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Tadano TT-600XL-1 Truck Crane Service Manual SN 437273 – PDF DOWNLOAD
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Description
Tadano TT-600XL-1 Truck Crane Service Manual SN 437273 – PDF DOWNLOAD
FILE DETAILS:
Tadano TT-600XL-1 Truck Crane Service Manual SN 437273 – PDF DOWNLOAD
Language : English
Pages : 261
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Tadano TT-600XL-1 Truck Crane Service Manual SN 437273 – PDF DOWNLOAD
Safety:
1. Fundamental cautions:
Servicemen inexperienced in the units of this machine should be cautious about safety operations. They must acquire sufficient knowledge about the equipment before dismounting and disassembling it. Before dismounting each component, a serviceman should read this service manual thoroughly and find out the weight of the component, then lift it by proper means.
The following are cautions to be observed all the time.
1. Before starting repairs, find out the origin of the problem. When it becomes clear that disassembly and maintenance are necessary, first of all read this manual and parts catalog and thoroughly understand the principle of operation and construction. Then carefully check and examine each portion. Don’t disassemble portions unrelated to the problem. Unless taking all possible measures before starting disassembly, new troubles or decline in performance may be induced.
The following are cautions to be observed all the time.
1. Before starting repairs, find out the origin of the problem. When it becomes clear that disassembly and maintenance are necessary, first of all read this manual and parts catalog and thoroughly understand the principle of operation and construction. Then carefully check and examine each portion. Don’t disassemble portions unrelated to the problem. Unless taking all possible measures before starting disassembly, new troubles or decline in performance may be induced.
2. Before operating the machine, oiling or repairing, read warning labels and instructions on the machine and understand the contents.
3. Wear a safety helmet and safety shoes whenever you carry out maintenance operation around the machine. Be sure to wear safety goggles when you hit the machine or its attachments with a hammer. In welding operation, wear safety gears such as leather gloves, helmet, goggles, apron and proper working clothes, but don’t wear loose or torn clothes. Take a ring and so on off your finger when you conduct maintenance or repair.
4. Park the machine on as level and hard ground as possible. Place chocks under wheels to prevent the vehicle from moving when doing maintenance on or below the machine.
5. Before starting maintenance, remove cables to the battery and allow the capacitors to discharge. Pull out the ignition key and hang a tag saying, “Don’t start the engine.” in the cab.
6. Don’t carry out maintenance while lifting the vehicle with only a jack or a hoist. Sustain the vehicle positively with blocks and so on to prevent fatal accidents, as there is a possibility that the vehicle loses its balance and falls down on a worker in a dismounting process of certain units.
7. When the working is done on a team of more than one person, make arrangements about co-operation and communication between workers beforehand. Give a sign without fault and make sure that the sign has been transmitted to other workers before starting the next operation.
8. When it is inevitable to measure oil pressure, rotational speed, and temperature for machine inspection without stopping the engine, be careful not to be caught or pinched in rotating or moving parts such as a fan, fan belt. Make sure that there is no obstruction or no person around the machine before operating it.
