Tadano Faun Crane ATF 65G-4 Operating Service and Maintenance Manual

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Tadano Faun Crane ATF 65G-4 Operating Service and Maintenance Manual
Size: 25.3 MB
Format: PDF
Language: English
Brand: Tadano Faun
Type of Machine: Crane
Type of Manual: Operating Service and Maintenance Manual, Electric and Hydraulic Diagrams
Model: Tadano Faun ATF 65G-4 Crane
Number of Pages: 1013 Pages

Contents:
Part A: Technical Detail
1 General technical details (chassis)

1.1 Dimensions and weights​

1.2 Driving performance data (according to DIN 70020)​

2 Technical details of components (chassis))

2.1 Engine​

2.2 Gearbox​

2.3 Transfer box​

2.4 Axles​

2.5 Axle suspension​

2.6 Power transmission​

2.7 Wheels and tires​

2.8 Brakes​

2.9 Steering​

2.10 Electrical equipment​

2.11 Instruments​

2.12 Driver’s cab​

2.13 Heating system​

2.14 Frame​

2.15 Outriggers​

2.16 Fuel system​

2.17 Tools, accessories, acceptance inspection​

2.18 Painting​

2.19 Optional equipment​

3 Technical details of components (superstructure)

3.1 Engine​

3.2 Hydraulic system​

3.3 Hoisting gear​

3.4 Telescopic boom​

3.5 Boom elevation​

3.6 Swing drive​

3.7 Superstructure frame​

3.8 Safety equipment​

3.9 Electrical equipment​

3.10 Electronic Automatic Safe Load Indicator (ASLI)​

3.11 Superstructure cabin​

3.12 Heating system​

3.13 Painting​

3.14 Acceptance inspection​

3.15 Counterweights​

3.16 Optional equipment​

3.17 Noise level when the engine is operating under load and at max. engine speed​

3.18 Vibration values in the crane cabin during crane work​

4 Illustration of the vehicle
5 Notes referring to the load (lifting capacity) and supporting forces charts

5.1 Explanation regarding a load chart​

5.2 Supporting forces charts​

Part B.0: Safety Instructions
1 Requirements and conditions for vehicles used in public road traffic

1.1 Important instructions regarding the load ratings of tires depending on the maximum travelling speeds and the stress to which the rims are subject​

2 Instructions for the crane operator

2.1 Applications planning​

2.2 Steps to be taken before crane operation​

2.3 Supporting the crane by outriggers​

2.4 Counterweight​

2.5 Hoist winch and reeving of the winch rope​

2.6 Taking account of the wind velocities​

2.7 Hand signals recommended for communication between the crane operator and his assistant​

2.8 Work in the vicinity of electrical overhead lines​

2.9 How to behave in case of sparkover (if the crane has touched the power line)​

2.10 Grounding the crane and the load​

2.11 Work in the vicinity of supply lines​

2.12 Crane work with a load​

2.13 Notes regarding work with two cranes​

2.14 Notes referring to crane operation​

2.15 Crane application in accordance with the intended use​

2.16 Crane application not in accordance with the intended use​

2.17 Potential causes of accidents​

2.18 Fire, smoke, inflammation and explosion hazard​

2.19 Instructions and regulations concerning the compressed air tanks installed in air-operated braking systems​

3 Instruction Sheet for Overload Safety Devices for Boom Cranes (excerpts)
Part B: Operating Instructions
B1 Chassic
1 General instructions concerning operation of the vehicle

