Tadano GR-500XL Service Manual

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GR-500XL

50 Ton Capacity (45.4 Metric Tons)

HYDRAULIC ROUGH TERRAIN CRANE

DIMENSIONS

GENERAL DIMENSIONS

(23.5 - 25 20PR Tires)

Turning radius 4 wheel steer 2 wheel steer Tail swing of counterweight

Note : Dimension is with boom angle at -0.8 degree.

Feet Meters

22' 6.7 38' 4-5/8" 11.7 13' 5" 4.12

Specifications are subject to change without notice.

CRANE SPECIFICATIONS

BOOM * Maximum permissible line pull may be affected by wire rope

Four section full power synchronized telescoping boom, strength.

33.5'~108.3' (10.2m~33m), of round hexagonal box construction with four sheaves, 15-5/8" (0.396m) root diameter, at boom head. WIRE ROPE - Warrington seal wire, extra improved plow steel, The synchronization system consists of a double acting telescope preformed, independent wire rope core, right regular lay. cylinder, two extension cables and retraction cables. Hydraulic 3/4"(19 mm) 6X37 class cylinder fitted with holding valve. Two easily removable wire rope guards, rope dead end provided on both sides of boom head. HOOK BLOCKS Boom telescope sections are supported by wear pads both vertically and horizontally. 50 ton (45.4 metric ton) - 5 sheaves with swivel hook and Extension speed 74.8' in 69 seconds. safety latch, for 3/4"(19mm) wire rope.(OPTIONAL)

30 ton (27.2 metric ton) - 3 sheaves with swivel hook and

BOOM ELEVATION - By a double acting hydraulic cylinder safety latch, for 3/4"(19mm) wire rope.(OPTIONAL)

with holding valve. Elevation -0.8 hand or foot operation. Boom angle indicator. safety latch, for 3/4"(19mm) wire rope. Automatic speed reduction and soft stop function.

Elevating speed -0.8

~80o in 51 seconds.

JIB - Two stage bi-fold lattice type, 5

Single sheave, 15-5/8"(0.396m) root diameter, at base and top PUMPS - Two variable piston pumps for crane functions. jib head. Stored alongside base boom section. Jib length is Tandem gear pump for steering, swing and optional equipment.

28.9' (8.8m) or 50' (15.2m). Self stowing jib mounting pins. Powered by carrier engine. Pump disconnect for crane is

AUXILIARY LIFTING SHEAVE (SINGLE TOP) (OPTIONAL) -

Single sheave, 17-5/16"(0.44m) root diameter. Mounted to main CONTROL VALVES - Multiple valves actuated by pilot boom head for single line work (stowable). pressure with integral pressure relief valves.

~80o, combination controls for 5.5 ton (5.0 metric ton) - Weighted hook with swivel and

HYDRAULIC SYSTEM

, 25o or 45o offset (tilt type).

engaged/ disengaged by rotary switch from operator's cab.

ANTI-TWO BLOC

- Pendant type over-winding cut out RESERVOIR - 148 gallon (560 lit.) capacity. External sight device with audio-visual (FAILURE lamp/BUZZER) warning level gauge. system.

FILTRATION - 26 micron return filter, full flow with bypass

protection, located inside of hydraulic reservoir. Accessible for

SWING easy replacement.

Hydraulic axial piston motor driven through planetary swing speed reducer. Continuous 360 turntable at 2.7rpm. Equipped with manually locked/released swing brake. A 360

positive swing lock for pick and carry

full circle swing on ball bearing OIL COOLER - Air cooled fan type.

and travel modes, manually engaged in cab. Twin swing system: CAB AND CONTROLS

Free swing or lock swing controlled by selector switch on front console.

Automatic speed reduction and soft stop function. Both crane and drive operations can be performed from one (swing range restricted only) cab mounted on rotating superstructure.

HOIST Left side, 1 man type, steel construction with sliding door

access and safety glass windows opening at side. Door

MAIN HOIST - Variable speed type with grooved drum driven window is powered control. Windshield glass window and roof

by hydraulic axial piston motor through winch speed reducer. glass window are shatter-resistant. Tilt-telescoping steering Power load lowering and raising. Equipped with automatic wheel. Adjustable control lever stands for swing, boom hoist, brake (neutral brake) and counterbalance valve. Controlled boom telescoping, auxiliary hoist and main hoist. Control lever independently of auxiliary hoist. Equipped with cable follower stands can change neutral positions and tilt for easy access to and drum rotation indicator. cab. Engine throttle knob. Foot operated controls: boom hoist,

boom telescoping, service brake and engine throttle. Hot water

DRUM - Grooved 15-3/4"(0.40m) root diameter x 22-3/4" cab heater and air conditioning (OPTIONAL).

