Tadano Faun ATF 220G-5 Crane Operating, Service and Maintenance Manual – PDF

Description

The Tadano Faun ATF 220G-5 Operating, Service and Maintenance Manual is the complete multi-part technical documentation set issued by FAUN GmbH for the ATF 220G-5 all-terrain mobile crane. This manual is the working reference for daily operation, scheduled servicing, fault diagnosis and component repair of both the 10×6 / 10×8 chassis and the superstructure. Every section is organised around the actual assemblies fitted to the ATF 220G-5 — from the Mercedes-Benz OM502LA carrier engine and ZF-AS Tronic 16 AS 2602 gearbox through to the seven-section 68 m telescopic boom, the 71 t divisible counterweight system and the automatic safe load indicator.

File Details

• Manual type: Operating, Service and Maintenance Manual
• Brand: TADANO FAUN / FAUN GmbH
• Model: ATF 220G-5
• Language: English
• Page count: 1078 pages
• File format: PDF
• Manufacturer: FAUN GmbH, Postfach 10 01 08, D-91205 Lauf a.d. Pegnitz
• After-Sales Service: TADANO FAUN GmbH, Postfach 10 02 64, D-91205 Lauf a.d. Pegnitz
• Vehicle identification number format shown: WFN5 RUG R1 62036…

Chapters Covered

• Part A — Technical Details: chassis dimensions and weights, driving performance data, Mercedes-Benz OM502LA engine, ZF-AS Tronic 16 AS 2602 gearbox, transfer box VG 3750, axles 10×6 and 10×8, hydro-pneumatic axle suspension, brakes, ZF Servocom steering, electrical equipment, driver’s cab, frame, outriggers, fuel system; superstructure technical details including OM 906 LA engine, hydraulic system, hoisting gear, seven-section telescopic boom, boom elevation, swing mechanism, safety equipment, superstructure cabin, 71 t counterweight, noise and vibration values
• Part B0 — Safety Instructions: requirements for public road traffic, tire load ratings and speed limits, instructions for the crane operator, applications planning, outrigger support, ground pressure tables, distances from ditches and slopes, counterweight, hoist winch and rope reeving, wind speed assessment, hand signals, work near electrical overhead lines and supply lines, crane work with a load, two-crane lifts, potential causes of accidents, fire and explosion hazards, compressed air tank regulations, overload safety device instruction sheet
• Part B1 — Operating Instructions Chassis: warning and instruction plates, component locations, transport condition, driver’s cab controls, FAUN Cockpit Graphic Control System, start-up checks, electrical equipment, heating and ventilation, engine start and stop, suspension and level control, centralized lubrication system, gearshift and driving, differential locks and 2nd axle drive, lifting axle, brakes, engine brake, Intarder, Cruise Control, steering including construction site modes, towing, outrigger stabilisation, emergency controls, winter operation, access devices
• Part B2 — Operating Instructions Superstructure: crane cabin controls, seat and armrest adjustment, superstructure locking system, CGC operation, start-up checks, outrigger operation from the superstructure, crane movements under no-load, hoisting gear and auxiliary hoisting gear, boom elevation, telescoping with automatic sequence and emergency manual reset, slewing, counterweight mounting and depositing for 0 t, 12 t, 23.5 t, 35 t, 47 t and 71 t variants, rope reeving, safety equipment inspection, jib mounting and offset angle changes, heavy-lift sheave, single top, two-hook operation, emergency control of the superstructure
• Part C1 — Service and Maintenance Chassis: general service instructions, welding precautions, maintenance intervals and schedule, engine, gearbox, transfer box, axles, propeller shafts, eddy-current brake, breathers, hydraulic system including steering, suspension and outriggers with test connectors and measured values, brake system with test and setting values, electrical equipment with fuse and relay arrangements, wheels and tires including tightening torques, outrigger adjustment, driver’s cab, trailer coupling devices, oil types and capacities, lubricating grease types, inspection, cleaning, oil level and lubricating schemes
• Part C2 — Service and Maintenance Superstructure: maintenance intervals and schedule, engine, hydraulic system with set-point pressures and measuring connectors, swing mechanism, hoisting gear and auxiliary hoisting gear, winch rope inspection and replacement, electrical equipment including AML maintenance, crane cab, telescopic boom lubrication, boom elevation cylinder, bottom block, counterweight, jib, centralized lubrication system
• Part D — Circuit and Piping Diagrams: electric circuit diagrams for chassis and superstructure, CAN connections, slipring, emergency OFF, Webasto heater units, pneumatic diagrams for the compressed air system, hydraulic piping diagrams for the hydraulic system, steering, transfer box, front and rear outriggers, oil tank, engine, emergency control
• Part E — Crane Testing Instructions: inspection of supporting steel structures with guidelines for areas to be checked, inspection of hook blocks including hook mouth widening and wear limits, inspection of lifting ropes including discarding criteria, working life of the rope winch gear assemblies with theoretical service life calculation, monitoring the slewing device
• Part F — Troubleshooting: fault tables for chassis and superstructure covering engine, gearbox, transfer box, axle differential locks, hydraulic system, steering, suspension, outriggers, brake system, electrical equipment, eddy-current brake, slewing gear, telescoping mechanism, boom elevation, hoisting gear, counterweight
• Part G — Annex: ZF-AS Tronic gearbox operating instructions, ZF-Intarder operating instructions, ZF chart of approved lubricants, centralized lubrication system documentation, AML (Automatic Safe Load Indicator) operation manual with function keys, displays, work range limits, speed pre-selection, Lift Adjuster, counterweight status, and complete warning and error code list, Wölfle heating, ventilation and air conditioning documentation

