ± 22

ft-lbf).

• Retighten hub nuts after checking the brake force

(See “6. Braking force”.), and before shipment.

(The hub nuts must be settled before retightening.

When the load is applied to the wheel mounting

sections during braking force check, the nuts

settle.)

• Put the retightening torque for the hub nuts (the

torque of the latest tightening) on the hub nut

torque check record.

10. Fuel air bleeding procedure

1. Keep the state of starter switch ON (electric lift

pump actuation) for 30 seconds, and then after

confirming that the electric lift pump is stopped,

turn OFF the starter switch. Repeat this operation

for 10 times.

2. Set the starter switch to START, then start the

engine.

At this time, maintain the cranking state for 10 to

15 seconds until the engine starts running.

If the engine does not start, repeat the procedure

of steps 1 and 2.

△

345-808-

13000

Page 81

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

11. Axle alignment adjustment procedure

[NOTICE]

◆This section describes the adjustment procedure

performed in the TADANO manufacturing line.

11.1 Align the axle center with frame center

1. Set the centers of 1st through 4th axles as well as

the center of steering cylinder mounting pin as the

axle center. (Refer to Detail 1.)

Hang a plumb bob from the axle center, or mount

the adjustment jig.

2. Perform the suspension up of vehicle. After a jack

up, stop the engine.

3. Set up a string or point with laser at between the

punches at the center of outer case bottom

surfaces for front and rear outriggers.

(When the punch does not exist, mark the outer

case center by using a punch or others.)

4. Adjust so that the spacing between the string or

laser described in 3 and the plumb bob of each

axle is set as described below.

- Center of 1st axle is offset 2 mm to the vehicle right

- Center of 2nd axle is offset 2 mm to the vehicle right

- Center of 3rd axle is offset 2 mm to the vehicle left

- Center of 4th axle is offset 2 mm to the vehicle left

Make adjustments by adjusting the lateral rod

length. (Refer to Detail 2.)

The tightening torque of locking bolts at rod ends

shall be 75.5 to 93.2 N-m (7.7 to 9.5 kgf-m).

Be careful not look directly at the laser light

source.

(Units: mm)

(1 mm = 3.93701 × 10

-2

in)

Page 82

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

11.2 Align each axle using 1st axle as datum axle

1. Remove the greasing joints located under the king

pin of each axle, and mount the measurement jig.

(Refer to Detail 3)

2. Measure the distance between the 1st axle and

2nd axle, between the 1st axle and 3rd axle, and

between the 3rd axle and 4th axle (both left and

right).

For the dimensions, refer to the figure below.

3. If there is a dimensional deviation, adjust the

length of torque rods at the bottom surfaces on

the left and right.

Because only one adjustment-type torque rod is

mounted to each of the axles, make adjustments

by providing an adjustment-type torque rod to any

position where a length adjustment is necessary.

(Units: mm)

Page 83

WY05-3920E

Y- 7

Assembly Adjustment (Traveling Device)

12. Wheel alignment adjustment procedure

[NOTICE]

◆This section describes the adjustment procedure performed in the TADANO manufacturing line.

12.1 Work preparation

• Perform the suspension down operation on a flat,

stable ground. Next, by the suspension free

switch, return the vehicle height to that of during

traveling, and then jack up the vehicle.

• Operate the rear steering, and align the center of

straight travelling detection switch with the center

of cam.

(To ensure safety, do not enter the area of tire

movable range.)

• Stop the engine, then insert the jig, and check that

the rear steering lock pin and lever hole are

aligned.

• Set up a string to between the front and rear

outrigger end faces. Set up the string at a height

that it passes through the wheel center as much as possible. Also, with the lengths  and  from

the outrigger end face to the string, set so that

they become the same in the front and rear.

• Measure the distances A and B from the string to

the wheel disc surface. Make fine adjustments by

steering so that the distance becomes as "A = B".

(This can be operated while engine is stopped.)

• Measure A through P, and record them in the

record sheet.

(1 mm = 3.93701 × 10

-2

in)

Page 84

WY05-3920E

Y- 7.

Assembly Adjustment (Traveling Device)

12.2 Front wheel adjustment

• Make adjustments by changing the length of

steering rod (2) so that C = D

+2 0

(mm) is achieved.