(0.578m) wide. Wire rope: 597' of 3/4"diameter rope (182m of 19mm). Drum capacity: 905' (276m) 6 layers. Maximum line Dash-mounted engine start/stop, monitor lamps, cigarette pull (permissible): 14,272lbs. (6,474kg)*. Maximum line speed: lighter, drive selector switch, parking brake switch, steering 472FPM (144m/min). mode select switch, power window switch, pump engaged/

disengaged switch, swing brake switch, telescoping/auxiliary

AUXILIARY HOIST (OPTIONAL) - Variable speed type winch select switch, outrigger controls, free swing / lock swing

with grooved drum driven by hydraulic axial piston motor selector switch and ashtray. through winch speed reducer. Power load lowering and raising. Equipped with automatic brake (neutral brake) and Instruments - Torque converter oil temperature, engine water counterbalance valve. Controlled independently of main hoist. temperature, air pressure, fuel, speedometer, tachometer and Equipped with cable follower and drum rotation indicator. hour meter. Hydraulic oil pressure is monitored and displayed

on the AML-L display panel.

DRUM - Grooved 15-3/4"(0.40m) root diameter x 22-3/4"

(0.578m) wide. Wire rope: 345' of 3/4"diameter rope (105m of 19mm). Drum capacity: 905' (276m) 6 layers. Maximum line pull (permissible): 14,272lbs. (6,474kg)*. Maximum line speed: 417FPM (127m/min).

Tadano electronic LOAD MOMENT INDICATOR system TADANO AML-L monitors outrigger extended length and (AML-L) including: automatically programs the corresponding "RATED LIFTING

 Control lever lockout function CAPACITIES" table.  Lift status indicator  Outrigger status indicator Operator's right hand console includes transmission gear  Warning buzzer selector and sight level bubble. Upper console includes  Boom angle / boom length / jib offset angle / load working light switch, roof washer and wiper switch, oil

radius / rated lifting capacities / actual loads read out cooler switch, emergency outrigger set up key switch

 Ratio of actual load moment to rated load moment and air conditioning control switch. Swing lock lever and

indication 3 way adjustable seat with high back and seat belt.

 Automatic Speed Reduction and Soft Stop function

on boom elevation and swing.(swing range restricted only)

 Working condition register switch  Load radius / boom angle / tip height / swing range

preset function NOTE: Each crane motion speed is based on unladen

 External warning lamp conditions.

CARRIER SPECIFICATIONS

SUSPENSION - Front: Semi-elliptic leaf springs with hydraulic

TYPE - Rear engine, left hand steering, 4x2 front drive or lockout device. Rear: Semi-elliptic leaf springs with hydraulic

4x4 front and rear drive, selected by 2-way manual switch. lockout device.

FRAME - High tensile steel, all welded mono-box construction. BRAKE SYSTEMS - Service: Air over hydraulic disc brakes on

all 4 wheels. Parking/Emergency: Spring applied-air released

TRANSMISSION - Electronically controlled full automatic brake acting on input shaft of front axle. Auxiliary: Electro-

transmission. Torque converter driving full powershift with pneumatic operated exhaust brake. driving axle selector. 6 forward and 2 reverse speeds, constant mesh. TIRES - 23.5-25 20PR(OR)

4 speeds - high range - 2 wheel drive; 4 wheel drive 4 speeds - low range - 4 wheel drive OUTRIGGERS - Four hydraulic, beam and jack outriggers.

Vertical jack cylinders equipped with integral holding valve. Each

TRAVEL SPEED - 31 mph (50 km/h) outrigger beam and jack is controlled independently from cab.

Beams extend to 22'11-5/8" (7.0 m) center-line and retract to

AXLE - Front: Full floating type, steering and driving axle with within 9' 10-1/8" (3.0 m) overall width with floats. Outrigger jack

planetary reduction. Rear: Full floating type, steering and driving floats are attached thus eliminating the need of manually axle with planetary reduction and non-spin rear differential. attach and detach them. Controls and sight bubble located in

superstructure cab. Three outrigger extension lengths are

STEERING- Hydraulic power steering controlled by steering provided with corresponding "RATED LIFTING CAPACITIES" for

wheel. Three steering modes available: 2 wheel front, 4 wheel crane duty in confined areas. coordinated and 4 wheel crab. Mid. Extension 16' 4-7/8" center to center

Mid. Extension 21' 3-7/8" center to center Max. extension 22' 11-5/8" center to center

Float size(Diameter) 1'7-11/16"(0.5m)

ENGINE

Model Mitsubishi 6M60-TLA3B Radiator Fin and tube core, thermostat controlled Type Direct injection diesel Fan, in.(mm) Suction type, 6-blade, 23.6 (600) dia. No. of cylinders 6 Starting 24 volt Combustion 4 cycle, turbo charged and after cooled Charging 24 volt system, negative ground BoreXStroke, in.(mm) 4.646 X 4.528 (118X115) Battery 2-120 amp. Hour Displacement, cu. in (liters) 460 (7.54) Compressor, air, CFM(l /min) 29 CFM (830) at 2,600rpm Air inlet heater 24 volt preheat Horsepower (kW) Gross 267 (200) at 2,600rpm Air cleaner Dry type, replaceable element Torque, Max. ft-lb (kgm) 579 (80) at 1,400rpm Oil filter Full flow with replaceable element Capacity, gal.(liters) Fuel filter Full flow with replaceable element Cooling water 3.4 (13) Fuel tank, gal.(liters) 79.2 (300), right side of carrier Lubrication 3.4-4.0 (13-15)

