TM ZR860 1 - S1 1e

Publication No.
TM-ZR860-1/S1-1E
01
Cargo Crane
Model TM-ZR860-1
Applicable Serial No. 655980--
Safety
Safety
Most accidents that occur during machine operation [NOTICE]
and maintenance are caused by failure to observe [NOTICE] indicates an important operational or
basic safety rules and precautions. Before operating maintenance procedure or condition, which, if not
strictly observed, can result in damage to machine
your machine or performing maintenance, read and
components or deteriorated machine performance.
become familiar with all the safety precautions and
recommendations given in this section. It is virtually impossible to anticipate every situation
Remember that failure to observe even a single pre- that might present a hazard. The safety precautions
caution could involve you and the people around the given in this manual and on the machine labels are
machine in a serious accident. not exhaustive.
Foreseeing potential dangers is vital for preventing It is important, therefore, to strictly follow the instruc-
accidents. All personnel working with the machine, tions in this manual and be sensitive to potential dan-
including the supervisor, machine operator and oiler, gers in order to prevent bodily injury and damage to
should be sensitive to potentially dangerous situations the machine.
and take the necessary measures to prevent Remember that your most important duty is to ensure
accidents. the safety of you, your co-workers and any other peo-
Safety precautions and recommendations are outlined ple in the area.
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 identi-
fied as "DANGER", "WARNING", "CAUTION" or "NO-
TICE". These terms are defined as follows:
DANGER
DANGER indicates an imminently hazardous
situation, which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation, which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in
a minor or moderate injury.
1 WA01-0041E
Safety
1. Fundamental cautions fatal accidents, as there is a possibility that the

vehicle loses its balance and falls down on a
Servicemen inexperienced in the units of this machine worker in a dismounting process of certain units.
should be cautious about safety operations. They
must acquire sufficient knowledge about the equip- 7.When the working is done on a team of more than
ment before dismounting and disassembling it. one person, make arrangements about
Before dismounting each component, a serviceman co-operation and communication between workers
should read this service manual thoroughly and find beforehand. Give a sign without fault and make
out the weight of the component, then lift it by proper sure that the sign has been transmitted to other
means. workers before starting the next operation.
The following are cautions to be observed all the time. 8.When it is inevitable to measure oil pressure,
rotational speed, and temperature for machine
1.Before starting repairs, find out the origin of the
inspection without stopping the engine, be careful
problem. When it becomes clear that
not to be caught or pinched in rotating or moving
disassembly and maintenance are necessary, first
parts such as a fan, fan belt. Make sure that
of all read this manual and parts catalog and
there is no obstruction or no person around the
thoroughly understand the principle of operation
machine before operating it.
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, 2. Cautions in working
new troubles or decline in performance may be
induced. 2.1 General
2.Before operating the machine, oiling or repairing, 1.When hoisting up components weighing more than
read warning labels and instructions on the 20 kg, use hoist or the like to prevent injury to your
machine and understand the contents. lumbar or spine. For specific components, their
weights are listed on the chapter for "service data"
3.Wear a safety helmet and safety shoes whenever
in this manual.
you carry out maintenance operation around the
machine. Be sure to wear safety goggles when 2. When using eyebolts, lift parts vertically so that
you hit the machine or its attachments with a only tension is applied to them.
hammer. In welding operation, wear safety gears
such as leather gloves, helmet, goggles, apron 3.Protect wire ropes and plastic lifting slings by
and proper working clothes, but don't wear loose covering corners with pads so that they are not
or torn clothes. Take a ring and so on off your bent sharply by directly contacting corners.
finger when you conduct maintenance or repair. Keep the sling angle of wire ropes within 60°and
as vertical as possible.
4.Park the machine on as level and hard ground as
possible. Place chocks under wheels to prevent 4.Be careful about hot or heated portions when
the vehicle from moving when doing maintenance conducting repair or maintenance just after the
on or below the machine. vehicle has stopped or the machine operation has
been finished or interrupted.
5.Before starting maintenance, remove cables to the
battery and allow the capacitors to discharge. 5.When hitting parts, be sure to either hit on a pad
Pull out the ignition key and hang a tag saying, placed on the parts or use a plastic hammer.
"Don't start the engine." in the cab.
6.Put units, especially similar parts, in order. Mark
6.Don't carry out maintenance while lifting the them with tags or a marker if necessary.
vehicle with only a jack or a hoist. Sustain the
vehicle positively with blocks and so on to prevent
2 WA01-0041E
Safety
7.Put disassembled parts in order so that parts such In case that the position of the center of gravity is
as bolts are not left behind in the machine. And not clear and there is a possibility of swing of load
check that no parts run short at assembly. after removing, use two hoists.
8.Watch your step in the following cases: 8.If a part cannot be lifted smoothly, make sure that
all the fasteners are removed and other parts don't
When stepping up to or stepping down from the
hinder removing.
upper surface of a boom for replacing wire ropes
and applying grease. Be careful not to stumble 2.3 Remounting and assembling
on protrusions on the upper surface of a boom.
When greasing at the root of a elevating cylinder 1.Before assembling, clean all the parts and repair
When checking engine oil, radiator coolant, or or replace defective parts.
battery fluid.
2.As dirt and soil adversely affect sliding portions
When replacing a filter of air cleaner.
and they may decrease the life of the machine,
When getting on and off the cab.
pay special attention to avoid intrusion of dirt and
Be careful not to slip in the above operations in soil.
winter as snow and ice may attach to the exterior
3.Use special tools for parts when specified to do so.
of boom and it becomes very slippery.
4.Remove dirt, soil, water, and resin completely from
2.2 Dismounting and disassembling surfaces where liquid gasket will be applied.
1.Before dismounting and disassembling, make sure 5.After remounting, be sure to inspect the machine
of the construction and part sales unit by reading and verify that there is no error by oversight. If
this manual and the separate parts catalog, then adjustment or air bleeding is required, conduct it
understand the procedures of dismounting and according to instructions. Conduct function and
remounting and disassembling and reassembling. performance test to verify its integrity.
2.When dismounting piping or equipment that may
contain pressurized oil or air, be extremely
cautious and dismount them only after discharging 3. Cautions in operation
the confined pressure.
3.Before removing, clean the part to be dismounted 3.1 Brake fluid replenishment
and the area surround it. Seal the opening with a
1.When the brake-warning lamp (for fluid level) is
plug or tape, etc. to prevent foreign material from
lighted, replenish brake fluid and check and make
entering it.
sure of the thickness of disk brake pads. (Refer
4.Measure and record the data such as shim to Chapter Y for periodical inspection periods.)
thickness adjustment and pre-load at disassembly
2.Check the thickness of disk brake pads whenever
that will be required at reassembly.
brake fluid is replenished.
5.If required, before disassembling clearly put marks
to avoid errors at reassembling. 3.2 Handling of battery
6.If a part cannot be removed after removing bolts or 1.Erroneous handling of a battery may cause it to
nuts fixing it, don't apply too much force to it but catch fire and explode.
check the part for the cause. Only after relieving Be extremely sure to avoid short circuits, sparks
the cause, proceed disassembling. and fire of cigarettes and the like when using a
jumper cable. They are very dangerous.
7.Use lifting slings appropriate for the weight and Charge up batteries and use them only in well
characteristics of a part. Lift up it in balanced ventilated places.
condition.
3 WA01-0041E
Safety
2.Battery fluid (dilute sulfuric acid) may cause loss of 4.1 Gasoline
sight or burn injury.
1.Spill or leak: Review fire and explosion hazards
If battery fluid stains an eye, skin, or clothes,
before proceeding with clean up. Use appropriate
immediately wash down them with a great deal
personal protective equipment during clean up.
of water.
Dike spill. Prevent liquid from entering sewers,
If battery fluid enters into an eye, immediately
waterways, or low areas. Soak up with sawdust,
wash it down with water and see a doctor for
sand, oil dry or other absorbent material. Shovel or
medical aid.
sweep up.
3.When removing terminals, remove the minus (–)
2.Remove source of heat, sparks, flame, impact,
terminal first. When connecting terminals,
friction or electricity including internal combustion
connect minus (–) terminal last.
engines and power tools. If equipment is used for
spill cleanup, it must be explosion proof and
3.3 Handling of radiator
suitable for flammable liquid and vapor.
1.Don't open the radiator cap while the coolant is still
Note: Vapors released from the spill may create an
hot.
explosive atmosphere.
2.Check the coolant at the reservoir tank.
3.Waste disposal method: Treatment, storage,
3.If high-pressure water is used for radiator cleaning, transportation and disposal must be in accordance
fins may be damaged. with applicable federal, state, provincial, and local
regulations. Do not flush to surface water or
3.4 Cooling fan sanitary sewer system.
1.Stop the engine completely before checking the 4.By itself, the liquid is expected to be a RCRA
tension of the engine fan belt. ignitable hazardous waste.
2.The oil cooler fan may rotate the moment the

4.2 Hydraulic oil
engine is started. Be sure to pull out the ignition
key before accessing the cooling fan. 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,
4. About waste disposal followed by soaking up of residual fluids by use of
absorbent materials. Remove contaminated items
1.Waste oils, used filters, and other such
including contaminated soil and place in proper
petrochemical-related products, if disposed of
containers for disposal. Avoid washing, draining or
thoughtlessly, will cause environmental
directing material to storm or sanitary sewers.
contamination.
2.Waste disposal method: Recycle as much of the
2.Obtain a proper-sized vessel before releasing
recoverable product as possible. Dispose of
waste oils from the machine. Never discharge
nonrecyclable material as a RCRA hazardous
waste oils on the ground or into rivers, lakes or
waste by such methods as incineration, complying
marshes.
with federal, state, and local regulations.
3.Follow all governing environmental rules and
regulations when disposing of oils, fuels, cooling 4.3 Motor oil
water, brake fluid, solvents, filters, batteries or any See HYDRAULIC OIL above.
other damaging substances.
4 WA01-0041E
Foreword
Foreword
Boom nameplate
This service manual describes the systems and (1) Boom specification number
components of the TM-ZR860 series cranes, its repair, (2) Serial number
check and adjustment methods and other relevant
matters.
Read the separate operation and maintenance manual,

the mounting manual and the parts catalog for repair
and maintenance of the crane in conjunction with this Frame nameplate
manual. (1) Model
(2) Frame specification number
When carrying out repairs, check the parts catalog for
(3) Serial number
structure and sales units of the parts beforehand. (4) Date of mounting
(5) ID number of the dealer
1. Applicable specification number

The unit Nos. of the cranes to which this manual is
applicable are listed below. Check the unit No. of your
crane on the nameplate attached to the crane before
using this manual.
Boom Frame
Model specification specification 2. Separate service manual
number number
The repair manual documents for your crane are
TM-ZR865RS comprised of this manual and the separate documents

(TM-86Z-1- 410-491-05185 410-491-04185 listed below.
03185)
Separate service
Publication No.
TM-ZR865RS manual
(TM-86Z-1- 410-491-05185 410-491-04285
03285) General Cautions SA01-01-2E
Error Code List ERROR_CODE_LIST(TM)-1E
Please note that, for product improvement, some

changes may have been incorporated in the
machine that are not covered in this manual.
1 WA04-2950E
Foreword
3. Outline of specifications
Specification number
Item TM-86Z-1-03185 TM-86Z-1-03285
(For Taiwan) (For Australia)
No. of boom sections 5-section
Hydraulic motor driven, spur gear speed reduction,

Winch
provided with automatic brake and cable follower
Outriggers extended width Min. 2,250mm Mid. 3,500mm Max. 4,800mm
Operation Radio remote controls
Maximum lifting capacity 8,200 kg
AML (Automatic Moment Limiter) AML (Automatic Moment Limiter)

Load indication Load indication
Warning alarm Warning alarm
Over load limiter Over load limiter
WHL (Working Height Limiter) WHL (Working Height Limiter)
Load meter Load meter
Load indicator Radius indicator
Emergency stop switch on radio controller Emergency stop switch on radio controller
Terminal for emergency stop switch Terminal for emergency stop switch
Safety devices
Over-winding alarm Over-winding alarm
Hoisting limiter Hoisting limiter
P.T.O indicator lamp P.T.O indicator lamp
Hook safety latch Hook safety latch
Hydraulic safety valves, check valves and Hydraulic safety valves, check valves and
holding valves holding valves
Level gauge Level gauge
Jack interlock
2 WA04-2950E
Foreword
4. Conversion table
Length
millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’ mile, mi kilometer, km
-1 -3 -2 -3
1 1×10 1×10 3.93701×10 3.28084×10 1 1.60934
-2 -1 -2 -1
1×10 1 1×10 3.93701×10 3.28084×10 6.21373×10 1
3 2
1×10 1×10 1 3.93701×10 3.28084
-2
2.54×10 2.54 2.54×10 1 8.33333×10-2
3.048×102 3.048×10 3.048×10-1 1.2×10 1
Speed
km/h mile/h
1 6.21373×10-1
1.60934 1
Area
square millimeter, mm2 square centimeter, cm2 square meter, m2 square inch, in2 square foot, ft2
1 1×10-2 1×10-6 1.55×10-3 1.07639×10-5
1×102 1 1×10-4 1.55×10-1 1.07639×10-3
1×106 1×104 1 1.55×103 1.07639×10
2 -4
6.4516×10 6.4516 6.4516×10 1 6.94444×10-3
9.2903×104 9.2903×102 9.2903×10-2 1.44×102 1
Volume
cubic centimeter,
cubic meter, m3 cubic inch, in3 cubic foot, ft3 gallon, gal cubic inch, in3 liter, lit, L
cm3, cc
1 1×10-6 6.10237×10-2 3.53147×10-5 1 2.31×102 3.78541
6 4 -3
1×10 1 6.10237×10 3.53147×10 4.329×10 1 1.63871×10-2
1.63871×10 1.63871×10-5 1 5.78704×10-4 2.64172×10-1 6.10237×10 1
2.83168×104 2.83168×10-2 1.728×103 1
Force
N kgf lbf
-1
1 1.01972×10 2.24809×10-1
9.80665 1 2.20462
-1
4.44822 4.53592×10 1
Mass
gram, g kilogram, kg ounce, oz pound, lb metric ton, 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
1×103 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
3 WA04-2950E
Foreword
Pressure
Pa kPa MPa kgf/cm2 lbf/in2, psi
1 1×10-3 1×10-6 1.01972×10-5 1.45038×10-4
1×103 1 1×10-3 1.01972×10-2 1.45038×10-1
1×106 1×103 1 1.01972×10 1.45038×102
9.80665×104 9.80665×10 9.80665×10-2 1 1.42233×10
3 -3 -2
6.89476×10 6.89476 6.89476×10 7.03072×10 1
bar MPa kgf/cm2

1 1×10-1 1.01972
1×10 1 1.0972×10
-1 -2
9.80665×10 9.80655×10 1
Torque
inch-pound,
N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf
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
-2 -2 -2
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10-1
9.80665×102 9.80665 1×102 1 7.23301 8.67961×10
2 -1
1.35582×10 1.35582 1.38255×10 1.38255×10 1 1.2×10
-1 -2 -2
1.12985×10 1.12985×10 1.152513 1.15213×10 8.33333×10 1
N-m kgf-m ft-lbf

-1
1 1.01972×10 7.37562×10-1
9.80665 1 7.23301
-1
1.35582 1.38255×10 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(ToF-32)/9, T°F=(9×t°C+160)/5
4 WA04-2950E
5. Group index
A
B Hydraulic Power Generating System
C Outrigger System
D Swing System
E Boom Elevating System
F Winch System
G Boom Telescoping System
H Safety System
V Radio-control System
Y Data, Adjustment and Checks
Z System Diagrams
5 WA04-2950E
Foreword
6. Contents
Chapter Section TM-86Z-1-03185 TM-86Z-1-03285
General
A General Cautions Refer to separate service manual
Hydraulic Power Generating System
Manual Control Valve (Outrigger) B-1
Center Joint B-2
Outrigger System
Jack Cylinder C-1
C Pilot Check Valve (Jack) C-2
Power Slide Cylinder C-3
Swing System
Hydraulic Motor (Swing) D-1
D Swing Speed Reducer D-2
Swing Bearing D-3
Boom Elevating System
Boom Elevating Cylinder E-1

E
Counterbalance Valve (Elevating) E-2
6 WA04-2950E
Foreword
Winch System
Hydraulic Motor (Winch) F-1

F
Winch F-2
Boom Telescoping System
Boom (Five-section boom) G-1
G Telescoping Cylinder (Five-section boom) G-2
Counterbalance Valve (Telescoping) G-3
Safety Devices
Error Code List Refer to separate service manual
AML (Automatic Moment Limiter) H-1

H
Length Detector (Boom) H-2
Angle Detector (Boom) H-3
Radio-control System
Configurations of Radio-control System V-1
Radio-control Valve V-2

