Tadano GR-1600XL-2 User manual

Foreword
1
WA04-5330E
Foreword
This service manual describes the composition of the Model GR-1600XL-2 rough terrain crane, its adjustment
methods and hydraulic and electric circuit diagrams.
This service manual applies to the cranes with the specification numbers given below. Check the specification
number on the nameplate of your crane.
Read the separate service manual, the operation manual and the parts catalog for repair and maintenance of the
crane in conjunction with this manual. If the parts needs to be replaced, check the disassemble units and sales
units in the parts catalog before replacing them.
1. Applicable spec. and serial number
Spec. No. Applicable serial number
GR-1600-2-00103 FE5027--
GR-1600-2-00104
Separate service manual
Separate Service Manual Publication No.
1 General Cautions WA01-0121E
2 Load Moment Indicator (AML-C) W301-0414E
3 Multiplex Data Transmitter (MDT-9) W303-0582E
4
Torque Converter (EXEDY)
to be published
Transmission (EXEDY)
5 Driving Axle (ASANO) to be published
Please note that, for product improvement, some changes which are not
covered in this manual may have been incorporated in the machine.
And please note that this manual may cover the functions and equipment
which are not equipped with your machine.
Please check your actual machine for repair and maintenance.

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

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3. Outline of specifications
No. Item
Spec. No.
GR-1600-2-00103 GR-1600-2-00104
2M2D
(South America, South Africa)
1 No. of boom sections 6
2 No. of jib stages (base (jib1), top (jib2)) 2
3 Single top Fitted
4 Jib
Manual offset jib
(Fix jib)
Hydraulic offset jib
(Power tilt jib)
5 Winch
Main winch Fitted
Auxiliary winch Fitted
Winch high-speed selection Fitted
Winch brake Automatic brake (Neutral brake)
Drum
rotation
indicator
Main and
auxiliary
Visual type Fitted
Vibration type Option
6 Counterweight Self-removable type
7 Outrigger Self-removable type
8 Load moment indicator (AML) AML-C
9 Auto. stop solenoid valve energizing type Normally energized
10 Anti-two-block device Fitted
11 External warning lamp (AML) Fitted
12 Oil cooler Fitted
13 Air conditioner Fitted
14 ICF (information controller) Fitted
15 SCT (satellite communications terminal) Option
16 Eco mode system, Fuel consumption monitor Fitted
17 Removable outrigger boxes system Fitted
18 Emergency steering system Option
19 Over-unwinding prevention Option
20 Searchlight Option
21 Anemometer Option
22 Aviation obstruction light Option
23 Removable boom system Option
24 Engine model MITSUBISHI 6M60-TL
25 Tires 26.5R25

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4. Conversion table
Length
millimeter
mm
centimeter
cm
meter
m
inch
in, ”
foot
ft, ’
mile
mi
kilometer
km
1 1×10
-1
1×10
-3
3.93701×10
-2
3.28084×10
-3
1 1.60934
1×10 1 1×10
-2
3.93701×10
-1
3.28084×10
-2
6.21373×10
-1
1
1×10
3
1×10
2
1 3.93701×10 3.28084
2.54×10 2.54 2.54×10
-2
1 8.33333×10
-2
3.048×10
2
3.048×10 3.048×10
-1
1.2×10 1
Speed
km/h mile/h, mph
1 6.21373×10
-1
1.60934 1
Area
square millimeter
mm
2
square centimeter
cm
2
square meter
m
2
square inch
in
2
square foot
ft
2
1 1×10
-2
1×10
-6
1.55×10
-3
1.07639×10
-5
1×10
2
1 1×10
-4
1.55×10
-1
1.07639×10
-3
1×10
6
1×10
4
1 1.55×10
3
1.07639×10
6.4516×10
2
6.4516 6.4516×10
-4
1 6.94444×10
-3
9.2903×10
4
9.2903×10
2
9.2903×10
-2
1.44×10
2
1
Volume
cubic centimeter
cm
3
, cc
liter
lit, L
cubic meter
m
3
cubic inch
in
3
cubic foot
ft
3
gallon (US)
gal
1 1×10
-3
1×10
-6
6.10237×10
-2
3.53147×10
-5
2.64172×10
-4
1×10
3
1 1×10
-3
6.10237×10 3.53147×10
-2
2.64172×10
-1
1×10
6
1×10
3
1 6.10237×10
4
3.53147×10 2.64172×10
2
1.63871×10 1.63870×10
-2
1.63871×10
-5
1 5.78704×10
-4
4.329004×10
-3
2.83168×10
4
2.83168×10 2.83168×10
-2
1.728×10
3
1 7.48051
3.78541×10
3
3.78541 3.78541×10
-3
2.31×10
2
1.33680×10
-1
1
Force
N kgf lbf
1 1.01972×10
-1
2.24809×10
-1
9.80665 1 2.20462
4.44822 4.53592×10
-1
1