Cooling Liquid pressurized, recirculating by-pass Fuel 79.2 (300)

STANDARD EQUIPMENT

- Four section full power synchronized boom 33.5'~108.3' - Independently controlled outriggers (10.2 m~33 m) - Three outrigger extension positions

- 28.9'~50' (8.8 m~15.2 m) bi-fold lattice jib (tilt type) - Self-storing outrigger pads

- Variable speed main hoist with grooved drum, cable follower - Mitsubishi 6M60-TLA3B turbo charged after cooled engine

- Drum rotation indicator (thumper type) main hoist - Electronic controlled automatic transmission driven by torque

- Anti-Two block device (overwind cutout) converter

- Boom angle indicator - 4 x 4 x 4 drive/steer

- Tadano electronic load moment indicator system (AML-L) - Non-spin rear differential

- Outrigger extension length detector -

- Electronic crane monitoring system device (front and rear)

- Tadano twin swing system and 360

- Self centering finger control levers with pilot control - Disc brakes

- Control pedals for boom hoist and boom telescoping - Fenders

- 3 way adjustable cloth seat with armrests, high back - Air drye

- Tilt-telescoping steering wheel - Engine over-run alarm

- Tinted safety glass and sun visor - Back-up alarm

- Front windshield wiper and washer - Low oil pressure/high water temp. warning device (visual)

- Roof window wiper and washer - Rear steer centering light

- Power window (cab door) - Air cleaner dust indicator

- Rear view mirrors (right and left side) - Full instrumentation package

- Mirror for main and auxiliary hoists - Complete highway light package

- Cigarette lighter and ashtray - Flood lights and work lights

- Cab floor mat - Tire inflation kit

- Pump disconnect in operator's cab - 24 volt electric system

- Hydraulic oil cooler - 5.5 ton (5.0 metric ton) hook with swivel

, 25o or 45o pinned offsets and self storing pins. - Outrigger hose protection

with 5 and 597' of 3/4" cable. (267HP) with exhaust brake

Semi-elli

positive swing lock - 23.5-25 20PR (OR) tires

tic leaf springs suspension with hydraulic lockout

and seat belt - Water separator with filter

Electric fan in cab - Tool storage compartment

- Towing hooks-Front and rear

- Lifting eyes

- Hook block tie down (front bumper)

- Weighted hook storage compartment

OPTIONAL EQUIPMENT

- Variable speed auxiliary hoist with grooved drum, cable follower, drum rotation indicator and 345' of 3/4" cable.

- Auxiliary lifting sheave (single top) stowable

- 50 ton (45.4 metric ton) 4 sheave hook block

- 30 ton (27.2 metric ton) 3 sheave hook block

- Hot water cab heater and air conditioner

HOISTING SPECIFICATIONS

LINE SPEEDS AND PULLS DRUM WIRE ROPE CAPACITIES

Main or auxiliary hoist - 15'-3/4" (0.4m) drum

Layer Speed

Line speeds

Available

Line pulls 3/4" (19mm) wire rope

Permissible

F.P.M m/min Lbs. kgf Lbs. kgf Feet Meters Feet Meters

1st

High 367 112

2nd

High 400 122

3rd

High 433 132

4th

High 466 142

5th

High 502 153

High 534 163

6th

Developed by machinery with first layer of wire rope, but not based DRUM DIMENSIONS on rope strength or other limitation in machinery or equipment. Inch mm Line speeds based only on hook block, not loaded. Root diameter 15-3/4" 400 Sixth layer of wire rope is not recommended for hoisting Length 22-3/4" 578 operations. Flange diameter 25-3/8" 645 Permissible line pull may be affected by wire rope strength.

15,698 7,121 14,272 6,474 14,647 6,644 13,315 6,040 13,520 6,133 12,292 5,576 12,557 5,696 11,417 5,179 11,721 5,317 10,657 4,834 10,989 4,985 9,991 4,532

Wire rope layer

1 2 3 4 5

Main and auxiliary drum grooved lagging

Rope per layer Total wire rope

123.0 37.5 123.0 37.5

134.2 40.9 257.2 78.4

145.3 44.3 402.5 122.7

156.5 47.7 559.0 170.4

167.7 51.1 726.7 221.5

178.8 54.5 905.5 276.0

GR-500XL WORKING RANGE CHART

GR-500XL RATED LIFTING CAPACITIES (IN POUNDS

)

(

)

(

)

(

)

(

)

(

)

(

ON OUTRIGGERS FULLY EXTENDED 22' 11-5/8'' (7.0m) SPREAD

360o ROTATION

A 33.5' 46' 58' 71' 83' 96' 108.3'

(10.2m)

(14.02m) (17.68m) (21.64m)

(25.3m)

(29.26m)

(33.0m)