• When C > D + 2 (mm) is true, shorten the

steering rod (2).

(A single turn of rod alters the difference

between C and D by approximately 5 mm.)

• When C < D is true, lengthen the steering rod

(2).

• After checking that A = B is achieved (if it is

moved, adjust with steering), confirm that

C = D

+2 0

(mm) is achieved.

• Measure A through H, and record them in the

record sheet.

12.3 Rear wheel adjustment

• Make adjustments by changing the length of

steering rod (3) so that M = N

+1 0

(mm) is achieved.

• When M > N + 1 (mm) is true, lengthen the

steering rod (3).

(A single turn of rod alters the difference

between M and N by approximately 5 mm.)

• When M < N is true, shorten the steering rod

(3).

• Make adjustments by changing the length of

steering rod (4) so that O = P

+1 0

(mm) is achieved.

• When O > P + 1 (mm) is true, lengthen the

steering rod (4).

(A single turn of rod alters the difference

between M and N by approximately 5 mm.)

• When O < P is true, shorten the steering rod

(4).

When an adjustment amount is large, it may

become impossible to turn the rod.

(Because the steering cylinder is locked by the

check valve)

In such cases, operate the rear steering to left and

right once to release the steering cylinder

pressure.

• After operating the rear steering to left and right,

align the lock pin center again, and confirm that M

+1 0

(mm) and O = P

+1 0

(mm) are achieved.

• Measure I through P, and record them in the

record sheet.

12.4 Checking procedure

• In the testing ground, measure the side slip and

axle slip.

Tester status:

• "SIDE SLIP" and "AXLE'S SLIP" display status

• HOLD mode

• With the measurement, record the values all

through one axle, and reset the values every time

the measurement of one axle is finished.

• Target value:

• Side slip IN or OUT

Within 3 mm

• Axle slip LEFT or RIGHT

Within 4 mm (1st, 2nd axle)

Within 10 mm (3rd, 4th axle)

If the value deviates from the target value, identify

the wheel status based on the measurement

value, and make adjustments again with an

improved accuracy according to the procedures

described in 12.2 and 12.3.

12.5 After checking

• Tighten the adjustment bolts of steering rods (1)

through (4) to the tightening torque of 76 to 93

N-m (7.75 to 9.5 kgf-m).

△

345-804-

24600

Page 85

Y- 8

Operation Check (Crane Operation)

WY05-3930E

Y-8 Operation Check

(Crane Operation)

1. Outrigger status indicator by operating outrigger inside cab

2. Outrigger status indicator by lower outrigger control box

Shift lever: Not in N position

Parking brake switch: AUX

Operate the outrigger extend/retract selector switch.

Icon flashes on the AML display.

Press all outrigger control switch.

Outriggers do not operate.

Parking brake switch: AUX

Lower outrigger control box: ON

Operate the outrigger extend/retract selector switch.

Press all outrigger control switch.

Outriggers operate.

Shift lever: N position

Parking brake switch: AUX

Operate the outrigger extend/retract selector switch.

Icon flashes on the AML display.

Press all outrigger control switch.

Outriggers operate.

Shift lever: N position

Parking brake switch: Not in AUX

Operate the outrigger extend/retract selector switch.

Icon flashes on the AML display.

Press all outrigger control switch.

Outriggers do not operate.

Parking brake switch: AUX

Lower outrigger control box: ON

Operate the outrigger extend/retract selector switch.

Press all outrigger control switch.

Outriggers do not operate.

Page 86

-8 Y-8

Operation Check (Crane Operation)

WY05-3930E

3. Boom telescoping control

[Boom length: 9.8 - 44.0 m (32.1 - 144.3 ft)]

CN503(1): Emergency telescoping switch for 4th

to top boom sections

CN503(2): Emergency telescoping switch for 2nd

and 3rd boom sections

CN506: Extension switch for 4th to top boom

sections (ISO layout)

CN507: Extension switch for 4th to top boom

sections (TADANO layout)

AML: Telescoping correction switch for 2nd and

3rd boom sections CN485: Boom/jib operation selection CN552: Full-retraction detection limit switch for

4th to top boom sections

3.1 Extension

3.2 Retraction

3.3 Emergency telescoping

9.8 m (32.1 ft) boom (base) Turn the AML emergency switch to “ON” (emergency) side.

