Tadano TR-800XXL-4 Rough Terrain Crane Service Manual

Tadano TR-800XXL-4 Rough Terrain Crane Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1,306

File Size: 59.94 MB (Speed Download Link)

File Count: 5 PDF files

Brand: Tadano

Model: TR-800XXL-4

Equipment Type: Rough Terrain Crane

Manuals Included: 4 separate publications

Type of Document: Service Manual

Serial No.: 545870 and up

Searchable: Yes, text is searchable and copyable

Delivery: Instant download after payment

Categories: PDF, Tadano

$ 55

Tadano TR-800XXL-4 Rough Terrain Crane Service Manual

A Tadano TR-800XXL-4 is a single-cab rough terrain crane that works on uneven job sites, using a telescopic boom and outriggers to set and lift loads where a truck crane can't go. When one of these comes into the shop out of warranty, or a used unit arrives with no paperwork, the service manual is the book you open before pulling anything apart. Rental fleet mechanics and independent shops use it to find the procedure, the adjustment and the fault cause.

What this manual helps you do

Troubleshoot the hydraulic power generating system, from pump output to the circuits it feeds.
Rebuild or replace components in the outrigger, swing, boom elevating, winch and boom telescoping systems.
Check the safety system and control system when a function stops responding or behaves oddly.
Trace wiring and circuits using the electric system section and the system diagrams.
Adjust and verify steering, brake and suspension settings against the data, adjustment and checks section.

Who this is for

A crane service technician or rental fleet mechanic who is repairing these cranes in-house. It also suits independent repair shops and dealer technicians who need workshop procedures on the bench, not a summary.

FAQ

Q: What do I receive and how is it organised?

A: You get the set: 5 PDF files, 1,306 pages in total, in English. It holds 4 separate manuals: the main manual for Serial No. 545870 and up (435 pages), Publication GR-800XXL-1-S1(U)-1E / Serial No. 545419 (332 pages), Publication W561-0051E (79 pages), and Publication GR-800XXL-1-S2(U)-1E / Serial No. 545870 and up (460 pages). The text is searchable and copyable.

Q: Which machine does it fit?

A: The main manual cover shows serial number 545870 and up for the TR-800XXL-4. The same manual also covers the GR-800XL-1, and the title wording reads "GR-800XL-1 Service Manual".

Q: How does it fit the job I'm doing?

A: If you're replacing a component, chasing a fault or setting something back to spec, the system sections let you go straight to the circuit or assembly you're working on. Search for a term and you're there.

Keep it on the shop computer, find the procedure, and get the crane back to work.

Does this manual fit your machine?

Model	Serial No.
TR-800XXL-4	545870 and up

The serial number shown is the one printed on the manual cover. Check the model and serial number on your machine's data plate before ordering.

Models covered by this manual

This service manual is also used for one further Rough Terrain Crane model: GR-800XL-1. Check the model and serial number on your data plate before ordering.

