Tadano GR-130EX User manual

Foreword
1
WA04-5470E
Foreword
This service manual describes the composition of the Model GR-130EX-2 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 service manuals, the operation manual and the parts catalog for repair and maintenance of
the crane in conjunction with this manual. If any part 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-130E-2-00103 FD3305--
Separate service manual
Separate Service Manual Publication No.
1 General Cautions WA01-0121E
2 Automatic Moment Limiter (AML-C) to be published
3 Multiplex data Transmitter (MDT-9) to be published
4
Torque Converter (EXEDY)
W561-0131E
Transmission (EXEDY)
5 Driving Axle (OKUBO GEAR) W563-0091E
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.

Foreword
2
WA04-5470E
2. External view
The following is the traveling posture of the H-type outrigger specification machine.
Front, rear, right, and left are the directions viewed from a position when operator sits on operator's seat with the
boom directed to the front of the frame. Those directions remain invariant regardless of slewing direction of the
superstructure.

Foreword
3
WA04-5470E
3. Outline of specifications
No. Item
Spec. No.
GR-130E-2-00103
2M2D
(Australia)
1 No. of boom sections 6
2 No. of jib stages (base (jib 1), top (jib 2)) (Power tilt jib) 2
3 Single top Fitted
4 Winch
Main winch Fitted
Auxiliary winch Fitted
Winch high-speed hoisting down Fitted
Winch brake Automatic brake (Neutral brake)
Drum
rotation
indicator
Main and
Auxiliary Visual type Fitted
5 Automatic moment limiter (AML) AML-C
6 Auto. stop solenoid valve energizing type Normally energized
7 Anti-two-block device Fitted
8 External warning lamp (AML) Fitted
9 Oil cooler Fitted
10 Air conditioner Fitted
11 ICF (information controller) Fitted
12 SCT (satellite communications terminal) Option
13 GSMT (global system for mobile communications terminal) -
14 Eco mode system, Fuel consumption monitor Fitted
15 Emergency steering Option
16 Engine model
Mitsubishi
4M50-TLU3B [EUROMOT Stage IIIA]
4M50-TLA3B [EPA Tier3]
17 Tires 315/80 R22.5

Foreword
4
WA04-5470E
4. Conversion table
Length
millimeter
mm
centimeter
cm
meter
m
inch
in, ”
foot
ft, ’
mile
mi
kilometer
km
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
1×10
3
1×10
2
1 3.93701×10 3.28084
2.54×10 2.54 2.54×10
-2
1 8.33333×10
-2
3.048×10
2
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
mm
2
square centimeter
cm
2
square meter
m
2
square inch
in
2
square foot
ft
2
1 1×10
-2
1×10
-6
1.55×10
-3
1.07639×10
-5
1×10
2
1 1×10
-4
1.55×10
-1
1.07639×10
-3
1×10
6
1×10
4
1 1.55×10
3
1.07639×10
6.4516×10
2
6.4516 6.4516×10
-4
1 6.94444×10
-3
9.2903×10
4
9.2903×10
2
9.2903×10
-2
1.44×10
2
1
Volume
cubic centimeter
cm
3
, cc
liter
lit, L
cubic meter
m
3
cubic inch
in
3
cubic foot
ft
3
gallon (US)
gal
1 1×10
-3
1×10
-6
6.10237×10
-2
3.53147×10
-5
2.64172×10
-4
1×10
3
1 1×10
-3
6.10237×10 3.53147×10
-2
2.64172×10
-1
1×10
6
1×10
3
1 6.10237×10
4
3.53147×10 2.64172×10
2
1.63871×10 1.63870×10
-2
1.63871×10
-5
1 5.78704×10
-4
4.329004×10
-3
2.83168×10
4
2.83168×10 2.83168×10
-2
1.728×10
3
1 7.48051
3.78541×10
3
3.78541 3.78541×10
-3
2.31×10
2
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