10' 100,000 48,500 47,000 41,000 12' 77,000 48,500 47,000 41,000 36,600 R W R W R W R W R W R W

15' 67,200 48,500 47,000 41,000 36,600 30,400 80 20' 52,700 48,500 42,700 36,400 31,100 27,500 20,000 75 25' 36,500 43,000 37,500 32,000 26,900 23,700 20,000 70 30' 33,700 33,200 28,600 23,600 20,700 19,100 65 35' 25,300 26,100 25,500 20,900 18,400 16,700 60

40' 20,700 20,900 18,500 16,400 14,700 55 45' 16,700 17,000 16,500 14,800 13,200 50 50' 13,700 14,100 13,900 13,400 11,900 45 55' 11,700 11,900 11,600 10,800 40 60' 10,000 10,200 10,000 9,700 35 65' 8,700 8,700 8,700 30 70' 7,300 7,300 7,600 25

Boom Angle

Degree

o o o o o

o o o o o o o

108.3' (33.0m) Boom + 28.9' (8.8m) Jib 108.3' (33.0m) Boom + 50.0' (15.2m) Jib

5o offset 25o offset

offset 25o offset 45o offset45o offset

19.0 9,900 28.5 8,150 35.4 6,000 24.9 5,900 40.7 4,000 52.8 2,850

31.5 9,900 40.0 7,200 46.9 5,700 39.4 5,900 54.5 3,500 65.3 2,550

43.6 8,600 51.5 6,300 57.4 5,300 52.8 4,900 67.3 3,100 76.8 2,400

55.1 6,900 62.3 5,500 67.3 4,850 65.9 4,100 79.4 2,850 87.6 2,300

65.9 5,800 72.5 4,800 76.4 4,400 78.4 3,500 90.9 2,650 97.4 2,200

76.1 4,900 82.0 4,150 85.3 3,950 90.2 3,000 101.1 2,350 106.6 2,100

85.6 4,100 90.6 3,700 93.2 3,500 100.7 2,650 110.6 2,150 114.5 1,950

94.2 3,500 98.4 3,100 100.1 2,850 110.6 2,250 119.1 1,950 121.7 1,800

101.7 2,750 105.3 2,450 119.4 1,650 126.6 1,550

108.6 2,150 111.6 2,000 127.6 1,200 133.2 1,150

114.8 1,650 117.1 1,650

119.8 1,350 121.7 1,400 75' 6,300 6,350 6,600 80' 5,400 5,700 A: Boom length in feet 85' 4,750 4,900 B: Load radius in feet 90' 4,150 C: Minimum boom angle (deg.) for indicated length (no load) 95' 3,650 D: Loaded boom angle (deg.)

100' 3,150 R: Load radius in feet

C W: Rated lifting capacity in pounds

LIFTING CAPACITIES AT ZERO DEGREE BOOM ANGLE ON OUTRIGGERS FULLY EXTENDED

22' 11-5/8'' (7.0m) SPREAD 360

ROTATION

A 33.5' 46' 58' 71' 83' 96' 108.3'

26.2 32,200 38.7 21,500 50.7 13,400 63.6 8,900 75.6 6,200 88.7 4,200 101.0 3,100

10.2m)B

(14.02m)

(17.68m)

(21.64m)

B(25.3m)B

(29.26m)

B(33.0m

ON OUTRIGGERS MID. EXTENDED 21' 3-7/8"(6.5m) SPREAD

A 33.5' 46' 58' 71' 83' 96' 108.3'

(14.02m) (17.68m) (21.64m)

10.2m

25.3m

(29.26m)

10' 100,000 48,500 47,000 41,000 12' 77,000 48,500 47,000 41,000 36,600 R W R W R W R W R W R W 15' 67,200 48,500 47,000 41,000 36,600 30,400 80

20' 52,700 48,500 42,700 36,400 31,100 27,500 20,000 75 25' 36,500 39,300 37,500 32,000 26,900 23,700 20,000 70 30' 28,100 28,300 28,600 23,600 20,700 19,100 65 35' 21,000 21,300 21,800 20,900 18,400 16,700 60 40' 17,000 17,300 17,300 16,400 14,700 55 45' 13,700 14,000 14,100 14,300 13,200 50 50' 11,100 11,500 11,700 11,800 11,450 45 55' 9,500 9,700 9,900 9,800 40 60' 8,000 8,200 8,300 8,200 35

