PDF Service Manual Tadano Faun GR-550XL-2 Rough Terrain Crane - 1 MB
This service manual for the Tadano Faun GR-550XL-2 Rough Terrain Crane focuses on circuit diagrams and technical data.
It is an invaluable resource for technicians troubleshooting electrical and hydraulic systems.
The detailed schematics and specifications are crucial for accurate diagnostics and repairs.
This manual is essential for maintaining the complex systems of your crane.
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--- Page 1 ---
Publication No. GR-550XL-2/C1(U)-1E
(Circuit Diagrams and Data)
01
Rough Terrain Crane
Model GR-550XL-2
Applicable Serial No. 540642 --
--- Page 3 ---
Y-1 Y-1
Service Data
3. Hydraulic device
3.1 Hydraulic pump
Item Standard value Remarks
Speed reducing ratio 0.918
-1
Idling (min ) 730 ± 27 Eng. 670 ± 25
Crane pump
-1
Max. (min ) 2342 Eng. 2150 (PTO - ON)
3
Displacement (cm /rev) 82 + 82
Speed reducing ratio 1.066
-1
Idling (min ) 629 ± 23 Eng. 670 ± 25
Steering pump
-1
Max. (min ) 2683 ± 38 Eng. 2860 ± 40
3
Displacement (cm /rev) 34 + 16 +16
Speed reducing ratio 1.066
-1
Charging pump Idling (min ) 629 ± 23 Eng. 670 ± 25
(Torque converter) -1
Max. (min ) 2683 ± 38 Eng. 2860 ± 40
3
Displacement (cm /rev) 33.2
Emergency steering 3
Displacement (cm /rev) 14.56
pump
3.2 Hydraulic motor -1
(1 L/min = 2.64172 × 10 gal/min)
Item Standard value Remarks
Winch 3
Displacement (cm /rev) 195
(main, auxiliary)
366-638-00010 △
0 Drain (when running) 6.5 L/min at maximum For reference
Swing 3
Displacement (cm /rev) 45.3
366-631-70010 △
0 Drain (when running) 7 L/min at maximum For reference
3.3 Hydraulic cylinder -2
(1 mm = 3.93701 × 10 in)
Item Standard value Limit value Remarks
3 mm or less/30 6 mm or less/30 With boom raised to horizontal,
Elevating
Amount of spontaneous minutes minutes fully retracted
retraction when lever 6 mm or less/30 9 mm or less/30 Boom extended by approx. 100
Telescoping
is neutral, and the minutes minutes mm with elevating angle at Max.
engine stopped. 3 mm or less/15 6 mm or less/15 Jack extended close to the
Jack
hours hours cylinder's stroke end
2 WY01-2220E
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Y-2 Y-2
Adjusting Pressure (Hydraulic Pressure)
3. Elevating
[NOTICE]
Oil temperature: 50 ± 5°C (113 - 131°F) (Hydraulic oil: TADANO Hydraulic Oil LL)
Confirm set pressure on the crane information screen in the maintenance mode of AML.
Shift the control lever or switch while the engine is idling, then increase engine speed.
Item Set pressure Engine
speed Check procedure
（Mark） MPa kgf/cm
2
psi -1
(min )
Boom
2150
raising 22.1 ± 0.5 225 ± 5 3200 ± 70 Refer to “2.Telescoping”.
(MAX.)
(B)
1. Deactivate the slow stop circuit. (*1)
2. Turn the PTO switch ON
Boom
670 3. Fully retract the elevating cylinder.
lowering 2.9 30 420
(IDL.) 4. Move the elevating lever at its full stroke on the
(C)
lowering side.
5. In this state, check the pressure.
*1: To deactivate the slow stop circuit, disconnect the connector (O) of the elevation proportional solenoid
valve.
(After adjusting, connect the connector (O).)
12 WY02-1430E
--- Page 5 ---
Y-4 Y-4
Air Bleeding Procedure
2. Winch brake
[NOTICE]
To avoid damage to the friction plates of the winch
brakes, bleed the winch brakes following the
procedures below.
