Operating, Service and Maintenance Manual ATF 90G-4 Vehicle identification no: WFN4 RUL R5 72045 Manufacturer FAUN GmbH Postfach 10 01 08 D - 91205 Lauf a. d. Pegnitz Tel: (09123) 185-0 Fax: (09123) 7 53 20 TX: 622990 After-Sales Service: TADANO FAUN GmbH Postfach 10 02 64 D - 91205 Lauf a.d. Pegnitz Tel: (09123) 955-0 Fax: (09123) 18 51 55 TX: 62 29 90
PREFACE 1 Mounting locations of the vehicle identification number and of the nameplates 0020_EN_FA029_I_01_00_00_S.DOC 2007-01 1/11
Mounting locations of the vehicle identification number and of the nameplate V-1 4 Mounting locations of the vehicle identification number and of the nameplate: These plates are provided on the vehicle in the following locations: The vehicle identification number (1) is stamped on the frame, on the right side of the vehicle, between the 1 st and 2 nd axles. The nameplates bearing all the relevant vehicle data are located in the driver's cabin in the undercarriage (3) to the right of the passenger's seat, next to the cab door, and on the rear outside of the superstructure cabin (2). 1 = Vehicle identification number 2 = Nameplate, superstructure 3 = Nameplate, chassis 0045_EN_FA045_V_04_00_00 2003-01 2/11
C h a p t e r A ) T e c h n i c a l D e t a i l s 1 Specification sheet 1.1 Specification sheet 2 Load rating chart 2.1 Notes to the load rating chart 2.2 Boom 2.3 Fly jib 2.4 Counterweight configuration 2.5 Counterweight distribution depending on axle load 2.6 Moving the crane in full rig arrangement on construction sites 2008/4/30 3/11
C h a p t e r B ) C o n s t r u c t i o n & O p e r a t i o n & C i r c u i t s 1 Construction & Operation 2 Layout of components 2.1 Over-view 2.2 Driver s cab 2.3 Hydraulic system 3 Circuit diagrams 3.1 Key for diagrams 3.2 Assumption in electrical circuit diagrams 3.3 Electrical circuit 3.4 Hydraulic circuit 3.5 Pneumatic circuit B 1 ) C h a s s i s 4/11
C h a p t e r B ) C o n s t r u c t i o n & O p e r a t i o n & C i r c u i t s 1 System construction 1.1 Construction & Operation 1.2 AML-B operation manual 1.3 AML-B maintenance & adjustment manual 1.4 AML-B information & Data 2 Layout of components 2.1 Over-view 2.2 Crane s cab 2.3 Electric system 2.4 Hydraulic system 3 Circuit diagrams 3.1 Key for diagrams 3.2 Assumption in electrical circuit diagrams 3.3 Electrical circuit 3.4 Hydraulic circuit B 2 ) S u p e r s t r u c t u r e 5/11
C h a p t e r C ) S e r v i c e a n d M a i n t e n a n c e C 1 ) C h a s s i s 1 General information 2 Maintenance intervals 3 Engine(chassis) 4 Gearbox, Type ZF-AS-Tronic 12AS2302 5 Transfer box 6 Axles 7 Propeller shafts 8 Eddy-current brake 9 Breather 10 Hydraulic system 11 Brake system 12 Electrical equipment 13 Wheels and tires 14 Outriggers 15 Driver s cab 16 Miscellaneous; other points of lubrication, servicing and maintenance 24 Summary of oil types and filling capacities (Recommended oil types) 25 Summary of oil types and filling capacities (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 6/11
C h a p t e r C ) S e r v i c e a n d M a i n t e n a n c e C 2 ) S u p e r s t r u c t u r e 1 Maintenance intervals 2 Engine 3 Hydraulic system 4 Swing mechanism 5 Hoisting gear and auxiliary hoisting gear 6 Winch rope 7 Electrical equipment 8 Crane cab 9 Other points of lubrication, servicing and maintenance 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 Lubricating scheme 7/11
C h a p t e r D ) T r o u b l e s h o o t i n g D 1 ) C h a s s i s 1 Simple Troubleshooting 1.1 Engine 1.2 Gearbox 1.3 Transfer box 1.4 Axle differential locks and drive assemblies 1.5 Hydraulic system in general 1.6 Brake system 1.7 Electrical equipments 1.8 Eddy current brake 2 Emergency operation 2.1 Towing the vehicle 2.2 Emergency control functions and elements 3 Error Code List 3.1 Transmission (ZF AS-Tronic) 3.2 Intarder (ZF Intarder) 3.3 Rear steering (Mobile Electronic) 3.4 Tachograph (VDO MTCO1324) 3.5 ABV (Wabco) 8/11
C h a p t e r D ) T r o u b l e s h o o t i n g D 2 ) S u p e r s t r u c t u r e 1 Simple troubleshooting 1.1 Engine 1.2 Hydraulic system of the superstructure in general 1.3 Swing mechanism 1.4 Telescoping mechanism 1.5 Boom elevation 1.6 Hoisting gear 1.7 Counterweight 1.8 Electrical equipment 2 Emergency operation 2.1 Emergency control functions and elements 2.2 Emergency control of superstructure / emergency drainage device 2.3 Manual telescoping operation 3 Error code list 3.1 AML-B warning and error codes 9/11
C h a p t e r E ) D i s. / A s s e m b l y & A d j u s t m e n t E 1 ) C h a s s i s 1.1 Pressure adjustment C h a p t e r E ) D i s. / A s s e m b l y & A d j u s t m e n t E 2 ) S u p e r s t r u c t u r e 2.1 Pressure adjustment 2.2 Electric adjustment 10/11
C o m p o n e n t s / S p e c i a l T o o l The service manual of this machine consists of this manual and following separate component manuals. Separate component Manual Information No. 1 Engine(Daimler Chrysler) Maintenance and Repair (1511120902-1stedition)... (W556-0011E) Electronical Engine Control (1511121002-1stedition)... (W556-0021E) ADM2-FRO... (W556-0031E) 2 Transmission(ZF AS-Tronic) Operating manual (1328_758_104)... (W562-0021E) Installation manual (1327_754_106)... (W562-0031E) Repair manual (1327_751_101a)... (W562-0041E) Preparation for the clutch installation... (W562-0051E) ZF_Sachs_clutch_information... (W562-0061E) 3 Intarder(ZF Intarder) Operating Manual (6085 758 102a)... (W564-0121E) 4 Steering(ZF servocom) Operation, Maintenance and Inspection (G8096B)... (W571-0011E) 5 Axle(Kessler) Service manual (51_61_71_81)... (W563-0101E) 6 Central lubricating system(beka-max) Repair instructions (PDQ8939000406D7GB)... (W590-0031E) Central Lubricating System... (W590-0041E) 7 Tachograph(VDO MTCO1324) VDO MTCO1324... (W590-0051E) 8 Air conditioning(wolfle) Operating Instructions... (W701-0251E) Air conditioning system... (W701-0261E) 9 Anti-Lock Braking System for Commercial Vehicles (ABV)(Wabco) Anti-Lock Braking System for Commercial Vehicles (ABV)... (W577-0231E) 10 Brake(Kontt) Maintenance and Repair Instructions TM 89/03... (W577-0241E) 2008/4/30 11/11
c200 PRINTED IN JAPAN 0801 E