V
Accelerator Cylinder V-3
Action Against Emergency V-4
7 WA04-2950E
Foreword
Data, Adjustment and Checks
Service Data Y-1
Y Adjustment (Hydraulic) Y-2
Adjustment (Electric) Y-3
System Diagrams
Hydraulic Circuit Z-1
Electric Circuit Z-2
Z Location of Hydraulic Parts Z-3
Location of Electrical Parts Z-4
Harness Z-5
8 WA04-2950E
Foreword
7. Name of each part
9 WA04-2950E
Foreword
10 WA04-2950E
B B
Hydraulic Power Generating System
Contents
B-1 Manual Control Valve

(Outrigger)................................ 1
1. Structure .................................................... 1
B-2 Center Joint ...................................... 4
1. Structure .................................................... 4
i
B-1 B-1
Manual Control Valve (Outrigger)
B-1 Manual Control Valve (Outrigger)
[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.
1. Structure
General view
1. Cover assembly 4. Valve assembly 6. Relief valve 9. Valve assembly

2. Valve assembly (Front-right) 7. O-ring (Rear-right)
(Extension/retraction) 5. Valve assembly 8. Bolt 10. Valve assembly
3. Valve assembly (Front-left) (Rear-left)
1 W113-0422E
B-1 B-1
Extension/retraction
33. O-ring 38. O-ring 42. Spool end 45. Hexagon socket head bolt
34. Oil seal 40. Retainer (Spring) 43. Cover 46. Hexagon socket head bolt
37. Retainer 41. Spring 44. Cover 57. Bracket
Front-right
33. O-ring 44. Cover 67. Spool end 70. Retainer

34. Oil seal 45. Hexagon socket head bolt 68. Case 71. Steel ball
39. Retainer 66. Retainer 69. Spring 75. Hexagon socket head bolt
43. Cover
2 W113-0422E
B-1. B-1.
Front-left
Rear-right
Rear-left
33. O-ring 39. Retainer 66. Retainer 70. Retainer

34. Oil seal 43. Cover 67. Spool end 71. Steel ball
37. Retainer 44. Cover 68. Case 75. Hexagon socket head bolt
38. O-ring 45. Hexagon socket head bolt 69. Spring
Relief valve
83. Spring 85. O-ring 90. Spring

84. O-ring 86. O-ring 94. O-ring
Thread size and tightening torque
Tightening torque
Sign / Port Thread size Remarks
N-m kgf-m ft-lbf
A, B, C port G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
E, P, T, V port G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.6
G port G1/4 26.4 - 32.4 2.7 - 3.3 19.4 - 23.8 Pressure gauge
366-379-10000 △
0
3 W113-0422E
B-2 B-2 B-2
Center Joint
B-2 Center Joint
1. Structure
General view
4 W181-0520E 4
B-2. B-2.
Center Joint
1. Body 7. Spring washer 13. Plate (3 poles) 19. Bolt

2. Core 8. Bolt 14. Plate 20. Cap
3. Packing 9. Plain washer 15. Support 21. Plate
4. Ring seal 10. Connecter (2 poles) 16. Bolt 22. Harness (For 2 poles)
5. Slip ring assembly 11. Plate (2 poles) 17. Spring washer 23. Harness (For 3 poles)
6. Bolt 12. Connecter (3 poles) 18. Plate 24. Harness (For 4 poles)
25. Connecter (4 poles)
26. Plate (4 poles)
Tightening torque
Sign / Port Thread size
N-m kgf-m ft-lbf
A2, B2, A4, B4 G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
A3, B3 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7
Body side Rc3/8 44.1 - 61.7 4.5 - 6.3 32.5 - 45.5

D1
Core side Rc1/4 19.6 - 34.3 2.0 - 3.5 14.5 - 25.3
316-318-90001 △
0
5 W181-0520E
C C
Outrigger System
Contents
C-1 Jack Cylinder .................................. 1
1. Structure .................................................... 1
2. Tightening torques (check valve) ............... 1
C-2 Pilot Check Valve

(Jack) ........................................ 2
1. Structure .................................................... 2
C-3 Power Slide Cylinder ..................... 3
1. Structure .................................................... 3
i
C-1. C-1.
Jack Cylinder
C-1 Jack Cylinder
[NOTICE]
1. Structure
General view
1. Cylinder 4. Backup ring 7. Plain bearing 10. Rod cover

2. Piston 5. O-ring 8. Rod 11. Packing
3. Packing 6. Backup ring 9. O-ring 12. Backup ring
13. Dust seal
2. Tightening torques (check valve)
Check valve
Tightening torque:
43.1-49.0 N•m (4.4-5 kgf•m)
(31.7-36.1 ft•lbf)
IW151-0242E02
360-348-10000 △
0
1 W151-0244E
C-2. C-2.
Pilot Check Valve (Jack)
C-2 Pilot Check Valve (Jack)
[NOTICE]
1. Structure
General view
1. Plug 3. Spring 5. Piston 7. Body

2. O-ring 4. Poppet 6. O-ring
Tightening torque
N-m kgf-m ft-lbf
A, B port G1/4 26.4 - 32.4 2.7 - 3.3 19.5 - 23.9
Plug-1 G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
Mounting bolt M10 43 - 49 4.4 - 5.0 31.7 - 36.1
366-239-30000 △
1
2 W115-0353E
C-3. C-3.
Power Slide Cylinder
C-3 Power Slide Cylinder
[NOTICE]
1. Structure
General view
1. Dust seal 4. O-ring 7. Rod 10. Backup ring

2. ------------- 5. Rod cover 8. Piston 11. O-ring
3. Packing 6. Cylinder 9. Packing 12. Nut
360-435-20001 △
0
3 W153-0220E
D
Swing System D
Contents
D-1 Hydraulic Motor (Swing).................. 1
1. Structure .................................................... 1
2. Disassembly .............................................. 2
3. Reassembly ............................................... 2
4. Operation test ............................................ 2
D-2 Swing Speed Reducer ..................... 3
1. Structure .................................................... 3
2. Dismounting and remounting..................... 4
3. Disassembly .............................................. 4
D-3 Swing Bearing .................................. 6
1. Structure .................................................... 6
2. Note for installation .................................... 7
i
D-1 D-1
Hydraulic Motor (Swing)
D-1 Hydraulic Motor (Swing)
[NOTICE]
1. Structure
Drain
Pliot
A B
Lock cylinder assembly
Hydraulic symbol
IW102-0512E01
1. Shaft 6. Oil seal 11. Bottom cover 16. Lock cylinder assembly
2. Bearing 7. Retaining ring 12. Bearing 17. ------
3. Housing 8. Thrust plate 13. Pin 18. ------
4. O-ring 9. Cylinder block 14. O-ring 19. Parallel key
5. Oil seal cover 10. Valve plate 15. Bolt 20. Plug
21. Thread protector
1 W102-0513E
D-1. D-1.
Tightening torque
N-m kgf-m ft-lbf
A, B G3/8 39.2 - 49.0 4.0 - 5.0 28.9 - 36.1
Pilot and Drain G1/4 19.6 - 29.4 2.0 - 3.0 14.5 - 21.7
Mounting bolt M12 68.6 - 82.4 7.0 - 8.4 50.6 - 60.8
2. Disassembly 4. Operation test

1. Loosen the bolts (15) to separate the bottom 1. Run the motor at idling speed under no load for 15
cover (11) about 10 mm (0.4 in). This is necessary to 20 minutes, and check for the following.
to prevent the shaft (1) from popping out by the
• Excessive rise in oil temperature
force of the center spring.
• Unusual noise
2. Remove the retaining ring (7). • Vibration
• Leakage
3. Insert the flat blade of a screwdriver into the slot
of the oil seal cover (5) to remove the oil seal (6). 2. If the test above reveals no fault, gradually
[NOTICE] increase the load up to the maximum operating
Do not pull out the shaft (1). pressure. During this process, check for the above
As it is difficult to engage the male spline teeth of listed four points again.
the shaft (1) with the female ones of the cylinder
block (9), reassembly will be troublesome. 3. At the maximum pressure, run the motor for 1 to 2
minutes and check for abnormality. If there is no
3. Reassembly abnormality, reduce the pressure to the normal
level.
1. Make sure that the O-rings (4) and (14) are placed
in position.
2. Apply grease to the lip area of the oil seal (6).

Install the oil seal (6), together with the oil seal
cover (5), into the housing (3).
3. Securely put the retaining ring (7) into the groove

of the housing (3).
4. Install the bottom cover (11) as before.

[NOTICE]
When putting the retaining ring (7), be sure to place
the rounded edge inside (next to the bearing).
If the rounded edge is place outside, there is a
possibility that the retaining ring may come off
because of an internal force such as spring force
and hydraulic force.
When dismounting and remounting the motor
assembly, always keep it in its horizontal position.
After remounting, fill the motor housing with
hydraulic oil through the drain port. 366-626-00000 △
1
2 W102-0513E
D-2 D-2
Swing Speed Reducer
D-2 Swing Speed Reducer

[NOTICE]
1. Structure
Apply THREE BOND 1215 when shrink-fitting
Fill lithium grease between the lips
(Oil supply
opening) Take care of the installing order
(The seal of the upper bearing is different
from the one of the lower bearing )
Apply THREE BOND 1104
Apply THREE BOND 1305

(Oil exhaust opening)
IW511-014001E
1. Snap ring 8. Seal washer 15. Bearing 22. Pin

2. Spacer 9. Plug 16. Bolt 23. Air breather
3. Shim set 10. Spur gear 17. Key 24. Nameplate
4. Bearing 11. Sleeve 18. Worm wheel 25. Rivet
5. Worm 12. Oil seal 19. Gear case 26. Washer
6. Bearing 13. Gear case 20. Bearing
7. Oil gauge 14. Bearing 21. Nut
3 W511-0173E
D-2 D-2
Swing Speed Reducer
2. Dismounting and remounting

[NOTICE]
When the swing speed reducer is removed, the swing post is freed. Before removing the reducer, fasten the
swing post to the lower frame with a wire rope to prevent its rotation.
Fill the reducer with gear oil (Mobil Gear 632) to the middle point on the oil gauge. (To check the oil level, just
place the gauge on the gauge hole)
Quantity: 1.1 L (0.3 gal)
3. Disassembly
1. Remove plug(9), and drain the oil.
2. Remove oil gauge(7).
3. Remove snap ring-1 and remove spacer(2) and thim set(3).

To facilitate extracting worm(5), turn the spur gear(10) while shaking it slightly.
4. Extract worm(5) together with bearing(4) and(6) toward the motor side.
5. Separate the spur gear(10) and gear case(13) from the gear case(19).
Use the separating tap (M12, coarse thread) to separate them following the procedure below because the
pin(22) is tightly fit. (The separating tap is made on the hole for the bolt(16).)
Put a spacer on the bottom of the separating tap to prevent damage to the hole in the gear case(19) for the
bolt(16).
Then screw a bolt into a separating tap in the gear case(13) to separate the gear case(13) from the gear
case(19).
6. Remove bolt(16), then remove spur gear(10) together with gear case(13) and bearings(14), (15) and (20).
7. Remove nut(21), then remove bearing(20), worm wheel(18), and key(17) from spur gear(10).
8. Remove spur gear(10) from gear case(13), then remove bearings(14) and(15), oil seal(12) and sleeve(11).
Notes for reassembly

With regard to the handling of oil seals and bearings, refer to the separate service manual, "General Cautions"
("Sealing Parts" and "Mechine Elements" sections).
Maintenance Standards
Item Maintenance standards Correction
Bearing damage/wear No vibration/shakiness caused by damage/wear Replace
Backlash between 0.11 - 0.19 mm

Standard value Replace
worm and worm wheel (0.004 - 0.007 in)
4 W511-0173E
D-2. D-2.
Swing Speed Reducer
Tightening torque
N-m kgf-m ft-lbf
7 – 88.3 - 147 9.0 - 15.0 65.1 - 108
9 R3/8 32.4 - 35.3 3.3 - 3.6 23.9 - 26 Seal tape
16 M10 57 5.8 42
Apply adhesive
21 AN11 167 - 216 17.0 - 22.0 123 - 159
(Threebond 1305)
360-813-80000 △
3
360-815-50000 △
1
360-817-50000 △
0
5 W511-0173E
D-3 D-3
Swing Bearing
D-3 Swing Bearing
[NOTICE]
1. Structure
General view
1. Swing bearing 5. Plain washer 9. O-ring 13. Hexagon socket head bolt
2. Bolt 6. Grease nipple 10. Bolt 14. Spring washer
3. Plain washer 7. Cap 11. Plain washer
4. Bolt 8. Swing speed reducer 12. Hydraulic motor
6 W512-0250E
D-3. D-3.
Swing Bearing
2. Note for installation

When installing the inner ring of the swing bearing, face the soft zone (stop plug) to the R position shown in
the figure on the previous page.
To tighten the bolts(2),(4),(10), follow the procedures below.

Tighten all the bolts temporarily with approximately half the specified tightening torque.
Then tighten the bolts securely. After tightening one bolt in this case, tighten the diagonally opposite bolt.

Tightening torque
N-m kgf-m ft-lbf
2 M20 466 - 505 47.5 - 51.5 343.7 - 372.4
Apply a torque control
4 M22 628 - 672 64 - 68.5 463.2 - 495.6 agent to the threaded
sections of the bolts.
10 M16 171 - 200 17.4 - 20.4 126.1 - 147.5
13 M12 68.6 - 82.3 7.0 - 8.4 50.6 - 60.7
313-016-20000 △
0
7 W512-0250E
E
Boom Elevating System
E
Contents
E-1 Boom Elevating Cylinder ................ 1
1. Structure .................................................... 1
E-2 Counterbalance Valve

(Elevating) ................................ 2
1. Structure .................................................... 2
i
E-1. E-1.
Boom Elevating Cylinder
E-1 Boom Elevating Cylinder
[NOTICE]
1. Structure
General view
1. ------- 7. Rod 13. Dust seal 19. Grease nipple

2. Plain bearing 8. Plain bearing 14. Retaining ring 20. Plug
3. Piston 9. O-ring 15. Retaining ring 21. --------
4. Plain bearing 10. Rod cover 16. O-ring 22. Backup ring
5. O-ring 11. Packing 17. Plate 23. Packing
6. Cylinder 12. Backup ring 18. Set screw
360-263-50000 △
2
1 W155-0212E
E-2. E-2.
Counterbalance Valve (Elevating)
E-2 Counterbalance Valve (Elevating)

[NOTICE]
1. Structure
1. Body 5. Spring 9. Plug 13. O-ring

2. Spool 6. O-ring 10. Poppet 14. O-ring
3. Plug 7. Plug 11. Spring
4. Backup ring 8. Plug 12. O-ring
Tightening torque
N-m kgf-m ft-lbf
Plug-3, 9
G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
Port-A, B
Plug - 7 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.6
Mounting bolt M10 34.3 - 39.2 3.5 - 4.0 25.3 - 28.9