Foreword:
- This service manual describes the composition of the Model TT-600XL-1 truck crane, its repair, checks and
adjustment methods and other relevant matters. Note that this service manual does not provide the information
in the separate service manuals given below. - This service manual applies to the cranes with the specification numbers given below. Check the specification
number on the nameplate of your crane. - Read the separate operation and maintenance manual and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Tadano TT-600XL-1 Truck Crane Service Manual SN 437273 – PDF DOWNLOAD
GT-600XL-1/S1(U)-1E............................................................................ 1 Safety..................................................................................... 2 1.Fundamental cautions................................................................. 3 2.Cautions in working.................................................................. 3 2.1General......................................................................... 3 2.2Dismounting & disassembling..................................................... 4 2.3Remounting & assembling......................................................... 4 3.Cautions in operation................................................................ 4 3.1Brake fluid replenishment....................................................... 4 3.2Handling of battery............................................................. 4 3.3Handling of radiator............................................................ 5 3.4Cooling fan..................................................................... 5 4.About waste disposal................................................................. 5 4.1Gasoline........................................................................ 5 4.2Hydraulic oil................................................................... 5 4.3Motor oil....................................................................... 5 Foreword................................................................................... 6 1.Applicable spec. NO.................................................................. 6 2.Separate service manual.............................................................. 6 3.Outline of specifications............................................................ 7 4.Conversion table..................................................................... 8 5.Contents............................................................................. 11 (B) Hydraulic Power Generating System...................................................... 16 Hydraulic Power Generating System...................................................... 18 1.Functions of units............................................................... 18 1.1Hydraulic pump.............................................................. 18 1.2Rotary joint................................................................ 18 1.3Hydraulic pilot control valve............................................... 18 1.4Sequence valve.............................................................. 18 1.5Flow control valve.......................................................... 18 1.6Solenoid valve (for venting pressure for remote control).................... 18 1.7Hydraulic motor (for oil cooler)............................................ 18 1.8Solenoid valve (for oil cooler)............................................. 18 Hydraulic Pump......................................................................... 19 1.Structure........................................................................ 19 1.1General view................................................................ 19 1.2Inside view................................................................. 20 1.3Pump Mounting............................................................... 28 1.4Gear ass’y.................................................................. 29 Flow Control Valve..................................................................... 31 1.Structure........................................................................ 31 Rotary Joint........................................................................... 32 1.Structure........................................................................ 32 2.Potentiometer.................................................................... 38 2.1Adjustment.................................................................. 38 2.2Soldering................................................................... 38 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch).......................... 39 1.Structure........................................................................ 39 Sequence Valve (Pilot Pressure)........................................................ 51 1.Structure........................................................................ 51 Solenoid Valve (Pilot Pressure) (~#437377)............................................. 54 1.Structure........................................................................ 54 Solenoid Valve (Pilot Pressure) (#437378~)............................................. 55 1.Structure........................................................................ 55 Solenoid Control Valve (Jib Set and Counterweight Cylinder)............................ 57 1.Structure........................................................................ 57 Pilot Check Valve (Jib Set)............................................................ 63 1.Structure........................................................................ 63 Solenoid Valve (Oil Cooler)............................................................ 64 1.Structure........................................................................ 64 Hydraulic Motor (Oil Cooler)........................................................... 66 1.Structure........................................................................ 66 2.Air bleeding procedure........................................................... 66 Jib Lock Pin........................................................................... 67 1.Structure........................................................................ 67 Jib Offset Cylinder.................................................................... 68 1.Structure........................................................................ 68 Counterweight Cylinder................................................................. 69 1.Structure........................................................................ 69 Pilot Check Valve...................................................................... 70 1.Structure........................................................................ 70 Check Valve (Gauge lsolator)........................................................... 71 1.Structure........................................................................ 71 (D) Swing System........................................................................... 72 Swing System........................................................................... 73 1.Description of the units......................................................... 73 1.1Swing drive unit............................................................ 73 1.2Hydraulic pilot control valve............................................... 73 1.3Solenoid valve (swing free/lock select).................................... 73 1.4Select valve (dolly)........................................................ 73 2.Swing slow stop................................................................. 73 2.1Condition for slow stop..................................................... 73 2.2Control element............................................................. 73 Swing Ass’y............................................................................ 74 1.Structure........................................................................ 