1. With switch CN503(1) pressed, extend the 4th,

5th, and top boom sections by approximately 1 m (3.3 ft) each. At this time, AML displays an error code immediately after boom extension starts . Check that the error code is W0019.

2. With switch CN503(2) pressed, fully extend the

2nd and 3rd boom sections. At this time, AML error code changes immediately after boom extension starts. Check that the error code is W0019 until the boom length reaches 23.1 m (75.8 ft).

3. With switch CN503(2) pressed, retract the 2nd

and 3rd boom sections. At this time, the 4th to top boom sections may also retract because the No. 3 cylinder is connected to the tank through the hydraulic valve orifice.

4. With switch CN503(1) pressed, retract the 4th to

top boom sections.

9.8 m (32.1 ft) boom (base)

Only 2nd and 3rd boom sections can be telescoped. (When you use lever to telescope the boom, turn ON the switch CN485.)

Boom length: 23.3 m (76.4 ft)

Switch CN506 (CN507): OFF

2nd and 3rd boom sections can be moved to the stroke ends. (AML works on the basis of performance with 23.5-m boom.) (If the stroke end cannot be reached, refer to "When Adjusting Boom Length" in the section "Action against Emergency" of Operation Manual.)

Switch CN506 (CN507): ON

4th to top boom sections can be extended. (When the switch CN552 turns OFF, AML works on the basis of performance with

30.3-m boom.)

Approx. 30.0 m (98.4 ft) boom

4th to top boom sections retract.

Switch CN552 : ON

2nd and 3rd boom sections retract. (Even if stroke remains for the 4th to top

boom sections at this time, the hydraulic valve orifice causes them to fully retract.)

2017.2.Rev.

Page 87

Y- 8

Operation Check (Crane Operation)

WY05-3930E

4. Hoisting

[Condition]

• Load : None

• Engine speed : Approximately 700 min

-1

to medium speed

[Procedure]

1. Shift the telescoping lever to full stroke first.

2. Make sure that the main winch moves slowly

while the auxiliary winch lever is slightly operated.

3. Make sure that the main winch does not move

while the auxiliary winch lever is operated to full

stroke.

5. Backward stability control

[NOTICE] Extend the outrigger, and set up the machine

horizontally.

1. Select the on-rubber for outrigger set status on

the AML.

2. The boom raising operation must be stopped at

73° automatically.

However, while the boom length is 9.8 m (32.1 ft)

and the over-front detection switch is OFF, the

boom raising operation must be stopped at 60°

automatically.

3. The boom lowering must be available.

Page 88

Y- 8

Operation Check (Crane Operation)

WY05-3930E

6. Jib side-up function

1. Automatic stop by two-blocking must not occur

while the jib set status is registered.

2. While the jib is mounted, check that the jib

stowing (by retracting the cylinder) is not available

when the jib connection pin is not inserted.

3. Check the jib lock icon (indicating that the jib lock

pin is inserted).

• When the jib is secured on the bottom face of

the boom, the icon shown below appears.

• After jib side-up stowing operation is completed,

check that the symbol goes out.

4. Check that the jib raising (by extending the jib tilt

cylinder) is not available when the jib lock pin is

inserted.

5. Check that the jib raising (by extending the jib tilt

cylinder) is not available when the jib lock pin is

engaged.

6. Check the jib drop prevention function.

following check.

• While the jib lock pin is inserted and jib

connection is not inserted (assuming the

condition that the jib is swung from the bottom

face of the boom to the front of the boom

during jib mounting), check that you cannot

extend the boom when the boom angle is less

than 73°.

• While the jib lock pin and jib connection pin are

inserted (assuming the condition that the jib is

secured on the bottom face of the boom and

going to be stowed by side-up), check that

you cannot extend the boom when the boom

angle exceeds 5°.

7. Checking indication of jib full retraction

• While the jib lock pin is not inserted (assuming

the condition that the jib is suspended vertical

toward the ground and going to be secured on

the bottom face of the boom during jib

stowing), the icon appears when the jib tilt

cylinder is fully retracted.

• Check that the icon goes out when the jib tilt

cylinder extends by 30 mm (1.2 in).