33.0m

Boom Angle

Degree

o o o o o o o o o

360

ROTATION

108.3' (33.0m) Boom + 28.9' (8.8m) Jib 108.3' (33.0m) Boom + 50.0' (15.2m) Jib

offset 25o offset

5o offset 25o offset

offset45o offset

19.0 9,900 28.5 8,150 35.4 6,000 24.9 5,900 40.7 4,000 52.8 2,850

31.5 9,900 40.0 7,200 46.9 5,700 39.4 5,900 54.5 3,500 65.3 2,550

43.6 8,600 51.5 6,300 57.4 5,300 52.8 4,900 67.3 3,100 76.8 2,400

55.1 6,900 62.3 5,500 67.3 4,850 65.9 4,100 79.4 2,850 87.6 2,300

65.9 5,800 72.5 4,800 76.4 4,400 78.4 3,500 90.9 2,650 97.4 2,200

76.1 4,500 82.0 3,850 85.3 3,850 90.2 3,000 101.1 2,350 106.6 2,100

85.6 3,300 90.6 2,850 93.2 2,900 100.7 2,050 110.6 1,750 114.5 1,750

94.2 2,350 98.4 2,000 100.1 2,050 110.6 1,350 119.1 1,150 121.7 1,150

101.7 1,650 105.3 1,450

108.6 1,150 111.6 1,000 65' 7,000 7,000 7,000 70' 5,900 5,900 6,000 75' 5,000 5,000 5,100 80' 4,300 4,400 A: Boom length in feet 85' 3,700 3,700 B: Load radius in feet 90' 3,100 C: Minimum boom angle (deg.) for indicated length (no load) 95' 2,700 D: Loaded boom angle (deg.)

100' 2,200 R: Load radius in feet

C W: Rated lifting capacity in pounds

LIFTING CAPACITIES AT ZERO DEGREE BOOM ANGLE ON MID. EXTENDED

21'3-7/8''

6.5m) SPREAD 360o ROTATION

A 33.5' 46' 58' 71' 83' 96' 108.3'

26.2 32,200 38.7 17,600 50.7 10,900 63.6 7,300 75.6 4,900 88.7 3,300 101.0 2,200

10.2m)B

(14.02m)

(17.68m)

(21.64m)

B(25.3m)B

(29.26m)

B(33.0m

GR-500XL RATED LIFTING CAPACITIES (IN POUNDS)

(

ON OUTRIGGERS MID. EXTENDED 16' 4-7/8"(5.0m) SPREAD

A 33.5' 46' 58' 71' 83' 96' 108.3'

B (10.2m) (14.02m) (17.68m) (21.64m) (25.3m) (29.26m) (33.0m)

10' 100,000 48,500 47,000 41,000 12' 77,000 48,500 47,000 41,000 36,600 R W R W R W R W R W R W 15' 61,300 48,500 47,000 41,000 36,600 30,400 20' 38,500 38,200 38,200 36,400 31,100 27,500 20,000 25' 24,500 25,900 25,900 26,400 26,900 23,700 20,000 30' 18,600 19,000 19,400 19,800 19,600 19,100 35' 13,200 14,400 14,800 15,000 15,000 15,000 40' 11,200 11,700 11,900 11,900 11,900 45' 8,800 9,300 9,500 9,500 9,600 50' 7,000 7,500 7,700 7,700 7,800

Boom

Angle

80 75 70 65 60 55 50

ROTATION

360

108.3' (33.0m) Boom + 28.9' (8.8m) Jib 108.3' (33.0m) Boom + 50.0' (15.2m) Jib

ree

offse

19.0 9,900 28.5 8,150 35.4 6,000 24.9 5,900 40.7 4,000 52.8 2,850

31.5 9,900 40.0 7,200 46.9 5,700 39.4 5,900 54.5 3,500 65.3 2,550

43.6 8,150 51.5 6,300 57.4 5,300 52.8 4,900 67.3 3,100 76.8 2,400

55.1 5,500 62.3 4,700 67.3 4,350 65.9 3,900 79.4 2,850 87.6 2,300

65.9 3,400 72.5 3,150 76.4 3,000 78.4 2,400 90.9 1,950 97.4 1,900

76.1 2,200 82.0 2,000 85.3 2,000 90.2 1,300 101.1 1,130 106.6 1,100

85.6 1,300 90.6 1,150 93.2 1,200

25ooffse

45ooffse

5o offse

25ooffse

45ooffse

55' 6,000 6,100 6,150 6,300 60' 4,850 5,000 5,000 5,100 65' 4,050 4,050 4,150 70' 3,300 3,300 3,400 75' 2,650 2,700 2,800 A: Boom length in feet 80' 2,100 2,200 B: Load radius in feet 85' 1,600 1,700 C: Minimum boom angle (deg.) for indicated length (no load) 90' 1,300 D: Loaded boom angle (deg.) 95' 900 R: Load radius in feet

LIFTING CAPACITIES AT ZERO DEGREE BOOM ANGLE ON OUTRIGGERS MID. EXTENDED

16'4-7/8''

5.0m) SPREAD 36

ROTATION

W: Rated lifting capacity in pound

A 33.5' 46' 58' 71' 83' 96'

D B (10.2m) B (14.02m) B (17.68m) B

26.2 22,700 38.7 11,600 50.7 6,900 63.6 4,300 75.6 2,600 88.7 1,400

(21.64m)

B(25.3m)B

(29.26m)

Boom length in feet

NOTE:Load radiuses for jib operation are given for reference with the boom fully extended to 108.3' (33m).

4,700 lbs. (2,132 kg) shall be subtracted from the rated lifting capacity of the main boom, when 28.9' jib is attached to main boom head. 28.9' jib weight is 1,250 lbs. (567 kg)

6,600 lbs. (3,000 kg) shall be subtracted from the rated lifting capacity of the main boom, when 50.0' jib is attached to main boom head. 50.0' jib weight is 1,780 lbs. (807 kg)

Standard number of parts of line for outrigger operation should be according to the following table.