Foreword
5
WA04-5470E
Mass
gram
g
kilogram
kg
ounce
oz
pound
lb
metric ton
t
short ton
s. t
1 1×10
-3
3.5274×10
-2
2.20462×10
-3
1×10
-6
1.10231×10
-6
1×10
3
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
4.53592×10
2
4.53592×10
-1
1.6×10 1 4.53592×10
-4
5×10
-4
1×10
6
1×10
3
3.5274×10
4
2.20462×10
3
1 1.10231
9.07185×10
5
9.07185×10
2
3.2×10
4
2×10
3
9.07185×10
-1
1
Pressure
pascal
Pa
kPa MPa kgf/cm2lbf/in2, psi bar
1 1×10
-3
1×10
-6
1.01972×10
-5
1.45038×10
-4
1×10
-5
1×10
3
1 1×10
-3
1.01972×10
-2
1.45038×10
-1
1×10
-2
1×10
6
1×10
3
1 1.01972×10 1.45038×10
2
10
9.80665×10
4
9.80665×10 9.80665×10
-2
1 1.42233×10 9.80665×10
-1
6.89476×10
3
6.89476 6.89476×10
-3
7.03072×10
-2
1 6.89475×10
-2
1×10
5
1×10
2
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
1×10
2
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
9.80665×10
2
9.80665 1×10
2
1 7.23301 8.67961×10
1.35582×10
2
1.35582 1.38255×10 1.38255×10
-1
1 1.2×10
1.12985×10 1.12985×10
-1
1.152513 1.15213×10
-2
8.33333×10
-2
1
Power
watt
W
kW PS
1 1×10
-3
1.35962×10
-3
1×10
3
1 1.35962
7.355×10
2
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

6
WA04-5470E
Foreword
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.

7
WA04-5470E
6. Group index
System Diagrams
Data, Adjustment and Checks
Y
Z
Y
Z

8
WA04-5470E
Foreword
7. Contents
Chapter
Section
Spec. No.
GR-130E-2-00103
2M2D
(Australia)
Data, Adjustment and Checks
Y
Service Data Y-1
Adjusting Pressure (Hydraulic Pressure) Y-2
Adjusting Pressure (Pneumatic Pressure) Y-3
Air Bleeding Procedure Y-4
Adjusting Procedure (Electric) Y-5
Assembly Adjustment (Crane Operation) Y-6
Assembly Adjustment (Traveling Device) Y-7
Operation Check (Crane Operation) Y-8
Operation Check (Traveling Device) Y-9
Inspection and Maintenance Y-10
Boom Connecting Pin
and Thread Size Table
Y-11
System Diagrams
Z
Hydraulic Circuit Z-1
Torque Converter Circuit Z-2
Pneumatic Circuit Z-3
Electric Circuit (Upper) Z-4
Electric Circuit (Lower) Z-5

9
WA04-5470E
Foreword
Chapter
Section
Spec. No.
GR-130E-2-00103
2M2D
(Australia)
Z
Location of Installation
Hydraulic Parts Location Diagram (Upper) Z-6
Hydraulic Parts Location Diagram (Lower) Z-7
Hydraulic Parts Location Diagram
(Torque Converter)
Z-8
Pneumatic Parts Location Diagram Z-9
Electric Parts Location Diagram (Upper) Z-10
Electric Parts Location Diagram (Lower) Z-11
Harness Diagrams
Harness (Upper) Z-12
Harness (Lower) Z-13
View System Z-14

i
Y
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 Slide plate................................................... 5
5.2 Boom bending and deformation ................. 6
5.3 Jib bending and deformation ...................... 7
5.4 Wire rope .................................................... 7
5.5 Sheave ....................................................... 8
5.6 Inspection of the hook block....................... 8
6. Criteria for maintenance
and replacement of vehicle............ 9
6.1 Power transmission device......................... 9
6.2 Braking device ............................................ 9
6.3 Steering device......................................... 10
7. Mass table ...............................................11
Y-2 Adjusting Pressure
(Hydraulic Pressure)..............12
1. Location (position of relief valve etc.) ...... 12
2. Items .................................................... 13
2.1 Winch ........................................................13
2.2 Elevating ...................................................15
2.3 Slewing......................................................16
2.4 Outrigger ...................................................17
2.5 Remote control pilot valve.........................18
2.6 Steering .....................................................19
2.7 Torque converter oil pressure ...................20
2.8 Hook-in......................................................20
2.9 Jib tilt .........................................................21
Y-3 Adjusting Pressure
(Pneumatic Pressure)............22
Y-4 Air Bleeding Procedure .................23
1. Hydraulic pump ....................................... 23
1.1 Gear pump ................................................23
1.2 Variable piston pump ................................23
1.3 Variable piston pump
(when the tank pressurization
tool is used).........................................24
1.4 Tank pressurization tool ............................24
1.5 Other (cylinder) .........................................24
2. Winch brake ............................................ 25
3. Service brake .......................................... 25
Y