This manual is far more than a general operating booklet. It is the complete factory documentation set for the ATF 220G-5, presented in the same multi-part structure FAUN uses internally: technical data, safety instructions, chassis and superstructure operating procedures, full service and maintenance schedules, circuit and piping diagrams, crane testing instructions, troubleshooting tables and the manufacturer annexes for the ZF transmission, Intarder, centralized lubrication system and automatic safe load indicator. A technician working on this crane can move from a fault symptom in the troubleshooting table straight into the relevant wiring or hydraulic diagram, then into the service procedure and finally into the tightening torque or pressure value that applies.

What This Manual Enables You to Do

• Carry out the complete maintenance schedule for the carrier and superstructure at the correct intervals
• Diagnose electrical, hydraulic, pneumatic and mechanical faults using the dedicated troubleshooting tables
• Read and interpret the chassis and superstructure electric circuit diagrams, pneumatic diagrams and hydraulic piping diagrams
• Service the Mercedes-Benz OM502LA and OM 906 LA engines, ZF-AS Tronic 16 AS 2602 gearbox, transfer box, axles and swing mechanism
• Check hydraulic pressures at the labelled measuring connectors and compare against the set-point tables
• Perform brake system testing and set pressure limiting valves to the specified values
• Adjust outrigger slide pieces, slideway liners and extension chains
• Inspect steel structures, hook blocks and lifting ropes against the documented discarding criteria
• Calculate the remaining theoretical service life of the hoist winch and determine when a general overhaul is due
• Operate the Automatic Safe Load Indicator (AML) correctly, register crane configurations, set work range limits and decode error codes

Getting these procedures right is not optional on a 60 t all-terrain crane. An incorrectly set counterweight, an out-of-adjustment outrigger, an ignored hydraulic pressure deviation or a rope that should have been discarded all translate directly into risk. The service and maintenance sections specify the exact intervals, pressures, torques and discarding limits the crane was designed around, and the troubleshooting tables tell you which of those values to suspect first when something is wrong.

IMAGES PREVIEW

Supplied as an instant PDF download, this Tadano Faun ATF 220G-5 Operating, Service and Maintenance Manual can be viewed on any device, searched on screen or printed page by page for the workshop. There is no shipping and no waiting — payment completes and the file is available immediately.