Boom Length in Feet

(meters)

Number of parts of line

The lifting capacity data stored in the LOAD MOMENT INDICATOR (AML-L) is based on the standard number of parts of line listed in the chart. Maximum lifting capacity is restricted by the number of parts of line of LOAD MOMENT INDICATOR (AML-L).

33.5'

(10.2)

33.5' to 71'

(10.2 to 21.64)

71' to 108.3'

(21.64 to 33.0)

Single top

Jib

WARNING AND OPERATING INSTRUCTIONS FOR LIFTING CAPACITIES

GENERAL 10. When making lifts at a load radius not shown, use the next

1. RATED LIFTING CAPACITIES apply only to the machine as longer radius to determine allowable capacity. originally manufactured and normally equipped by TADANO 11. Load per line should not exceed 11,500 lbs. (5,200kg) for LTD. Modifications to the machine or use of optional main winch and 11,000 lbs. (5,000kg) for auxiliary winch. equipment other than that specified can result in a reduction 12. Check the actual number of parts of line with LOAD MOMENT of capacity. INDICATOR (AML-L) before operation. Maximum lifting

2. Hydraulic cranes can be hazardous if improperly capacity is restricted by the number of parts of line of LOAD operated or maintained. Operation and maintenance of this MOMENT INDICATOR (AML-L). Limited capacity is as machine must be in compliance with information in the determined from the formula, Single line pull for main winch Operation and Maintenance Manual supplied with (11,500 lbs.) x number of parts of line. the crane. If this manual is missing, order a replacement 13. The boom angle before loading should be greater to account through the distributor. for deflection.

3. The operator and other personnel associated with this 14. The 33.5' (10.2m) boom length capacities are based on boom machine shall fully acquaint themselves with the latest fully retracted. If not fully retracted [less than 46'(14.0m) American National Standards Institute (ANSI) safety boom length], use the rated lifting capacities for the 46' (14.0m) standards for cranes. boom length.

SET UP attempted within the limits of the RATED LIFTING CAPACITIES.

1. Rated lifting capacities on the load chart are the maximum The ability to telescope loads is limited by hydraulic pressure, allowable crane capacities. They are based on the machine boom angle, boom length, crane maintenance, etc. standing level on a firm supporting surface under ideal job 16. For lifting capacity of single top, reduce the rated lifting conditions. Depending on the nature of the supporting capacities of relevant boom by the mass of the main hook surface, it may be necessary to have structural supports block. Capacities of single top shall not exceed 11,000 lbs. under the outrigger floats or tires to spread the loads to a (5,000kg) including main hook. larger surface. 17. When erecting and stowing jib, be sure to retain it by hand or by

2. For outrigger operation, outriggers shall be properly extended other means to prevent its free movement. with tires free of supporting surface before operating crane. 18. 4,700 lbs. (2,132 kg) shall be subtracted from the rated lifting

OPERATION boom head. 28.9' jib weight is 1,250 lbs. (567 kg)

1. Rated lifting capacities have been tested to and meet 6,600 lbs. (3,000 kg) shall be subtracted from the rated lifting minimum requirements of SAE J1063-Cantilevered Boom capacitiy of the main boom, when 50.0' jib is attached to main Crane Structures Method of Test. boom head. 50.0' jib weight is 1,780 lbs. (807 kg)

2. Rated lifting capacities do not exceed 85 % of the tipping 19. Use Anti-two block (OVERWIND CUTOUT) disable switch load on outriggers fully extended as determined by SAE when erecting and stowing jib and when stowing hook block. J765-Crane Stability Test Code. While the switch is pushed, the hoist does not stop, even when Rated lifting capacities for partially extended outriggers are overwind condition occurs. determined by this formula, Rated Lifting Capacities 20. For boom length with 28.9' (8.8m) jib, rated lifting capacities are =(Tipping Load - 0.1 x Tip Reaction)/1.25. determined by loaded boom angle only in the column headed

3. Rated lifting capacities above bold lines in the chart are "108.3' (33.0m) boom + 28.9' (8.8m) jib". based on crane strength and those below, on its stability. For boom length with 50' (15.2 m) jib, rated lifting capacities They are based on actual load radius increased by boom are determined by loaded boom angle only in the column deflection. headed "108.3' (33.0m) boom + 50' (15.2m) jib".

4. The weight of load handling device such as hook blocks, For angles not shown, use the next lower loaded boom angle slings, etc., must be considered as part of the load and must to determine allowable capacity. be deducted from the lifting capacities. 21. When lifting a load by using jib (aux. winch) and boom (main

5. Rated lifting capacities are based on freely suspended loads winch) simultaneously, do the following: and make no allowance for such factors as the effect of wind, sudden stopping of loads, supporting surface conditions, operation. inflation of tires, operating speeds, side loads, etc. Side pull on the boom or jib is extremely dangerous. within rated lifting capacity for jib.