1.1 Warning and instruction plates​

1.2 Location of warning and instruction plates​

1.3 Components, assemblies - installation location and position​

1.4 Transport condition of the crane when used in public road traffic​

2 Driver's cab

2.1 Explanation of the control elements and of the equipment​

2.3 Front cover​

2.4 Seat adjustment n​

2.5 Adjustment of the steering wheel​

2.6 Actuation of the roller sun visor​

2.7 Seat belts​

2.8 Cab lighting​

4 How to put the machine into operation

4.1 Steps to be taken and checks to be made before start-up​

4.2 Operation of the electrical equipment of the chassis​

4.3 Functional check of the electrical equipment of the vehicle before starting driving operation​

4.4 Air distribution; fan; heater unit; air circulation and air conditioner**)​

4.5 Starting the engine​

4.6 Monitoring the indicating, pilot, warning lamps and the instruments while the engine is running​

4.7 Hydraulic system of suspension; inclination adjustment; level control​

5 Gearshift and driving operation

5.1 Gearbox​

5.2 Transfer box​

5.4 Connecting and disconnecting the differential locks, inter-wheel locks, 2nd axle drive**)​

5.6 Brakes​

5.7 Cruise control​

5.8 Temposet​

5.9 Steering​

6 Outrigger the vehicle

6.1 The axle suspension must be locked and the vehicle must be lowered.​

6.2 Control of the electric outrigger actuation​

6.3 Outrigger operation from the chassis​

6.4 Instructions regarding outrigger operation​

6.5 Extending the outrigger beams​

6.6 Extending the outrigger cylinders​

6.7 Outriggers - retracting the outrigger cylinders / outrigger beams​

7 Emergency control features

7.1 Hydraulic system​

7.2 Centering the 3rd and 4th axles​

8 Operation in winter

8.1 Engine​

8.2 Gearbox​

8.3 Warming up the hydraulic oil or changing the oil type​

8.4 Batteries​

8.5 Adjustable air vents​

8.6 Windshield washing system​

9 Steps for access to the superstructure
10 Attachments, optional equipment and accessories

10.1 Fog lights​

10.2 Acoustic reversing signal - warning device​

10.3 City / country horn (Supertone horn)​

10.4 Electronc immobilizer (FinTronic Car Bloc TTS 24/12)​

10.5 Air conditioner​

10.6 WEBASTO - Thermo 90 S / with engine pre-heating​

10.7 WEBASTO diesel heater unit​

10.8 Eddy-current brake​

10.9 Checking the air accumulator retaining force on upward gradients - vehicles equipped with trailer coupling device​

10.10 Trailer Coupling Device​

10.11 Starting the engine in the chassis with current supplied from an external power source​

10.12 Battery charging plugbox​

10.13 Switch "Emergency OFF, engine in chassis"​

10.14 Centralized lubrication system​

11 Instrument panel - chassis

11.1 Pilot, indicator and warning lamps​

11.2 Other components​

11.3 Instruments​

11.4 Switches, rocker switches (WS) and rocker tip switches (WT)​

Part B: Operating Instructions
B2 Superstructure
1 General information

1.1 Warning and instruction plates​

1.2 Location of warning and instruction plates​

1.3 Components, assemblies - installation location and position​

2 Crane cabin

2.1 Explanation - control elements​

2.2 Adjustment of the seat in the superstructure​

2.3 Roller sun visor - skylight​

2.4 Opening the windscreen​

2.5 Opening the rear window​

2.6 Cab lighting​

2.7 Emergency exit​

2.8 Assignment of functions to the crane control levers​

2.9 Superstructure locking mechanism​

4 How to put the machine into operation

4.1 Steps to be taken and checks to be made before start-up​

4.2 Operation of the electrical equipment​

4.3 Functional check of the electrical equipment of the vehicle before starting work​

4.4 Blower fan, heating, air regulation​

4.5 Starting the engine​

4.6 Monitoring the pilot, indicating and warning lamps and the instruments while the engine is running​