366-051-80001 △
3
366-065-50000 △
2
366-055-20000 △
3
366-056-00000 △
2
2 W119-0285E
F
Winch System
FF
Contents
F-1 Hydraulic Motor (Winch) ................. 1
1. Structure .................................................... 1
F-2 Winch ................................................ 3
1. Structure .................................................... 3
i
F-1 F-1
Hydraulic Motor (Winch)
F-1 Hydraulic Motor (Winch)
[NOTICE]
1. Structure
General view
1 W102-0433E
F-1. F-1.
Hydraulic Motor (Winch)
1. Shaft 17. Air bleeding screw 40-1. Body; relief valve 56. Oil seals
2. Bearing 18. O-ring 40-2. Poppet; relief valve 57. Retaining ring
3. Retaining ring 19. O-ring 40-3. Spring seat 58. Spring; brake
4. Housing 20. Bottom cover 40-4. Spring 59. Plate; spring
5. Cam Plate 21. Plug 40-5. O-ring 60. Facing
6. Spring pin 22. Choke M4 40-6. Adjusting screw 61. Disk brake
7. Cylinder barrel assembly 23. Spool; counter balance 40-7. S-nut 62. Retaining ring
7-1. Cylinder barrel 24. Piston 40-8. O-ring 63. Sleeve
7-2. Seat; center spring 25. O-ring 40-9. O-ring 64. Pin
7-3. Center spring 26. Spring washer 41. Spool; change 65. Pin
7-4. Retaining ring 27. Nut 42. Spring seat 66. O-ring
7-5. Plunger 28. Spring seat 43. Spring; change 67. Backup ring
7-6. Plunger bearing 29. Counter balance piston 44. Plug; change 68. O-ring
8. Pin; cylinder barrel 30. Return spring 45. O-ring 69. Backup ring
9. Plunger holder assembly 31. Return spring 46. Cap; check valve 70. Piston
9-1. Plunger holder 32. Cap 47. O-ring 71. O-ring
9-2. Spherical ring 33. O-ring 48. Hexagon socket head bolt 72. Spring washer
10. Parallel pin 34. Cap; pilot 49. Hexagon socket head bolt 73. Hexagon socket head bolt
11. Plate cylinder barrel 35. Hexagon socket plug 50. Spring washer 74. Spring washer
12. Valve plate 36. Poppet 51. O-ring 75. Hexagon socket head bolt
13. Retaining ring 37. Spring; check 52. O-ring 76. Plug; sleeve
14. Spring pin 38. Plug 53. Choke 77. O-ring
15. Bearing 39. O-ring 54. Key 78. Retaining ring
16. Hexagon socket plug 40. Relief valve assembly 55. Flange
Tightening torque
N-m kgf-m ft-lbf
A, B G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7
Drain R3/8 44.1 - 61.7 4.5 - 6.3 32.5 - 45.5
Mounting bolt M12 106 - 120 10.8 - 12.2 78.2 - 88.5
366-604-90000 △
2
2 W102-0433E
F-2. F-2.
Winch
F-2 Winch
[NOTICE]
1. Structure
25 19
2 1
8
9
22
17
18
16
21
7
26 27
3
HOIST GEAR
DATA
NO.
4
TADANO LTD.
20
6
11,12 10 13,14
M14 23
15 5
Mounting bolt IW526-0270E01
1. Gear case 8. Ball bearing 15. Hexagon socket plug 22. Spur gear
2. Gear case 9. Oil seal 16. Hexagon socket plug 23. Washer
3. Motor bracket 10. Oil seal 17. U-Nut 24. -----------
4. Spur gear 11. Hexagon socket head bolt 18. Spacer 25. Cap
5. Ball bearing 12. Spring washer 19. Spur gear 26. Nameplate
6. Ball bearing 13. Hexagon socket head bolt 20. Key 27. Rivet
7. Ball bearing 14. Spring washer 21. Pin

Tightening torque
N-m kgf-m ft-lbf
Bolt-11 M8 33.3 3.4 24.6
Bolt-13 M10 65.7 6.7 48.5
Plug-15 R3/8 15.7 1.6 11.6
Plug-16 R1/8 9.8 1.0 7.2
Mounting bolt M14 119 - 133 12.1-13.6 87.8 - 98.1
360-732-00000 △
0
3 W526-0273E
G
Boom Telescoping System
Contents G
G-1 Boom (Five-Section Boom) ............. 1 G-3 Counterbalance Valve
(Telescoping) .........................16
1. Structure .................................................... 1
1. Structure .................................................. 16
2. Notes for reassembly................................. 2
3. Boom adjustment procedures .................... 3

3.1 Top slide plate installation procedure ......... 3
3.2 Adjustment of clearance between boom
sections ................................................ 3
G-2 Telescoping Cylinder

(Five-Section Boom)................ 4
1. Structure .................................................... 4
2. Description of operation............................. 7
2.1 Control of telescoping sequence ................ 7
3. Notes for reassembly of cylinder

assembly ........................................ 9
4. Notes for reassembly of telescoping

cylinder......................................... 11
5. Telescoping wire rope adjustment

procedure ..................................... 13
5.1 Wire rope adjustment with the telescoping
cylinder out of the boom..................... 13
cylinder installed in the boom............. 15
i
G-1 G-1 G-1
Boom (Five-Section Boom)
G-1 Boom (Five-Section Boom) [NOTICE]

◆There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
1. Structure much difference in functions and disassembly procedures, make sure of the serial number of this machine and
General view the part sales unit described in the parts catalog before starting disassembling operations.
1. Base boom section 36. Flange bolt

2. 2nd boom section 37. Sheave
3. 3rd boom section 38. Pin
4. 4th boom section 39. Pin
5. Top boom section 40. Set screw
6. Roller assembly 41. Nut
7. Pin 42. Spacer
8. Retaining ring 43. Shim
9. Grease nipple 44. Slide plate
10. Grease nipple 45. Cap
11. Plain bearing 46. Flange bolt
12. Slide plate 47. Shim
13. Slide plate 48. Bolt
14. Slide plate 49. Spring washer
15. Slide plate 50. Button bolt
16. Button bolt 51. Bolt
17. Pin 52. Cover
18. Retaining ring 53. Plate
19. Spacer 54. Plate
20. Pin 55. Bolt
21. Pin 56. Slide plate
22. Retaining ring 57. Shim
23. Roller 58. Shim
24. Pin 59. Plate
25. Retaining ring 60. Spacer
26. Pin 61. Nut
27. Plate 62. Nameplate
28. Plate 63. -------------
29. Bolt 64. Plate
30. Tapping screw 65. Hexagon socket head bolt
31. Spring washer 66.Plug
32. Slide plate
33. Slide plate
34. Plate
35. Slide plate
312-030-30101 △
6
312-043-70100 △
4
1 W536-0533E 1
G-1 G-1
2. Notes for reassembly

4. Install the top boom telescoping support in
1. Apply grease to the boom inside surfaces that rub accordance with the following steps (see Fig. 4):
against slide plates.
• Apply thread locking compound (Threebond 1305
2. Press-fit the plain bearings at the base of the or equivalent) to the button bolts and use them to
boom with their grease grooves on the outside loosely fit the top boom telescoping support.
(see Fig. 2).
• Tighten the bolts until the top boom telescoping
support's longitudinal play is eliminated, then lock
them in position with the nuts.
Verify through the inspection holes that the top
boom telescoping support is pressed firmly
against the stopper.
• Tighten the button bolts to a torque of 24.5 N-m

(2.5 kgf-m) (18.1 ft-lbf).
Fig. 2
3. Bend down the plate on the boom elevating

cylinder pivot pin after installing the bolts
(see Fig. 3).
Base boom sec.

Second boom sec. Fig. 4
Third boom sec.
Telescoping
cylinder
Boom elevating
cylinder pivot pin
Bolt
Plate
IW536-0530E02
Fig. 3
2 W536-0533E
G-1. G-1.
3. Boom adjustment procedures

Before performing this work, supply grease (TNR) to
each slide plate and to each grease cup.
a
A
3.1 Top slide plate installation procedure Slide plate
Apply thread locking compound (Threebond 1305 b

or equivalent) to the button bolts before using
them to secure the slide plate.
After tightening the button bolts, loosen each of 1 Shim (For the fixation)
them by half a turn and make sure the slide plate
2 Shim (For the adjustment)
can move longitudinally (see Fig. 5).
3 Shim (For the adjustment)
Button bolt
View A IW536-0532E02
Fig. 6
Slide plate
Boom fully retracted
IW536-0272E02
Fig. 5 Max. 35 mm
(1.38 in)
3.2 Adjustment of clearance between boom Boom fully extended
sections
1. Adjust dimension "a" (see Fig.6) to the following

Adjustment of boom lateral bending
values: IW536-0272E05
Fig. 8
• With boom fully extended: a = 2 mm (0.08 in)
And locks it with the nut.
100 N
2. Adjust dimension "b" (see Fig. 6) using shims(1), (10kgf)
(2), and (3) such that the boom's degree of lateral (22 lbf)
bending and the boom's degree of lateral play
Max. 80 mm
comply with the following values: (3.15 in)
• Boom lateral bending: max. 35 mm (1.38 in) 100 N Boom fully extended
(10kgf)
(see Fig. 8) (22 lbf)
Adjustment of boom lateral play
• Boom lateral play: max. 80 mm (3.15 in) IW536-0533E01
(see Fig. 9) Fig. 9
[NOTICE]
Install the slide plates before assembling the boom.
Shim(1) serves to retain the other shims, so it must
be installed last.
312-030-36001 △
0
3 W536-0533E
G-2 G-2 G-2
Telescoping Cylinder (Five-Section Boom)
G-2 Telescoping Cylinder (Five-Section Boom) [NOTICE]

◆There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
1. Structure much difference in functions and disassembly procedures, make sure of the serial number of this machine and
General view the part sales unit described in the parts catalog before starting disassembling operations.
Tightening torque: 19.6 N-m (2kgf·m)

7
(14.5 ft-lbf)
8
Apply grease 3 9 10 12
11
Extending wire rope Tightening torque
1 2 4 28 5 6 Clinched part on inside 34.3-39.2 N-m (3.5-4.0 kgf·m)
Apply grease to the top surface of the cylinder
(25.3-28.9 ft-lbf)
A 2-G3/8
Wire rope guide support (2 places) Retracting wire rope

Wire rope guide Apply grease
(2 places) 29 1. Cylinder assembly 16.Bolt
2. Wire rope 17. Support
13,14 3. Support assembly 18. Sheave assembly
4. Nut 19. Retaining ring
5. Wire rope 20. Pin
6. Sheave assembly 21. Plate
15
7. Hexagon socket head bolt 22. Bolt
29 8. Spring washer 23. Support
16 9. Support 24. Plate
13,14
10. Spring washer 25. -------------
11. Bolt 26. Plate
15
12. Counterbalance valve 27. Machine screw
17 18 19 20 21
13. Hexagon socket head bolt 28. Nut
Clinched part on outside 23 26 27 14. Spring washer 29. -------------
Section B-B
15. Support
22 Section C-C
24
View A IW157-0353E01
312-116-30001 △
2
4 W157-0354E 4
G-2 G-2 G-2
Cylinder assembly
1. Nut 28. Plain bearing

2. Spring washer 29. O-ring
3. Piston 30. Piston
4. O-ring 31. Set screw
5. Plain bearing 32. Rod (No. 1)
6. Plain bearing 33. Cylinder (No. 1)
7. Plain bearing 34. O-ring
8. Piston 35. Packing
9. Cylinder (No. 3) 36. Backup ring
10. Rod (No. 3) 37. Dust seal
11. Rod cover 38. Rod cover
12. O-ring 39. Roller assembly
13. Packing 40. Retaining ring
14. Backup ring 41. O-ring
15. Dust seal 42. Hexagon socket head bolt
16. O-ring 43. Slide plate
17. Check valve assembly 44. Machine screw
18. O-ring 45. Button bolt
19. Packing 46. Slide plate
20. Backup ring 47. Slide plate
21. Dust seal 48. Machine screw
22. Rod cover 49. Roller assembly
23. Check valve assembly 50. Roller assembly
24. Stopper 51. Plain bearing
25. Pipe 52. Roller assembly
26. Cylinder (No. 2) 53. Hexagon socket head bolt
27. Rod (No. 2)
360-167-20001 △
4
5 W157-0354E 5
G-2 G-2
Check valve assembly (cylinder assembly part (17))
1. O-ring 6. O-ring
2. Backup ring 7. Spring
3. Check valve 8. Plug
4. O-ring 9. O-ring
5. Valve seat 10. Plug
Check valve assembly (cylinder assembly part (23))
1. O-ring 8. Body
2. Spring 9. O-ring
3. Check valve 10. O-ring
4. Rod 11. Hexagon socket head bolt
5. O-ring 12. Plug
6. Backup ring 13. Spacer
7. Cap
6 W157-0354E
G-2 G-2
2. Description of operation
2.1 Control of telescoping sequence
1. When the No. 1 cylinder has been fully extended, the No. 2 cylinder is extended.
2. When the No. 2 cylinder has been fully extended, the No. 3 cylinder is extended.
7 W157-0354E
G-2 G-2
3. When the No. 3 cylinder has been fully retracted, the No. 2 cylinder is retracted.
4. When the No. 2 cylinder has been fully retracted, the No. 1 cylinder is retracted.
8 W157-0354E
G-2 G-2

5. Apply thread locking compound to the items listed
of cylinder assembly below before installing the items (see Figs. 4 - 6).
1. Make sure each seal, O-ring, and plain bearing is • Check valve mounting bolts-N
correctly aligned.
• Machine screws and button bolts used to mount
2. Before installing the piston of the No. 1 cylinder, slide plates at front ends of No.1 and No.2
apply adhesive (Loctite 638) to the three cylinders
consecutive crests of the rod's external thread,
starting with the second crest (see the areas
marked with "※" in Fig. 3).
• Tightening torque: 98.1 N-m (10.0kgf-m)

(72.4 ft-lbf)
Fig. 3
3. Before installing the piston of the No.2 cylinder,

apply adhesive (Loctite 638) to the two
Fig. 4
starting with the second crest (see the area
marked with "※※" in Fig. 3).
• Tightening torque: 98.1 N-m (10.0 kgf-m)

(72.4 ft-lbf)
4. Before installing the piston of the No.3 cylinder,

apply adhesive (Loctite 638) to the four
starting with the second crest (see the area
marked with "※※※" in Fig. 3).
• Tightening torque: 98.1 N-m (10.0 kgf-m)

(72.4 ft-lbf)
9 W157-0354E
G-2 G-2
• Machine screws used to mount slide plate at rear • Hexagon socket head bolts at rear end of cylinder
end of No. 2 and No. 3 cylinder assembly
Fig. 6
6. Before fitting the rod cover, apply rust inhibitor

(Threebond 1104 or equivalent) to the thread.
Perform this step with each rod cover.
• Tightening torque: 343 - 392 N-m (35 - 40 kgf-m)

(253 - 289 ft-lbf)
7. After installing the cylinder, bend the end of the

cylinder down onto the rod cover in one place.
Perform this step with each cylinder.
Fig. 5
Fig. 8
10 W157-0354E
G-2 G-2

8. When reassembling each roller assembly, apply
grease to the pin. of telescoping cylinder
1. Install the sheave assembly at the rear end of the
No. 3 cylinder with the clinched part on the inside.
Fig. 9
Fig. 10
2. Install the sheave assembly at the front end of the

No. 3 cylinder with the clinched part on the
outside.
Fig. 11
3. Before installing the extending wire rope, install

the retracting wire rope end loop support and the
plate.
Fig. 12
11 W157-0354E
G-2 G-2
4. When passing the extending and retracting wire 6. When installing the telescoping cylinders in the
ropes through their respective wire rope end loop boom, align the groove on the outside of the
support, be sure to follow these instructions: sheave at the rear end of the No. 3 cylinder
(marked with a "A") in the direction as shown
• Align the wire rope's center mark with the center
Fig15.
of the wire rope end loop support.
• After passing each wire rope through the wire

rope end loop support, bend down the wire rope
guides.
• Extending wire rope: two wire rope guides
After passing the retracting wire rope through the Fig. 15

retracting wire rope end loop support, apply
7. Apply grease to the surface that rubs against the
thread locking compound to the machine screws
slide plate (see Figs. 4 and 5). At the same time,
and use the machine screws to install the wire
apply grease to the top surface of the No. 3
rope guide supports.
cylinder.
• Retracting wire rope: two wire rope guide
supports
Fig. 13
5. Tighten each of the support mounting bolts shown

in Fig. 14 to torque of 19.6 N-m (2 kgf-m)
(14.5 ft-lbf).
Fig. 14
12 W157-0354E
G-2 G-2
5. Telescoping wire rope

3. With the heads of the extending wire rope
adjustment procedure adjusting bolts pressing firmly against the
adjusting bolt mounting surface, adjust dimension
5.1 Wire rope adjustment with the telescoping "E" (see Fig. 18) to 120 - 121 mm (4.72 - 4.76 in).
cylinder out of the boom
(The bolts should be tightened for a turn from the
1. Fully retract the telescoping cylinder. At this time, position where the pin becomes forced against
maintain pressure on the retraction side of the cylinder assembly.)
telescoping cylinder to prevent dimension "D" (see At this time, make sure the most external flats of
Fig. 16) from changing. the adjusting bolts are horizontal as shown in Fig.
Dimension "D": 156.1 mm (6.146 in) 18.
Fig. 18
Fig. 16
4 With the head of the retracting wire rope adjusting
2. Attach the extending wire rope and retracting wire bolt pressing firmly against the adjusting bolt
rope, and fold the two wire rope guides. mounting surface, tighten the adjusting bolt until
Then attach the two wire rope guide supports after the plate is slightly separated from the cylinder
applying screw locking agent to the threaded support (see Fig. 19).
portion of the machine screw. At this time, make sure the most external flat of
the adjusting bolt is horizontal as shown in Fig.
19.
Fig. 19
Fig. 17
13 W157-0354E
G-2 G-2
5. Use the specified jig to retain the top boom 9. After adjustment is completed, thrust the support
telescoping support in the position at which against the horizontal face of the extending wire
dimension "C" (see Fig. 20) is 300 mm (11.8 in). rope adjusting bolt and secure the support using
the hexagon socket head bolts and the spring
washers (see the Fig. 21).
Fig. 20
6. With the jig still fitted, tighten the extending wire

rope adjusting nut (see Fig. 20).
Adjusting nut tightening torque:
4.9 N-m (0.5 kgf-m) (3.6 ft-lbf) Fig. 21
• If the length of the wire rope projecting from the 10.After adjustment is completed, thrust the support
adjusting nut is too short to tighten the nut using againt the horizontal face of the retracting wire
the jig, tighten the extending wire rope adjusting rope adjusting bolt and secure the support using
bolts on the right and left close to the boom head the hexagon socket head bolts and the spring
equally. washers. (see Fig. 22)
Adjusting bolt tightening torque:
9.8 N-m (1.0 kgf-m) (7.2 ft-lbf)
7. With the jig fitted, tighten the retracting wire rope

adjusting nut until the jig slightly comes off.
• If the length of the wire rope projecting from the

adjusting nut is too short to tighten the nut using
the jig, tighten the retracting wire rope adjusting
bolt close to the boom head.
8. After 7., secure the nuts using the lock nuts.
Fig. 22
14 W157-0354E
G-2. G-2.

