Tadano FAUN ATF 220G-5 Installation and user guide

Operating, Service and
Maintenance Manual
ATF 220G - 5
Vehicle identification no: WFN5 RUG R1 62036…
Manufacturer After-Sales Service:
FAUN GmbH
Postfach 10 01 08
D - 91205 Lauf a.d. Pegnitz
Phone: [phone] - 0
Fax: [phone]
TX: 62 29 90
TADANO FAUN GmbH
Postfach 10 02 64
D - 91205 Lauf a.d. Pegnitz
Phone: [phone] - 0
Fax: [phone]
TX: 62 29 90

0010_EN_FA036_K_00_00_00_FA029
Dear Customer,
We have gone to great lengths to provide the conditions for a long
service life of your FAUN crane.
High-grade coatings, multi-layer paint systems and high-performance
application procedures with a high process reliability characterize the
excellent visual appearance of our FAUN cranes. Service and upkeep
are indispensable to maintain this finish:
1. Paint takes some time to develop its maximum resistance. Thus,
please do not clean your crane with excessively hot water, nor
with excessive water pressure during the first 8 weeks. Avoid
steam-jet units.
2. When using the crane on construction sites, when loading it with
load take-up equipment and wooden planks, damage to the
paint is inevitable. Such damage will result in corrosion or rust
and must therefore be repaired in an expert fashion without de-
lay.
3. Damage may also be caused by stone impact during travel. This
also requires immediate action.
4. The paintwork is also vulnerable to weather conditions and thaw-
ing salt. Thus, regular cleaning of the crane and preservation of
connectors, welts and screw couplings is necessary.
Customer satisfaction is our aim !

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TABLE OF CONTENTS

TABLE OF CONTENTS
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2002-12 1/22
PREFACE
1 How to use this Operating Manual
2 Technical data, operation, maintenance, troubleshooting
3 Handling of this Operating Manual
4 Mounting locations of the vehicle identification number and of the nameplates

TABLE OF CONTENTS
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Part A) Technical Details
1 General technical details (chassis)
1.1 Dimensions and weights
1.2 Driving performance data (according to DIN 70020)
2 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 Standard equipment
2.18 Painting
2.19 Optional equipment

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Part A) Technical Details (cond’t.)
3Technical 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 mechanism
3.7 Safety equipment
3.8 Electrical equipment
3.9 Superstructure cabin
3.10 Counterweight
3.11 Heating system
3.12 Superstructure frame
3.13 Painting
3.14 Acceptance inspection
3.15 Optional equipment
3.16 Noise level when the engine is operating under load and at working speed (1,500 r.p.m)
3.17 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

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Part B0) 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 by outriggers
2.4 Counterweight
2.5 Hoist winch and reeving of the winch rope
2.6 Taking account of the wind speeds
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 spark-over (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 Instructions for 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)

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Part B) Operating Instructions
B1) Chassis
1 General instructions concerning operation of the vehicle
1.1 Warning and instruction plates
1.3 Components, assemblies - installation location and position
1.4 Transport condition of the vehicle when used in public road traffic
1.5 Wheel chocks
2 Driver’s cab
2.1 Explanation of the control elements and of the equipment
2.3 Front lid
2.4 Seat adjustment
2.5 Adjustment of the steering wheel
2.6 Actuation of the roller sun visor
2.7 Seat belts
2.8 Cab lighting
3 FAUN Cockpit Graphic Control System
3.1 Main screen
4How 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 driving operation
4.4 Air distribution; fan; heater unit; air circulation and air conditioning
4.5 Start the engine
4.6 Monitoring the pilot, indicator and warning lamps and the instruments while the engine is running
4.7 Hydraulic system of suspension, inclination adjustment, level control
4.8 Centralized lubrication system
4.9 Central warning, CGC

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Part B) Operating Instructions (cont’d)
B1) Chassis
5 Gearshift and driving operation
5.1 Gearbox
5.2 Transfer box
5.4 Engaging the inter-axle and inter-wheel differential locks / axle drive
5.5 Lifting axle
5.6 Brakes
5.7 Cruise Control
5.9 Steering
5.10 Towing the vehicle
5.11 Engine speed regulation (manual throttle, working speed)
6 Stabilizing the vehicle by outriggers
6.1 Control panel
6.2 Preparation for outrigger operation
6.3 Instructions regarding outrigger operation
6.4 Extending the outrigger beams
6.5 Extending the outrigger cylinders
6.6 Outriggers - retracting the outrigger cylinders / outrigger beams
6.7 Moving the vehicle with the complete counterweight mounted
7 Emergency control functions and elements
7.1 Hydraulic system
7.2 Centering the 4th and 5th 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 Devices facilitating access to the superstructure