📘 Show Index

Serial No. 545870 and up (435 pages)
- Safety
  - Fundamental cautions
  - Cautions in working
  - Cautions in operation
- Foreword
  - Applicable spec. No./Crane model
  - Separate service manual
  - Outline of specifications
- (B) Hydraulic Power Generating System
  - B-1 Hydraulic Power Generating System
  - B-2 Hydraulic Pump (Double Variable Displacement Pump)
  - B-3 Hydraulic Pump (Double Gear Pump)
- (C) Outrigger System
  - C-1 Outrigger System
  - C-2 Jack Cylinder
  - C-3 Pilot Check Valve (Jack Cylinder Retracting Prevention)
- (D) Swing System
  - D-1 Swing System
  - D-2 Swing Assembly
  - D-3 Hydraulic Pilot Control Valve (Swing)
- (E) Boom Elevating System
  - E-1 Elevating System
  - E-2 Elevating Cylinder
  - E-3 Counterbalance Valve (Elevating)
- (F) Winch System
  - F-1 Winch System
  - F-2 Winch
  - F-3 Hydraulic Motor (Winch)
- (G) Boom Telescoping System
  - G-1 Telescoping System
  - G-2 Boom (Five-Section Boom)
  - G-4 Telescoping Cylinder
- (H) Safety System
  - H-1 Safety System
  - H-2 Boom Length and Angle Detector
  - H-3 Outrigger Extension Length Detector
- (L) Control System
  - L-1 Control System
  - L-2 Remote Control Valve (Lever)
  - L-3 Remote Control Valve (Pedal)
- (N) Electric System
  - N-1 Engine Control Unit (ECU)
- (S) Steering System
  - S-1 Steering System
  - S-2 Priority Valve
  - S-3 Orbitrol
- (T) Brake System
  - T-1 Brake System
  - T-2 Brake (Service Brake)
  - T-3 Brake Valve
- (U) Suspension System
  - U-1 Suspension System
  - U-2 Suspension Lock Cylinder
  - U-3 Pilot Check Valve (Suspension Lock Cylinder)
- (Y) Data, Adjustment and Checks
  - Y-1 Hydraulic Pressure Setting Table
  - Y-2 Pneumatic Pressure Setting Table
  - Y-3 Air Bleeding Procedure
- (Z) System Diagrams
  - Z-1 Hydraulic Circuit
  - Z-2 Torque Converter Circuit
  - Z-3 Brake Circuit (Pneumatic Circuit)
- History of revision
Publication GR-800XXL-1-S1(U)-1E / Serial No. 545419 (332 pages)
- Safety
  - 1.Fundamental cautions
  - 2.Cautions in working
  - 3.Cautions in operation
- Foreword
  - 1.Applicable spec. NO
  - 2.Separate service manual
  - 3.Outline of specifications
- (B) Hydraulic Power Generating System
  - Hydraulic Power Generating System
  - Hydraulic Pump (Double Variable Displacement Pump)
  - Hydraulic Pump (Double Gear Pump)
- (C) Outrigger System
  - Outrigger System
  - Jack Cylinder
  - Pilot check Valve (jack Cylinder Retracting Prevention)
- (D) Swing System
  - Swing System
  - Swing Ass’y
  - Hydraulic Pilot Control Valve (Swing)
- (E) Boom Elevation System
  - Elevating System
  - Elevating Cylinder
  - Counterbalance Valve (Elevating)
- (F) Winch System
  - Winch System
  - Winch
  - Hydraulic Motor (Winch)
- (G) Telescoping System
  - Telescoping System
  - Boom (Five-Section Boom)
  - Jib
- (H) Safety System
  - Safety System
  - Boom Length and Angle Detector
  - Outrigger Extension Length Detector
- (L) Control System
  - Control System
  - Remote Control Valve (Lever)
  - Shuttle Valve (Lever
- (S) Steering System
  - Steering System
  - Priority Valve
  - Orbitrol
- (T) Brake System
  - Brake System
  - Brake (Service Brake)
  - Brake Valve
- (U) Suspension System
  - Suspension System
  - Suspension Lock Cylinder
  - Pilot Check Valve (Suspension Lock Cylinder)
Publication W561-0051E (79 pages)
- Foreword
  - 1.Contents
- Structure
  - 1.Torque converter
  - 2.Transmission
- Function
  - 1.Torque converter
  - 2.Transmission
- Troubleshooting
  - 1.Output remains low
  - 2.Non – power transmission
  - 3.Abnormal rise of oil temperature
- Disassembly
  - 1.Torque converter
  - 2.Transmission
- Checks
  - 1.Torque converter
  - 2.Transmission
- Reassembly
  - 1.Torque converter
  - 2.Transmission
- Oil
  - 1.Recommended oil
  - 2.Oil change procedure
- Test
  - 1.Checking operating conditions
  - 2.Hydraulic pressure measurement
  - 3.Stall test
- Maintenance standard
  - 1.Overhaul interval
  - 2.Replacing intervals of parts
  - 3.Part replacing standard
- History of revision
Publication GR-800XXL-1-S2(U)-1E / Serial No. 545870 and up (460 pages)
- Safety
- Foreword
- (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
- (L) Control System
- (S) Steering System
- (T) Brake System
- (U) Suspension System
- (Y) Data, Adjusting and Checks
- (Z) System Diagrams
- History of revision
- Contents of Information
- Hydraulic System Troubleshooting
- Dismounting and Remounting
- Disassembly and Reassembly
- Sealing Parts
- Piping Procedure
- Machine Elements
- Hydraulic Oil

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