cylinder installed in the boom 1. When "F" is 2 mm (0.08 in) or shorter
re-adjustment is not necessary.
Telescope the boom for several strokes and check
the dimension of "F" (clearance between the top 2. When "F" is longer than 2 mm (0.08 in) and does
boom section and 3rd boom section). not exceed 4 mm (0.16 in)
Make adjustment in the following order:
• Remove the top cover. (Take care not to damage

the cord on the cord reel.)
• Remove the adjusting bolt locking plates,

hexagon socket head bolts, and the spring
washers, and loosen the extending wire rope
adjusting bolts on the right and left for one turn
(see the Fig. 21).
• Remove the adjusting bolt locking plates,

hexagon socket head bolts and the spring
washers, and tighten the retracting wire rope
adjusting bolt until "F" is 2 mm (0.08 in) or shorter
(see the Fig. 22).
• Attach the adjusting bolt locking plates, hexagon

socket head bolts and spring washers (both for
the retracting wire rope and for the extending
wire rope). Then attach the top cover.
3. When "F" is longer than 4 mm (0.16 in)

Fig. 23
Perform the "5.1 Wire rope adjustment with the
telescoping cylinder out of the boom" again.
312-116-31101 △
0
15 W157-0354E
G-3. G-3.
Counterbalance Valve (Telescoping)
G-3 Counterbalance Valve (Telescoping)

[NOTICE]
1. Structure
1. Body 5. Spring 9. Plug 13. O-ring

2. Spool 6. O-ring 10. Poppet 14. O-ring
3. Plug 7. Plug 11. Spring
4. Backup ring 8. Plug 12. O-ring
Tightening torque
N-m kgf-m ft-lbf
Plug-3, 9
G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
Port-A, B
Plug - 7 G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.6
Mounting bolt M10 34.3 - 39.2 3.5 - 4.0 25.3 - 28.9

366-051-80001 △
3
366-065-50000 △
2
366-055-20000 △
3
366-056-00000 △
2
16 W119-0285E
H
Safety System
Contents
H-1 AML (Automatic Moment Limiter)... 1 4. Adjustment of AML .................................. 13

H
4.1 Precautions when mounting crane
1. Name of each part ..................................... 1 main body ...........................................13
4.2 Adjusting front zone ranges after
2. Terminology and feature............................ 3 mounting .............................................14
2.1 Overload limit function................................ 3 4.3 ID registration and special specification
2.1.1 Pre-alarm.............................................. 3 setting procedure ................................16
2.1.2 Limit alarm............................................ 4 4.4 Adjustment mode operation procedure.....18
2.2 Configuration of AML.................................. 5 4.5 Adjustment procedure of AML
2.3 Name of each part (settings of crane model/performance
(control panel)(left side) ....................... 5 classifications) ....................................23
2.4 Mode indicator ............................................ 6 1) A1: Settings of crane model/performance
2.5 Alarm and recovery operation .................... 7 classifications......................................24
2.6 Outrigger extension 2) A2: Zero/span adjustments of boom length
State indicator lamp ............................. 8 detector ...............................................25
2.7 AML pre-operational inspection.................. 9 3) A3: Zero/span adjustments of boom angle
2.8 Working height limit function .................... 10 detector ...............................................26
2.8.1 Setting the working 4) Outrigger extension width check
Height limit.......................................... 10 lamp - check .......................................27
2.8.2 Canceling the working 5) A6: Accuracy check...................................29
height limit .......................................... 11 6) A7: Moment adjustment
(When A6: Accuracy check results are
3. Caution about installing incorrect) .............................................30
length detector ............................. 12
H-2 Length Detector (Boom) ................31
1. Structure .................................................. 31
2. Specifications........................................... 31
H-3 Angle Detector (Boom) ..................32
1. Structure .................................................. 32
i
H-1 H-1
AML (Automatic Moment Limiter)
H-1 AML (Automatic Moment Limiter)
[NOTICE]
1. Name of each part
1 W301-0400E
H-1 H-1
2 W301-0400E
H-1 H-1
2. Terminology and feature
2.1 Overload limit function
WARNING
・Regard the AML as a reference of the operation. During crane operation, check the
empty chassis rated lifting capacity table, and perform safe operation.
When the lifted load sways or operation speed is high, the inertia force of the lifted
load may increase the load even if the AML operates, resulting in the overturning or
damage to the machine.
・Do not operate the crane within the
boom angle limit area.
No limit alarm indicating overload is
issued within the limit area, letting the
machine overturn or be damaged,
resulting in a serious accident.
Do not raise the boom fully.
The AML is equipped with the overload limit function. It prevents the overturning or damage to the machine
during crane operation.
Measures the load applied to the crane such as boom length, boom angle and lifted load.
When the load approaches the rated capacity, the pre-alarm is issued. When the load reaches the rated
capacity, the limit alarm is issued and the crane operation is stopped to prevent the overturning or damage
to the crane.
2.1.1 Pre-alarm Because the load approaches the limit, operate

the machine carefully.
When the rated capacity decreases close to the
current load, the following events occur.
• Alarm buzzer sounds
(repeated short high beeps).
• Moment bar graph on the transmitter extends
to the yellow area.
• Limit warning lamps on the control panel flash.
3 W301-0400E
H-1 H-1
2.1.2 Limit alarm
When the rated capacity is reached, the following

events occur.
• Alarm buzzer sounds (high beep).
• Hook block hoisting up stops.
• Boom extension stops.
• Boom lowering stops.
• The limit waning lamps on the control panel light

up.
When the alarm is issued during the clearing the

load of the ground... Lower the load.
When the alarm is issued during the lifting
operation... Lower the load, or retract or raise the
boom.
4 W301-0400E
H-1 H-1
2.2 Configuration of AML
2.3 Name of each part (control panel) (left side)
5 W301-0400E
H-1 H-1
2.4 Mode indicator
Displays the information as shown in the table below depending on the machine state.
Crane state Mode indicator Contents of display
Manual operation Displays the actual load.
Radio controller mode Displays L1

(radio controller mode selection symbol).
Working height limit function is Displays H (boom height limit symbol) and
set. actual load.
Volume adjustment Displays the volume of the alarm buzzer.
Communication error Displayed when radio disturbance occurs.
System malfunction Displays the error code.
NOTICE
The displayed actual load is a reference value, and does not indicate the accurate
weight of the lifted load.
6 W301-0400E
H-1 H-1
2.5 Alarm and recovery operation

Alarm Crane state Alarm buzzer Display Actions
Limit alarm Rated capacity High beep Limit warning • When the alarm is
decreases to the current lamp... Lights up issued during clearing
load the load off the ground
and the hook block
hoisting up stops, lower
the lifted load.
• When the alarm is
issued during the lifting
operation and the hook
block hoisting up, boom
extension, or boom
lowering stops, lower the
lifted load, or
retract/raise the boom.
Pre-alarm Rated capacity Repeated short Limit warning Operate the machine
decreases close to the high beeps lamp... Flashes carefully.
current load
Boom angle Within upper limit area Low beep Limit warning Lower the boom out of
limit lamp... Lights up the limit area.
Mode indicator
displays "----."
System System malfunction Repeated short Limit warning lamp Refer to "V-4 Action
malfunction occurs. low beeps Lights up Against Emergency"
(page 16).
Mode indicator
displays error
code ("E**").
When the boom is lowered from the maximum boom angle, the operation speed decreases even
under no load.
Stop the boom operation when the boom angle limit alarm stops, and operate the boom again.
7 W301-0400E
H-1 H-1
2.6 Outrigger extension state indicator lamp

Indicates the outrigger extension state.
According to the lighting state of the indicator lamp, the crane capacity changes.
The lighting condition of the LEDs on the display on the side of the post corresponds to the outrigger
extension state indicator lamps on the control panel.
8 W301-0400E
H-1 H-1
2.7 AML pre-operational inspection
WARNING
Before crane operation, check that the AML operates normally.
If the AML is not operating normally, the machine may overturn or be damaged,
resulting in a serious accident.
Before the crane operation, follow the procedure below to perform the AML preoperational inspection.
1. Extend the outriggers, and set up the machine 3. Hoist up the hook block and create an overwind
horizontally. state, and then check the following.
Check the following. • Hook block hoisting up stops.
• The left and right outrigger extension state • Alarm buzzer sounds (high beep).
indicator lamps indicate the actual outrigger Now, the AML pre-operational inspection is
completed.
extension width
Extension
Maximum Middle Minimum
width
Lighting Green
Green Red
color and red
2. Swing the boom to the over-side (right or left), and

fully lower the boom.
Hoist down the hook block to cancel the overwind
state, and check the following.
• Mode indicator displays "0.0."
9 W301-0400E
H-1 H-1
2.8 Working height limit function

2. Press the working height limit switch on the
Prevents the boom from colliding with the upper left-side control panel to turn it on.
obstacles by limiting the boom height during crane • Notification sound (ding-dong) is heard, and the
operation. working height limit is set.
When the boom reaches the height limit, the
following operations stop.
• Boom extension
• Boom raising
3. Check that the mode indicator on the left-side

control panel displays "H"(boom height limit
symbol) and the actual load.
2.8.1 Setting the working height limit
NOTICE
・The boom may collide with the obstacles
depending on the working state and operation
method even when the working height limit is set.
Observe the following.
- Set the working height limit under no load.
- Keep a sufficient clearance from the obstacles
before setting the working height limit.
- When the boom approaches the working height
limit during crane operation, operate the
machine slowly.
・When the PTO is set to "OFF," the working height
limit is erased.
1. Raise the boom to the desired limit height.
10 W301-0400E
H-1 H-1
2.8.2 Canceling the working height limit
1. Press the working height limit switch on the

left-side control panel and turn it off.
• Notification sound (ding-dong) is heard, and the
working height limit is canceled.
2. Check that the mode indicator displays the actual

load only.
11 W301-0400E
H-1 H-1
3. Caution about installing length detector

1. Adjust the cord for length detector assy so that the yellow tape on the cord is located as shown in the
drawing when the boom is fully retracted.
2. The stopper is attached to the cord. Do not remove the stopper from the cord when installing the detector on
the boom, otherwise the cord will be reeled in all the way, leading to damage to the potentiometer.
After installing the detector, attach the stopper to the end of the cord for next maintenance work.
313-511-50000 △
1
12 W301-0400E
H-1 H-1
4. Adjustment of AML
4.1 Precautions when mounting crane main body
1) Precautions when mounting

Mount the crane main body so as to be perpendicular to the chassis frame of the vehicle
(in the state of Fig. 1).
Unless the crane main body is perpendicular to the chassis frame of the vehicle (in the state of Fig. 2),
difference between the right and left zone detecting ranges occurs.
13 W301-0400E
H-1 H-1
4.2 Adjusting front zone ranges after mounting
1. Swing the boom clockwise from the rear zone. Measure the dimension A in Fig. 3 at the position where the
front zone lamp 3 of the signal transmitter ASSY (refer to Fig. 5 on the next page) lights up.
2. When the dimension A is within the allowable value in the table 1, go on to "3."
When the dimension A is out of the allowable value in the table 1, make an adjustment according to the
method described below, and then go on to "3."
Table 1 Allowable value of front zone range adjustment
Allowable value
ZR860
A, B 0 to 250 mm(0 to 10 in)
Adjustment method
- When the dimension A is larger than the maximum allowable value, move the plate N in the direction C,
and then fix it.
- When the dimension A is smaller than the minimum allowable value, move the plate N in the direction D,
and then fix it.
[NOTICE]
◆ Tightening torque for the bolt should be 113 to 118 N⋅m {11.5 to 12.0 kgf-m }(83.3 to 87.0 ft-lbf)
◆ Before installing the bolt, apply thread lock agent (ThreeBond 1305 or its equivalent).
14 W301-0400E
H-1 H-1
3. Return the boom to the rear zone, and swing it counterclockwise. Measure the dimension B in Fig. 4 at the
position where the front zone lamp 3 of the signal transmitter ASSY lights up.
4. When the dimension B is within the allowable value in the table 1, adjustment is completed.
When the dimension B is out of the allowable value in the table 1, make an adjustment according to the
method described below, and then go on to "5."
Adjustment method
- When the dimension B is larger than the maximum allowable value, move the plate N in the direction D,
and then fix it.
- When the dimension B is smaller than the minimum allowable value, move the plate N in the direction C,
and then fix it.
5. Perform "1" again. When the value is within the allowable range, adjustment is completed.
When the value is out of the allowable range, repeat "2" to "5."
313-621-30300 △
0
15 W301-0400E
H-1 H-1
4.3 ID registration and special specification setting procedure
313-621-31300 △
0
16 W301-0400E
H-1 H-1
[Table 1] Special specification setting No. list
Required Simultaneous
Special
Function (setting detail) special spec setting prohibition
spec. No. No. special spec No.
01 STD specification
03 With accelerator cylinder control 27
05 Jack interlock (alarm specification)
06 No hook-in specification
07 Winch independent hook-in specification
09 Full-automatic boom stowage specification
10 Jack interlock stop (stop specification, to be set together with 05) 04 or 05
12 Safety device specification 31
14 Manual specification
15 Safety device stop specification 12
16 No advance alarm function by manual lever 12
17 With WHL function 12
25 Special AML specification 12
32 Alarm sound selection for overseas use + emergency stop function + over-unwinding cutout function
33 Outrigger intermediate extension performance specification 32
34 Swing motor lock output when swing operation is not performed
Capacity selection type 1
35 (Narrower outrigger extension width capacity is selected regardless of the boom swing 32
direction.)
[Table 2] Special specification basic setting list
313-621-30410 △
1
17 W301-0400E
H-1 H-1
4.4 Adjustment mode operation procedure
18 W301-0400E
H-1 H-1
1) Adjustment mode list

(1mm = 3.93701×10-2 in)
Adjust
Classifi-
-ment Name Initial value Minimum value Maximum value
item cation
c1 Maximum engine rpm "1.5" 1.5 "-1.5" -1.5 "13.5" 13.5
c2 Intermediate engine rpm "1.2" 1.2 "-1.5" -1.5 "13.5" 13.5
c3 Low engine rpm "0.9" 0.9 "-1.5" -1.5 "13.5" 13.5 A
c4 Idling engine rpm "0.6" 0.6 "-1.5" -1.5 "13.5" 13.5

c6 Jack auto accelerator engine rpm "1.2" 1.2 "-1.5" -1.5 "13.5" 13.5
Hoist-down adjustment at hook-out
c8 (boom-raise and hoist down)
"3.0" 3.0 mm "0.0" 0.0 mm "6.3" 6.3 mm
Hoist-down adjustment at hook-out
c9 (boom-extension and hoist down)
"3.0" 3.0 mm "0.0" 0.0 mm "6.3" 6.3 mm
B
Raise adjustment at hook-out
c10 (boom-raise and hoist down)
"3.0" 3.0 mm "0.0" 0.0 mm "6.3" 6.3 mm
c17 Jack auto retraction offset time "0.00" 0.00 s "-5.00" -5.00 s "5.00" 5.00 s
Classification
A: To be adjusted at mounting.
B: To be adjusted if required after checking operation.
368-058-20120 △
1
19 W301-0400E
H-1 H-1
2) Engine rpm adjustment in mounting