5 Gearshift, driving and outrigger operation from the superstructure

5.1 Changing-over to driving from the superstructure​

5.2 Starting the engine in the chassis from the superstructure​

5.3 Air brake system​

5.4 Driving operation from the superstructure​

5.5 Driving from the superstructure with complete counterweight​

5.6 Outrigger operation from the superstructure​

6 Crane movements in no-load condition

6.1 Notices regarding actuation of the crane control levers​

6.2 Actuation of the hoisting gear​

6.3 Boom elevation​

6.4 Telescoping​

6.5 Slewing the superstructure​

6.6 Counterweights​

6.7 Work involving metallic ropes​

6.8 Inspection of the safety equipment​

7 Crane operation with a load fixed to the boom

7.1 Crane operation with the machine stabilized by outriggers​

7.2 Crane operation "free on wheels"​

7.3 Driving with a load​

7.4 Moving the crane in full rig arrangement on construction sites​

8 Emergency control
9 Operation in winter

9.1 Engine​

9.2 Hydraulic oil​

9.3 Batteries​

9.4 Adjustable air vents Verstellbare Luftdüsen​

9.5 Windshield washing system **)​

11 Attachments, optional equipment and accessories

11.1 Mirror heating on boom​

11.2 Aircraft warning lamp​

11.3 Working floodlight on the hoist winch​

11.4 Working floodlight on boom​

11.5 Working floodlight – adjustable via motor​

11.6 Hook height indication, auxiliary hoist winch​

11.7 Centralized lubrication system​

11.8 Air conditioning​

11.9 Switch "Emergency OFF, superstructure engine"​

11.10 Positioning the double ladder​

11.11 Mounting the jib (boom extension)​

11.12 Jib [boom extension]​

11.13 Starting the engine with current supplied from an external power source​

11.14 Battery charging plugbox​

11.15 Hourmeter, hoist winch​

11.16 Hourmeter, auxiliary hoist winch​

11.17 1,6 m jib​

11.18 Single top​

11.19 Removal of the auxiliary hoist winch, mounting the balancing weight​

11.20 Emergency control of superstructure / emergency drainage device​

12 Instrument panel

12.1 Monitoring superstructure and chassis, driving and outrigger operation from the superstructure, AML control unit​

12.2 Operation of the superstructure​

Part C: Service and Maintenance
C1 Chassic
1 General information

1.1 Before starting service and maintenance work​

1.2 Welding and straightening work​

1.3 Inspection of screw couplings​

1.4 Checking the hydraulic system and its screw couplings for leakage​

1.5 Cleaning​

1.6 After having finished service and maintenance work​

1.7 Configuration of electronic components​

2 Maintenance intervals

2.1 Maintenance schedule​

3 Engine

3.1 Oil level inspection​

3.2 Oil change / oil filter replacement​

3.3 Inspection of hose clamps of the charge air hoses​

3.4 Fuil tank​

3.5 Coolant​

3.6 Cleaning of radiator​

3.7 Air cleaner​

3.8 Exhaust system​

4 Gearbox

4.1 Oil level inspection​

4.2 Oil change / oil filter replacement​

4.4 Clutch, and clutch control mechanism​

5 Transfer box

5.1 Oil level inspection​

5.2 Oil change​

6 Axles

6.1 Oil level inspection in the axle drive assemblies of the driven steering axles, and in the planetary gears​

6.2 Oil change in axle drive assemblies and planetary gears​

6.4 Greasing the axles​

6.5 Check for leakage / visual inspection / inspection of the control function​

6.6 Checking the axial play of the steering axle bearings and the planetary bearings; check the wheel bearing backlash.​

6.7 Checking screws and bolts on axles for tight fit; check axle fastening, drop arms, thrust rod fastening, etc.​

6.8 Preservation of axle and planetary gearings​

6.9 Checking the propeller shaft flange screws for tight fit​

7 Propeller shafts

7.1 Inspection of backlash​

7.2 Noise test​

7.3 Checking the flange couplings​