74 2.Swing bearing mounting bolt...................................................... 75 2.1Bearing Inner ring bolts.................................................... 75 2.2Bearing outer ring bolts.................................................... 76 Hydraulic Pilot Control Valve (Swing).................................................. 77 1.Structure........................................................................ 77 Hydraulic Motor (Swing)................................................................ 84 1.Structure........................................................................ 84 Swing Speed Reducer.................................................................... 86 1.Structure........................................................................ 86 Select Valve (Dolly)................................................................... 88 1.Structure........................................................................ 88 (E) Boom Elevation System.................................................................. 89 Elevating System....................................................................... 90 1.Description of the units......................................................... 90 1.1Elevating cylinder.......................................................... 90 1.2Counterbalance valve........................................................ 90 1.3Select valve (dolly)........................................................ 90 Elevating Cylinder..................................................................... 91 1.Structure........................................................................ 91 Counterbalance Valve (Elevating)....................................................... 93 1.Structure........................................................................ 93 2.Function......................................................................... 95 2.1When control valve is at the neutral position............................... 95 2.2While actuator is being pushed up........................................... 95 2.3While actuator descends..................................................... 95 Select Valve (Dolly)................................................................... 96 1.Structure........................................................................ 96 (F) Winch System........................................................................... 97 Winch System........................................................................... 98 1.Description of the units......................................................... 98 1.1Hydraulic motor............................................................. 98 1.2Counterbalance valve........................................................ 98 1.3Hydraulic valve............................................................. 98 1.4Solenoid valve (telescoping/aux. hoist)..................................... 98 Winch.................................................................................. 99 1.Structure........................................................................ 99 Hydraulic Motor (Winch)................................................................101 1.Structure........................................................................101 2.Air bleeding procedure...........................................................103 Counterbalance Valve (Winch)...........................................................104 1.Structure........................................................................104 2.Function.........................................................................105 2.1Balancing and holding functions.............................................105 2.2Overload relief function....................................................105 3.Principle of operation...........................................................106 3.1When control valve is in neutral............................................106 3.2Hoisting up.................................................................106 3.3Hoisting down...............................................................106 Hydraulic Valve (Winch Brake Release)..................................................107 1.Structure........................................................................107 (G) Telescoping System ....................................................................108 Telescoping System.....................................................................110 1.General..........................................................................110 1.1Telescoping cylinder........................................................110 1.2Counterbalance valve........................................................110 1.3Hydraulic valve.............................................................110 1.4Hose reel...................................................................110 2.Description of telescoping system(Refer to the circuit diagram in Chapter Z.)....111 2.1Extension circuit...........................................................111 2.2Retraction circuit..........................................................111 Boom (Four-Section Boom)...............................................................112 1.Structure........................................................................112 2.Disassembly......................................................................115 2.1Removing the 2nd boom section...............................................115 2.2Removing the 3rd boom section...............................................116 2.3Removing the top boom section...............................................117 3.Check............................................................................118 3.1Boom........................................................................118 3.2Slide plate.................................................................118 3.3Sheave......................................................................118 3.4Boom telescoping wire rope..................................................118 4.Reassembly.......................................................................118 4.1Greasing....................................................................118 4.2Install anti-buckling bolts for telescoping cylinder........................118 4.3Installing lower slide plates...............................................118 4.4Installing slide plates onto sides of rear end..............................118 5.Adjustment.......................................................................119 5.1 Adjusting clearance for the boom...........................................119 5.2 Adjusting boom telescoping wire rope.......................................119 6.Test.............................................................................120 6.1Operation test..............................................................120 6.2Boom lateral warp test......................................................120 6.3Other functional test.......................................................120 Jib....................................................................................121 1.Structure........................................................................121 1.1Location of Jib.............................................................121 1.2Jib main body...............................................................123 2.Adjustment.......................................................................125 2.1Adjusting jib 1-2 connecting spring pin.....................................125 2.2Adjusting jib inclination...................................................125 2.3Adjusting inclination of jib 2..............................................126 Telescoping