1. When assembling piping, plug the piping between
the hoist-down port of each main and auxiliary
winch motor and the corresponding hydraulic pilot
control valve (main). (For plugging, attach plugs to
the pipe end closer to the hoist-down port of each
motor and the one closer to the corresponding
hydraulic pilot control valve port.)
[NOTICE]
After assembly, do not perform hoisting operation.
Hereafter, hoist-up operation by the main and
auxiliary winches is prohibited until bleeding of the
winch brakes is completed.
2. Perform hoist-down operation of each main and
auxiliary winch using the corresponding air-bleed
plug of the winch brake.
• Engine: idling
• Corresponding control lever moved fully to the
hoist-down side
(You need not move the winch lever to and fro.)
• When no more bubbles come out of the plug,
bleeding is completed.
3. After bleeding of the winch brakes is completed,
remove the plugs from the piping and connection
sections, and reassemble the piping.
22 WY05-3230E
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Y-6 Y-6
Assembly Adjustment (Crane Operation)
8. When the wire rope is tense:
8.1 Tighten nut-A by approx. a third turn.
8.2 Extend the boom by 200 to 300 mm (8 to 12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
NG OK
9. When only the 3rd boom section is not fully retracted: END
9.1 Tighten two nut-C’s by approx. a third turn equally.
9.2 Extend the boom by 200 to 300 mm (8 to 12 in) by operating the boom telescoping
NG
control lever and then retract it fully. Check the boom is fully retracted.
OK
END
32 WY05-3240E
--- Page 7 ---
Y-8 . Y-8 .
Operation Check (Crane Operation)
7. Warning
Type of
Item Sound Checking procedure
alarm
• 280Hz Occurs at 100% when main switch is ON and PTO switch is
Electronic
AML limit • Continuous ON. (Intermittent low tone sound occurs at 90% and above.)
buzzer
low tone
• 2300Hz
Overwind Electronic Occurs when the overwind switch contact of either the main
• Continuous
warning buzzer
high-low tones or auxiliary winch is turned OFF by winch hoist-up operation.
Outrigger • 2300Hz Sounds when either the outrigger extension/retraction or jack
Electronic
operation switch • Intermittent slide selector switch has been left in any position other than
buzzer
detection beeping neutral 10 seconds after operation is completed.
E/G cover • AML buzzer: When main switch is ON and PTO switch is ON, make sure
Electronic
interference sounds 3 that the operation stops while boom angle is 5° or less and
buzzer
automatic stop seconds swing angle is between 155° and 205°.
8. Outrigger slide plate adjustment 9. Eco mode operation check
While the PTO is engaged, select the Eco mode 1
and Eco mode 2, and depress the accelerator
pedal fully. Then check that the maximum engine
speed lowers while the respective mode is
selected.
-1
Eco mode Max. engine speed (min )
OFF Approx. 2150
1 Approx. 1750
2 Approx. 1500
Use the AML to select the Eco mode 1 or Eco
mode 2. The maximum engine speeds above
listed are for reference.
1. With the outriggers fully retracted, install the slide
plate and the plate into the outrigger box.
2. Adjust the slide plate with the bolt X so that the
slide plate is 2mm (0.08 in) away from the upper
surface of outrigger box bottom plate.
3. If the slide plate is 2 mm (0.08 in) or more away,
make sure that the bolt X does not protrude
beyond the plane Z.
4. Tighten the bolts of Y slightly to fix the slide plate.
Then tighten the nuts of Y hard.
5. Tighten the nut of X. 345-806-54500 △
0
42 WY05-3380E
--- Page 8 ---
Z-1 Hydraulic Circuit Z-1 Z-1
Applicable serial No. △
1 ：540677 --
“Location” shows each applicable paragraph No. of this manual’s contents.
Z-1 Hydraulic Circuit Refer to the contents.
1. Comparison table of hydraulic parts (Part No., Part name and Location)
Part No. Part name Location Part No. Part name Location Part No. Part name Location Part No. Part name Location
1 Variable piston pump 24-1 Steering cylinder (FL) 48-4 Pressure switch (aux. winch hoist-up) 73 -
Z-8 2.