8 Eddy-current brake **)

8.1 Service​

9 Breather
10 Hydraulic system

10.1 Inspection of hydraulic oil level​

10.2 Replacement of filter cartridges​

10.3 Oil change​

10.4 Changing the oil type​

10.5 Hydraulic system of steering assembly​

10.6 Hydraulic system of the suspension​

10.7 Hydraulic system of outriggers​

10.8 Test connectors and measured values​

10.9 Location of the hydraulic measuring points on the vehicle​

11 Brake system

11.1 Drainage valves in the compressed air tanks​

11.2 Air drier​

11.3 Pressure governor with tire inflator socket (integrated in the air drier)​

11.4 Brake cylinders​

11.5 Inspection of wheel brakes​

11.6 Wheel brakes - Maintenance​

11.7 Check pressure limiting valve​

11.8 Automatic anti-block system (ABV) - Maintenance​

11.9 Engine brake​

11.10 Test connectors​

11.11 Test and setting values​

11.12 Locations of the measuring and test connectors​

12 Electrical equipment

12.1 Batteries​

12.2 Three-phase generator​

12.3 Starter​

12.4 Lamps and lights​

12.5 Fuse arrangement​

12.6 Relay arrangement​

13 Wheels and tires

13.1 Measures to be taken to avoid accidents caused​

13.2 Checking the wheel nuts on the disc wheel for tight fit​

13.3 Tightening torque of wheel nuts (with thrust plate)​

13.4 Tire pressure​

13.5 Replacement of a disc wheel​

13.6 Interchanging wheels in view of tire wear​

14 Outriggers

14.1 Adjusting the slideway liner and the slide pieces​

14.2 Check cable drag chain​

15 Driver’s cab

15.1 Warm water heating​

15.2 Wiper-blade elements / washing system​

15.3 Air conditioner **)​

15.4 Supplementary heater unit**)​

15.5 Engine pre-heating unit **)​

16 Miscellaneous; other points of lubrication, servicing and maintenance

16.1 Other points of lubrication​

16.2 Replacement of filter in the fuel pipe of the supplementary heater unit **)​

16.3 Trailer coupling device **)​

16.4 Sliding coupling​

16.5 Steering​

16.6 Suspension​

16.7 Centralized lubrication system​

24 Summary of oil types and filling capacities
25 Summary of lubricating grease types (recommended grease types)
26 Chart of approved consumables and lubricants
27 Inspection scheme (before start-up, daily)
28 Inspection and Cleaning Scheme
29 Oil/coolant level inspection and change scheme
30 Lubrication Scheme
Parts C: Service and Maintenance
C2 Superstructure
1 Maintenance intervals

1.1 Maintenance schedule - superstructure​

2 Engine

2.1 Oil level inspection​

2.2 Oil change / oil filter replacement​

2.3 Inspection of hose clamps of the charge air hoses​

2.4 Fuel tank​

2.5 Coolant​

2.6 Cleaning the radiator​

2.7 Air cleaner​

2.8 Exhaust system​

3 Hydraulic system

3.1 Oil level inspection​

3.2 Replacement of filter cartridges​

3.3 Oil change​

3.4 Changing the oil type​

3.5 Replacement of filter insert of pressure filter​

3.6 Checking and retightening the screw couplings of the hydraulic assemblies and pipes​

3.7 Oil cooler / supplementary oil cooler**)​

3.8 Maintenance instructions for hydraulic cylinders​

3.9 Speeds of the working hydraulics of the superstructure​

3.10 Pressure check in the hydraulic system of the superstructure​

3.12 Measuring connectors​

4 Slewing gear

4.1 Check for correct oil level and leakage​

4.2 Oil change​

4.3 Inspection of the hydraulic oil in the service brake circuit of the swing mechanism​

4.4 Check tooth face backlash on swing motor gearbox drive shaft​

4.5 Slewing gear - greasing ring gear and pinion​

4.6 Greasing the ball bearing slewing ring​

4.7 Greasing the slewing gear locking pin​

4.8 Check mechanical superstructure lock and proximity switch for proper working order​

4.10 Checking the ring gear connecting bolts, the securing bolts of the hydraulic motor and the gearbox flange bolts for tight fit​