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Part B) Operating Instructions (cont’d)
B1) Chassis
10 Attachments, optional equipment and accessories
10.1 Acoustic reversing signal - warning device
10.2 City / country horn (Supertone horn)
10.3 ABV system (Automatic Anti-Lock System)
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 Underride guard
10.15 Rear area surveillance
10.16 Spare wheel
11 Instrument panel
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)

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Part B) Operating Instructions
B2) Superstructure
1General information about operation
1.1 Warning and instruction plates
1.2 Location of the warning and instruction plates
1.3 Components, assemblies - installation location and position
2Crane cabin
2.1 Explanation - control elements
2.2 Adjustment of the seat
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 system
3 FAUN Cockpit Graphic Control System
3.1 Main screen
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 Start the engine.
4.6 Monitoring the pilot, indicator and warning lamps and the instruments while the engine is running
4.7 Centralized lubrication system
4.8 Central warning, CGC
5 Outrigger operation from the superstructure
5.1 Changing-over to outrigger operation from the superstructure
5.2 Starting the engine in the chassis from the superstructure
5.6 Outrigger operation from the superstructure

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Part B) Operating Instructions (cont’d)
B2) Superstructure
6 Crane movements in no-load condition
6.1 Instructions regarding actuation of the crane control levers
6.2 Actuation of the hoisting gear (main 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
6.9 Over-overriding cutout device for auxiliary winch
7Crane 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 functions and elements
9 Operation in winter
9.1 Engine
9.2 Warming up the hydraulic oil or changing the oil type
9.3 Batteries
9.4 Adjustable air vents
9.5 Windshield washing system

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Part B) Operating Instructions (cont’d)
B2) Superstructure
11 Attachments, optional equipment and accessories
11.1 Optional equipment mentioned in other sections
11.2 Positioning the double ladder for mounting the jibs, and for access to the crane superstructure
11.3 Mounting the jib (boom extension)
11.4 Jib
11.5 Heavy-lift sheave
11.6 Single top
11.7 Heating of working mirror
11.8 Aircraft warning lamp on the boom
11.9 Working floodlight on the hoist winch
11.10 Working floodlight - electrical adjustment
11.11 Hook height indication, auxiliary hoist winch
11.12 Air conditioning system
11.13 Mounting/removal of the auxiliary winch
11.14 Switch "Emergency OFF, superstructure engine”
11.15 Starting the engine with current supplied from an external power source
11.16 Battery charging plugbox
11.17 Hourmeter, hoist winch
11.18 Hourmeter, auxiliary hoist winch
11.19 Emergency control of superstructure / emergency drainage device
12 Instrument panel
12.1 Monitoring superstructure, chassis, and outrigger operation from the superstructure, ASLI control unit
12.2 Operation of the superstructure

TABLE OF CONTENTS
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Part C) Service and Maintenance
C1) Chassis
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 Fuel tank
3.5 Coolant
3.6 Cleaning the radiator
3.7 Air cleaner
3.8 Exhaust system
4 Gearbox
4.1 Oil level inspection
4.2 Oil change/oil filter change
4.4 Clutch, and clutch control mechanism
5 Transfer box
5.1 Oil level inspection
5.2 Oil change
5.3 Cleaning the radiator

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Part C) Service and Maintenance (cont’d)
C1) Chassis
6 Axles
6.1 Checking the oil level in the axle drive assemblies of the steering driven axles and the planetary gears
6.2 Oil change in the 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 gears
6.9 Checking the propeller shaft flange screws for tight fit
7Propeller 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 Check the hydraulic oil level.
10.2 Replacement of filter cartridges
10.3 Oil change in the hydraulic system
10.4 Changing the oil type
10.5 Hydraulic system of steering assembly
10.6 Hydraulic system of suspension
10.7 Hydraulic system of outriggers
10.8 Test connectors and measured values
10.9 Location of the hydraulic measuring connectors

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Part C) Service and Maintenance (cont’d)
C1) Chassis
11 Brakes
11.1 Drainage valves in the compressed air tanks
11.2 Air drier
11.3 Pressure governor with tire inflation socket (integrated in air drier)
11.4 Brake cylinder
11.5 Inspection of the wheel brakes
11.6 Wheel brakes - Maintenance
11.7 Check pressure limiting valve
11.8 Automatic anti-lock system (ABV) - Maintenance
11.9 Engine brake
11.10 Test connectors for inspection of the compressed air brake system
11.11 Test and setting values
11.12 Location 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-/Relayarrangement
13 Wheels and tires
13.1 Measures to be taken to avoid accidents caused by the wheels
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
14.2 Inspection and, if necessary, adjustment of the slide pieces and slideway liners
14.3 Inspection and, if necessary, readjustment of chains for extension and retracting

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Part C) Service and Maintenance (cont’d)
C1) Chassis
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**)
15.6 Control and Service System
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
16.8 Supplementary heater unit
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 Lubricating scheme