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Mass
gram
g
kilogram
kg
ounce
oz
pound
lb
metric ton
t
short ton
s. t
1 1×10
-3
3.5274×10
-2
2.20462×10
-3
1×10
-6
1.10231×10
-6
1×10
3
1 3.5274×10 2.20462 1×10
-3
1.10231×10
-3
2.83495×10 2.8349×10
-2
1 6.25×10
-2
2.83495×10
-5
3.12494×10
-5
4.53592×10
2
4.53592×10
-1
1.6×10 1 4.53592×10
-4
5×10
-4
1×10
6
1×10
3
3.5274×10
4
2.20462×10
3
1 1.10231
9.07185×10
5
9.07185×10
2
3.2×10
4
2×10
3
9.07185×10
-1
1
Pressure
pascal
Pa
kPa MPa kgf/cm2lbf/in2, psi bar
1 1×10
-3
1×10
-6
1.01972×10
-5
1.45038×10
-4
1×10
-5
1×10
3
1 1×10
-3
1.01972×10
-2
1.45038×10
-1
1×10
-2
1×10
6
1×10
3
1 1.01972×10 1.45038×10
2
10
9.80665×10
4
9.80665×10 9.80665×10
-2
1 1.42233×10 9.80665×10
-1
6.89476×10
3
6.89476 6.89476×10
-3
7.03072×10
-2
1 6.89475×10
-2
1×10
5
1×10
2
1×10
-1
1.01972 1.45038×10 1
Torque
N-cm N-m kgf-cm kgf-m
foot-pound
ft-lbf
inch-pound
in-lbf
1 1×10
-2
1.01972×10
-1
1.01972×10
-3
7.37562×10
-3
8.85074×10
-2
1×10
2
1 1.01972×10 1.01972×10
-1
7.37562×10
-1
8.85074
9.80665 9.80665×10
-2
1 1×10
-2
7.23301×10
-2
8.67961×10
-1
9.80665×10
2
9.80665 1×10
2
1 7.23301 8.67961×10
1.35582×10
2
1.35582 1.38255×10 1.38255×10
-1
1 1.2×10
1.12985×10 1.12985×10
-1
1.152513 1.15213×10
-2
8.33333×10
-2
1
Power
watt
W
kW PS
1 1×10
-3
1.35962×10
-3
1×10
3
1 1.35962
7.355×10
2
7.355×10
-1
1
Centigrade-Fahrenheit
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -62.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 4.44 90 32.22 140 60 190 87.78
-50 -45.56 0 -17.78 50 10 100 37.78 150 65.56 200 93.33
Conversion equation: t [
°
C] = 5 (T [
°
F] -32) / 9, T [
°
F] = (9 × t [
°
C] + 160) / 5

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5. Drawing method of illustrations in this service manual
The third angle projection method of mechanical drawing is used for the illustrations in this service manual.
The third angle projection method is generally composed of the front view (the figure viewed from the front:
A), top view (the figure viewed from the top: B), and right-side view (the figure viewed from the right: C) as
shown below. Draw the top view immediately above the front view, and draw the right-side view on the right
side of the front view. Tridimensional shape can generally be drawn with the figures viewed from 3 directions.
For those which cannot be drawn with the figures viewed from 3 directions, the additional figures, such as
left-side view (the figure viewed from the left: D), back view (the figure viewed from the back: E), or bottom
view (the figure viewed from the bottom: F) may be used.
For other cases, when individual detailed drawing is required, an arrow view, sectional view, or detail drawing
may be used separately.
A: Front view
B: Top view
C: Right
-side view
D: Left
-side view
E: Back view
F: Bottom view

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6. Group index
System Diagrams
Data, Adjustment and Checks
Y
Z
Y
Z

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7. Contents
Chapter
Section
Spec. No.
GR-1600-2-00103 GR-1600-2-00104
2M2D
(South America, South Africa)
Data, Adjustment and Checks
Y
Service Data Y-1
Adjusting Pressure (Hydraulic Pressure) Y-2
Adjusting Pressure (Pneumatic Pressure) Y-3
Air Bleeding Procedure Y-4
Adjusting Procedure (Electric) Y-5
Assembly Adjustment (Crane Operation) Y-6
Assembly Adjustment (Traveling Device) Y-7
Operation Check (Crane Operation) Y-8
Operation Check (Traveling Device) Y-9
Inspection and Maintenance Y-10
Boom Connecting Pin
and Thread Size Table Y-11
System Diagrams
Z
Hydraulic Circuit Z-1
Torque Converter Circuit Z-2
Pneumatic Circuit Z-3
Electric Circuit (Upper) (Crane) Z-4
Electric Circuit (Upper) (Carrier) Z-5
Electric Circuit (Lower) Z-6

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Chapter
Section
Spec. No.
GR-1600-2-00103 GR-1600-2-00104
2M2D
(South America, South Africa)
Z
Location of Installation
Hydraulic Parts Location Diagram (Upper) Z-7
Hydraulic Parts Location Diagram (Lower) Z-8
Hydraulic Parts Location Diagram
(Torque Converter) Z-9
Pneumatic Parts Location Diagram Z-10
Electric Parts Location Diagram (Upper) Z-11
Electric Parts Location Diagram
(AML, Two-blocking) Z-12
Electric Parts Location Diagram (ICF, SCT) Z-13
Electric Parts Location Diagram (Lower) Z-14
Harness Diagrams
Harness (Upper) (Crane) Z-15
Harness (Upper) (Carrier) Z-16
Harness (Lower) Z-17
Searchlight, Anemometer,
Aviation Obstruction Light (Option) Z-18