4.11 Checking the slewing gear for wear​

5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)

5.1 Check for correct oil level and leakage​

5.2 Oil change​

5.5 Check tooth face backlash on hoisting gear motor gearbox drive shaft​

5.6 Greasing of hoisting gear drum bearing bush​

5.7 Preservation of the hoisting gear drive​

5.8 Inspection of hoisting gear brake​

5.9 Checking the hoist limit switch for proper working order​

5.10 Checking the rope limit switch of the hoisting gear​

5.11 Length transmitter rope​

6 Winch rope

6.1 Inspection of the rope​

6.2 Cleaning and lubrication of the rope​

6.3 Removal (replacement) of the rope​

6.4 Inspection of rope drum​

6.5 Placing a new winch rope​

6.6 Care to the winch rope​

7 Electrical equipment

7.1 Batteries​

7.2 Three-phase generator​

7.3 Starter​

7.4 Lamps and lights​

7.5 Load moment limiter (AML - Automatic Safe Load Indicator)​

7.6 Inspection of the AML at regular intervals according to the legal regulations​

7.7 Fuse / relay arrangement​

7.8 Relay arrangement, counterweight control​

8 Crane cabin

8.1 Air conditioner**)​

8.2 Wiper-blade elements / washing system​

8.3 Replacement of dust filter and fuel filter​

8.4 Heating system​

9 Other points of lubrication, servicing and maintenance

9.1 Telescopic boom​

9.2 Boom elevation cylinder​

9.3 Bottom block​

9.5 Counterweight​

9.6 Boom extension**)​

9.7 Centralized lubrication system**)​

9.8 Other points of lubrication​

9.9 1.6 Jib **)​

15 Summary of oil types and filling capacities
16 Summary of lubricating grease types (recommended grease types)
17 Chart of approved consumables and lubricants
18 Inspection scheme (before start-up, daily)
19 Inspection and Cleaning Scheme
20 Oil/coolant level inspection and change scheme
21 Lubrication Scheme
Part D: Circuit and Piping Diagrams
D1 Chassic
1 Electric circuit diagrams

1.1 Chassis (99707782433)​

1.2 Differential locks 8 x 4 drive (99707782433)​

1.3 Differential locks 8 x 6 drive (99707782433) **)​

1.4 Differential locks 8 x 8 drive (99707782433)**)​

1.5 Chassis (99707782433)​

1.6 ABV (99707782433)​

1.7 Gearbox control (99707782433)​

1.8 Chassis (99707782433)​

1.9 Axle suspension (99707782433)​

1.10 Outriggers (99707782433)​

1.11 Eddy-current brake (99707782433)**)​

1.12 Slipring (99707782431)​

1.13 Outrigger actuation, right-hand (99707782412)​

1.14 Outrigger actuation, left-hand (99707782410)​

2 Pneumatic diagrams

2.1 Compressed air system / Brake system (99707783969_01)​

2.2 Compressed air system / auxiliary equipment (99707783969_02)​

2.3 Axle differential locks and axle connection / drive 8x8 (99707783984_01)**)​

2.4 Axle differential locks and axle connection / drive 8x6 (99707783985_01)**)​

3 Hydraulic piping diagrams

3.1 Hydraulic system (99707783384)​

3.2 Steering (99707783385)​

3.3 Front outriggers (99707783394)​

3.4 Rear outriggers (99707783395)​

3.5 Oil tank (99707783401)​

3.6 Gearbox (99707783399)​

3.7 Fan drive (99707783396)​

3.8 Pump assembly (99707783397)​

3.9 Engine (99707783398)​

Part D: Circuit and Piping Diagrams
D2 Superstructure
1 Electric circuit diagrams