Caution Before engine rpm adjustment, be sure to warm up the engine until its idling speed stabilizes.
Caution Depending on a chassis, an error (such as engine warning) may occur or the engine rpm may not
be controlled. Be sure to check the whether the engine speeds are adjusted by operating the crane.
[1] Change the initial values of control unit of radio control as follows.
1. Idling engine rpm adjustment "c4": Change (0.6) to (0.0).
2. Maximum engine rpm adjustment "c1": Change (1.5) to (13.5).
3. Intermediate engine rpm adjustment "c2": Change (1.2) to (5.5).
4. Low engine rpm adjustment "c3": Change (0.9) to (0.0).
(Idling speed increasing adjustment)
5. Jack auto accelerator engine rpm adjustment "c6": Change (1.2) to (5.5).
[2] Refer to the mounting part selection table for the maximum engine rpm adjustment value (A).
Maximum engine rpm adjustment value: A min. (TADANO PTO) or (manufacturer PTO)
[3] Start the engine, set PTO to ON, and set the current engine rpm as the "initial value" to start the adjustment.
Pull a cable with the vehicle-side governor link (such as of electronic governor accelerator sensor). Measure
the cable stroke or governor link stroke until the "initial value" (idling engine rpm) changes to the maximum
engine rpm adjustment value "A."
( [NOTICE] For some vehicles, the engine rpm may not reach "A", even though the vehicle-side governor
link is fully pulled.
In this case, define the value 100 rpm smaller than the engine rpm at the time the link is fully pulled as "A,"
and perform the adjustments below.)
Among the cable strokes of link holes in the table below, select a link hole that is larger than the measured
cable stroke and the nearest, and install an accelerator cable. Secure approximately 2 mm (0.08 in) for a
vehicle-side cable play allowance.
Also, pay attention so that the governor link operation force or accelerator cable wiring resistance will not be
large to exceed the accelerator cylinder cable pulling force in the table below. If it exceeds the value,
recheck the cable for bend and twisting.
(1mm = 3.93701×10-2 in)
(1kg = 2.20462 lbf)
20 W301-0400E
H-1 H-1
[4] Adjustment of maximum engine rpm

[NOTICE] In the radio control operation shown below, when the cable is pulled by the maximum amount,
confirm that the amount does not exceed the vehicle accelerator lever operation amount.
If it exceeds the operation amount, the vehicle accelerator lever or related parts will be damaged.
Therefore, pay attention to the operation.
[4]-1. At winch winding up/down operation in the high-speed mode of the radio control transmitter, when the
speed control lever is moved to the full stroke, compare the current engine rpm with the engine
maximum rpm adjustment value "A."
[NOTICE] In the manual operation and operation in the radio control individual mode, it is impossible to
measure the maximum engine rpm. Be sure to perform the winch winding up/down operation by
using radio control, and check the above.
In the operation above, when the engine rpm to the maximum engine rpm adjustment value "A" is
as follows, follow the instruction:
a: Smaller by 10% (approx. 200 rpm) or more: Go back to 3) and reselect the link hole. (Move to
the lower link hole.)
b: Larger by the range within 0 to 10% (approx. 0 to 200 rpm): Go on to 4)-2.
c: Smaller by the range within 5 to 0% (approx. 0 to 100 rpm): The maximum rpm adjustment is
completed. Go on to 5).
d: Smaller by 5% (approx. 100 rpm) or more: Go back to 3) and reselect the link hole. (Move to
the upper link.)
[4]-2. Adjust by maximum engine rpm adjustment "c1."
[5] Low engine rpm adjustment

Check that the set value of "c3" is (set to) "0.0" in the adjustment mode.
Do not increase the idle speed.
[6] Intermediate engine rpm adjustment

Select "c2" in the adjustment mode. When the HORN switch is pressed, the value appears in the display, and
the accelerator cylinder extends by 5.5 mm (0.22 in).
At this time, confirm that the engine rpm is within the range from the intermediate value between the ("initial
value" of) idling engine rpm and the maximum engine rpm adjustment value "A rpm" to "intermediate value -
100 rpm."
If it is out of the range, adjust the accelerator cylinder stroke in the adjustment mode so that the engine rpm
is within the range.
Example) When the maximum engine rpm adjustment value "A" in the mounting part inspection results is
1500 rpm:
Intermediate engine rpm adjustment value "B" = 1500 x 3/5 = 900 rpm
Adjust within the range of "800" to "900" rpm.
[7] Jack auto accelerator rpm adjustment

When "c6" is selected in the adjustment mode, the accelerator cylinder becomes 5.5 mm (0.22 in) longer
than that at the time of maximum engine rpm. Confirm that the rpm is the same value as the intermediate
engine rpm in [6].
If it is not, adjust the accelerator cylinder stroke in the adjustment mode in "4.5-1) Adjustment mode list" to
adjust the engine rpm.
21 W301-0400E
H-1 H-1
[8] Check
Turn OFF PTO, and after the engine restarts, turn ON PTO.
Operate the crane, and check the following.
Maximum engine rpm check: For the radio control operation, in the high-speed mode, with any one of
Extension/Winch/Raise operations, fully pull the speed control lever. For the manual operation, with the low
speed switch in OFF, fully operate the lever with any one of Extension/Winch/Raise operations.
Intermediate engine rpm check: For the radio control operation, in the high-speed mode, perform any one of
Retraction/Lower/Swing operations in the high-speed mode or Telescoping/Winch/Elevating/Swing
operations in the intermediate-speed mode to full stroke. For the manual operation, with the Low-speed
switch in OFF, fully operate any one of the levers of Retraction/Lower/Swing operations.
Jack auto accelerator engine rpm check: Operate the jack switch.
a: All of the above are normal.

The adjustment is completed.
b: Though the engine rpm increases, it does not match the adjustment range.
Perform the applicable adjustment.
Operate the crane again, and check.
c: The engine rpm does not increase at all.
The setting value of the idling engine rpm is too small.
Turn OFF PTO, and stop the engine. After the engine restarts, turn ON PTO.
In [3], set the setting value to the value set in [6].
d: In the maximum engine rpm check, the rpm returns to the idling rpm after it increases.
The setting value of the maximum engine rpm is too large.
Turn OFF PTO, and stop the engine. After the engine restarts, turn ON PTO.
In [4], check the setting value, and readjust.
e: In the intermediate engine rpm check, the rpm returns to idling rpm after it increases.
The setting value of the maximum engine rpm is too large.
Turn OFF PTO, and stop the engine. After the engine restarts, turn PTO ON.
Set the value specified in [5].
[NOTICE] For the cases in c to e, depending on the chassis, the engine warning lamp will light up.
If the warning lamp does not go out even though the engine is stopped and restarted, turn the key
switch to "ACC" or "LOCK" and hold for 5 seconds or more. And then start the engine.
[NOTICE] The setting value of each engine rpm is in the range below.
If the adjustment value of the engine rpm does not increase or decrease, check the upper and lower
setting values for each.
-1.5 c 4 (idling engine rpm) c 3 (low engine rpm) c 2 (intermediate engine rpm) c1
(maximum engine rpm) 13.5
22 W301-0400E
H-1 H-1
4.5 Adjustment procedure of AML (settings of crane model/performance classifications)
At shipment from the factory, the settings of crane model/performance classifications are completed.
Confirm the following just to make sure.
1) A1: Settings of crane model/performance classifications
2) A2: Zero/span adjustments of boom length detector
3) A3: Zero/span adjustments of boom angle detector
4) Check of the outrigger extension width check lamp
5) A6: Accuracy check
6) A7: Moment adjustment (When A6: Accuracy check results are incorrect)
23 W301-0400E
H-1 H-1
1) A1: Settings of crane model/performance classifications

Data for several crane models is stored, therefore, select the necessary crane model and performance
classification.
("Crane model/performance classifications" are set at the shipment from TADANO factory. At the mounting
factory, confirm that there is no error in the following items.)
Table 1 *For "Load": The weights of hook (90 kg) ｛198 lb｝
and lifting bracket (20 kg) ｛44 lb｝ are excluded.
Display When checking accuracy
Crane Frame Performance Standard
model classification classification Crane Load R1 R2
Performance Outrigger Boom radius
model (t) (m) (m)
classification
classification extension state telescoping (m)
｛lbf｝｛ft｝｛ft｝
｛ft｝
Middle (1.0) (7.27) (7.64) (7.47)

ZR865 STD B 865 2 extension 4-section
{2205} {23.85} {25.07} {24.51}
24 W301-0400E
H-1 H-1
2) A2: Zero/span adjustments of boom length detector

For adjustment, lower the boom toward rear to the stroke end.
Table 2
Range of zero point Zero point Span point
Crane model adjustment setting setting
Boom length detector value value
ZR865 4.30 to 4.50 4.40 15.92
25 W301-0400E
H-1 H-1
3) A3: Zero/span adjustments of boom angle detector

Perform the adjustment on the over-right side, with the boom fully retracted.
Table 3
Range of zero point Zero point Span point
Crane model adjustment setting setting
Boom angle detector value value
ZR865 0.8 to 1.2 1.0 82.0
26 W301-0400E
H-1 H-1
4) Outrigger extension width check lamp - check
Be sure to start under the condition below:

- Outrigger: stowed - Boom: fully retracted
- Boom elevation angle: maximum - Swing position: swung to the over-right area
(Confirm that the over-front lamp has gone out.)
Check the lamp on the body panel upper part and the LED lamp of post side control.
For Taiwan
27 W301-0400E
H-1 H-1
For Australia
28 W301-0400E
H-1 H-1
5) A6: Accuracy check

Set the boom to the over-right. However, the swing direction is not in the over-front area.
(Confirm that the over-front lamp has gone out.)
*1. By pressing the HORN switch, the setting and adjustment

contents can be retained.
*2. To get out of the adjustment mode, turn the vehicle key
switch to OFF.
model (t) (m) (m)
classification
｛ft｝
Middle (1.0) (7.27) (7.64) (7.47)

{2205} {23.85} {25.07} {24.51}
29 W301-0400E
H-1. H-1.
6) A7: Moment adjustment (When A6: Accuracy check results are incorrect)
model (t) (m) (m)
classification
｛ft｝
Middle (1.0) (7.27) (7.64) (7.47)

{2205} {23.85} {25.07} {24.51}
313-621-30210 △
0
313-621-30200 △
1
30 W301-0400E
H-2. H-2.
Length Detector (Boom)
H-2 Length Detector (Boom)

[NOTICE]
1. Structure
Connection diagram
Potentiometer Cable
Connector
0.5B (black) B
1
0.5R (red) R
2
0.5W (white) W
3 15 16
(Length detector portion) Shield
4
IW305-0172E01
1 7 19
2 3 4 12 9 6 10
Water 20
cutout hole
8 5 11
18 Yellow tape
GND(B)
Air vent
Power Water
supply(R) cutout hole
Output(W)
14 13
Shield(G)
17
IW305-0172E02
1. Base plate 6. Case 11. Cord clamp 16. Sleeve

2. Case 7. Packing 12. Gear 17. Cord guide
3. Drum assembly 8. O-ring 13. Terminal 18. Cord assembly
4. Slip ring assembly 9. Bracket 14. Sleeve 19. Cord lock
5. Contactor assembly 10. Potentiometer 15. Terminal 20. Stopper
2. Specifications
Speed reducer Reduction ratio: 3/10

Resistance: 5000 ± 250 Ω
Potentiometer
Mechanical turning angle: 3600° (10 turns type) 361-317-40000 △
0
361-317-50000 △
0
Revised May. 2017 31 W305-0172E

H-3. H-3.
Angle Detector (Boom)
H-3 Angle Detector (Boom)

[NOTICE]
Illustrations etc may differ from this machine parts.
This machine may be damaged with static electricity.
Do not charge terminals of connectors with static electricity.
This machine uses electromagnetic exchange-devices as detectors.
Do not get detectors near electro magnets etc.
1. Structure
361-406-60000 △
1
32 W305-0660E
V
Radio Control System
Contents
V-1 Configurations of Radio-control V-2 Radio-control Valve .........................8

System...................................... 1
1. Hydraulic circuit ......................................... 8
1. Part name and function of the radio
controller ........................................ 1 2. Electric circuit ............................................ 9
1.1 Transmitter ................................................. 1
1.2 Communication unit.................................... 2 3. General view............................................ 10
2. Safety function for the 4. Tightening tie-bolts .................................. 11

radio controller ............................... 3
2.1 Emergency stop function............................ 3 5. Removing solenoid valves....................... 11
2.1.1 Activating the emergency stop ............. 3
2.1.2 Canceling the 6. Exchanging O-rings ................................. 11
emergency stop.................................... 3
2.2 Automatic power off function ...................... 3 7. Removing and Installing filter .................. 11
2.3 Switch failure detection function................. 3
2.4 Instant stop alarm function ......................... 4 8. Cross section........................................... 12
3. Safety device ............................................. 4 9. Front cover .............................................. 13

3.1 Alarm function............................................. 4
10. Solenoid valve ......................................... 14
3.2 Contents of alarm and actions.................... 5
3.3 Notification sound....................................... 7
3.4 Volume adjustment..................................... 7
V-3 Accelerator Cylinder ......................15
1. Structure .................................................. 15
i
V-4 Action Against Emergency ........... 16
1. When the machine cannot Be operated by

the radio controller ....................... 16
2. When an error occurs in the overwind

cutout device ................................ 17
3. When the indicator lamps on the

transmitter flash............................ 18
4. When an error code is displayed ............. 18
5. Electrical system...................................... 18
5.1 Replacement of battery ............................ 18
6. Error code list........................................... 19
7. If the machine cannot be operated

by the radio controller and
manual levers ............................... 22
7.1 Using the emergency
overwind switch .................................. 22
7.2 Tightening the unload valve ..................... 22
ii
V-1 V- 1
Configurations of Radio-control System
V-1 Configurations of Radio-control System
1. Part name and function of the radio controller
1.1 Transmitter
(1) User mode indicator lamp (7) Operation select switch

Lights up when the user mode is selected. Selects the crane operation.
(2) Speed mode indicator lamp (8) Hook-out switch
Displays the speed mode for the operating speed Does not work.
of the crane. (9) Horn switch
(3) Power lamp When this switch is pressed, the alarm buzzer
Displays the ON/OFF state of the transmitter sounds from the speaker.
power and battery level. (10) Emergency stop switch
(4) Power switch Immediately stops the crane operation when the
Turns on or off the power. machine cannot be controlled by the radio
(5) Throttle switch controller or in an emergency situation.
Selects the speed mode. (11) Emergency stop indicator lamp
(6) Hook-in switch Lights up when the emergency stop switch is
pressed.
Does not work.
(12) Speed lever
Adjusts the operation speed.
1 WV02-0080E
V-1 V- 1
1.2 Communication unit
Communication unit indicator lamp
The power lamp and communication/disturbance lamp are provided.
Lamp state Condition

Lights up in red Power ON
Power lamp Not lit Power OFF
Lights up in orange Failure
Lights up in green Communicating
Flashes in green Reconnecting
Communication / disturbance lamp Communication
Not lit
disconnected
Lights up in orange Failure
2 WV02-0080E
V-1 V- 1
2. Safety function for the radio controller 2.2 Automatic power off function
When all of the operation select switches are left

The radio-control system has the following
unoperated for approximately 10 minutes with the
functions to realize safety operations.
transmitter power turned on, the transmitter is
2.1 Emergency stop function turned off automatically to save the battery.
Use this function to immediately stop the crane • The power lamp on the transmitter
operation if the machine malfunctions during your
goes out, and the machine cannot be operated
radio control or in an emergency situation.
by the radio controller.
2.1.1 Activating the emergency stop When restarting the operation, turn on the power
again.
Press the emergency stop switch.
• The emergency stop indicator lamp
on the transmitter lights up, and the crane

operation stops immediately.
• Alarm buzzer sounds (high beep).
2.3 Switch failure detection function
In the following cases, the four indicator lamps on

the transmitter flash, and the mode indicator
displays the error code. In this case, the machine
cannot be operated by the radio controller.
2.1.2 Canceling the emergency stop • An operation select switch or speed lever fails.
Press the emergency stop switch again. • An operation select switch has been out of its
neutral position for 5 minutes.
• The emergency stop indicator lamp on the
transmitter goes out, and the emergency stop
state is canceled.
• Notification sound (Ding-dong) is heard.
3 WV02-0080E
V-1 V- 1
2.4 Receiving condition alarm function 3. Safety device

The following alarms are issued during operation
3.1 Alarm function
depending on the radio wave state.
WARNING
(1) Low beep
If the alarm volume is reduced, the alarm buzzer is
difficult to hear depending on the work environment.
Warns that the radio waves are weak.
If the alarm cannot be heard when overload state
occurs, you may fail to prevent the machine from
(2) Two low beeps
overturning or being damaged, resulting in a serious
accident.
When two consecutive low beeps are issued, the
Set the alarm volume to "3" before operation.
machine operation stops.
The alarms are issued in the following cases.
• System alert
High beep, low beep, or repeated short high

beeps
• System malfunction
Repeated short low beeps
• Notification sound
Ding-dong
When the alarm buzzer sounds, carry out

appropriate actions according to the chart below.
4 WV02-0080E
V-1 V- 1
3.2 Contents of alarm and actions

Alarm buzzer Crane state Actions
While the boom angle is in the upper limit area, Lower the boom out of the limit
the boom is extended/raised/lowered, or the area.
hook block is hoisted up.
Low beep Radio disturbance occurs. In this case, the machine cannot
be operated by the radio
controller.
Operate the machine manually
using the manual control levers.
(1) Hook block is overwound. Hoist down the hook block or
retract the boom to cancel the
(2) The hook block is overwound, and the boom
overwind state.
is extended/raised or the hook block is
hoisted up.
Rated capacity decreases to the current load. Lower the load, or retract/raise the
boom on the safe side to avoid the
overload state.
(1) Boom height reaches the limit value. Retract or lower the boom to
decrease the boom height.
(2) The working height is limited, and the boom
is extended or raised.
High beep An operation select switch is pressed before the Release the operation select
power switch is turned on. switch, and then turn on the power
again.
The emergency overwinding switch is pressed Carefully operate the machine. If
and an emergency operation has been failure occurs, perform the
performed. emergency operation, and then
contact your nearest TADANO
distributor or dealer for inspection
and repair.
(1) The emergency stop switch is pressed. Eliminate the cause by which the
emergency stop switch has been
(2) The crane is operated with the emergency
pressed.
stop switch pressed.
Repeated short high Rated capacity decreases close to the current Carefully operate the machine.
beeps load.
5 WV02-0080E
V-1 V- 1
Alarm buzzer Crane state Actions

A crane control switch is out of the neutral Return the operation switch to the
position when the power is turned on. neutral position, and then turn on
the power again.
Malfunction occurs in the radio controller control In this case, the machine cannot
system. be operated by the radio controller
or manually.
Refer to "V-4 Action Against
Emergency" (page 16).
Malfunction occurs in the power supply or
operating voltage.
Malfunction occurs in the radio controller

operation valve.
Repeated short low The crane control lever does not return to the
beeps neutral position even when the corresponding
operation select switch is returned to the neutral
position.
Malfunction occurs in the safety device system. In this case, the machine cannot
be operated by radio controller.
Malfunction occurs in the swing detection Operate the machine using the
circuit. manual control levers, and contact
Malfunction occurs in the boom elevating your nearest TADANO distributor
cylinder load detection circuit. or dealer for inspection and repair.
Malfunction occurs in the boom length detection
circuit.
Malfunction occurs in the boom angle detection
circuit.
Malfunction occurs in the acceleration cylinder.
6 WV02-0080E
V-1. V-1.
3.3 Notification sound

Notification sound Conditions for notification sound
An operation select switch is pressed with the battery voltage for the
transmitter decreased.
The working height limit is set.
The working height limit is canceled.
Ding-dong The acceleration limit function is set.