ii
4. Hydraulic motor assy .............................. 26
4.1 Slewing motor........................................... 26
4.2 Winch motor ............................................. 26
4.3 Air conditioner motor ................................ 26
5. Winch counterbalance valve
(main and auxiliary) ..................... 27
6. Slewing control valve
(back-pressure valve) .................. 27
7. Pilot circuit
(hydraulic pilot control valve) ....... 28
8. Hydraulic valve (winch brake) ................. 29
Y-5 Adjusting Procedure (Electric) ..... 30
1. 2nd/3rd boom full retraction
detection switch (CN553)............. 30
2. 4th/top boom full retraction
detection switch (CN859)............. 30
3. Jib lock pin detection switch (CN572) ..... 31
4. Jib connection pin
detection switch (CN549)............. 32
5. Main winch drum rotation
detection switch (CN591)............. 33
6. Aux. winch drum rotation
detection switch (CN592)............. 33
7. Over-front detection switch (CN521) ....... 34
8. Straight ahead
detection switch (CN408)............. 35
9. Rear steering lock pin
(IN) detection switch (CN417),
(OUT) detection switch (CN418).. 35
Y-6 Assembly Adjustment
(Crane Operation) ..................36
1. Adjusting boom telescoping wire ropes ... 36
1.1 Adjusting the telescoping wire rope
for the top and 5th boom sections ......36
1.2 Adjusting the telescoping wire rope
for the 3rd boom section .....................39
Y-7 Assembly Adjustment
(Traveling Device)..................40
1. Service brake adjustment........................ 40
1.1 Adjusting the brake pedal .........................40
1.2 Check after replacing brake hose .............40
2. Accelerator adjustment............................ 41
2.1 Accelerator pedal ......................................41
3. Parking brake adjustment........................ 42
3.1 Adjusting the clearance
(between brake shoe and drum).........42
3.2 Connecting the parking brake and
the brake chamber..............................42
4. Tire and steering angle adjustment ......... 42
4.1 Tire air pressure ........................................42
4.2 Adjusting the steering angle......................43
5. Engine speed (and governor setting)....... 43
6. Torque converter and transmission.......... 44
6.1 Maximum allowable speed........................44
6.2 Adding oil to the torque converter and
transmission........................................44
7. Camera mounting angle adjustment........ 44

iii
Y-8 Operation Check
(Crane Operation) .................. 45
1. Outrigger status indicator........................ 45
2. Hoisting................................................... 45
3. Jib .................................................... 46
4. Boom telescoping control........................ 47
4.1 Extension.................................................. 47
4.2 Retraction ................................................. 47
4.3 Emergency telescoping ............................ 48
5. Warning .................................................. 49
6. Eco mode operation check ..................... 49
Y-9 Operation Check
(Traveling Device).................. 50
1. Exhaust brake......................................... 50
2. Automatic transmission........................... 50
3. Rear steering lock................................... 51
3.1 Operation check A .................................... 51
3.2 Operation check B .................................... 52
3.3 Operation check C.................................... 52
4. Overshift prevention................................ 52
5. Warning .................................................. 53
6. Suspension lock...................................... 54
7. Speedometer .......................................... 54
Y-10 Inspection and Maintenance......... 55
Y-11 Boom Connecting Pin and
Thread Size Table .................. 56

Y-1
Y-1
Service Data
1
WY01-3270E
Y-1 Service Data
1. Amounts of oil and coolant
(1 L = 2.64172 × 10-1 gal)
Item
Standard
value (L)
Remarks
Amount of oil
Hydraulic oil
Total oil capacity Approx. 240 TADANO Hydraulic Oil LL
(TADANO Genuine)
Tank capacity Approx. 172
Speed reducer
gear oil
Slewing 0.5 Mobilgear 600 XP320 (Exxon Mobil)
Winch
Main 1.8 Gear oil GL-4 90
(JX Nippon oil & energy)
Auxiliary 1.8
Axle
Carrier differential 8 × 2
Shell gelco oil 5090 (Shell)
Planetary gear 0.7 × 4
Torque converter and transmission
(amount of replacement oil)
19.0
TADANO Genuine Torque Converter
Oil
Brake fluid Service brake 1.9
TADANO Genuine Brake Fluid
DOT-5.1
Engine oil 11.0
API Service Classification CD-SAE30
(SAE10W-30 for cold climates)
Grease 1
Daphne Eponex Grease SR No. 2
(Idemitsu)
Grease (centralized lubrication system) 0.6 Nigtight LE-0 (Nippon Grease)
Fuel 189 ASTM/D-975 Grade 2-D
Amount of
coolant
Coolant
Total volume 29.7
TADANO Genuine Long-life Coolant
Necessary volume of
long-life coolant
8.9 (*1)
(*1): When mixing ratio is 30%
2. Operating speed
Item Standard value Remarks
Operating
speed
Telescoping
Extending 18.5 m (60.6 ft) /52s
Retracting ―
Elevating
Raising -3° to 82°/29s
Lowering ―
Winch rope (hoisting up) speed
Main 125 m/min (410 ft/min) On 5th layer
Auxiliary 110 m/min (361 ft/min) On 3rd layer
Slewing 2.4 min-1
[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.

Y-1
Y-1
Service Data
2
WY01-3270E
3. Hydraulic device
3.1 Hydraulic pump
Item Standard value Remarks
Variable piston pump
Speed reducing ratio 1.044
Idling (min-1) 738 ± 19 Eng. 770 ± 20
Max. (min-1) 1628 ± 29 Eng. 1700 ± 30 (PTO - ON)
Displacement (cm3/rev) 45.8 + 45.8
Gear pump
Speed reducing ratio 1.073
Idling (min-1) 718 ± 19 Eng. 770 ± 20
Max. (min-1) 2796 ± 48 Eng. 3000 ± 50
Displacement (cm3/rev) 23.1 + 13.9
Charging pump
(torque converter)
Speed reducing ratio 1.073
Idling (min-1) 738 ± 19 Eng. 770 ± 20
Max. (min-1) 2796 ± 48 Eng. 3000 ± 50
Displacement (cm3/rev) 23.7
Emergency steering
pump
Displacement (cm3/rev) 14.6
3.2 Hydraulic motor
Item Standard value Remarks
Winch
(main, auxiliary)
Displacement (cm3/rev) 36.7 to 54.3
Variable displacement pump with
auto-brakes
Drain (when running) ―
Slewing
Displacement (cm3/rev) 22.9
Drain (when running) ―

Y-1
Y-1
Service Data
3
WY01-3270E
3.3 Hydraulic cylinder
[NOTICE]
Keep the hydraulic oil temperature during the following inspections.
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
0.1 m 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 maintenan
ce
mode. (Displays the value to the second
digit after decimal place.)
Jack
retracting
1 mm or
less/
5 hours
Inspection conditions
1. Boom stowed over-front
2. Slide fully extended
3. After retracting the jacks (approximately
10 mm) from fully extended status,
slightly extend them to set the crane
horizontally. (*2)
(If a tire cannot be raised after jack setting,
use a wood block to keep 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
1 mm 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.
(1 m = 3.28084 ft)
(1 mm = 3.93701 × 10-2 in)

Y-1
Y-1
Service Data
4
WY01-3270E
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 upper
limit (minimum jib offset angle)
2. Boom angle: 60° ± 2°
3. Engine stop
4. No load
Inspection method
After the disappearance of initial cylinder
retraction, read the variation of the jib offset
angle from the AML display after leaving as it
is 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
0.1 m 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 jib length on the integrated
information screen in the AML maintenan
ce
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.
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.
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.

Y-1
Y-1
Service Data
5
WY01-3270E
4. Slewing section
(1 mm = 3.93701 × 10-2 in)
Item Standard value Remarks
Amount of
slewing play
Horizontal play 3 mm or less
Vertical play 1.2 mm or less
5. Boom section
5.1 Slide plate
(1 mm = 3.93701 × 10-2 in)
Location used
Standard
thickness
(mm)
Replacement
standard
(mm)
Remarks
Limit value
Base boom
section Front
Side 21 19
Lower 12 9
2nd boom section
Front
Side 37 35
Lower 12 9
Rear Upper
corner
Upper 31 28
Side 33 31
3rd boom section
Front
Side 9 7
Lower 12 9
Rear
Upper 12 9
Side 15 12
4th boom section
Front
Side 9 7
Lower 12 9
Rear
Upper
corner
Upper 42 39
Side 33 31
Side 15 13
5th boom section
Front
Side 44 42
Lower 12 9
Rear
Upper 12 9
Side 15 13
Top boom section
Rear
Upper 12 9
Side 15 13

Y-1
Y-1
Service Data
6
WY01-3270E
5.2 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)
Vertical
Base boom
2nd boom section
3rd boom section
4th boom section
5th boom section
Top boom section
B ≤7
B ≤ 8
B ≤ 7
B ≤ 7
B ≤ 7
B ≤ 7
B ≤ 1.5 × L /1000
L: length of each
boom section
Lateral
Base boom
2nd boom section
3rd boom section
4th boom section
5th boom section
Top boom section
C ≤ 5
C ≤ 5
C ≤ 5
C ≤ 5
C ≤ 5
C ≤ 5
C ≤ 1.0 × L /1000
Indentations at boom overlap
sections
(Bending at boom lower plate)
t
D
IWY01-001003
2nd boom section
3rd boom section
4th boom section
5th boom section
Top boom section
In vertical direction
D ≤ 3
D ≤ 3
D ≤ 3
D ≤ 2
D ≤ 3
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
E
IWY01-001004
E ≤ 5
Check for dents and other localized indentation
1
G
Depth F
IWY01-0010E05
L
F ≤ 2
(at L1≥ 50 mm)
Generally dent G on the 4 corners
cannot be repaired.

Y-1
Y-1
Service Data
7
WY01-3270E
5.3 Jib bending and deformation
(1 mm = 3.93701 × 10-2 in)
Item Standard value (mm) Remarks
Check for bending of the whole jib
a ≤ 5.1
No significant bending in vertical and
horizontal direction shall be found.
a ≤ 1.5 + L /1000
L = 3600
(jib full retraction)
Check for dents and other localized indentation or
bending
IWY01-0010E08
d
L
d ≤ 0.8
(for indentations with L ≥ 15 mm)
5.4 Wire rope
[NOTICE]
If the local laws, regulations or rules concerning the criteria of wire rope replacement are stricter than the
standard described in this manual, observe the local ones.
(1 mm = 3.93701 × 10-2 in)
Item Standard value
Limit
value
Remarks
For main winch
Wire rope diameter (mm)
11.2 (Nominal diameter)
10.5
Construction
IWRC 6×Fi (29) O/O
370-018-08700,-09700
Number of broken wire (pcs.)
–
13
For auxiliary winch
Wire rope diameter (mm)
11.2 (Nominal diameter)
10.5
Number of broken wire (pcs.)
–
13
For boom
extension
3rd
Wire rope diameter (mm)
14 (Nominal diameter)
13.1
Construction
IWRC 6×Fi (29) O/O
370-019-17900,-17960,-17880
Number of broken wire (pcs.) – 13
5th
Wire rope diameter (mm)
10 (Nominal diameter)
9.3
Number of broken wire (pcs.)
–
13
Top
Wire rope diameter (mm)
9 (Nominal diameter)
8.4
Number of broken wire (pcs.) – 13
For boom
retraction
3rd
Wire rope diameter (mm)
8 (Nominal diameter)
7.5
Construction
IWRC 6×Fi (29) O/O
370-019-17920,-17940
Number of broken wire (pcs.)
–
13
Top Wire rope diameter (mm) 8 Nominal diameter) 7.5
Number of broken wire (pcs.)
–
13
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.