• After the check, always retract the jib tilt

cylinder fully and stow the jib.

Jib connection pin

Page 89

WY05-3930E

Y- 8.

Operation Check (Crane Operation)

7. Warning

[NOTICE] For the location of the buzzers, refer to "Z-10 Electric Parts Location Diagram (Upper), 1. Inside cab".

Item

Warning

buzzer

Sound Checking procedure

AML limit

Buzzer (CN818)

• 280Hz

• Continuous

low tone

Buzzer sounds at 100% when main switch is ON and PTO

switch is ON. (Intermittent low tone sound occurs at 90% and

above.)

Two-blocking warning

Buzzer (CN817)

• 2300Hz

• Continuous

high-low tones

Buzzer sounds when the two-blocking detection switch

contact of either the main or auxiliary winch is turned OFF by

winch hoisting up operation.

Outrigger operation switch detection

Buzzer (CN818)

• 620Hz

• Intermittent

beeping

Buzzer sounds when either the outrigger extend/retract or

jack slide selector switch has been left in any position other than neutral for 10 seconds or more after operation is

completed.

AUX brake detection

Buzzer (CN818)

• 620Hz

• Intermittent

beeping

With the parking brake switch set to AUX, and with the

outrigger not being operated, leave for 50 minutes or more. The check is not needed because an extended period is

required for the check.

Outrigger

malfunction

warning

Buzzer (CN818)

• 620Hz

• Continuous

beeping

With the outrigger not being operated, draw out the wire from the outrigger length detector for 100 mm (3.94 in) or more.

8. Eco mode operation check

While the PTO is engaged, select the Eco mode 1

and Eco mode 2, and depress the accelerator

pedal fully. Then check that the maximum engine

speed lowers while the respective mode is

selected.

Eco mode

Max. engine speed (min-1)

OFF

Approx. 1,550

Approx. 1,250

Approx. 1,100

Use the AML to select the Eco mode 1 or Eco

mode 2. The maximum engine speeds above

listed are for reference.

△

345-808-

15000

Page 90

Y- 9

Operation Check (Traveling Device)

WY05-3940E

Y-9 Operation Check (Traveling Device)

1. Permanent-magnetic retarder

1. Jack up the vehicle and select 6-wheel drive mode, and then set the retarder switch to ON (High and Low).

(The pilot lamp lights up.)

2. Set the shift lever from N to D position, and then depress the accelerator.

→ Release accelerator pedal: Retarder is operated.

→ Depress accelerator pedal again: Retarder does not operate.

(Check the retarder operating state by the valve operating sound.)

3. Accelerator OFF → Vehicle speed < 1 km/h (0.62MPH): Retarder does not operate.

Page 91

Y- 9

Operation Check (Traveling Device)

WY05-3940E

2. Automatic transmission

[NOTICE]

Numbers indicate speedometer readings (units: km/h).  ( ) Indicates lock-up ON/OFF point. 

Indicates downshift points when the accelerator position is 90% or above.

(These do not need to be checked.)

 (★) Indicates the lock-up OFF point when the accelerator position is 90% or above.

(These do not need to be checked.)

(1 km/h = 0.6214 MPH)

[High position]

Power mode: OFF

Power

mode: ON

Manual shift

[Low position

]

F6 (High 4th)

F5 (

High 3rd)

F4 (High 2nd)

F3 (High 1st)

F6 (High 4th)

F5 (High 3rd)

F4 (High 2nd)

F3 (High 1st)

F6 (High 4th)

F5 (High 3rd)

F4 (High 2nd)

F3 (High 1st)

F4 (Low 4th)

F3 (Low 3rd)

F2 (Low 2nd)

F1 (Low 1st)

Page 92

Y- 9

Operation Check (Traveling Device)

WY05-3940E

3. Rear steering lock

3.1 Operation check A

Turn the rear steering lock switch to "Release".

(The indicator turns on.)

The indicator is on. The indicator is off.

Check that the indicator is on.

Switch to 8-wheel, crab, or rear steering.

Check that the indicator is on.

(8-wheel, crab, or rear steering)

4-wheel steering indicator remains on and the 8-wheel, crab, or rear steering indicator flashes.

With the steering release switch pressed, slowly turn the steering wheel left and right.