The acceleration limit function is canceled.
The shock reduction function is set.
The shock reduction function is canceled.
The emergency stop function is canceled.
3.4 Volume adjustment
Adjusts the volume of the alarm buzzer.

Lower the volume if noise during night operation
poses a problem.
The volume can be adjusted in 4 stages using the

volume switch on the right-side control panel.
"UP": Increases the volume by 1 degree each

time the switch is moved up.
"DOWN": Decreases the volume by 1 degree each

time the switch is moved down.
7 WV02-0080E
V-2 V- 2
Radio-control Valve
V-2 Radio-control Valve

[NOTICE]
1. Hydraulic circuit
Refer to “Y-2 Adjustment(Hydraulic)” 8-page for the setting pressure.
8 W135-0300E
V-2 V- 2
Radio-control Valve
2. Electric circuit
9 W135-0300E
V-2 V- 2
Radio-control Valve
3. General view
Tightening torque
N-m kgf-m ft-lbf
G, M, PA, TA G1/4 26.4 - 32.4 2.7 - 3.3 19.5 - 23.9
A1 - A4, B1 - B4 G3/8 44.0 - 54.0 4.5 - 5.5 32.5 - 39.8
P, T G1/2 88.1 - 108.1 9.0 - 11.0 65.0 - 79.7
10 W135-0300E
V-2 V- 2
Radio-control Valve
4. Tightening tie-bolts 6. Exchanging O-rings

Tighten nuts for tie-bolts according to the shown Exchange all O-rings in all valve blocks when
sequence in order to avoid deformation of valve exchanging only one O-ring among the valve
body. blocks.
Tighten the nuts (from 1 to 8) lightly so that the

valve blocks are aligned correctly, and then 7. Removing and installing filter
tighten the nuts to specified torque below.
Remove the plug (111), and then remove the filter
・Nut tightening torque：19.6 N･m｛2.0kgf･m｝ (109).
Take care to the breakable filter.
Check the O-ring (119) for wear or damage before
installing the filter.
5. Removing solenoid valves

Remove the solenoid valve with the valve body laid on a unwoven cloth to prevent balls from missing.
11 W135-0300E
V-2 V- 2
Radio-control Valve
8. Cross section
Boom telescoping
Winch
Boom elevation
12 W135-0300E
V-2 V- 2
Radio-control Valve
Swing
9. Front cover
13 W135-0300E
V-2. V-2.
Radio-control Valve
10. Solenoid valve
14 W135-0300E
V-3. V-3.
Accelerator Cylinder
V-3 Accelerator Cylinder

[NOTICE]
1. Structure
1. Body 7. Steel ball 13. O-ring 19. Machine screw (M5×8)

2. Rod assy 8. Steel ball 14. Scraper 21. Corrugate tube
3. Spring A 9. O-ring 15. Differential transformer assy 22. Machine screw (M4×10)
4. Spring B 10. O-ring 16. Shim (T=0.2) 29. Plain washer
5. Seal cover 11. O-ring 17. Shim (T=0.3) 30. Shim (T=1.0)
6. Retaining ring 12. O-ring 18. Flange 31. Solenoid valve
360-628-20000 △
1
15 W165-0050E
V-4 V- 4
Action Against Emergency
V-4 Action Against Emergency

WARNING
Never operate the crane if it is out of order.
Operating the crane out of order may cause a serious accident.
Take an emergency procedure, and then contact your nearest TADANO distributor or
dealer for repair.
1. When the machine cannot be operated by the radio controller

When low beep or repeated short low beeps are heard and the crane stops, check the following.
State Actions
The transmitter is too far from the communication Bring the transmitter close to the communication unit.
unit. When the transmitter is too far from the
communication unit, the radio waves are difficult to
reach and easily affected by noise.
Radio controller is being used near the sources of the Turn off the power of the devices that generate noise.
noise such as rotary beacon, electric fan, or vehicle A motorcycle also generates noise.
air conditioner.
When the radio controller is affected by a motorcycle,
wait until the motorcycle passes over, and then retry
the operation.
The crane is lifting a large metallic load. Move to the position where you can see the
communication unit and operate the radio controller.
There are obstacles such as wire mesh and metallic
door between the transmitter and communication
unit.
Nothing appears on the display when the power Refer to "V-4 Replacement of battery" (page18) and
switch for the transmitter is pressed. replace the battery.
16 W307-0140E
V-4 V- 4
State Actions
Error codes appear on the mode indicator even when Refer to "V-4 When an error code is displayed"
the hydraulic pump is restarted. (page18). Check the error, and take the appropriate
measures.
Machine can be operated manually. After operating the crane manually, contact your
nearest TADANO distributor or dealer for inspection
and maintenance.
If the manual operation does not work manually, refer
to "V-4 If the machine cannot be operated by the
radio controller and manual levers" (page22), and
stow the crane.
2. When an error occurs in the

overwind cutout device
If the alarm buzzer sounds and the following
occurs even when the weight for the overwind
cutout device does not touch the hook block, the
overwind cutout device is out of order.
• The hook block cannot be hoisted up.
• The boom cannot be extended.
• The boom cannot be raised.
Follow the procedure below to retract the boom

and outriggers
1. Lower the load.
2. While pressing the emergency overwinding

switch, stow the boom.
3. Retract the outriggers.
17 W307-0140E
V-4 V- 4
3. When the indicator lamps on the 5. Electrical system

transmitter flash 5.1 Replacement of battery
When malfunction occurs in the transmitter, the CAUTION

emergency stop indicator lamp, user mode Insert the batteries in the correct direction
indicator lamp, speed mode indicator lamp and ("+" and "-").
power lamp flash. Otherwise, fluid leak, fire, heating, and explosion
may occur, and result in injury.
Release all switches and speed lever on the
transmitter, and turn on the power again.
NOTICE
When the indicator lamps go out, the operation
Securely tighten the fixing screw on the battery
can be continued. When they do not go out, the
cover. Otherwise, water may enter and cause a
transmitter needs repair. In this case, operate the transmitter failure.
machine manually.
1. Open the battery cover, and remove the old
batteries.
2. Insert the new batteries, and then close the

battery cover and tighten it with the fixing screw.
Use four AA batteries.
Do not mix old batteries/different types of

batteries with new ones.
4. When an error code is displayed

When malfunction occurs in the operation, check
the mode indicator on the left-side control panel,
and take the appropriate measures against the
malfunction.
Depending on the error, the machine may not
operate normally. In this case, refer to "If the
Machine Cannot be Operated by the Radio
Controller and Manual Levers" described in the
next section.
18 W307-0140E
V-4 V- 4
6. Error code list

When multiple malfunctions occur, the error codes flash by turns.
Error code Detail of failure and action
E000–E011 Machine cannot be operated by the radio controller (R specification) and manual levers.
E014 Follow the procedure "If the machine cannot be operated by the radio controller and
E100 manual levers" described in the next section and stow the crane.
E120
E200–E209
E250–E271
E301–E310
E350–E371
E401
E450
E464
Overload limit function, working height limit function, automatic stowing function, boom
interlock, and jack interlock do not work.
Stow the crane.
For a crane with overload automatic stop feature (option), boom extension, boom
lowering and hoist-up operation are halted.
Follow the procedure "If the machine cannot be operated by the radio controller and
manual levers" described in the next section and stow the crane.
E013
E022 WARNING
E026 The alarm buzzer will not sound even when an overload state occurs.
E082 If an overload state occurs, the machine overturns or is damaged, resulting in a
E083 serious accident.
E500–E507
E520 The alarm buzzer will not sound even when the boom head reaches the set height
E521 limit.
E523 If the boom head exceeds the height limit, it touches an obstacle, resulting in a
serious accident.
If "E521" appears during boom lowering, stop operation. After the displayed
number goes out, you can continue the operation.
19 W307-0140E
V-4 V- 4

Machine cannot be operated by the radio controller (R specification).
Failed system cannot be operated by the manual levers.
When you are attempting radio-control operation, stop the operation and operate the
crane by manual levers.
Return the control lever corresponding to the error code to the neutral position by hand.
When the error code disappears, you can continue the operation.
If the control lever does not return to the neutral position or the error code remains, the
failed system cannot be operated by radio control (R specification) nor manual levers.
E101–E104
E121–E124
E141–E145 WARNING
E522 When the control lever for the failed system cannot be returned to the neutral
position, do not operate other systems. Otherwise, the failed system may operate
simultaneously, resulting in an accident.
"E101", "E121", "E141": Boom telescoping operation

"E102", "E122", "E142": Hook block hoisting-up/down operation
"E103", "E123", "E143": Boom elevating operation
"E104", "E124", "E144": Boom swing operation
"E522", "E145": Jack operation
Operation speed cannot be adjusted by manual levers.
Stow the crane.
E105 WARNING
E125
Accident may occur because the operation speed cannot be adjusted.
Stop working with the crane.
E084 Machine cannot be operated by the radio controller (R specification).

E085 Operate the crane manually.
E402–E409

Operate the crane manually.
If an error code "EE93", "EE94", "EE98" or "EE99" appears on the transmitter,

E042
release all switches and speed lever on the transmitter and turn on the transmitter
power again.
If the error code remains, the machine cannot be operated by the radio controller.
20 W307-0140E
V-4 V- 4

E410
Operation speed cannot be adjusted by the manual levers.
E411
The hook block cannot be stowed by the hook-in switch on the radio controller
(R specification) and hook-in/out switch on the crane body.
When the crane operation is complete, attach a retaining rope to the hook
block, and hoist up the hook block by the winch lever while pressing the
overwind cutout release switch to fix the hook block.
E451
NOTICE
The boom and wire rope may be damaged during emergency operation. Do not
stow the hook block. Fix the hook block to the truck bed.
If the hook block must be stowed, hoist up gradually until the wire rope is
tensioned slightly.
Jacks cannot be operated by the radio controller (R specification) nor manual switches.
E452–E455
E460–E463 Follow the procedure "If the machine cannot be operated by the radio controller and
manual levers" described in the next section and stow the crane.
Failed system cannot be operated by the radio controller.
Release all the switches and turn on the power again.
"E600", "E601", "E650": Hook-in/out system
"E602", "E603", "E606", "E607", "E616", "E617", "E618", "E619", "E651", "E653",
E600–619 "E657", "E658": Outrigger jack
E650–658 "E604", "E605", "E608", "E609", "E652", "E654": Outrigger beam
"E610", "E611", "E655": Accelerator
"E612", "E613", "E656": Alarm volume
"E614": Overwind cutout release system
"E615": Horn
E80 Optional working lamps and warning lamps do not work.

E81 After the job is completed, contact a TADANO distributor or dealer.
21 W307-0140E
V-4. V-4.
7. If the machine cannot be operated by 7.2 Tightening the unload valve

the radio controller and 1. Remove the cap nut from the emergency
manual levers unload valve.
2. Loosen the lock nut, and tighten the adjusting

WARNING
screw lightly until it does not rotate.
This operation makes the machine operate forcibly.
Before operation, check the following. • This allows the emergency operation.
• No one is around the machine.
• The control levers of the machine are in the 3. Lower the lifted load.
neutral position.
4. Stow the boom.
The procedure below describes the stowing
5. Fix the hook block.
method of the crane when the crane no longer
operates because of the electric failure. NOTICE
In order to avoid damage to the boom and wire
7.1 Using the emergency overwind switch rope, do not stow the hook during emergency
operation, but fix it on the truck bed.
1. Lower the lifted load.
If the hook block must be stowed unavoidably, wind
the wire rope slowly until it is slightly tensed.
2. While pressing the emergency overwinding
switch, stow the boom by the manual control.
3. Fix the hook block.
22 W307-0140E
Y
Data, Adjustment and Checks
Contents
Y-1 Service Data ..................................... 1 Y-3 Adjustment (Electric) .......................9
1. Amounts of oil ............................................ 1 1. Adjusting outrigger part

proximity switch.............................. 9
2. Operating speed ........................................ 1
3. Hydraulic device ........................................ 2

3.1 Hydraulic pump........................................... 2
3.2 Hydraulic motor .......................................... 2
3.3 Hydraulic cylinder ....................................... 2
4. Swing section............................................. 2
5. Boom section ............................................. 3

5.1 Slide plate(5-section boom)........................ 3
5.2 Boom bending and deformation ................. 4
5.3 Wire rope .................................................... 5
5.4 Sheave ....................................................... 5
5.5 Inspection the hook block........................... 6
6. Mass table ................................................. 7
Y-2 Adjustment (Hydraulic) ................... 8
1. Pressure setting......................................... 8
1.1 Radio-control valve..................................... 8
1.2 Manual control valve (outrigger)................. 8
i
Y- 1 Y- 1
Service Data
Y-1 Service Data [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.
1. Amounts of oil
(1L = 2.64172×10-1 gal)
Standard
Item Remarks
value :L
Tank capacity 90
TADANO Hydraulic Oil LL
Hydraulic oil
Amount of oil
(TADANO Genuine)
Total oil capacity 142
Swing 1.1 Mobilgear 600XP 320

Speed reducer gear oil ISO VG 320
Winch 2.3 API classification GL-3
2. Operating speed
(1m = 3.93701×10 in)
Item Standard value Remarks
Extending 5-section boom：11.52 m／40 s

Telescoping
Retracting －
Raising 1°～82°／18 s
Operating
Elevating
speed
Lowering －
Winch rope (hoist-up) speed 45 m/min On 4th layer
Swing 2.5 min-1 {rpm}
1 WY01-1890E
Y- 1 Y- 1
Service Data
3. Hydraulic device
3.1 Hydraulic pump
Refer to “Mounting Manual” for displacement reduction gear ratio, and revolution on the pump.
3.2 Hydraulic motor
Winch Displacement 45 cm3/rev (2.75 in3/rev)
Swing Displacement 39.3 cm3/rev (2.40 in3/rev)
3.3 Hydraulic cylinder

(1mm = 3.93701×10-2 in)
Item Standard value Limit value Remarks
4 mm or less / 8 mm or less / With boom raised to horizontal, fully

Amount of Elevating 30 minutes 30 minutes retracted
spontaneous
retraction when 6 mm or less / 12 mm or less / Boom extended by approx. 100 mm
Telescoping 30 minutes 30 minutes
lever is neutral, with elevating angle at Max.
and the engine
5 mm or less/ 10 mm or less/ Jack extended close to the
stopped. Jack 15 hours 15 hours cylinder's stroke end
4. Swing section
(1mm = 3.93701×10-2 in)
Horizontal play 2.5 mm or less (TES)
Amount of swing play Swing hunting Load does not sway (TES)
Responsibility
(Response delay) 1 second or less (TES)
2 WY01-1890E
Y- 1 Y- 1
Service Data
5. Boom section
5.1 Slide plate(5-section boom)

