Tadano GR-500EXL-3 User manual

Foreword
1
WA04-4610E
Foreword
This service manual describes the composition of the Model GR-500EXL-3 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 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.
1. Applicable spec. and serial number
Spec. No. Applicable serial number
GR-500E-3-00102 541100--
Separate service manual
Separate Service Manual Publication No.
1 General Cautions WA01-0121E
2 Automatic Moment Limiter (AML-C) to be published
3 Data Transmitter (DCU2 and VCU) to be published
4
Torque Converter (EXEDY)
to be published
Transmission (EXEDY)
5 Driving Axle (KESSLER) 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.

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Foreword
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.

Foreword
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3. Outline of specifications
No. Item
Spec. No.
GR-500E-3-00102
2M2D
(General Export)
1 No. of boom sections 5
2 No. of jib stages (base (jib 1), top (jib 2)) 2
3 Single top Fitted
4 Winch
Main winch Fitted
Auxiliary winch Fitted
Winch brake Automatic brake (Neutral brake)
Drum rotation indicator Main and auxiliary Visual type Fitted
5 Counterweight Fixed type
6 Automatic moment limiter (AML) AML-C
7 Auto. Stop solenoid valve energizing type Normally energized
8 Anti-two-block device Fitted
9 External warning lamp (AML) Fitted
10 Oil cooler Fitted
11 Air conditioner Fitted
12 ICF (information controller) Fitted
13 SCT (satellite communications terminal) Option
14 GSMT (global system for mobile communications terminal) Option
15 Eco mode system, Fuel consumption monitor Fitted
16 Emergency steering system Option
17 Over-unwinding prevention Option
18 Anemometer Option
19 Beacon lamp Option
20 Centralized greasing Option
21 Engine model MITSUBISHI 6M60-TL
22 Tires 505/95R25

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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
3.048×1023.048×10 3.048×10-1 1.2×10 1
Speed
km/h mile/h
1 6.21373×10
-1
1.60934 1
Area
square millimeter, 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
1×106 1×1041 1.55×1031.07639×10
6.4516×1026.4516 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
cubic meter, m
3
cubic inch, in
3
cubic foot, ft
3
gallon, gal cubic inch, in
3
liter, lit, L
1 1×10
-6
6.10237×10
-2
3.53147×10
-5
1 2.31×10
2
3.78541
1×10
6
1 6.10237×10
4
3.53147×10 4.329×10
-3
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
2.83168×10
4
2.83168×10
-2
1.728×10
3
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
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
1×10
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
4.53592×1024.53592×10-1 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

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Pressure
Pa kPa MPa kgf/cm
2
lbf/in
2
, psi
1 1×10
-3
1×10
-6
1.01972×10
-5
1.45038×10
-4
1×10
3
1 1×10
-3
1.01972×10
-2
1.45038×10
-1
1×1061×1031 1.01972×10 1.45038×102
9.80665×1049.80665×10 9.80665×10-2 1 1.42233×10
6.89476×10
3
6.89476 6.89476×10
-3
7.03072×10
-2
1
bar MPa kgf/cm
2
1 1×10
-1
1.01972
1×10 1 1.0972×10
9.80665×10-1 9.80655×10-2 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
1×1021 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
9.80665×1029.80665 1×1021 7.23301 8.67961×10
1.35582×1021.35582 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
N-m kgf-m ft-lbf
1 1.01972×10
-1
7.37562×10
-1
9.80665 1 7.23301
1.35582 1.38255×10-1 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(ToF-32)/9, T°F=(9×t°C+160)/5

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Foreword
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-500E-3-00102
2M2D
(General Export)
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) Z-4
Electric Circuit (Lower) Z-5

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Chapter
Section
Spec. No.
GR-500E-3-00102
2M2D
(General Export)
Z
Location of Installation
Hydraulic Parts Location Diagram (Upper) Z-6
Hydraulic Parts Location Diagram (Lower) Z-7
Hydraulic Parts Location Diagram
(Torque Converter) Z-8
Pneumatic Parts Location Diagram Z-9
Electric Parts Location Diagram (Upper) Z-10
Electric Parts Location Diagram (Lower) Z-11
Harness Diagrams
Harness (Upper) Z-12
Harness (Lower) Z-13
Anemometer (Option) Z-14
Beacon Lamp (Option) Z-15
Centralized Lubrication System (Option) Z-16