6. Rated lifting capacities do not account for wind on lifted load or boom. We recommend against working under the condition DEFINITIONS

that the load is out of control due to a strong wind. During 1. Load Radius: Horizontal distance from a projection of the axis boom lift, consider that the rated lifting capacity is reduced of rotation to supporting surface before loading to the center of by 50% when the wind speed is 20mph (9m/s) to 27mph the vertical hoist line or tackle with load applied. (12m/s) ; reduced by 70% when the wind speed is 27mph 2. Loaded Boom Angle: The angle between the boom base (12m/s) to 31mph (14m/s). If the wind speed is 31mph section and the horizontal, after lifting the rated lifting capacity (14m/s) or over, stop operation. During jib lift, stop operation at the load radius. if the wind speed is 20mph (9m/s). 3. Working Area: Area measured in a circular arc about the

7. Rated lifting capacities at load radius shall not be exceeded. centerline of rotation. Do not tip the crane to determine allowable loads. 4. Freely Suspended Load: Load hanging free with no direct

8. Do not operate at boom lengths, radii, or boom angle, where external force applied except by the hoist line. no capacities are shown. Crane may overturn without any 5. Side Load: Horizontal side force applied to the lifted load either load on the hook. on the ground or in the air.

9. When boom length is between values listed, refer to the rated lifting capacities of the next longer and next shorter booms for the same radius. The lesser of the two rated lifting capacities shall be used.

15. Extension or retraction of the boom with loads may be

capacitiy of the main boom, when 28.9' jib is attached to main

 Enter the operation status as jib operation, not as boom  Before starting operation, make sure that mass of load is

GR-500XL RATED LIFTING CAPACITIES (IN POUNDS)

(

)

Over Front

Boom Length in Feet

33.5'

(10.2m)

10'

38,500

37,000 15' 20' 25'

33,700

25,500

17,400 30' 12,700 35' 40' 45' 50'

58'

(17.68m)

33,60012' 29,000 22,500 17,800 13,100 10,000 7,800 6,100

5,000 55' 60' 65' 70' 75'

LIFTING CAPACITIES AT ZERO DEGREE BOOM ANGLE ON RUBBER OPERATION

Over Front

33.5'

(10.2m)

B D

26.2 ##### 50.7 4,700

0

(17.68m)

75.6 1,100

ON RUBBER TIRE: 23.5-25 22PR

Stationary

360

Rotation

Boom Length in Feet

83'

(25.3m)

33.5'

(10.2m)

58'

(17.68m)

28,000

18,700 16,000

22,000 16,900

9,900 6,100

22,500 17,500 10,500

6,900

4,700 9,600 7,500 5,700

3,100

2,000

1,100 4,500 3,500 2,700 2,100 1,650 1,200

Stationary

360 Rotation

(25.3m)

(10.2m)

26.2 5,500

83'

(25.3m)

33.5'

(10.2m)

35,700 30,800 25,200

10,800

18,500 7,300 14,100 5,100 3,500 2,300 1,400

33.5' 58'58' 83' 33.5'

26.2

Creep

Over Front

Boom Length in Feet

58'

(17.68m)

32,000 26,400 20,000 15,400 12,100 10,000 7,800 6,100 5,000

Creep

Over Front

(10.2m)

13,100

(17.68m)

4,700

(25.3m)

18,700 15,800 12,700

9,600 7,500 5,700 4,500 3,500 2,700 2,100 1,650 1,200

75.6

83'

(25.3m)

1,100

Boom length in feet

Load radius in Minimum boom angle

Loaded boom angle (deg.

eet

deg.) for indicated length (no load

Boom length in feet Working area

Over front

NOTE:

Standard number of parts of line for on rubber operation should be according to the following table. The lifting capacity data stored in the LOAD MOMENT INDICATOR (AML-L) is based on the standard number of parts of line listed in the chart.

Boom mode

Number of parts of line

Boom

Single top

Approx. 2

WARNING AND OPERATING INSTRUCTIONS FOR ON RUBBER LIFTING CAPACITIES

360

Rear

1. Rated lifting capacities on rubber are in pounds and do not exceed 6. Over front operation shall be performed within two degrees in front of 75 % of tipping loads as determined by SAE J765-Crane Stability chassis. Test Code. 7. On rubber lifting with "jib" is not permitted. Maximum permissible

2. Rated lifting capacities shown in the chart are based on condition boom length is 83 ft. (25.3m). that crane is set on firm level surfaces with suspension lock applied. 8. When making lift on rubber (stationary), set parking brake. Those above bold lines are based on tire capacity and those 9. For creep operation, boom must be centered over front of machine, below, on crane stability. They are based on actual load radius swing lock engaged, and load restrained from swinging. Travel increased by tire deformation and boom deflection. slowly and keep the lifted load as close to the ground as possible,

3. If the suspension lock cylinders contain air, the axle will not be and especially avoid any abrupt steering, accelerating or braking. locked completely and rated lifting capacities may not be obtainable. 10. Do not operate the crane while carrying the load. Bleed the cylinders according to the operation safety and 11. Creep is motion for crane not to travel more than 200 ft. (60 m) in maintenance manual. any 30 minute period and to travel at the speed of less than 1 mph

4. Rated lifting capacities are based on proper tire inflation, capacity (1.6 km/h). and condition. Damaged tires are hazardous to safe operation of 12. For creep operation, set drive select switch to "4-WHEEL (Lo)" and crane. set gear shift lever to "1".

