Tadano GR-800XL-4 - User Manual

The Tadano GR-800XL-4 is a hydraulic rough terrain crane with an 80-ton (72.6 metric ton) lifting capacity. It is designed for heavy-duty lifting operations in various terrains, offering robust construction and advanced control systems.

Function Description

The GR-800XL-4 functions as a versatile lifting machine, capable of hoisting and positioning heavy loads. Its primary components include a multi-section telescoping boom, a bi-fold lattice jib for extended reach, and powerful winches for precise load handling. The crane is equipped with a sophisticated hydraulic system that powers all crane functions, including boom elevation, telescoping, slewing, and winch operations. An electronic Load Moment Indicator (AML-E2) system provides critical operational data and safety warnings, ensuring safe lifting practices. The carrier is designed for rough terrain, featuring a robust frame, multiple steering modes, and an air-over-hydraulic disc brake system.

Important Technical Specifications

Lifting Capacity: 80 tons (72.6 metric tons).
Boom: 5-section full power synchronized telescoping boom, 39.4' to 154.2' (12.0 m to 47.0 m) in length. It features a round box construction with 5 sheaves and a 17-5/16" (0.44 m) root diameter at the boom head. The synchronization system uses two telescope cylinders, an extension cable, and a retraction cable, with a hydraulic cylinder fitted with a holding valve. Boom sections are supported by wear pads, and the extension speed is 114.8' in 142 seconds.
Boom Elevation: Controlled by a double-acting hydraulic cylinder with a holding valve, offering an elevation range of -1.5° to 80.5°. It includes combination controls for hand or foot operation, a boom angle indicator, and automatic speed reduction/slow stop functions. Boom raising speed from 20° to 60° is 46 seconds.
Jib: 2-stage bi-fold lattice type, 33.2' (10.1 m) or 58.1' (17.7 m) in length, with 3.5°, 25°, or 45° offset (tilt type). It has a single sheave, 15-5/8" (0.396 m) root diameter, at the head of both jib sections. The jib is stored alongside the base boom section and features assistant cylinders for mounting and stowing.
Auxiliary Lifting Sheave (Single Top): Single sheave, 15-5/8" (0.396 m) root diameter, mounted to the main boom head for single line work (stowable).
Wire Rope: Non-rotating 3/4" (19mm) PS (19) + 39 x P.7, with a breaking strength of 72,800 lbs (33,000 kg).
Winch: Main and auxiliary winches are variable speed types with grooved drums, driven by hydraulic axial piston motors through speed reducers. They feature power load lowering and raising, automatic brakes (neutral brake), and counterbalance valves. Both are controlled independently and equipped with cable followers and drum rotation indicators.
- Drum (Main/Auxiliary): Grooved 14-1/4" (0.362 m) root diameter x 26-13/16" (0.681 m) wide.
- Main Winch Rope: 830' of 3/4" diameter rope (253 m of 19 mm). Drum capacity: 1135' (346 m) 7 layers. Maximum single line pull: 1st layer 20,000 lbs (9,090 kg).
- Auxiliary Winch Rope: 456' of 3/4" diameter rope (139 m of 19 mm). Drum capacity: 1135' (346 m) 7 layers. Maximum single line pull: 1st layer 20,000 lbs (9,090 kg).
Hook Blocks: 80 ton (72.6 metric ton)-6 sheaves with swivel hook and safety latch for 3/4" (19 mm) wire rope. 7.3 ton (6.6 metric ton)-weighted hook with swivel and safety latch for 3/4" (19 mm) wire rope.
Counterweight: 9,600 lbs (4,350 kg).
Hydraulic System: Two variable piston pumps for crane functions, and a tandem gear pump for steering, slewing, and other hydraulic systems. The system includes a 210-gallon (795 lit.) reservoir with an external sight level gauge, a BETA10=10 return filter, and an air-cooled fan type oil cooler.
Engine: Cummins B6.7, direct injection diesel, 6 cylinders, 4-cycle, turbo-charged and after-cooled. Max. HP: 280 (209 kW) at 2,200 rpm. Max. Torque: 850 ft-lb (1,152 Nm) at 1,500 rpm. Fuel tank capacity: 79.2 gal (300 lit.).
Transmission: Electronically controlled full automatic transmission with torque converter, 6 forward and 2 reverse speeds.
Travel Speed: 22 mph (36 km/h).
Axles: Front and rear are full floating type, steering and driving axles with planetary reduction. The rear axle has a non-spin differential.
Steering: Hydraulic power steering with four modes: 2-wheel front, 2-wheel rear, 4-wheel coordinated, and 4-wheel crab.
Brake Systems: Service brakes are air-over-hydraulic disc brakes on all 4 wheels. Parking/Emergency brake is spring-applied, air-released on the input shaft of the front axle. Auxiliary brake is electro-pneumatic operated exhaust brake.
Tires: 29.5-25 34PR (OR), air pressure 57 psi (400 kPa).
Outriggers: Four hydraulic, beam and jack outriggers with integral holding valves. Beams extend to 23' 11-3/8" (7.3 m) center-line and retract to 10' 10-1/2" (3.315 m) overall width with floats. Four extension lengths are provided.
Dimensions (Approximate): Overall length 47' 2" (14.375 m), overall width 10' 10-1/2" (3.315 m), overall height 12' 6-7/16" (3.820 m).
Turning Radius (29.5-25 Tires): 4-wheel steer 22' 4" (6.8 m), 2-wheel steer 35' 9-3/32" (10.9 m).

Usage Features

The GR-800XL-4 is designed for operator comfort and efficiency. The cab is a 20° tilt, left-side, 1-man type, steel construction with a sliding door, safety glass windows, and a powered door window. It features a tilt-telescoping steering wheel, adjustable control lever stands for crane functions (slewing, boom elevating, telescoping, winches), and a 3-way adjustable operator's seat. Foot-operated controls are available for boom elevating, telescoping, service brake, and engine throttle. The cab includes hot water heating and air conditioning.

The dash-mounted instrument panel provides essential information such as torque converter oil temperature, engine water temperature, air pressure, fuel, speedometer, tachometer, hour meter, and odometer/tripmeter. A Multi-Function Display shows DEF level and fuel consumption.

Safety features include an Anti-Two Block system with audio-visual warnings, a 360° positive slewing lock for pick and carry/travel modes, and twin slewing system (free or lock slewing). The Tadano AML-E2 system provides control lever lockout, boom position, outrigger state, slewing angle, load radius, rated lifting capacities, and automatic speed reduction functions. It also includes an emergency steering system, electronic crane monitoring, rear and right-front view cameras, and a complete highway light package.

Maintenance Features

The crane is built with features to facilitate maintenance. The hydraulic system's return filter is located inside the hydraulic reservoir and is accessible for easy replacement. The engine's air cleaner is a dry-type replaceable element, and both oil and fuel filters are full-flow with replaceable elements. The cooling system is liquid pressurized and recirculating. The AML-E2 system monitors various parameters, aiding in diagnostics and preventive maintenance. The manual provides detailed instructions for proper operation and maintenance, and replacement manuals can be ordered through distributors. Specifications are subject to change without notice.