2 Gear pump Z-8 1. 24-2 Steering cylinder (RR) 48-5 Pressure switch (main winch hoist-up) 74 Jib lock pin cylinder
3 Pump (for emergency steering) (option) Hydraulic oil temperature switch (50°C) 48-6 Pressure switch (boom raising) 75 Jib offset cylinder
25
4 Oil filter (122°F) 48-7 Pressure switch (boom lowering) 76-1 Pilot check valve (for jib lock)
Z-8 5.
5 Oil tank Z-8 5. Hydraulic oil temperature switch (85°C) Pressure switch Z-7 12. 76-2 Pilot check valve (for jib offset) Z-7 13.
26 48-8
6 Oil filter (185°F) (aux. winch hoist-down) 77-1 Orifice (for jib lock)
8 Solenoid control valve 27 Priority valve Pressure switch 77-2 Orifice (for jib offset)
Z-7 9. 48-9
Solenoid (for O/R extending/retracting) 28 Orbitrol (main winch hoist-down) 78 Solenoid control valve (jib set)
- Z-8 4. Filter (for swing proportional valve circuit 48-10 Pressure switch (boom retracting)
(SL20, SL21) 30-1 80 Oil cooler Z-8 5.
- Solenoid (for suspension lock) (SL04) (right swing)) 50 Shuttle valve (lever/pedal) Solenoid valve (for positive control)
Z-7 11. 82 Z-8 4.
9 Check valve Filter (for swing proportional valve circuit Proportional control valve (SL96)
30-2 51
Solenoid valve (for O/R, J/S selection) (left swing)) (for elevation slow stop) 83 -
10-1 30-3 Filter (for priority valve) Z-7 9.
(FR) (SL22) (SL23) Boom raising proportional control valve Z-7 8. 84 -
-
Solenoid valve (for O/R, J/S selection) 30-4 Filter (for solenoid valve (pilot pressure)) Z-7 5. (SL124) 85 -
10-2
(FL) (SL24) (SL25) Z-8 3. Filter (for remote control valve (left side) Boom lowering proportional control valve 86 Filter assy (swing, steering circuit) Z-7 9.
30-5 -
Solenoid valve (for O/R, J/S selection) (aux. winch/telescoping, swing)) (SL125)
10-3 Z-7 11.
(RR) (SL26) (SL27) Filter (for remote control valve (right side) Solenoid valve
30-6 52
Solenoid valve (for O/R, J/S selection) (main winch, elevation)) (boom telescoping/aux. winch)
10-4
(RL) (SL28) (SL29) Filter (for elevation proportional valve Solenoid (for boom extending/hoist-down)
30-7 - Z-7 1.
11-1 Slide cylinder (FL) circuit (boom lowering)) (SL143)
Z-7 8.
11-2 Slide cylinder (FR) Filter (for elevation proportional valve Solenoid (for boom retracting/hoist-up)
30-8 -
11-3 Slide cylinder (RL) circuit (boom raising)) (SL144)
11-4 Slide cylinder (RR) 30-9 Filter (for remote control valve (pedal)) Z-7 11. 53 Hydraulic pilot control valve Z-7 5.
12-1 Jack cylinder (FL) 30-10 Filter (for solenoid valve (positive control)) Z-8 4. 54 Counterbalance valve (for elevation)
Z-7 3.
12-2 Jack cylinder (FR) 30-11 - 55 Elevation cylinder
Z-8 6. 30-13 Filter (for solenoid control valve (jib set)) Z-7 5. Counterbalance valve
12-3 Jack cylinder (RL) 56
12-4 Jack cylinder (RR) Filter (for solenoid valve (suspension lock (for telescoping cylinder (No.1)) Z-7 2.
30-14 Z-8 2.