1.1 Chassis control system (99707782366)​

1.2 Superstructure (99707782366)​

1.3 Chassis control system (99707782366)​

1.4 Superstructure (99707782366)​

1.5 AML (99707782366)​

1.6 Crane control (99707782366)​

1.7 AML, hoist limit switch override /AML (99707782366)​

1.8 Crane control (99707782366)​

1.9 Telescope control (99707782366)​

1.10 Crane control – emergency mode (99707782366)​

1.11 Telescope control (99707782366)​

1.12 Superstructure (99707782366)​

1.13 Counterweight (99707782366)​

1.14 Telescope control (99707782366)​

1.15 Crane control (99707782366)​

1.16 AML (99707782366)​

1.17 Folding fly jib (99707782366)**)​

1.18 Heavy-lift fly jib, single top (99707782366)**)​

1.19 Superstructure (99707782366)​

1.20 Heating, Webasto Thermo 50 (99707782366)​

1.21 Heating, Webasto Thermo 90 (99707782366)**)​

1.22 Air conditioning system (99707782366)**)​

1.23 Superstructure (99707782366)​

1.24 1.6 m jib (99707778645)**)​

2 Pneumatic diagrams

2.1 Compressed air system / superstructure (99707770571)​

3 Hydraulic piping diagrams

3.1 Hydraulic system (99707783595)​

3.2 Valve group (99707016912)​

3.3 Pump assembly (99707783596)​

3.4 Boom elevation cylinder (99707785434)​

3.5 Swing mechanism (99707785436)​

3.6 Telescopic cylinder (99707785435)​

3.7 Hoist winch (99707785437)​

3.8 Auxiliary hoisting winch (99707785439)**)​

3.9 Counterweight (99707785440)​

3.10 Emergency control (99707785480)**)​

3.11 Supplementary oil cooler (99707785438)**)​

Part E: Crane Testing Instructions
1 Inspection of supporting steel structures

1.1 Guidelines for areas to be checked​

2 Inspection of the hook blocks

2.1 Inspection for widening of the hook mouth​

2.2 Inspection for wear​

2.3 Inspection for corrosion​

3 Inspection of lifting ropes

3.1 Lifting ropes: Long lay - Cross-lay​

3.2 Replacement state of repair of metallic ropes due to​

3.3 Replacement of a metallic rope​

3.4 Service and Maintenance​

3.5 Elimination of elongation spin​

4 Working life of the rope winch gear assemblies

4.1 Theoretical service life of the winch​

4.2 Consumed portion of the theoretical service life​

4.3 Determination of the consumed portion of the theoretical service life​

5 Monitoring the slewing device

5.1 Inspection of the ring-gear securing pins​

Part F: Troubleshooting
F1 Chassic
1 Engine
2 Gearbox
3 Transfer box
4 Axle differential locks and drive assemblies
5 Hydraulic system in general

5.1 Steering system - mechanical section​

5.2 Steering system - hydraulic / electrical section​

5.3 Hydraulic system of suspension​

5.4 Inclination adjustment and level control​

5.5 Hydraulic system of outriggers​

6 Brake system
7 Electrical equipment
8 Eddy current brake**)
Part F: Troubleshooting
F2 Superstructure
1 Engine
2 Hydraulic system of the superstructure in general
3 Slewing gear
4 Telescoping mechanism
5 Boom elevation
6 Hoisting gear
7 Counterweight
8 Electrical equipment
Part F: Troubleshooting
F3 Connection Diagrams
1 Connection diagram
Part G: Annex
G1 Chassic
Operating instructions for ZF gearbox
Operating instructions for ZF-Intarder
Chart of lubricants for ZF gearbox
Central grease Lubrication system
G2 Superstructure
Operating Load Moment Limiter (AML)
Central grease Lubrication system
Documents regarding heating, ventilation and the air conditioning system**) -
superstructure cabin

 

[Momed80]

Thanks for your sharing.

 

[Alex169]

Thanks for your post.

 

[machine]

Thanks for your sharing.

 

[cranes]

Good job thanks for coming.