Check that the indicators are ON.

Turn the steering wheel and check the steering.

After checking that the indicator turns off and on, turn the steering wheel to a position where the indicator is on.

Turn the rear steering lock switch to "Lock".

If the pin does not engage, adjust the position of the detector cam so that the detector switch activates when the pin can be inserted.

Check that the indicators are OFF.

8-wheel, crab or rear steering indicator flashes. Switch to 4-wheel steering, and check that 4-wheel steering indicator

turns on and the

8-wheel, crab, or rear steering indicator turns off.

IW05-0141E17

Release

IWY05-0141E15

Release

Lock

Page 93

Y- 9

Operation Check (Traveling Device)

WY05-3940E

3.2 Operation check B

1. With the state of lock pin engaged, upshift to the

3rd gear, and then check that the lock pin does

not come out even when the rear steering lock

switch is set to release.

2. Upshift to the 4th gear, then perform the same

check described in step 1.

3. Downshift to the 1st gear, and set the rear

steering lock switch to release, then check that

the lock pin disengages (indicator lamp lights up).

4. With the state of lock pin disengaged, check that

the gear does not upshift to 3rd or higher gear.

3.3 Operation check C

1. With the state of lock pin disengaged, check that

the lock pin lamp flashes in high speed when the

vehicle speed is accelerated to 15 km/h or more.

4. Overshift prevention

(1 km/h = 0.6214 MPH)

[NOTICE]

Jack-up the crane and set the drive mode to

6-WD/High position, and then perform the operations below and check the shift position on the combination meter.

Perform the operation with each of the power mode

ON/OFF.

1. Move the shift lever to “D” and increase speed to

42 km/h or more. Check that transmission shifts

to 4th gear (display: D).

2. Gradually reduce speed. Maintain a speed of 39

km/h. Move the shift lever to “2.” Check that

transmission does not downshift (display: D).

3. Gradually reduce speed. Check that transmission

downshifts to 3rd gear when the speed is 35 km/h

(display: 3).

4. Gradually reduce speed. Check that transmission

downshifts to 2nd gear when the speed is 22

km/h (display: 2).

5. Maintain a speed of 16 km/h. Move the shift lever

to “1.” Check that transmission does not

downshift (display: 2).

6. Gradually decrease speed. Check that

transmission downshifts to 1st gear at 11 km/h

(display: 1).

It is also acceptable to measure the vehicle

speed on the vehicle information screen in the

maintenance mode of AML.

Meter speed Combination meter display

42 D

16 2

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Operation Check (Traveling Device)

WY05-3940E

5. Warning

(1 km/h = 0.6214 MPH)

[NOTICE] For the location of the buzzers, refer to "Z-10 Electric Parts Location Diagram (Upper), 1. Inside cab".

Item

Warning

buzzer

Sound Check conditions

Low air pressure

and parking brake

applied

Buzzer

(CN818)

• 620 Hz

• Continuous beep

Buzzer sounds when the following conditions are met.

1. Air pressure is 540 kPa (5.5 kgf/cm2) (78.3 psi) or less, when the main switch is turned ON and the parking brake is not applied.

2. Shift lever is out of N position when the parking brake is

applied.

Engine overrun

Buzzer

(CN818)

• 620 Hz

• Intermittent beeping

It is not necessary to check because the buzzer sounds at

engine speed of 2360 min

-1

by the mechanism.

Buzzer turns OFF at 2100 min-1.

Speed warning

Buzzer

(CN818)

• 620 Hz

• Continuous and

intermittent sounds

Attach a step-up gear to the vehicle speed detection

gearbox. During accelerating: Speedometer reading 58 km/h: Intermittent sound 61 km/h: Continuous sound During decelerating: Speedometer reading 59 km/h: Intermittent sound

54 km/h: OFF

Torque converter low pressure

Buzzer

(CN818)

• 620 Hz

• Continuous beep

Buzzer sounds if the torque converter pressure is 1.0 MPa

(10.2 kgf/cm2) (145 psi) or less while the parking brake is

not applied.

Parking brake

non-operation

warning

Buzzer

(CN818)

• 620 Hz

• Continuous beep

Buzzer sounds if the main switch is turned OFF while the

parking brake is not applied and the main switch is turned

ON (or the engine is running).