5. Tires shall be inflated to correct air pressure.

Tires

23.5-25 20PR

Air Pressure

68 psi. (4.75kgf/cm2)

WARNING AND OPERATING INSTRUCTIONS

FOR USING THE LOAD MOMENT INDICATOR (AML-L)

1. When operating crane on outriggers:  Press the boom mode select key to select the boom

 Before outrigger operation, the suspension lock operation

must be performed. Suspension lock system can only be Pay attention to the following : performed in the over-front area. (1) For stationary operation :

 Push and hold the suspension lock switch to the "LOCK"  The front capacities are attainable only when the over fr

position until suspension lock lamp changes from flashing position symbol comes on. When the boom is more than to a solid light and the suspension is fully retracted. 1 degree from centered over front of chassis, 360 (Outrigger and crane operations cannot be performed capacities are in effect. until suspension lock operation has been completed.)

 Set P.T.O. switch to "ON". to the side area, make sure the value of the LOAD  Extend the outriggers and level the crane. MOMENT INDICATOR(AML-L) is below the 360 lifting  Press the outrigger mode select key to register for the capacity.

outrigger operation. Press the register key, then the outrigger (2) For creep operation : mode indicative symbol changes from flashing to a solid light.

 Press the lift mode select key to select the lift status that in the straight forward position of chassis and the over

corresponds to the actual boom configuration. front position symbol is on. If boom is not in the straight Each time the lift mode select key is pressed, the status forward position of chassis, never lift load. changes. 3. A swing does not automatically stop even if the crane Press the register key to register the lift status, becomes overloaded. then the lift indicative symbol changes from flashing to a 4. During crane operation, make sure that the displays on front solid light. panel are in accordance with actual operating conditions.

 When mounting and stowing jib, select the jib set status. 5. The displayed values of LOAD MOMENT INDICATOR

(The jib state indicative symbol will be flashing.) (AML-L) are based on freely suspended loads and make no

2. When operating crane on rubber: allowance for such factors as the effect of wind, sudden

 Before on rubber operation, the suspension lock operation stopping of loads, supporting surface conditions, inflation of

must be performed. Suspension lock system can only be tires, operating speed, side loads, etc. For safe operation, it performed in the over-front area. is recommended when extending and lowering boom or

 Push and hold the suspension lock switch to the "LOCK" swinging, lifting loads shall be appropriately reduced.

position until suspension lock lamp changes from flashing 6. LOAD MOMENT INDICATOR (AML-L) is intended as an aid to a solid light and the suspension is fully retracted. to the operator. Under no condition should it be relied upon (Crane operations cannot be performed until suspension to replace use of capacity charts and operating instruction. lock operation has been completed.) Sole reliance upon LOAD MOMENT INDICATOR(AML-L)

 Set P.T.O. switch to "ON". aids in place of good operating practice can cause an  Press the outrigger mode select key. The on rubber mode accident. The operator must exercise caution to assure

indicative symbol comes on. Each time the outrigger mode safety. select key is pressed, the status changes. When the stationary operation is selected, the on rubber status symbol will be a solid light. When the creep operation is selected, the on rubber status symbol will be a flashing light.

status that corresponds to the actual boom configuration.

 When a load is lifted in the front position and then swung

 The creep capacities are attainable only when boom is

GR-500XL Axle weight distribution chart

KilogramsPounds

GVW Base machine 35,390 37,160 32,902 16,051 16,851 Remove: 1. Auxiliary hoist with 345' (105m) of 3/4" (19mm) 440 -2,270 -830 200 -1,030

2. 5.5 ton (5.0 metric ton) hook ball -410 120 -132 -186 54

3. Top jib (21') -600 70 -240 -272 32

4. Base jib (28.8') -2,070 820 -567 -939 372

5. EXT. Counter weight 890 -2,650 -798 404 -1,202

Option: 1. Auxiliary lifting sheave 390 -240 68 177 -109

2. 50 ton (45.4 metric ton) hook block 1,367 -580 357 620 -263

3. 30 ton (27.2 metric ton) hook block 1,090 -460 285 494 -209

4. Hot water cab heater and air conditioner 70 150 100 32 68

72,550

-1,830

-290

-530

-1,250

-1,760 150

787 630 220

Front Rear GVW Front Rear

MEMO

TADANO LTD. (INTERNATIONAL DIVISION) TADANO AMERICA CORPORATION

4-12, Kamezawa 2-chome, Sumida-ku, 4242 West Greens Rd. Tokyo 130-0014, JAPAN Houston, Taxas, 77066 U.S.A. PHONE: 81-3-3621-7750 PHONE: 281) 869-0030 FAX: 81-3-3621-7785 FAX: 281) 869-0040 http://www.tadano.co.jp/indexe.html http://www.tadanoamerica.com

Form No. GR-500-1-00311/US-42

Tadano GR-500XL Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual