Tadano TR-800XXL4 User manual

Publication No. GR-800XXL-1/S2(U)-1E
01
Rough Terrain Crane
TR-800XXL- 4
Applicable Serial No. 545870, 545961--
Model
◯
ｃ2006
PRINTED IN JAPAN
0608 K
Service Manual GR-800XXL-1/S2(U)-1E

Safet
y
1 WA01-0041E
Safety
Most accidents that occur during machine operation
and maintenance are caused by failure to observe
basic safety rules and precautions. Before operating
your machine or performing maintenance, read and
become familiar with all the safety precautions and
recommendations given in this section.
Remember that failure to observe even a single
precaution could involve you and the people around
the machine in a serious accident.
Foreseeing potential dangers is vital for preventing
accidents. All personnel working with the machine,
including the supervisor, machine operator and oiler,
should be sensitive to potentially dangerous situations
and take the necessary measures to prevent
accidents.
Safety precautions and recommendations are outlined
in this section and are also included in the operation
and maintenance instructions given in subsequent
sections. Warning labels are also provided on the
machine.
The cautionary instructions in this manual are
identified as "DANGER", "WARNING", "CAUTION" or
"NOTICE". These terms are defined as follows:
[NOTICE]
[NOTICE] indicates an important operational or
maintenance procedure or condition, which, if not
strictly observed, can result in damage to machine
components or deteriorated machine performance.
It is virtually impossible to anticipate every situation
that might present a hazard. The safety precautions
given in this manual and on the machine labels are
not exhaustive.
It is important, therefore, to strictly follow the
instructions in this manual and be sensitive to
potential dangers in order to prevent bodily injury and
damage to the machine.
Remember that your most important duty is to ensure
the safety of you, your co-workers and any other
people in the area.
DANGER indicates an imminently hazardous
situation, which, if not avoided, will result in death
or serious injury.
DANGER
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
WARNING
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
a minor or moderate injury.
CAUTION

Safet
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2 WA01-0041E
1. Fundamental cautions
Servicemen inexperienced in the units of this machine
should be cautious about safety operations. They
must acquire sufficient knowledge about the
equipment before dismounting and disassembling it.
Before dismounting each component, a serviceman
should read this service manual thoroughly and find
out the weight of the component, then lift it by proper
means.
The following are cautions to be observed all the time.
1.Before starting repairs, find out the origin of the
problem. When it becomes clear that
disassembly and maintenance are necessary, first
of all read this manual and parts catalog and
thoroughly understand the principle of operation
and construction. Then carefully check and
examine each portion. Don't disassemble
portions unrelated to the problem. Unless taking
all possible measures before starting disassembly,
new troubles or decline in performance may be
induced.
2.Before operating the machine, oiling or repairing,
read warning labels and instructions on the
machine and understand the contents.
3.Wear a safety helmet and safety shoes whenever
you carry out maintenance operation around the
machine. Be sure to wear safety goggles when
you hit the machine or its attachments with a
hammer. In welding operation, wear safety gears
such as leather gloves, helmet, goggles, apron
and proper working clothes, but don't wear loose
or torn clothes. Take a ring and so on off your
finger when you conduct maintenance or repair.
4.Park the machine on as level and hard ground as
possible. Place chocks under wheels to prevent
the vehicle from moving when doing maintenance
on or below the machine.
5.Before starting maintenance, remove cables to the
battery and allow the capacitors to discharge.
Pull out the ignition key and hang a tag saying,
"Don't start the engine." in the cab.
6.Don't carry out maintenance while lifting the
vehicle with only a jack or a hoist. Sustain the
vehicle positively with blocks and so on to prevent
fatal accidents, as there is a possibility that the
vehicle loses its balance and falls down on a
worker in a dismounting process of certain units.
7.When the working is done on a team of more than
one person, make arrangements about
co-operation and communication between workers
beforehand. Give a sign without fault and make
sure that the sign has been transmitted to other
workers before starting the next operation.
8.When it is inevitable to measure oil pressure,
rotational speed, and temperature for machine
inspection without stopping the engine, be careful
not to be caught or pinched in rotating or moving
parts such as a fan, fan belt. Make sure that
there is no obstruction or no person around the
machine before operating it.
2. Cautions in working
2.1 General
1.When hoisting up components weighing more than
20 kg, use hoist or the like to prevent injury to your
lumbar or spine. For specific components, their
weights are listed on the chapter for "service data"
in this manual.
2. When using eyebolts, lift parts vertically so that
only tension is applied to them.
3.Protect wire ropes and plastic lifting slings by
covering corners with pads so that they are not
bent sharply by directly contacting corners.
Keep the sling angle of wire ropes within 60°and
as vertical as possible.
4.Be careful about hot or heated portions when
conducting repair or maintenance just after the
vehicle has stopped or the machine operation has
been finished or interrupted.
5.When hitting parts, be sure to either hit on a pad
placed on the parts or use a plastic hammer.
6.Put units, especially similar parts, in order. Mark
them with tags or marker if necessary.

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3 WA01-0041E
7.Put disassembled parts in order so that parts such
as bolts are not left behind in the machine. And
check that no parts run short at assembly.
8.Watch your step in the following cases:
When stepping up to or stepping down from the
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder
When checking engine oil, radiator coolant, or
battery fluid.
When replacing a filter of air cleaner
When getting on and off the cab
Be careful not to slip in the above operations in
winter as snow and ice may attach to the exterior
of boom and it becomes very slippery.
2.2 Dismounting and disassembling
1.Before dismounting and disassembling, make sure
of the construction and part sales unit by reading
this manual and the separate parts catalog, then
understand the procedures of dismounting and
remounting and disassembling and reassembling.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging
the confined pressure.
3.Before removing, clean the part to be dismounted
and the area surround it. Seal the opening with a
plug or tape, etc. to prevent foreign material from
entering it.
4.Measure and record the data such as shim
thickness adjustment and pre-load at disassembly
that will be required at reassembly.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling.
6.If a part cannot be removed after removing bolts or
nuts fixing it, don't apply too much force to it but
check the part for the cause. Only after relieving
the cause, proceed disassembling.
7.Use lifting slings appropriate for the weight and
characteristics of a part. Lift up it in balanced
condition.
In case that the position of the center of gravity is
not clear and there is a possibility of swing of load
after removing, use two hoists.
8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
hinder removing.
2.3 Remounting and assembling
1.Before assembling, clean all the parts and repair
or replace defective parts.
2.As dirt and soil adversely affect sliding portions
and they may decrease the life of the machine,
pay special attention to avoid intrusion of dirt and
soil.
3.Use special tools for parts when specified to do so.
4.Remove dirt, soil, water, and resin completely from
surfaces where liquid gasket will be applied.
5.After remounting, be sure to inspect the machine
and verify that there is no error by oversight. If
adjustment or air bleeding is required, conduct it
according to instructions. Conduct function and
performance test to verify its integrity.
3. Cautions in operation
3.1 Brake fluid replenishment
1.When the brake-warning lamp (for fluid level) is
lighted, replenish brake fluid and check and make
sure of the thickness of disk brake pads. (Refer
to Chapter Y for periodical inspection periods.)
2.Check the thickness of disk brake pads whenever
brake fluid is replenished.
3.2 Handling of battery
1.Erroneous handling of a battery may cause it to
catch fire and explode.
Be extremely sure to avoid short circuits, sparks
and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
Charge up batteries and use them only in well
ventilated places.

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4 WA01-0041E
2.Battery fluid (dilute sulfuric acid) may cause loss of
sight or burn injury.
If battery fluid stains an eye, skin, or clothes,
immediately wash down them with a great deal
of water.
If battery fluid enters into an eye, immediately
wash it down with water and see a doctor for
medical aid.
3.When removing terminals, remove the minus (－)
terminal first. When connecting terminals,
connect minus (－) terminal last.
3.3 Handling of radiator
1.Don't open the radiator cap while the coolant is still
hot.
2.Check the coolant at the reservoir tank.
3.If high-pressure water is used for radiator cleaning,
fins may be damaged.
3.4 Cooling fan
1.Stop the engine completely before checking the
tension of the engine fan belt.
2.The oil cooler fan may rotate the moment the
engine is started. Be sure to pull out the ignition
key before accessing the cooling fan.
4. About waste disposal
1.Waste oils, used filters, and other such
petrochemical-related products, if disposed of
thoughtlessly, will cause environmental
contamination.
2.Obtain a proper-sized vessel before releasing
waste oils from the machine. Never discharge
waste oils on the ground or into rivers, lakes or
marshes.
3.Follow all governing environmental rules and
regulations when disposing of oils, fuels, cooling
water, brake fluid, solvents, filters, batteries or any
other damaging substances.
4.1 Gasoline
1.Spill or leak: Review fire and explosion hazards
before proceeding with clean up. Use appropriate
personal protective equipment during clean up.
Dike spill. Prevent liquid from entering sewers,
waterways, or low areas. Soak up with sawdust,
sand, oil dry or other absorbent material. Shovel or
sweep up.
2.Remove source of heat, sparks, flame, impact,
friction or electricity including internal combustion
engines and power tools. If equipment is used for
spill cleanup, it must be explosion proof and
suitable for flammable liquid and vapor.
Note: Vapors released from the spill may create an
explosive atmosphere.
3.Waste disposal method: Treatment, storage,
transportation and disposal must be in accordance
with applicable federal, state, provincial, and local
regulations. Do not flush to surface water or
sanitary sewer system.
4.By itself, the liquid is expected to be a RCRA
ignitable hazardous waste.
4.2 Hydraulic oil
1.Spill of leak: Contain spill immediately in smallest
area possible. Recover as much of the product
itself as possible by such methods as vacuuming,
followed by soaking up of residual fluids by use of
absorbent materials. Remove contaminated items
including contaminated soil and place in proper
containers for disposal. Avoid washing, draining or
directing material to storm or sanitary sewers.
2.Waste disposal method: Recycle as much of the
recoverable product as possible. Dispose of
nonrecyclable material as a RCRA hazardous
waste by such methods as incineration, complying
with federal, state, and local regulations.
4.3 Motor oil
See HYDRAULIC OIL above.

Foreword
1 WA04-2070E
Foreword
This service manual describes the composition of the Model TR-800XXL-4 rough terrain crane, its repair, check
and adjustment methods and other relevant matters. Note that this service manual does not provide the
information in the separate service manuals given below.
This service manual applies to the cranes with the specification numbers given below. 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. NO.
SPEC. NO. SERIAL.
KAGAWA, JAPAN
NO.
MFG.DATE.
ISA04-001601
Spec. No. Applicable serial No.
GR-800-1-00211 545870--
2. Separate service manual
Separate Service Manual Information No.
General Cautions SA01-01-2E
Load Moment Indicator (AML) W301-0136E
Multiplex Data Transmitter W303-0257E
Torque Converter
Transmission W561-0101E
Driving Axle W563-0052E
Please note that, for product improvement, some changes may have been
incorporated in the machine that are not covered in this manual.

2 WA04-2070E
Foreword
3. Outline of specifications
Spec. No.
Item GR-800-1-00211
2M2D
(North America)
No. of boom sections 5
No. of jib stages 2
Single top Option
Main winch Fitted
Auxiliary winch Fitted
Winch brake Automatic brake (Neutral brake)
Winch
Drum rotation indicator Touch-type (Option)
Weight Counterweight Removable type
Load moment indicator (AML) AML-L2C
Auto. stop solenoid valve energizing type Normally energized
AML external indicator lamp Fitted
Oil cooler Fitted
Air conditioner Option
Emergency steering Option
Engine model MITSUBISHI 6M60-TLA3B
Tires 29.5 × 25 - 22PR, 29.5 × 25 - 28PR

3 WA04-2070E
Foreword
4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km
1 0.1 0.001 0.03937 0.00328 1 1.6093
10 1 0.01 0.3937 0.03281 0.6214 1
1000 100 1 39.37 3.281
25.4 2.54 0.0254 1 0.08333
304.8 30.48 0.3048 12 1
Area
square millimeter, mm2square centimeter, cm2square meter, m2square inch, in2square foot, ft2
1 0.01 0.000001 0.00155
100 1 0.0001 0.155 0.001076
1000000 10000 1 1550 10.764
645.2 6.452 0.000645 1 0.006944
92903 929.03 0.0929 144 1
Volume
cubic
centimeter,
cm3, cc cubic meter, m3cubic inch, in3cubic foot, ft3gallon,
gal cubic inch, in3liter, lit, L
1 0.000001 0.0610 0.0000353 1 231 3.785
1000000 1 61024 35.31 0.004329 1 0.01639
16.39 0.0000164 1 0.000579 0.2642 61.02 1
28320 0.02832 1728 1
Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, ton, t short ton, s. t
1 0.001 0.03527 0.0022
1000 1 35.27 2.205 0.001 0.001102
28.349 0.02835 1 0.0625 0.00002835 0.00003125
453.592 0.4536 16 1 0.0004536 0.0005
1000000 1000 35274 2205 1 1.102
907185 907.2 32000 2000 0.9072 1
Pressure
Pa kPa MPa kgf/cm2lbf/in2, psi
1 1X10-3 1X10-6 1.01972X10-5 14.5X10-5
1X1031 1X10-3 1.01972X10-2 14.5X10-2
1X1061X1031 1.01972X10 14.5X10
9.80665X1049.80665X10 9.80665X10-2 1 14.22
6895 6.895 0.006895 0.07031 1