13-1 Pilot check valve (FL) selection)) 57 Telescoping cylinder (No.1)
13-2 Pilot check valve (FR) 31 Sequence valve (pilot pressure) Z-7 5. 58-1 Main winch
13-3 Pilot check valve (RL) 32 Check valve (for air conditioner) 58-2 Aux. winch
13-4 Pilot check valve (RR) Solenoid valve (for air conditioner) 59-1 Main winch speed reducer Z-7 1.
33 Z-7 10.
(SL280) 59-2 Aux. winch speed reducer
Solenoid valve
14 34 Hydraulic motor (for air conditioner) 60 Hydraulic valve (winch brake) (main, aux.)
(for suspension lock selection)
- Solenoid (for suspension lock) (SL02) 35 Center joint Z-8 4. Filter
61
- Solenoid (for suspension free) (SL03) 36 Check valve (for orbitrol) Z-7 9. (for hydraulic valve (winch brake)) Z-7 5.
Pilot check valve (for suspension lock) 38 Hydraulic pilot control valve (for swing) 62-1 Check valve
15-1 Swing right proportional reducing △
1 62-2 Check valve Z-7 6.
(FL) -
Pilot check valve (for suspension lock) solenoid valve (SL120) △
1 62-3 Check valve Z-8 5.
15-2 Swing left proportional reducing Z-7 4. 63 Accumulator Z-7 5.
(RR) -
Z-8 2. solenoid valve (SL121) Orifice
16-1 Suspension lock cylinder (FL) 64
16-2 Suspension lock cylinder (RR) 39 Hydraulic motor (for swing) (for elevation cylinder)
Pilot check valve (for suspension lock) 40 Swing speed reducer Pressure sensor
17-1 65 Z-7 3.
(FR) 41 Solenoid valve (pilot pressure) (for elevation cylinder extending)
Pilot check valve (for suspension lock) Solenoid (for remote control pressure Pressure sensor
17-2 - 66
(RL) vent) (SL102) Z-7 5. (for elevating cylinder retracting)
18-1 Suspension lock cylinder (FR) Solenoid (for swing brake release) 67 -
-
18-2 Suspension lock cylinder (RL) (SL160) 68 -
Hydraulic valve (for emergency steering 42 Check valve (for main pressure) Orifice
20 Z-8 1. Z-7 7. 70-1
selection) (option) 43 Pressure sensor (for main pressure) (for main winch hoist-down pilot circuit)
Z-7 1.
Pilot check valve 44 Solenoid valve (for AML vent) (SL100) Z-7 6. Orifice
21 70-2
(rear steering hydraulic lock) 45-1 Remote control valve (right side) (for aux. winch hoist-down pilot circuit)
Solenoid valve 45-2 Remote control valve (left side) Z-7 11. Orifice
22 70-3 Z-7 8.
(for steering mode selection) 46 Remote control valve (pedal) (for boom retracting pilot circuit)
Z-8 2. 47 Check valve Z-7 6. Orifice (for swing brake release
Solenoid (crab: SL30), 70-4 Z-7 5.
- circuit)
(4 wheel: SL31) 48-1 Pressure switch (right swing)
23-1 Steering cylinder (FR) 48-2 Pressure switch (left swing) Z-7 12. 70-5 Orifice (for boom lowering pilot circuit) Z-7 8.
23-2 Steering cylinder (RL) 48-3 Pressure switch (boom extending) 71 Check valve Z-8 5.
72 -
1 WZ01-2760E 1
--- Page 10 ---
Z-4 Electric Circuit (upper) (Crane) Z-4 Z-4
To circuit (boom) To circuit (crane, main)
4.3.2 540712-- CN888 CN887 [NOTICE]
1
1.25 (233AA) Y/B
1 1. Number within ( ) indicate the circuit identification numbers (the numbering of wiring end).
Working lamp switch linked power supply 2 2 Working lamp switch linked power supply
3 3 2. Diameter of wiring type without indication is AVS 0.5mm2 (0.0008in2)
(304AA) G
Boom full retraction detection switch 4 4 Boom full retraction detection switch
Overwind (two-blocking) detection switch 5
(301AA) LG/Y