(1mm = 3.93701×10-2 in)
Standard thickness Replacement standard
Location used
mm mm
Base boom Bottom 10 7

Front
section Side 8 6
Bottom 10 7
2nd boom Front
Side 8 6
section
Rear Top 12 9
Bottom 10 7
3rd boom Front
Side 8 6
section
Rear Top 12 9
Bottom 9 6
4th boom Front
Side 8 6
section
Rear Top 12 9
Top boom
Rear Top 9 6
section
3 WY01-1890E
Y- 1 Y- 1
Service Data
5.2 Boom bending and deformation

(1mm = 3.93701×10-2 in)
Standard value mm(in)
Item Remarks
5-section boom
Overall boom bending No significant vertical or horizontal Place pads as
(at full extension, maximum elevation angle, with bends shall be found along the entire appropriate to set
rated load) boom length. the machine level.
IWY01-001001
Bend of individual boom Base boom B≦6 B≦

sections 2nd boom section 1.5 × L /1000
B≦6
Vertical
(Lengthwise direction) 3rd boom section L: length of each

B≦6
4th boom section boom section
B≦6
Top boom section B≦6
OR
B
L Base boom C≦4 C≦

IWY01-0010E02 2nd boom section C≦4 1.0 × L /1000
Lateral
3rd boom section C≦4

4th boom section C≦4
Top boom section C≦4
Indentations at boom overlap 2nd boom section D≦3 In vertical direction
sections 3rd boom section D≦ t/2
D≦2.5
(Bending at boom lower plate) 4th boom section
D≦2
Top boom section D≦1.6
t
D
IWY01-001003
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 E≦5
boom is fully extended.
IWY01-001004
Check for dents and other localized indentation. F≦2

Depth F
(at L1≧50 )
Generally dent G on the 4 corners
cannot be repaired.
L1
G IWY01-0010E05
4 WY01-1890E
Y- 1 Y- 1
Service Data
5.3 Wire rope

(1mm = 3.93701×10-2 in)
Standard
Item Limit value Remarks
value
10mm(Nominal Construction
Wire rope diameter 7.5 mm
diameter) 7×7+6×Fi (29) O/O
For winch
Number of broken wire – 13 pieces
370-018-06730
10mm(Nominal Construction
Wire rope diameter diameter) 9.3 mm
IWRC 6×Fi (29) O/O
For boom
extension
5-section 370-019-19270,-19280
boom 8 mm(Nominal Construction

Wire rope diameter 7.5 mm
diameter) IWRC 6×Fi (29) O/O
For boom
retraction
370-019-19300,-19310
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 six or more wires in one lay are broken, or if three or more
Criteria for wire rope
wires in one strand are broken.
replacement
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.
5.4 Sheave
(1mm = 3.93701×10-2 in)
Standard of minor Limit of minor
Item Remarks
diameter diameter
Determination of limit minor diameter

(When rope of nominal diameter less
Only sheaves of the hoisting than 25 mm are used)
systems are listed here.
Limit minor dia.
(Wear of sheave groove)
152 mm 149 mm = Standard minor dia. - (Nominal
Boom head sheave rope
dia. × 0.3)
Sheave of hook block
Nominal diameter of winch rope:
φ10 mm
5 WY01-1890E
Y- 1 Y- 1
Service Data
5.5 Inspection 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.
1. The sheave groove must be smooth to avoid Hook service limits

damaging the wire rope. Use a grinder to smooth (1mm = 3.93701×10-2 in)
and correct any sharp corners.
Hook capacity
Item
2. Check whether or not the sheave turns lightly. If it
8.2 t
is heavy, the wire rope will slide against the
sheave, and the rope may be damaged. This may Dimension : a 118
also impede free-fall. If the sheave is heavy, (Deformation)（mm）（5.9）
inspect the sheave bearings, and lubricate or
Limit wear :b（mm） 2.25
replace them if necessary.
Thickness : c（mm） 75
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. a
Punch mark
5. Replace any worn or damaged hook nuts
immediately.
6. Check that the wire rope latch functions correctly.

If necessary, replace the spring. b
c
IWY01-0250E01
7. Perform a magnetic flaw detection test at least
once a year to check for cracks or other flaws 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 (δ a) 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).
6 WY01-1890E
Y- 1 . Y-1.
Service Data
6. Mass table
The dry weights of the major components are shown in the table below.
Check the weights, and select appropriate hoisting devices when removing and installing the component.
(1kg = 2.205 lb)
Specifications
Assembly name
ZR860
Boom assembly
(including telescoping cylinders) 5-section boom（kg） 1390
Post and frame section

(including elevating cylinder) 1120
(not including boom section, outrigger assy)（kg）
Outrigger Assy(1 piece)

Standard（kg） 230
(including slide section, jack cylinder)
Entire machine mounted Standard（kg） Appox.3200
7 WY01-1890E
Y- 2 . Y-2.
Adjustment Procedure (Hydraulic)
Y-2 Adjustment (Hydraulic)

[NOTICE]
Oil temp: 50 ± 5°C (113 - 131°F) (Use TADANO Hydraulic Oil LL.)
◆Shift a control while the engine is idling, then increase engine speed.
1. Setting pressure
1.1 Radio-control valve
Setting pressure
Item Remarks
MPa {kgf/cm2} (psi)
Pressure setting condition:
Main relief valve：C 20.6~21.1 {210~215} (2988~3060)
at 60 L / min(16 gal / min)

Low-pressure relief valve：Z 2.94~3.92 {30~40} (426~569)
at 20 L / min(5.3 gal / min)

Back pressure valve：D 2.16~2.55 {22~26} (313~370)
at 6 L / min(1.6 gal / min)

P port flow rate
Reducing valve：E 2.00~2.20 {20.4~22.4} (290~319) at 6 L/min(1.6 gal / min)
Pilot flow rate
at 0.4 L / min(0.1 gal / min)

Pilot circuit relief valve：E at 1.5 L / min(0.4 gal / min)
2.26~2.85 {23~29} (328~413)
(for overload) Combined with reducing
valve function.
1.2 Manual control valve (outrigger)
Setting pressure
Item Remarks
2
MPa {kgf/cm } (psi)
Relief valve：RV2 20.6~21.1 {210~215} (2988~3060)
at 43 L / min(11 gal / min)
8 WY02-1130E
Y- 3 . Y-3.
Adjustment Procedure (Electric)
Y-3 Adjustment (Electric)

1. Adjusting outrigger part proximity switch
1) Checking outrigger extension state
Check the following, and if not properly detected, make an adjustment according to the adjustment
procedure 2).
A. Outrigger extension state detecting switch

1. Check that false detection is not made even if the outrigger inner case is swung to the right and left
both at maximum extension and minimum extension states.
Check lamp
Outrigger extension Max. extension Middle extension
state detecting switch detecting switch
Max. extension Lights up (Red) Goes off
[NOTICE]
Middle extension Goes off Lights up (Red) ◆ The check lamp is on
the proximity switch.
Min. extension Goes off Goes off
2) Adjusting outrigger extension state detecting switch
A. Outrigger extension state detecting switch
1. Measure the dimension when dimension C on the figure on the next page is minimized by lateral
looseness between the outrigger outer case and inner case.
2. Protrusion of the switch (dimension D) should be the "minimum value of the dimension C -2.5 mm
(0.1in)."
(Turn the proximity switch to contact with the side of the outrigger, then turn back the switch by half
and two turns.)
3. Check whether the detecting state has become normal.
4. If the detection is not carried out properly, perform the adjustment above again.
313-621-31300 △
0
9 WY04-1490E
Z
System Diagrams
Contents
Z-1 Hydraulic Circuit .............................. 1
1. Radio-control spec..................................... 1
Z-2 Electric Circuit.................................. 2
Z-3 Location of Hydraulic Parts ............ 3
Z-4 Location of Electrical Parts............. 4
1. Boom ....................................................... 4
2. Post and boom........................................... 5
3. Frame ....................................................... 6
Z-5 Harness............................................. 7
1. Post and boom........................................... 7
2. Frame ....................................................... 8
Z
i
Z-1. Z-1. Z-1.
Hydraulic Circuit
Z-1 Hydraulic Circuit

1. Radio-control spec.
314-019-40200 △
0
1 WZ01-2450E 1
Z-2. Electric Circuit Z-2. Z-2.
Z-2 Electric Circuit

Left side of vehicle Right side of vehicle
M CN51 F F CN51 M
R 1 4 B/G 4 B/G 1 R
Outrigger maximum
Outrigger maximum
extension lamp (green) M CN52 F F CN52 M
B extension lamp (green)
1 1B 1B 1 B
M CN53 F F CN53 M
R 1 4 B/R 4 B/R 1 R
Outrigger minimum
Outrigger minimum
Radio control valve (STD 6-connection) extension lamp (red) M CN54 F F CN54 M
B extension lamp (red)
1 1B 1B 1 B
M CN7 F
F CN14 M * 1 * M CN55 F F CN55 M
2 B/R 1 B SV1 Br 2 * SV1 Unload Overload/stability R 1 4 B/W 4 B/W 1 R Overload/stability
2 B/L B SV2 F CN8 M B 2 1B 1B B
2
* warning lamp (yellow) 2 warning lamp (yellow)
1B 3 Br 1 * Low pressure relief
1B Br Br 2 * SV2
4
2 G/B 5 B SB1
2 G/W B SA1 SB1 Extend (out)
6
2 G/R 7 B SB2 Telescoping
2 G/Y B SA2 SA1 Retract (in)
8
2 G/L 9 B SB3
SB2 Down (out)
2 G/O 10 B SA3 M CN11 F
2 Y/W 11 B SB4 Winding
Speaker
B/W 1 2 L/Y
SA2 Up (in)
2 Y/B 12 B SA4 G 2 2 L/G
13
SB3 Down (out)
14 Elevating
2 Br/Y 15 B SA5
2 Br/G B SB5 SA3 Up (in)
16
F CN71
SB4 Left (out) 1 R/W
R 2
Swing Power relay 4 1 R/Y
SA4 Right (in) 1R
1
Communication unit (RCS-FR1) 3 1 R/B
M CN16 F M CN24
Power(+) E B 1 1 Lg 1R 1
WB 2 1 Lg/R External forcible on-load
TXD-RS D
RXD-RS C G 3 1 Lg/B effective connector M CN22/CN22 F
TEST B WR 4 2 B/W 1 2 B/Y
Power(-) A R 5 1 Lg/L
6 F CN21 M
7 2 B/W 1 R
8 M CN15 F 2 B/Y 2 B
3 L/W 1 Y 2 B/G 3 W
3 L/R W L Emergency switch
2 LVDT1 4
3 L/O 3 B In Out 3 B/R 5 G
Controller (RCS-FC2) 3 G/B G LVDT1-2 Telescoping 1B Y
4 Ret. Ext. 6
3 G/W 5 L LVDT1-1
3 G/R G LVDT2-2 M CN26 F F CN25 M
Slide 2 (left extend)/lamp top Do11 P 1 6
Slide 1 (right retract)/lamp left Do10 P 2 3 G/Y 7 L LVDT2-1 R 1 3 Br 3 Br 1 R
3 G/L G LVDT3-2 Horn switch Y 2 1B 1B Y Horn switch
Slide 1 (right extend)/lamp right Do9 P 3 8 2
Self-winch (wind-down)/auto retraction Do8 P 4 3 G/O 9 L LVDT3-1 LVDT2 Accelerator switch R 3 3 B/L 3 B/L 3 R
Self-winch (wind-up)/lamp Do7 P 5 3 Y/W 10 G LVDT4-2 In Out
Winding Top: up B 4 3 W/B 3 W/B 4 B Top: up Accelerator switch
Jack 1 (left retract) - individual (left)/lamp down Do6 P 6 3 Y/B 11 L LVDT4-1 Up Down Bottom: down W 5 1B 1B 5 W Bottom: down
Jack 1 (left extend) - individual (right)/lamp up Do5 P 7 3 Br/Y 12 G LVDT5-2 Volume switch R 6 3 W/R 3 B/W 6 B
Auto accelerator switch
Jack 2 (right retract) - simultaneous (retract) Do4 P 8 3 Br/G 13 L LVDT5-1 Top: up
B 7 3 W/G 1B 7 W
(down: connection: on)
Jack 2 (right extend) - simultaneous (extend) Do3 P 9 14 W 8 1B 8
Bottom: down
Self unload Do2 P 10
Low pressure relief (LOW)Do19 P 11 2 B/L LVDT3
2 B/W In Out M CN4/CN48 F
Unload (UNLOD)Do18 P 12 Elevating
Jack operation/Illumiation mode (HORN)Do17 P 13 Y 1 4 W/Y
Up Down Height limit switch R 2 1B
Confluence (telescoping)/fire protection (spare) Do16 P 14
Confluence (telescoping)/fire protection (out) Do15 P 15
Confluence (winch)/fire protection (out)/option Do14 P 16
Confluence (winch)/fire protection (wind)/option Do13 P 17 Arranged by customer
Slide 2 (left retract)/lamp bottom Do12 P 18 LVDT4 W/Y
Overwinding Di3 N 19 3W In Out B
Neutral position of jack Di4 N 20 Swing
Right Left
Swing direction (right front) Di5 N 21 3 Sb When shipping M CN27 F
Swing direction (right rear) Di6 N 22 3V W/Y 1 3 W/Y
Swing direction (left front) Di7 N 23 3 Gy B 2 1B
Swing direction (left rear) Di8 N 24 3P G 2 B/G
Horn Di9 N 25 3 Br Emergency stop switch G 3 2 B/R
1 Lg/B 4
Communication unit communication (output) (FR2)EX-TXD P 26
Communication unit communication (output) (FR2)EX-TXD N 27
1 Lg/R
Communication unit communication (input) (FR2)EX-RXD P 28
1B
Communication unit communication (input) (FR2)EX-RXD N 29
Differential transformer GND FB-GND 30 3 L/O
Telescoping FB1-2 31 3 G/B
Telescoping FB1-1 32 3 G/W
3 G/R Accelerator cylinder
Winch FB2-2 33
Winch FB2-1 34 3 G/Y
Elevating FB3-2 35 3 G/L F CN6 M F CN6 M
Elevating FB3-1 36 3 G/O B 1 10 Br 1 B
3 Y/B Br 2 10 Lg B SA5 SA5 Extend (out)
Swing FB4-2 37 2
Swing FB4-1 38 3 Y/W B 3 10 Y 3 B 1B
Accelerator 3 Br/Y Br 4 10 YR B AB5 SB5 Retract (in) Frame
FB5-2 39 4
Accelerator FB5-1 40 3 Br/G
Boom telescoping extend (out) SA1 P 41 2 G/B M CN5 F M CN5 F

2 G/W G 1 10 LgR G LVDT5-2
Boom telescoping retract (in) SB1 P 42 10 LgB 1
SA2 P 43 2 G/R Y 2 2 Y LVDT5
Winch down (out)
SB2 P 44 2 G/Y W 3 10 GB 3 W In Out
Winch up (in) Telescoping
Elevating down (out) SA3 P 45 2 G/L 4 4 When PTO switch downstream is grounded
Ret. Ext.
SB3 P 46 2 G/O L 5 10 BY 5 L LVDT5-1
Elevating up (in)
2 Y/B B 10 L B PTO switch PTO lamp Fuse box Key switch Battery on vehicle
Swing left (out) SA4 P 47 6 6
Swing right (in) SB4 P 48 2 Y/W
Accelerator extend (out) SA5 P 49 2 Br/Y M CN1 F
Accelerator retract (in) SB5 P 50 2 Br/G 1
Auto accelerator Di10 N 51 3 B/W 2
Emergency operation Di11 N 52 3 B/R 3
Hook-out Di12 P 53 4
Hook retraction Di13 P 54 Chassis
Accelerator up Di14 N 55 3 B/L
Accelerator down Di15 N 56 3 W/B
Volume up Di16 N 57 3 W/R PTO lamp PTO switch Fuse box Key switch Battery on vehicle
Volume down Di17 N 58 3 W/G M CN1 F
Interlock Di18 N 59 3 W/Y 1 R/Y 1
Jack 2 (right extend) - simultaneous (extend) Di19 P 60 1 R/W 2
Jack 2 (right retract) - simultaneous (retract) Di20 P 61 1 R/B 3
Jack 1 (left extend) - individual (right) Di21 P 62 1B 4
Jack 1 (left retract) - individual (left) Di22 P 63 Chassis Controller (STM-P)
Slide 2 (right extend) Di23 P 64 When over-unwind is detected
Slide 2 (right retract) Di24 P 65 1 N Do8(100mA) (Drum free)
Outrigger 3 extend (right) Di25 P 66 4 B/Y Over-unwind M CN7 F 2 N Do7(100mA) (Working lamp)
4 B/L Br 1
Outrigger 4 extend (left) Di26 P 67
1B F CN8 M
Electronic governor detection L 2
3 N Do6(100mA) (Height limit lamp)
Main GND GND1 68 switch 4 N Do5(100mA) (Warning lamp/buzzer)
Electronic governor power SRC5(5V) 69 1 Br/R 1 Br/R 1 E. gov. power 5 N Pi2 Drum rotation times detector 2
Electronic governor output ACC(5V) 70 1 Br/W 1 Br/W 2 E. gov. output 6 P Di5 (Spare)
Electronic governor GND GND8 71 1 Br/B 1 Br/B 3 E. gov. GND M CN7 F 7 N Di3 (Swing position detection)
Communication unit power (FR2)VCC(5V) 72 1 Lg 4 G 1 Br Br 8 N Di1 (overwind detection)
Speaker AUDIO1 N 73 2 L/G G 2 B R 9 MBSRC Power input
Speaker AUDIO2 P 74 2 L/Y Br/W 10 Ai4 Rod pressure detector input
Primary differential transformer OSC1 P 75 3 L/W L/W 11 Ai3 Cylinder pressure detector input
Primary differential transformer OSC2 N 76 3 L/R Y/W 12 Ai2 Angle detector input
Communication unit GND (FR2)GND3 77 1 Lg/L G/W 13 Ai1 Length detector input
Main power SRC1 78 1R F CN3 M 14 N Pi1 Drum rotation times detector 1
Main power SRC2 79 1R GND
B 1 G/B 15 N Di4 Boom retraction detection
Main GND GND2 80 1B Power R 2 G/R 16 N Di2 (swing position detection)
Length detector Output W 3 G/W B 17 MBGND GND
Warning lamp Do1 P 81 4 B/W Shield G 4 G/L 18 RS-RXD Maintenance terminal
Maximum outrigger lamp Do20 P 82 4 B/G B 19 EX-RXDN Serial input
Minimum outrigger lamp Do21 P 83 4 B/R M CN4 F B 20 EX-TXDN Serial output
(Spare) ☆ Do22 P 84 Shield * 1 Y/L G/L 21 FGND1 Shield
(Spare) ☆ Ai5/Ao1 P 85 GND
B 2 Y/B Y/B 22 AGND1 GND
(Spare) ☆ Ai6/Ao1 N 86 Angle detector Output W 3 Y/W G/B 23 AGND1 GND
(Spare) ☆ Ai7/Ao2 P 87 Power R 4 Y/R Y/R 24 DTCSRC1 Detector power output
(Spare) ☆ Ai8/Ao2 N 88 G/R 25 DTCSRC1 Detector power output
(Spare) ☆ Di35 N 89 M CN6 F 26 RS-TXD Maintenance terminal
(Spare) ☆ Di36 N 90 Power R 1 L/R 27 BOOT Maintenance terminal
W 2 L/W W/R Serial input
Pulling-in winch selector Di27 N 91 Pressure detector Output
B 3 L/B W/G
28 EX-RXDP
Generator charging Di28 N 92 GND 29 EX-TXDP Serial output
Overwind (cylinder side) Y/L
Warning for overturning (right) Di29 N 93 Length detector 30 FGND1 Shield
Warning for overturning (left) Di30 N 94 detection switch M CN5 F Br/B 31 AGND1 GND
Maintenance terminal (maintenance) RS-TXD P 95 9 Lg/Y W W W W R B Power R 1 Br/R L/B 32 AGND1 GND
9 Lg/L 1B Pressure detector Output W 2 Br/W Br/R
Maintenance terminal (maintenance) RS-RXD P 96 Center joint 33 DTCSRC1 Detector power output
Maintenance terminal GND9 97 9 Lg/B (rod side) GND
B 3 Br/B L/R 34 DTCSRC1 Detector power output
Serial communication (output) (STM)EX-TXD P 98 4 W/R 1R
Serial communication (input) (STM)EX-RXD P 99 4 W/G F CN3 M
Maintenance terminal BOOT N 100 9 Lg/W 3W 1 W
(Spare) ☆ GND10 101 1 L/R 2 L L
(Spare) ☆ GND11 102 1R 3 R
(Spare) ☆ SRC6 103
Width of extended outrigger 1 (right) Di31 P 104 4 Br/R F CN4 M R R
Width of extended outrigger 2 (left) Di32 P 105 4 Br/W 3P 1 Sb
7R 3 Gy B
Pressure sensor power (left) SRC3 106 2 V B
R
7B 3V
Pressure sensor GND (left) GND4 107 F CN43
When jack pressure detector is detected 3 Gy
7 Br/B 7W 3 Sb
Pressure sensor shield (left) GND5 108 1 4 P
7G 7G 2 F CN46 M
Pressure sensor (left rod) ROD2 109 F CN43 M
7W F CN2 M F CN2 M
Pressure sensor (left cylinder) SYL2 110
F CN44 1 W R 1 Power Jack pressure 4 W/R 1 W/R W/R 1 W/R
(Spare) ☆ GND12/Di1 N 111 2 G W 2 Output detector
(Spare) ☆ GND13/Di2 N 7R 1 B 3 GND 4 W/G 2 W/G W/G 2 W/G
112
Maintenance terminal/working lamp Di33 N 113 9 Lg/R 7B 2 (left cylinder)
4 W/Y F CN44 M
F CN46 M
Height limit Di34 N 114 1 R F CN47 M
1R
(Spare) ☆ SRC7 115 F CN45
2 B R 1 Power Jack pressure 1 Br Outrigger middle extension detection switch (right)
Pressure sensor (right rod) 6G 7 Br/B 1 G 2 Output 4 Br/R 2 L
ROD1 116 detector
Pressure sensor (right cylinder) 6W B 3 GND
SYL1 117 F CN45 M (left rod)
6R F CN43 F CN46 M
Pressure sensor power (right) SRC4 118
6B 6W 1 Br 1R
Pressure sensor GND (right) GND6 119 1 1 Br
Pressure sensor shield (right) GND7 120
6 Br/B 6G 2 F CN46 M 4 Br/W 2 L Outrigger middle extension detection switch (left)
F CN43 M
F CN44 1 W R 1 Power Jack pressure
G W 2 Output F CN42 M
6R 2 detector 1R
CN17 F 1 B 3 GND 1 Br
1 9 Lg/W
6B 2 (right cylinder) 4 B/Y 2 L Outrigger maximum extension detection switch (right)
F CN44 M
2 9 Lg/Y 1 R F CN47 M
3 9 Lg/B F CN45
2 B R 1 Power Jack pressure F CN42 M
6 Br/B 1
4 9 Lg/B G 2 Output detector
1R 1 Br
5 9 Lg/L F CN45 M B 3 GND 4 B/L 2 L Outrigger maximum extension detection switch (left)
6 9 Lg/R
(right rod)
1 Br
IWZ03-4770E01
2 WZ03-4770E 314-030-30101 0 2
Z-3. Z-3. Z-3.
Location of Hydraulic Parts
Z-3 Location of Hydraulic Parts

316-492-81001 △
0
316-492-82000 △
1
316-318-90001 △
0
3 WZ07-2600E 3
Z-4 Z-4 Z-4
Location of Electrical Parts
Z-4 Location of Electrical Parts

1. Boom
313-728-20000 △
3
313-511-50000 △
1
4 WZ02-4510E 4
Z-4 Z-4 Z-4
2. Post and boom
313-621-33000 △
2
5 WZ02-4510E 5
Z-4. Z-4. Z-4.
3. Frame
313-621-31001 △
0
6 WZ02-4510E 6
Z-5 Z-5 Z-5
Harness
Z-5 Harness
1. Post and boom
313-621-33102 △
0
7 WZ04-3850E 7
Z-5. Harness Z-5. Z-5.
2. Frame
Controller (RCS-FC2) Switch assy

CN25 Emergency switch
CN21
(81～120) (41～80) (1～40) F
F
1 10 1 10 1 10
4 4 4 2 2 2 2 2 2 2 2 2 2 3 3 1 3 2 2 2
B/W B/G B/R G/B G/W G/R G/Y G/L G/O Y/B Y/W Br/Y Br/G W/B B/L B Br B/G B/Y B/W
9 9 9 4 4 9 3 3 3 3 3 3 3 2 2 3 1 3 1
Lg/Y Lg/L Lg/B W/R W/G Lg/W 1 3
B/W B/R B/L W/B W/R W/G W/Y B/L B/W W B B/W B
4 4 7 7 7 7 7 4 4 1 1 1 3 3 3 3 3 1 1 1 3 B B/R
Br/R Br/W R B Br/B G W B/Y B/L B Br/R Br/W Sb V Gy P Br Lg/B Lg/R B L/O
9 4 6 6 6 6 6 1 1 2 2 3 3 1 1 1 1 3 3 3 3 3 3 3 3 3 3
Lg/R W/Y G W R B Br/B Br/B Lg L/G L/Y L/W L/R Lg/L R R B G/B G/W G/R G/Y G/L G/O Y/B Y/W Br/Y Br/G Electric governor
31 40 31 40 31 40 Right side of vehicle
CN8
0
100
PTO switch 10 Outrigger maximum Outrigger minimum
F
CN1 extension lamp extension lamp
1 1
M
120
Br/W Br/R
CN51 CN52 CN53 CN54
50
0 1
12 1 1 Br/B
R/Y R/W F F F F
1 1
R/B B
4 1 4 1
B/G B B/R B
COTφ10
Emergency
30
Power relay
30
100
stop switch
CN71
CN27 Connector (for plug) Over-load/stability
1
1 R 1 1 CN27 warning lamp
CO
B F 100 30
100 7
30
CN55
30
7
R/W R M
30
CO 100
B
Tφ
Tφ
1
L/R 1 1 10
R/Y R/B
1 3
B W/Y W/Y B
0 F
F
2 2
B/R B/G G G 30 1 4
Right side of vehicle B B/W
2 2 400
50
50
L/G L/Y
COTφ7
0
Over-load/ W/Y
50
10
Outrigger maximum Outrigger minimum
stability 0
extension lamp extension lamp
10 10 Outrigger maximum Outrigger middle extension
warning lamp 0
CN11 extension lamp 　（right) lamp (right)
CN51 CN52 CN53 CN54 CN55 Speaker
CN42 CN46
F F F F F Outrigger maximum
F
Maintenance Connector (for plug) extension lamp (left) Radio controller valve F F
100 CN17 CN17
4
B/G
1
B
4
B/R
1
B
1
B
4
B/W 10 CN42
0 F M CN5 4 1
B/Y R
4 1
Br/R R
COTφ28
1 1 1 F
Lg/B Lg/R Lg CN6
100
9 9 9
1 Lg/B Lg/Y Lg/W F
COTφ10
Lg/L 4 1
9 9 9 B/L R M
1000
10 10 10
COTφ10
30 Lg/R Lg/L Lg/B
30
30 G/B Lg/B Lg/R 10 10

30
300
30
30
30
10 10 Br Lg
L B/Y 10 10
CN16
180
Y Y/R
Communication unit
COTφ15
(RCS-FR1)
150
Height limit switch
30
F
CN48
30
30
F
F 4 4
M6 4 1
30 W/G W/R
COTφ7
Br/W R
COTφ7
130
1 4
400
B W/Y
1B CN2
CO
COTφ10
47 φ7
CN46
100
30
0
T
Serial communication
200 Outrigger middle extension 1180
12
0
lamp (left) F
Switch assy 30
1 1 3
CN26 100 60 60 370 420 1650 200 250 900 R L/R W
COTφ10 COTφ15 COTφ28 COTφ28 COTφ28 COTφ28 COTφ15 COTφ10 COTφ10
50
250
COTφ10
300
30
CN3
100
Over-winding
COTφ15
3 3 1 3
W/B B/L B Br
550
1 3 3 1
10
B W/G W/R B F
0
0
10
30
30
3 3
30
30
50
30
30
Gy P
30
3 3
30
Sb V
F F F F F F
F M
F
M M
7 10 10 10 6
CN4
7 7 7 7 6 6 6 6
Swing direction
50
50
2 G W B R Br/B Lg/R Lg/B G/B 10 G W B R Br/B
2 1 10
B/Y B/W Lg
R 10 10 Br
External forcible on-load B/Y L 10 10
Y/R Y
CN22 CN24 effective connector
CN22 Unload CN43 CN44 CN45 CN5 CN43 CN44 CN45 F M
Connector (for plug) 1 1 2 2 3 3 3
F
Jack pressure detector (left) Jack pressure detector (right) L/W L/R L/O
CN6 B B B/L B/R
3 3 3 3
2 2 2 2
G/B G/W G/R G/Y
G/Y G/R G/W G/B
Accelerator cylinder 2 2 2 2
3
G/L
3
G/O
3
Y/W
Y/B Y/W G/O G/L
3 3 3
2 2 Y/B Br/Y Br/G
CN24 Br/G Br/Y
Connector (for plug)

CN14 CN15
Wire junction (The size of wires not specified is AVS 0.85.)
1 80 poles CN25 1 2 3 9
Radio control valve
B CN21 R B/W Br CN25 Lg/B
CN1 J15 CN21 80 poles
80 poles 80 poles
J5 CN52 CN54 CN71 40 poles
J13 J5
CN27 CN55
J7 J14 J7
CN52 CN54 CN42 CN42 CN46
CN55 AVS1.25
M6 J7
J3 AVS1.25 CN46 J9 J17 J4
CN48 CN17
J1 J2 J4 J6 J8 J12 J4 J6 J8 J16
J10 CN3 J4
CN26 AVS1.25 AVS1.25
J11
CN24 CN22 CN26
CN14
3 3 4 4 4 2 1
B/L W/B CN25 B/W B/R B/G B/R R/B
CN1
40 poles 40 poles 40 poles CN27
80 poles
CN53 CN51
CN55
CN71
CN55 CN53 CN51
J4 CN14
J4 J4 J4 AVS1.25
CN26
IWZ04-3850E02
8 WZ03-3850E 313-621-31103 0 8
Head Office
Ko-34, Shinden-cho, Takamatsu,
Kagawa, 761-0185, Japan
International Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku, Tokyo, 130-0014, Japan
TEL: +81-3-3621-7765
FAX: +81-3-3621-7785
Revision history
No. Date Chapter (Page)

1 May. 2017 H (31)
2
3
4
5

TM ZR860 1 - S1 1e

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Publication No.

1. Fundamental cautions fatal accidents, as there is a possibility that the

2.The oil cooler fan may rotate the moment the

Read the separate operation and maintenance manual,

1. Applicable specification number

TM-ZR865RS comprised of this manual and the separate documents

Error Code List ERROR_CODE_LIST(TM)-1E

Please note that, for product improvement, some

No. of boom sections 5-section

Hydraulic motor driven, spur gear speed reduction,

Outriggers extended width Min. 2,250mm Mid. 3,500mm Max. 4,800mm

Operation Radio remote controls

Maximum lifting capacity 8,200 kg

AML (Automatic Moment Limiter) AML (Automatic Moment Limiter)

bar MPa kgf/cm2

N-m kgf-m ft-lbf

-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(ToF-32)/9, T°F=(9×t°C+160)/5

B Hydraulic Power Generating System

E Boom Elevating System

G Boom Telescoping System

Y Data, Adjustment and Checks

A General Cautions Refer to separate service manual

Hydraulic Power Generating System

Manual Control Valve (Outrigger) B-1

Center Joint B-2

Jack Cylinder C-1

C Pilot Check Valve (Jack) C-2

Power Slide Cylinder C-3

Hydraulic Motor (Swing) D-1

D Swing Speed Reducer D-2

Swing Bearing D-3

Boom Elevating System

Boom Elevating Cylinder E-1

Hydraulic Motor (Winch) F-1

Boom Telescoping System

Boom (Five-section boom) G-1

G Telescoping Cylinder (Five-section boom) G-2

Counterbalance Valve (Telescoping) G-3

Error Code List Refer to separate service manual

AML (Automatic Moment Limiter) H-1

Angle Detector (Boom) H-3

Configurations of Radio-control System V-1

Radio-control Valve V-2

Action Against Emergency V-4

Data, Adjustment and Checks

Service Data Y-1

Y Adjustment (Hydraulic) Y-2

Adjustment (Electric) Y-3

Hydraulic Circuit Z-1

Electric Circuit Z-2

Z Location of Hydraulic Parts Z-3

Location of Electrical Parts Z-4

7. Name of each part

Hydraulic Power Generating System

B-1 Manual Control Valve

B-2 Center Joint ...................................... 4

B-1 Manual Control Valve (Outrigger)