4 WA04-2070E
Foreword
Work, energy
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
inch-pound,
in-lbf
1 1X10-2 1.01972X10-1 1.01972X10-3 0.00737 0.0885
1X1021 1.01972X10 1.01972X10-1 0.7376 8.851
9.80665 9.80665X10-2 1 1X10-2 0.0723 0.868
9.80665X1029.80665 1X1021 7.233 86.8
135.58 1.3558 13.83 0.1383 1 12
11.3 0.113 1.1525 0.01153 0.08333 1
Centigrade-Fahrenheit
゜F ℃゜F ℃゜F ℃゜F ℃゜F ℃゜F ℃
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -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: toC=5(ToF-32)/9, ToF=(9×toC+160)/5
Force
N kgf lbf
1 1.01972X10-1 2.24809X10-1
9.80665 1 2.20461
4.44822 0.45359 1

5 WA04-2070E
Outrigger System
Swing System
Boom Elevating System
Winch System
Boom Telescoping System
Safety System
Cab
Control System
Steering System
Brake System
Suspension System
System Diagrams
Data, Adjustment and Checks
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
A
GROUP INDEX
Hydraulic Power Generating System

6 WA04-2070E
Foreword
5. Contents
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
General
General Cautions Refer to separate manual SA01-01-2E
A
Hydraulic Power Generating System
Hydraulic Power Generating System B-1
Hydraulic Pump
(Double Variable Displacement Pump) B-2
Hydraulic Pump
(Double Gear Pump) B-3
Hydraulic Pump
(Gear Pump, Emergency Steering) (Option) B-4
Hydraulic Valve (Emergency Steering)
(Option) B-5
Flow Control Valve B-6
Pressure Reducing Valve (Pilot Pressure) B-7
Solenoid Control Valve (Outrigger) B-8
Rotary Joint B-9
Hydraulic Pilot Control Valve
(Elevating, Telescoping, Winch) B-10
Sequence Valve (Pilot Pressure) B-11
Solenoid Valve(Pilot Pressure) B-12
Solenoid Control Valve (Jib Set) B-13
Pilot Check Valve (Jib Set) B-14
Solenoid Valve (Oil Cooler) B-15
B
Hydraulic Motor (Oil Cooler) B-16

7 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Hydraulic Power Generating System
Jib Lock pin B-17
Jib Offset Cylinder B-18
Check valve (Gauge Isolator) B-19
B
Outrigger System
Outrigger System C-1
Jack Cylinder C-2
Pilot Check Valve
(Jack Cylinder Retracting Prevention) C-3
Extension Cylinder C-4
(UCHIDA) C-5
(TOKIMEC) C-6
Solenoid Valve (Slide/Jack)
(NACHI) C-7
C
Check Valve
(Outrigger Extending Prevention) C-8
Swing System
Swing System D-1
Swing Assembly D-2
Hydraulic Pilot Control Valve (Swing) D-3
Hydraulic Motor (Swing) D-4
D
Swing Speed Reducer D-5

8 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Boom Elevating System
Elevating System E-1
Elevating Cylinder E-2
Counterbalance Valve (Elevating) E-3
E
Winch system
Winch System F-1
Winch F-2
Hydraulic Motor (Winch) F-3
Counterbalance Valve (Winch) F-4
F
Hydraulic Valve (Winch Brake Release) F-5
Boom Telescoping system
Telescoping System G-1
Boom (Five-Section Boom) G-2
Jib G-3
Telescoping Cylinder G-4
Counterbalance Valve (Telescoping) G-5
Hose Reel G-6
Hydraulic Valve G-7
G

9 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Safety System
Safety System H-1
Load Moment Indicator (AML) Refer to separate manual W301-0136E
Boom Length and Angle Detector H-2
Outrigger Extension Length Detector H-3
H
Solenoid Valve (Auto Stop) H-4
Cab
Crane Cab Glass K-1
Air Conditioner (Option) K-2
Hydraulic Motor(Air conditioner, Option) K-3
Solenoid Valve(Air conditioner, Option) K-4
K
Control System
Control System L-1
Remote Control Valve (Lever) L-2
Remote Control Valve (Pedal) L-3
Shuttle Valve (Lever, Pedal) L-4
Solenoid Valve
(Boom Telescoping/Aux. Hoist) L-5
Solenoid Control Relief Valve
(Elevating Slow Stop) L-6
Solenoid Valve (Air) L-7
L

10 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Electrical System
N Multiplex Data Transmitter (MDT) Refer to separate manual W303-0257E
Driving Power Transmission System
Torque Converter and Transmission Refer to separate manual W561-0101E
R
Driving Axle Refer to separate manual W563-0052E
Steering System
Steering System S-1
Priority Valve S-2
Orbitrol S-3
Steering Cylinder S-4
Solenoid Valve (Steering Mode) S-5
S
Pilot Check Valve
(Rear Steering Cylinder Lock) S-6
Brake System
Brake System T-1
Brake (Service Brake) T-2
Brake Valve T-3
Booster (Brake) T-4
Air Dryer T-5
Brake (Parking Brake) T-6
Brake Chamber T-7
T
Solenoid Valve (Air) T-8

11 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Suspension System
Suspension System U-1
Suspension Lock Cylinder U-2
Pilot Check Valve
(Suspension Lock Cylinder) U-3
Solenoid Valve
(Suspension Lock Check Release) U-4
U
Data, Adjustment and Checks
Hydraulic Pressure Setting Table Y-1
Air Pressure Setting Table Y-2
Air Bleeding Procedure Y-3
Electric Switch Adjustment Y-4
Adjustment and Checks Y-5
Check (Crane Operation) Y-6
Check (Driving Devices) Y-7
Oils and Grease Table Y-8
Mass Table Y-9
Specifications Y-10
Boom Connecting Pin and Thread Size
Table Y-11
Y

12 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
System Diagrams
Hydraulic Circuit Z-1
Torque Converter Circuit Z-2
Brake Circuit (Pneumatic Circuit) Z-3
Electric Circuit (AML, Crane) Z-4
Electric Circuit (MDT, Carrier/Upper) Z-5
Electric Circuit (MDT, Carrier/Lower) Z-6
Location of Installation
Location of Hydraulic Parts (Upper) Z-7
Location of Hydraulic Parts (Lower) Z-8
Location of Air Parts Z-9
Location of Electric Parts (Inside Cab) Z-10
Location of Electric Parts
(Swing Table, Boom) Z-11
Location of Electric Parts
(RelayAssembly/Upper) Z-12
Location of Electric Parts (AML) Z-13
Location of Electric Parts (Lower) Z-14
Location of Electric Parts
(Box Assembly/Lower) Z-15
Harness Diagrams
Harness (Connector No. Table) Z-16
Harness (Inside Cab) Z-17
Z
Harness (Swing Table, Left) Z-18

13 WA04-2070E
Foreword
Spec. No.
Chapter Section
GR-800-1-00211
2M2D
(North America)
Harness (Swing Table, Right) Z-19
Harness (Boom) Z-20
Harness (AML, Upper) Z-21
Harness (Overwind) Z-22
Harness (Lower, Main) Z-23
Harness (Lower, Sub) Z-24
Z
Harness (Lower, Electronic Governor) Z-25

i
B
Hydraulic Power Generating System
Contents
B-1 Hydraulic Power Generating System
..................................................1
1. General..................................................... 1
B-2 Hydraulic Pump (Double Variable
Displacement Pump)...............4
1. Structure................................................... 4
2. Theory of operating of regulator section.. 10
3. Air bleeding procedure............................ 12
B-3 Hydraulic Pump
(Double Gear Pump)..............13
1. Structure................................................. 13
2. Air bleeding procedure............................ 15
B-4 Hydraulic Pump (Gear Pump,
Emergency Steering).............16
1. Structure................................................. 16
B-5 Hydraulic Valve (Emergency
Steering) (Option)..................17
1. Structure................................................. 17
B-6 Flow Control Valve.........................19
1. Structure .................................................19
B-7 Pressure Reducing Valve
(Pilot Pressure)......................20
1. Structure .................................................20
B-8 Solenoid Control Valve
(Outrigger)..............................21
1. Structure .................................................21
B-9 Rotary Joint....................................26
1. Structure .................................................26
2. Potentiometer..........................................33
2.1 Adjustment................................................33
2.2 Soldering...................................................33
B-10Hydraulic Pilot Control Valve
(Elevating, Telescoping, Winch)
.................................................34
1. Structure .................................................34
B

ii
B-11Sequence Valve (Pilot Pressure)..46
1. Structure................................................. 46
B-12Solenoid Valve (Pilot Pressure)....49
1. Structure................................................. 49
B-13Solenoid Control Valve (Jib Set)...51
1. Structure................................................. 51
B-14Pilot Check Valve (Jib Set)............57
1. Structure................................................. 57
B-15Solenoid Valve (Oil Cooler)...........58
1. Structure................................................. 58
B-16Hydraulic Motor (Oil Cooler).........60
1. Structure................................................. 60
2. Air bleeding procedure............................ 60
B-17Jib Lock Pin....................................61
1. Structure................................................. 61
B-18Jib Offset Cylinder.........................62
1. Structure................................................. 62
B-19Check Valve (Gauge lsolator).......63
1. Structure................................................. 63