Cylinder...................................................................127 1.Structure........................................................................127 Counterbalance Valve (Telescoping).....................................................129 1.Structure........................................................................129 2.Function.........................................................................130 2.1When control valve is at the neutral position...............................130 2.2While actuator is being pushed up...........................................130 2.3While actuator descends.....................................................130 Hose Reel..............................................................................131 1.Structure........................................................................131 2.Dismounting......................................................................132 3.Mounting.........................................................................132 4.Disassembly......................................................................132 5.Reassembly.......................................................................132 Hydraulic Valve........................................................................134 1. Structure.......................................................................134 (H) Safety System..........................................................................136 Safety System..........................................................................137 1.General..........................................................................137 1.1Pressure sensor.............................................................137 1.2Boom length and angle detector..............................................137 1.3Outrigger extension width detector..........................................137 1.4Other detectors and switches................................................137 1.5Moment limiter (AML-L) main body............................................137 1.6Auti-twoblock Device........................................................137 1.7Solenoid valve..............................................................137 2.Description of system............................................................137 Boom Length and Angle Detector.........................................................138 1.Structure and function...........................................................138 2.Disassembly and reassembly.......................................................140 2.1Removing the cord...........................................................140 2.2Installing the cord.........................................................140 2.3Replacing spiral spring.....................................................142 2.4Disassembling the potentiometer (for boom length detector..................142 2.5Reassembling potentiometer..................................................143 2.6Replacing the boom angle detector...........................................143 3.Adjustment.......................................................................143 Outrigger Extension Length Detector....................................................144 1.Structure and function...........................................................144 2.Disassembly......................................................................145 3.Reassembly.......................................................................146 Solenoid Valve (Auto Stop).............................................................148 1.Structure........................................................................148 (K) Cab....................................................................................150 Crane Cab Glass........................................................................152 1.Glass replacement procedure......................................................152 2.Bonding the joint between windshield glass and roof glass........................153 Air Conditioner........................................................................154 1.Component parts..................................................................154 2.Introduction to air conditioning.................................................155 2.1Principle of air conditioning...............................................155 3.Basic refrigeration cycle........................................................156 3.1Construction................................................................156 3.2Conditions for air conditioning equipment...................................157 3.3Refrigerant.................................................................158 3.4Refrigeration cycle of a car air conditioner................................159 3.5Comparison with a household air conditioner.................................159 3.6Receiver functions..........................................................160 3.7Reheat method (flow control valve)..........................................161 3.8Components..................................................................162 4.Layout...........................................................................164 4.1Overall layout..............................................................165 4.2Overall layout..............................................................165 4.3Evaporator section..........................................................166 5. Compressor ass’y................................................................167 6.Evaporator Ass’y.................................................................168 7.Condenser Ass’y..................................................................169 8.Electric.........................................................................170 8.1Electric circuit............................................................170 8.2Main harness A..............................................................171 8.3Main harness B..............................................................172 9.Important points for assembly (Layout)...........................................173 9.1Evacuation..................................................................173 9.2Charging with refrigerant...................................................173 9.3Check for gas leakage and amount of refrigerant charge......................174 9.4Heated water circuit........................................................174 9.5Run-in operation............................................................174 9.6Bolt size and tightening torque.............................................174 10.How to charge air conditioner gas...............................................175 10.1 Charging gas in automatic operation.......................................175 10.2 How to charge air conditioner gas.........................................177 10.3 How to check air conditioner..............................................179 11 Diagnosis table.................................................................180 11.1 Car air conditioner system diagnosis table I (Refrigerati.................180 11.2 Car air conditioner system diagnosis table II (External c.................183 11.3 Car air conditioner system diagnosis table III (Electrica.................185 11.4 Car air conditioner system diagnosis table IV (Electronic.................187 12.Compressor......................................................................189 12.1Compressor abnormal sound diagnosis chart..................................189 12.2Compressor diagnosis chart (1/2)...........................................190 13.Troubleshooting.................................................................192 14.Control table...................................................................198 Hydraulic Motor (Air Conditioner) (Option).............................................199 1.Structure........................................................................199 Solenoid Valve (Air Conditioner) (Option) (~#437381)...................................201 1.Structure........................................................................201 Solenoid Valve (Air Conditioner) (Option) (#437382~)...................................203 1.Structure........................................................................203 (L) Control System.........................................................................205 Control System.........................................................................206 1.Crane control devices............................................................206 Remote Control Valve (Lever)...........................................................208 1.Structure........................................................................208 Remote Control Valve (Pedal) (~#437296)................................................211 1.Structure........................................................................211 Remote Control Valve (Pedal) (#437297~)................................................213 1.Structure........................................................................213 Shuttle Valve (Lever / Pedal)..........................................................216 1.Structure........................................................................216 Solenoid Valve (Boom Telescoping / Aux. Hoist).........................................217 1.Structure........................................................................217 Solenoid Control Relief Valve (Elevating Slow Stop) (~#43737...........................219 1.Structure........................................................................219 Solenoid Control Relief Valve (Elevating Slow Stop) (#437378...........................220 1.Structure........................................................................220 (Y) Data, Adjustment and Checks............................................................222 Hydraulic Pressure Setting Table.......................................................224 Air Bleeding Procedure.................................................................225 1.Hydraulic pump...................................................................225 2.Accelerator circuit..............................................................226 3.Swing circuit....................................................................226 3.1Swing motor.................................................................226 3.2Swing hydraulic pilot control valve.........................................226 4.Winch circuit (main and aux.)....................................................227 4.1Winch motor.................................................................227 4.2Winch counterbalance valve..................................................227 4.3Winch brake release circuit.................................................227 5.Jib lock pin and jib offset cylinder.............................................227 6.Hydraulic pilot circuit..........................................................228 6.1Swing.......................................................................228 6.2Elevating...................................................................228 6.3Telescoping.................................................................228 6.4Winch (main and aux.).......................................................228 7.Oil cooler motor.................................................................228 8.Air condition motor (option).....................................................228 Electric Switch Adjustment.............................................................229 1.3rd / top boom full retraction detection limit switch (L7).......................229 2.2nd boom full retraction detection limit switch (L8).............................229 3.Jib stowed detection proximity switch (CS10).....................................229 4.Jib lock pin retraction detection limit switch (L1)..............................230 5.Main winch drum rotation proximity switch (CS13) (option)........................230 6.Aux. winch drum rotation detection proximity switch (CS14) ......................230 7.Swing dead angle detection proximity switch (CS11)...............................230 8.Swing brake holding detection switch (CS23)......................................231 9.Boom elevating control & main hoist control lever stand posit....................231 10.Swing control & boom telescoping/aux. hoist control lever st....................231 11.Counterweight equipped detection switch1 (CS18).................................232 12.Counterweight stowing position detection switch1 (CS24) ........................232 13.Front jack full retraction detection switch (S087)..............................233 Check (Crane Operation)................................................................234 1.Hoisting.........................................................................234 2.Jib..............................................................................234 3.Detection of contact of the front jack with ground...............................234 4.Setup the outrigger emergency....................................................234 5.Upper outrigger operation (option): It becomes possible whe......................234 6.Alarms...........................................................................235 7.Adjustment procedure of front jack overload detector switch .....................236 Adjustment and Checks..................................................................237 1.Engine speed adjustment procedure................................................237 1.1Speed control...............................................................237 1.2Accelerator pedal...........................................................239 1.3Engine speed................................................................239 2.Adjusting boom telescoping wire ropes............................................240 Oils and Grease Table..................................................................242 Mass Table.............................................................................243 Boom Connecting Pin and Thread Size Table..............................................244 (Z) System Diagrams........................................................................245 Hydraulic Circuit......................................................................246 Electric Circuit.......................................................................247 Electric Circuit (Outrigger Operation, Option).........................................248 Location of Hydraulic Parts............................................................249 Location of Electric Parts (Upper).....................................................250 Location of Electric Parts (Lower).....................................................251 Location of Electrical Parts (Outrigger Operation, Option).............................252 Hydraulic, Electric, Carrier Equipment Comparison Table................................253 Harness (Inside Cab)...................................................................254 Harness (Swing Table, Left)............................................................255 Harness (Swing Table, Right)...........................................................256 Harness (Boom).........................................................................257 Harness (AML, Upper)...................................................................258 Harness (Lower)........................................................................259 Harness (Outrigger Operation, Option)..................................................260 History of revision........................................................................261
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