Special steering mode selector switch reminder

warning

Buzzer

(CN818)

• 620 Hz

• Continuous beep

With the rear steering lock pin inserted, when 10 seconds elapses after the selection of other than front 4-wheel steering (8-wheel, crab, or rear steering), the buzzer

sounds.

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Operation Check (Traveling Device)

WY05-3940E

6. Speedometer

(1 km/h = 0.6214 MPH)

When the actual traveling speed of the vehicle is V

the reading of the speedometer (V

) shall meet the

following formula:

0 ≤ V

- V2 ≤ V2 / 10 + 6

Ex. Case of a vehicle of [45 km/h < Vmax ≤ 55 km/h] When the speedometer reading is 40 km/h, V

becomes 40 km/h. Thus

the tester speed (V

) shall be as

follows:

30.91 km/h ≤ V

≤ 40 km/h

[NOTICE]

Perform the measurement with the 3rd axle, and

place the 4th axle on the free roller.

Make sure to set the inter-axle differential lock to

ON (pilot lamp lights up).

7. Emergency accelerator switch

1. While the shift lever is in the N position, turn the

emergency accelerator switch ON.

2. Slightly depress the accelerator pedal, and check

that the engine speed becomes as the value

below.

Engine speed: 2270 ± 50 min

-1

8. Emergency transmission switch

1. While in the High position and the shift lever is in

the N position, turn the emergency transmission

switch ON.

2. Set the shift lever to the D position, and check

that only the transmission state indication "D" is lit

on the combination meter.

(When the emergency transmission switch is OFF,

both "D" and "1" light up.)

3. Slightly depress the accelerator pedal, then

operate the shift lever as 1 → 2 → D, and check

that the transmission state indication of

combination meter changes as 2 → 3 → D.

[NOTICE]

Because the over-shifting prevention function does

not work while the emergency transmission switch is ON, perform the downshifting with the vehicle parked.

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345-808-

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Operation Check (Traveling Device)

WY05-3940E

9. Hydraulic suspension

9.1 Normal operation

Check the suspension state and the suspension lock indicator with the following procedure.

Operation

Suspension lock indicator

Suspension state

Turn ON the main switch to start

engine.

↓

Keep pressing the suspension

free switch for 1 second or more.

 Check that the suspension emergency free switch

is on the normal position and put the vehicle into a traveling state while the boom is in a front-side.

Flashes slowly during leveling.

Goes out after leveling.

Free after leveling

(Normal traveling starts)

↓

Suspension up/down switch

 Leveling is impossible when the road surface is not flat.

In this case, adjust to the lock state by operating the suspension up/down switch, move to a flat ground, and then operate the suspension free switch again.

Operate in the following order.

1. Down operation .......... Flashes

(10 seconds or less) slowly

2. Up operation .............. Flashes

slowly

3. Down operation .......... Lights up

(10 seconds or more)

Locked after vehicle height is lowered

Locked after vehicle height is raised

Locked after suspension is fully retracted.

 Vehicle height is raised or lowered while the switch is being pressed.

The vehicle height is locked when the operation switch is released.

↓

Turn ON the PTO switch. Check that the operation status is on-rubber status on the AML.

Suspension lock indicator: Lights up Operation condition: On-rubber

Locked after suspension is fully retracted.

↓

Turn OFF the PTO switch. Keep pressing the suspension

free switch for 1 second or more.

Flashes slowly during leveling. Goes out after leveling.

Free after leveling (Normal traveling starts)

↓

Flashes slowly: 0.8 second interval Flashes fast: 0.4 second interval

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Operation Check (Traveling Device)

WY05-3940E

Operation

Suspension lock indicator

Suspension state

PTO－ON

Flashes slowly

Locked ↓

Extend the slides by the outrigger operation switch (central/individual) and jack up the crane. Set the outrigger status on the AML to extension status.

Lights up

Locked

 Suspension falls rapidly if the suspension free switch is pressed while

the boom is in front and the crane is in the jack-up state. Do not operate the switch.

↓

Slew the boom in an over-side direction.

Lights up Locked

↓

PTO－OFF

Lights up

Locked

 Check that the suspension does not fall even if the suspension

up/down switch or suspension free switch is pressed while the boom is in an over-side.

↓

Turn ON the PTO switch. After slewing the boom to the over-front, stow the jacks and slides.

Flashes slowly Locked

↓

Turn OFF the PTO switch. Keep pressing the suspension free switch for 1 second or more.

Flashes slowly during leveling. Goes out after leveling.

Free after leveling (Normal traveling starts)

↓

Turn OFF the main switch to stop engine.

Locked

↓

Complete  Next time the main switch is turned ON and the engine is started, the

suspension state before the engine is stopped will be resumed.

Page 98

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Operation Check (Traveling Device)

WY05-3940E

9.2 Emergency operation

Check the suspension state and the suspension lock indicator with the following procedure.

Operation

Suspension lock indicator

Suspension state

Turn ON the main switch to start

engine.

↓

Keep pressing the suspension free switch for 1 second or more.

 Check that the suspension emergency free switch

is on the normal position, and put the vehicle into a traveling state while the boom is in a front-side.

Flashes slowly during leveling. Goes out after leveling.

Free after leveling (Normal traveling starts)

↓

Suspension up/down switch

 Leveling is impossible when the road surface is not flat.

In this case, adjust to the lock state by operating the suspension up/down switch, move to a flat ground, and then operate the suspension free switch again.

 Press the suspension up/down switch for a moment to put into a

suspension lock state.

Flashes slowly

Locked

↓

Suspension emergency free switch

 Shift the suspension emergency free switch to Emergency.

Flashes slowly

Locked

↓

Keep pressing the suspension free switch for 1 second or more.

Flashes fast

Suspension emergency free

 Check that suspension up and down operations cannot be

performed.

↓

PTO－ON

Flashes fast

Suspension emergency free

↓

Keep pressing the suspension

free switch for 1 second or more.

Flashes fast

Suspension emergency free

↓

Flashes slowly: 0.8 second interval Flashes fast: 0.4 second interval

Page 99

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Operation Check (Traveling Device)

WY05-3940E

Operation

Suspension lock indicator

Suspension state

Extend the slides by the outrigger operation switch (central/individual) and jack up the crane. Set the outrigger status on the AML to extension status.

Lights up

Locked

 Suspension falls rapidly if the suspension free switch is pressed while

the boom is in front and the crane is in the jack-up state. Do not operate the switch.

↓

Slew the boom in an over-side direction. (Elevating angle shall be 20° to 50° if boom raising operation is also performed.)

Lights up Locked

↓

PTO－OFF

Lights up

Locked

 Check that the suspension does not fall even if the suspension

up/down switch or suspension free switch is pressed.

↓

PTO－ON

Lights up

Locked

↓

Stow the jacks and slides (with

the boom in the over-side).

Flashes slowly Locked

↓

Keep pressing the suspension free switch for 1 second or more.

Flashes fast

Suspension emergency free

↓

Perform boom extending operation.

Flashes fast

Suspension emergency free

 Check that the boom stops after it extends by 0.1 to 0.2 m (0.33 to

0.66 ft) from the fully retracted state.

↓

Perform boom raising operation.  Check that the boom stops at the elevating angle of 55°.

Flashes slowly

Locked after stop

↓

Set the crane in the traveling state by the telescoping, elevating and slewing operation, then turn OFF the PTO (with the suspension as

is).

Flashes slowly Locked

↓

Page 100

WY05-3940E

Y- 9.

Operation Check (Traveling Device)

Operation

Suspension lock indicator

Suspension state

Keep pressing the suspension

free switch for 1 second or more.

Flashes fast

Suspension emergency free

↓

Turn OFF the main switch to stop

engine.

Locked

↓

Turn ON the main switch to start

engine.

Flashes slowly Locked

↓

Keep pressing the suspension

free switch for 1 second or more.

Flashes fast

Suspension emergency free

↓

Suspension emergency free switch

 Shift the suspension emergency free switch to Normal.

Flashes slowly

Locked

↓

Keep pressing the suspension free switch for 1 second or more.

Flashes slowly during leveling. Goes out after leveling.

Free after leveling (Normal traveling starts)

↓

Turn OFF the main switch to stop

engine.

Locked

↓

Complete

△

345-807-

14500

Tadano GR-700N Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual