Tadano Faun GR-300EX-2 Rough Terrain Crane Service Manual SN 561378 – PDF DOWNLOAD

Description

Tadano Faun GR-300EX-2 Rough Terrain Crane Service Manual SN 561378 – PDF DOWNLOAD

FILE DETAILS:

Tadano Faun GR-300EX-2 Rough Terrain Crane Service Manual SN 561378 – PDF DOWNLOAD

Language : English
Pages : 440
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Tadano Faun GR-300EX-2 Rough Terrain Crane Service Manual SN 561378 – PDF DOWNLOAD

GR-300EX-2/S2-1E 1
Safety 2
1 Fundamental cautions 3
2 Cautions in working 3
2 1 General 3
2 2 Dismounting and disassembling 4
2 3 Remounting and assembling 4
3 Cautions in operation 4
3 1 Brake fluid replenishment 4
3 2 Handling of battery 4
3 3 Handling of radiator 5
3 4 Cooling fan 5
4 About waste disposal 5
4 1 Gasoline 5
4 2 Hydraulic oil 5
4 3 Motor oil 5
Foreword 6
1 Applicable spec and serial number 6
2 Separate service manual 6
3 External view 7
4 Conversion table 8
5 Outline of specifications 10
6 Group index 12
7 Contents 13
(B) Hydraulic Power Generating System 20
B-1 Hydraulic Power GeneratingSystem 22
1 Function 22
1 1 Hydraulic pump 22
1 2 Solenoid control valve(outrigger, suspension) 22
1 3 Center joint 22
1 4 Hydraulic pilot control valve(elevation, telescoping, main winch and auxiliary winch) 22
1 5 Sequence valve (pilot pressure) and solenoid valve (pilot pressure) 22
2 Hydraulic system description 23
2 1 Pump (P1) circuit 23
2 2 Pump (P2) circuit 23
2 3 Pump (P3) circuit 23
2 4 Pump (P4) circuit 23
B-2 Hydraulic Pump (Double Variable Displacement Pump) 24
1 Structure 24
1 1 General view 24
1 2 Pump main body 25
1 3 Regulator 26
2 Operation 28
2 1 Regulation of flow rate by discharging pressure 28
2 2 Regulation of flow rate by external pilot(positive control) 31
B-3 Hydraulic Pump (Double Gear Pump) 34
1 Structure 34
B-4 Hydraulic Pump (Gear Pump, Emergency Steering) 37
1 Structure 37
B-5 Hydraulic Valve (Emergency Steering) 38
1 Structure 38
B-6 Pressure Reducing Valve (Emergency Steering) 40
1 Structure 40
B-7 Center Joint 41
1 Structure 41
1 1 General view 41
1 2 Port size table 43
1 3 Swivel joint (hydraulics and pneumatics) 44
1 4 Swivel joint (heated water) 46
2 Slip ring 47
2 1 General view 47
2 2 Harness and connector 48
2 3 Maintenance of ring and brush 48
B-8 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch) 49
1 Structure 49
B-9 Sequence Valve (Pilot Pressure) 60
1 Structure 60
B-10 Solenoid Valve (Pilot Pressure) 63
1 Structure 63
B-11 Solenoid Valve (Positive Control) 65
1 Structure 65
B-12 Check Valve (Gauge lsolator) 67
1 Structure 67
(C) Outrigger System 68
C-1 Outrigger System 69
1 Function 69
1 1 Solenoid control valve (outrigger, suspension) 69
1 2 Solenoid valve (slide/jack) 69
1 3 Jack cylinder 69
1 4 Pilot check valve (jack cylinder retraction prevention) 69
1 5 Extension cylinder 69
1 6 Check valve (slide/jack extension prevention) 69
2 Hydraulic system description 69
2 1 Outrigger extension operation 69
2 2 Outrigger retraction operation 69
3 Electric system 70
3 1 Outrigger operation inside operation cab 70
C-2 Solenoid Control Valve (Outrigger, Suspension) 71
1 Structure 71
1 1 General view 71
1 2 Body assy (outrigger) 73
1 3 Body assy (suspension) 75
1 4 P cover assy 77
1 5 T cover assy 80
1 6 Tandem plate assy 83
C-3 Solenoid Valve (Slide/Jack) 84
1 Structure 84
2 Solenoid valve assy 85
2 1 Solenoid valve (Rexroth(UCHIDA)) 85
2 2 Solenoid valve (TOKIMEC) 86
2 3 Solenoid valve (NACHI) 87
C-4 Jack Cylinder 88
1 Structure 88
C-5 Pilot check Valve (Jack Cylinder Retracting Prevention) 89
1 Structure 89
C-6 Extension Cylinder 90
1 Structure 90
C-7 Check Valve (Slide/Jack Extending Prevention) 91
1 Structure 91
(D) Swing System 92
D-1 Swing System 93
1 Function 93
1 1 Swing drive unit (hydraulic motor and swing speed reducer) 93
1 2 Hydraulic pilot control valve (swing) 93
1 3 Solenoid valve (swing brake release) 93
1 4 Swing free function 93
2 Hydraulic system description 93
D-2 Hydraulic Pilot Control Valve (Swing) 94
1 Structure 94
D-3 Hydraulic Motor (Swing) 100
1 Structure 100
D-4 Swing Speed Reducer 102
1 Structure 102
2 Removing of hydraulic motor 103
3 Disassembly of reducer 103
4 Assembly of reducer 104
5 Installation of hydraulic motor 104
D-5 Swing Assembly 105
1 Structure 105
2 Swing bearing mounting bolt 106
2 1 Bearing inner ring bolts 106
2 2 Bearing outer ring bolts 107
(E) Boom Elevating System 108
E-1 Elevating System 109
1 Function 109
1 1 Elevating cylinder 109
1 2 Counterbalance valve 109
1 3 Pressure sensor 109
1 4 Elevation slow stop 109
2 Hydraulic system description 109
E-2 Elevating Cylinder 110
1 Structure 110
E-3 Counterbalance Valve (Elevating) 112
1 Structure 112
2 Function 114
2 1 When control valve is at the neutral position 114
2 2 While actuator is being pushed up 114
2 3 While actuator descends 114
E-4 Pressure Sensor 115
1 Structure 115
1 1 Internal section 115
1 2 Connection diagram 115
1 3 Specification 115
1 4 Conversion used by AML from sensor output voltage into hydraulic pressure 115
(F) Winch System 116
F-1 Winch System 118
1 Function 118
1 1 Hydraulic motor 118
1 2 Counterbalance valve 118
1 3 Hydraulic valve (winch brake) 118
1 4 Pressure sensor (for gauge isolator) 118
2 Hydraulic system description 118
F-2 Winch 119
1 Structure 119
1 1 General view 119
1 2 Reducer 120
F-3 Hydraulic Motor and Counterbalance Valve 121
1 Structure 121
1 1 Hydraulic symbol 121
1 2 General view 121
1 3 Hydraulic motor assy 122
2 Description of operation 124
2 1 Mechanical brake 124
2 2 Counterbalance valve 125
3 Troubleshooting 127
4 Disassembly procedure of motor 128
4 1 Washing hydraulic motor 128
4 2 Mounting hydraulic motor on a workbench 128
4 3 Draining gear oil 128
4 4 Removing cover [113] 129
4 5 Removing sun gear-1 [104] 129
4 6 Removing carrier assy 129
4 7 Removing planetary gear-2 [107] 130
4 8 Removing counterbalance valve 130
4 9 Removing rear flange [401] 131
4 10 Removing rear flange [401] attachment 132
4 11 Disassembling internal counterbalance valve 133
4 12 Disassembling counterbalance valve section 133
4 13 Disassembling hydraulic motor 134
4 14 Removing spring [214] of cylinder block [204] 136
4 15 Removing pivot [267] 136
4 16 Removing tapered roller bearing 137
4 17 Disassembling spindle [102] 137
4 18 Removing angular ball bearing 138
4 19 Removing accessories attached to spindle [102] 138
4 20 Primal washing 139
4 21 Final washing 139
5 Maintenance standards 140
5 1 Seal 140
5 2 Maintenance standards for parts subject to wear 140
6 Assembly 142
6 1 Preparation 142
6 2 General suggestion for work 142
6 3 Assembly procedure 142
7 Performance confirmation test 148
7 1 Required measurement instruments 148
7 2 Test procedure 148
8 Classifications of clearance adjustment parts 149
F-4 Hydraulic Valve (Winch Brake Release) 150
1 Structure 150
F-5 Accumulator (Winch Brake) 152
1 Structure 152
F-6 Pressure Sensor 153
1 Structure 153
1 1 Internal section 153
1 2 Connection diagram 153
1 3 Specification 153
1 4 Conversion used by AML from sensor output voltage into hydraulic pressure 153
(G) Boom Telescoping System 154
G-1 Telescoping System 156
1 Function 156
1 1 Telescoping cylinder 156
1 2 Counterbalance valve(No 1 telescoping cylinder)(No 2 telescoping cylinder) 156
1 3 Hose reel 156
1 4 Hydraulic valve (top cylinder selection) 156
2 Boom telescoping mechanism 157
3 System description 158
3 1 Extension operation 158
3 2 Retraction operation 158
G-2 Boom (Four-Section Boom) 159
1 Structure 159
2 Disassembly 162
2 1 Removing the 2nd boom section 162
2 2 Removing the 3rd boom section 163
2 3 Removing the top boom section 164
3 Check 164
3 1 Boom 164
3 2 Slide plate 164
3 3 Sheave 164
3 4 Boom telescoping wire rope 164
4 Reassembly 165
4 1 Greasing 165
4 2 Install anti-buckling bolts for telescoping cylinder 165
4 3 Installing lower slide plates 165
4 4 Installing slide plates onto sides of rear end 165
5 Adjustment 165
5 1 Adjusting clearance for the boom 165
6 Test 167
6 1 Operation Test 167
6 2 Boom lateral warp test 167
6 3 Other functional test 167
G-3 Jib 168
1 Structure 168
1 1 Location of Jib 168
1 2 Jib main body 170
G-4 Telescoping Cylinder 172
1 Structure 172
G-5 Counterbalance Valve (Telescoping) 174
1 Structure 174
2 Function 175
2 1 When control valve is at the neutral position 175
2 2 While actuator is being pushed up 175
2 3 While actuator descends 175
G-6 Hose Reel 176
1 Structure 176
2 Mounting 177
3 Disassembly 177
4 Reassembly 178
G-7 Hydraulic Valve 179
1 Structure 179
(H) Safty System 182
H-1 Safety System 183
1 Function of safety devices 183
1 1 Moment detector (pressure sensor) 183
1 2 Boom length and angle detector 183
1 3 Outrigger extension width detector 183
1 4 Swing angle detector 183
1 5 Other detectors and switches 183
1 6 AML main body 183
1 7 Overwind cutout (anti-twoblock) device 183
1 8 Solenoid valve (AML vent) 183
2 System description 183
3 Requirement of EN13000 184
3 1 Decelerating speed method 184
3 1 1 Relief valve (pilot pressure) 184
3 1 2 Flow control valve (swing) 184
3 1 3 Hydraulic valve (swing) 184
H-2 Boom Length and Angle Detector 185
1 Structure and function 185
2 Disassembly and reassembly 187
2 1 Removing the cord 187
2 2 Installing the cord 187
2 3 Replacing spiral spring 189
2 4 Disassembling the potentiometer (for boom length detector) 189
2 5 Reassembling potentiometer 190
2 6 Replacing the boom angle detector 190
3 Adjustment 190
H-3 Outrigger Extension Length Detector 191
1 Structure and function 191
2 Disassembly 192
3 Reassembly 193
H-4 Solenoid Valve (Auto Stop) 195
1 Structure 195
H-5 Relief Valve (Pilot Pressure) 197
1 Structure 197
H-6 Flow Control Valve (Swing) 200
1 Structure 200
H-7 Hydraulic Valve (Swing) 202
1 Structure 202
(K) Cab 205
K-1 Crane Cab Glass 207
1 Glass replacement procedure 207
2 Bonding the joint between windshield glass and roof glass 208
K-2 Air Conditioner 209
1 Component parts 209
2 Introduction to air conditioning 210
2 1 Principle of air conditioning 210
3 Basic refrigeration cycle 211
3 1 Structure 211
3 2 Conditions for air conditioning equipment 212
3 3 Refrigerant 213
3 4 Refrigeration cycle of a car air conditioner 214
3 5 Comparison with a household air conditioner 214
3 6 Receiver functions 215
3 7 Reheat method 216
3 8 Components 217
4 Layout 219
4 1 Overall layout 219
4 2 Overall layout 220
4 3 Evaporator section 221
5 Compressor Assy 222
6 Evaporator Assy 223
7 Condenser Assy 224
8 Electric 225
8 1 Electric circuit (–561607) 225
8 1 1 Main harness A (–561607) 226
8 1 2 Main harness B (–561607) 227
8 2 Electric circuit (561608–) 228
8 2 1 Main harness A (561608–) 229
8 2 2 Main harness B (561608–) 230
9 Important points for assembly (Layout) 231
9 1 Evacuation 231
9 2 Charging with refrigerant 231
9 3 Check for gas leakage and amount of refrigerant charge 232
9 4 Heated water circuit 232
9 5 Run-in operation 232
9 6 Bolt size and tightening torque 232
10 How to charge air conditioner gas 233
10 1 Charging gas in automatic operation 233
10 2 How to charge air conditioner gas 235
10 3 How to check air conditioner 237
11 Diagnosis table 238
11 1 Car air conditioner system diagnosis table I (Refrigeration circuit) 238
11 2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure) 241
11 3 Car air conditioner system diagnosis table III (Electrical system) 243
11 4 Car air conditioner system diagnosis table IV (Electronic thermo system) 245
12 Compressor 247
12 1 Compressor abnormal sound diagnosis chart 247
12 2 Compressor diagnosis chart 248
13 Troubleshooting 250
14 Control table 256
K-3 Hydraulic Motor (Air Conditioner) 257
1 Structure 257
K-4 Solenoid Valve (Air Conditioner) 259
1 Structure 259
(L) Control System 261
L-1 Control Device 262
1 Crane control 262
2 Driving control 264
3 Other control device 266
L-2 Shift Switch 268
1 Structure 268
2 Electric circuit 271
L-3 Solenoid Valve (Air) (2/4 Wheel Drive Shift) 272
1 Structure 272
L-4 Remote Control Valve (Lever) (–561657) 274
1 Structure 274
L-5 Remote Control Valve (Lever) (561658–) 277
1 Structure 277
L-6 Remote Control Valve (Pedal) 280
1 Structure 280
L-7 Shuttle Valve (Lever / Pedal) 283
1 Structure 283
L-8 Solenoid Valve (Boom Telescoping / Aux Winch) 284
1 Structure 284
L-9 Solenoid control Valve (Elevation Slow Stop) 286
1 Structure 286
(N) Electric System 288
N-1 Display Control Unit (DCU) 290
1 System configuration 290
2 Structure and function 292
3 Connector (pin assignment) 293
4 Input/output signal list 298
5 Data list 302
5 1 Engine speed pulse output 302
5 2 Vehicle speed signal pulse output 302
5 3 One-to-one correspondence input/output function 303
5 4 Integration for hour meter 304
5 5 Integration for odometer 304
5 6 Actual value conversion formula 305
5 7 PWM output (PWM: Pulse Width Modulation) 306
5 8 CAN communication 307
5 9 Integrated value rewriting function 307
5 10 DPF indicator function 308
5 10 1 Accumulation level indicator 308
5 10 2 DPF regeneration indicator 309
5 10 3 Engine ECU error (yellow) 310
5 11 DPF indicator check function 310
N-2 Combination Meter 311
1 System configuration 311
2 Display section 312
3 Specifications 314
3 1 Speedometer 314
3 2 Tachometer 314
3 3 Odo/trip meter, hour meter 314
3 4 Odometer 314
3 5 Trip meter 314
3 6 Hour meter 314
3 7 Fuel gauge 315
3 8 Coolant temperature gauge 315
3 9 Air pressure gauge 316
3 10 Torque converter oil temperature gauge 316
4 Electric circuit 317
N-3 Signal Transmitter (STM-E) 319
1 System configuration 319
2 Structure and function 321
3 Connector (pin assignment) 322
4 LED display 322
5 Input/output signal list 323
6 Data list 325
6 1 One-to-one correspondence input/output function 325
6 2 Integration function for remaining fuel amount 326
6 3 CAN communication 327
6 4 K-LINE communication specifications 329
6 5 Error transmission 330
6 6 Communication between the lower MDTand lower STM-E for machines without DPF 332
6 7 Conversion of fuel consumption unit 332
6 8 CAN and serial communication list 333
6 9 Specification of “DIAG on CAN” communication 334
N-4 Engine Control Unit (ECU) 335
1 System configuration 335
2 Diagnosis function 336
2 1 Check for a failure (user mode) 336
2 2 Diagnosis lamp lighting law when a failure is detected 336
2 3 How to call up faulty code 337
2 4 Diagnosis code chart 340
N-5 Telecommunications Terminal (ICF, GSMT) 364
1 System configuration 364
2 ICF 365
2 1 External view 365
2 2 Connector (pin assignment) 365
3 GSMT (global system for mobile communications terminal) 366
3 1 External view 366
3 2 Connector (pin assignment) 367
(R) Driving Power Transmission System 368
R-1 Driving Power Transmission System 369
1 Function 369
1 1 Engine 369
1 2 Torque converter 369
1 3 Transmission 369
1 4 Axles 369
2 System description 369
2 1 Torque converter circuit 369
2 2 PTO clutch 369
2 3 Lockup clutch 370
2 4 Shift of drive mode 370
3 Installation 371
3 1 Radiator 371
3 2 Power train 372
(S) Steering System 374
S-1 Steering System 375
1 Function 375
1 1 Priority valve 375
1 2 Orbitrol 375
1 3 Steering cylinder 375
1 4 Solenoid valve (steering mode) 375
1 5 Pilot check valve (rear steering hydraulic lock) 375
2 Hydraulic system description 375
S-2 Priority Valve 376
1 Structure 376
2 Function 376
3 Principle of operation 377
3 1 Neutral state 377
3 2 Right steering 377
3 3 Right steering to the end 377
S-3 Orbitrol 378
1 Structure 378
2 Function 381
S-4 Steering Cylinder 382
1 Structure 382
S-5 Solenoid Valve (Steering Mode) 383
1 Structure 383
2 Solenoid valve (steering mode) 384
3 Pilot check valve (rear steering hydraulic lock) 385
(T) Brake System 386
T-1 Brake System 388
1 Function 388
1 1 Brake 388
1 2 Brake valve 388
1 3 Booster 388
1 4 Air dryer 388
1 5 Brake chamber 388
1 6 Parking brake 388
1 7 Solenoid valve (Parking brake) 388
1 8 Pressure regulator 388
2 System Description 389
2 1 Service brake 389
2 2 Parking brake 389
2 3 Exhaust brake 389
T-2 Brake Valve 390
1 Structure and function 390
2 Description of operation 392
2 1 Generation of air pressure 392
2 2 Stabilization of air pressure 392
2 3 Release of air pressure 393
2 4 Operation under piping rupture 394
3 Dismounting and remounting 394
4 Disassembly 395
4 1 Disassembly of the mount plate 395
4 2 Disassembly of the body 395
5 Cleaning and checking 396
5 1 Cleaning 396
5 2 Checking 397
6 Reassembly 397
6 1 Reassembly of the secondary side 397
6 2 Reassembly of the primary side 397
6 3 Reassembly of the mount plate 399
7 Test 399
7 1 Air leakage through supply valve and exhaust valve 399
7 2 Air leakage in other parts 399
7 3 Operation test 399
7 4 Performance test 399
8 Maintenance standard 400
8 1 600-hour check 400
8 2 1200-hour or 1-year check 400
T-3 Booster 401
1 Structure 401
2 Function 402
2 1 Air cylinder 402
2 2 Oil cylinder 402
3 Operation of cylinder 403
3 1 Booster not in operation 403
3 2 Booster in operation 403
3 3 Brakes released 403
4 Removing of booster 403
5 Disassembly 404
5 1 Disassembly of cylinder 404
6 Check 405
6 1 Rubber parts 405
6 2 Air cylinder 405
6 3 Oil cylinder 405
7 Reassembly 406
8 Test 407
8 1 Testing equipment 407
8 2 Performance diagram 407
8 3 Test method 407
9 Maintenance standards 408
9 1 Daily check 408
9 2 1200-hours or one year check 408
T-4 Air Dryer 409
1 Structure 409
2 Function 413
2 1 Dehumidification 413
2 2 Regeneration 414
2 3 Intake position 415
2 4 Release position 415
3 Precautions for handling 416
4 Maintenance and inspection 416
4 1 Daily inspection 416
4 2 Inspection and part replacement every 1 year or 100,000 km (62,140 mi) of driving 417
5 Disassembly 417
5 1 Removing DU-3 417
5 2 Disassembly of cartridge 417
6 Reassembly 419
6 1 Cartridge (lower) 419
6 2 Tamping the desiccant 420
6 3 Cartridge (upper) 420
7 Troubleshooting 421
T-5 Brake Chamber 424
1 Structure 424
2 Function 425
3 Disassembly 425
4 Cleaning and checking 426
4 1 Cleaning 426
4 2 Checking 426
5 Reassembly 427
6 Test 427
6 1 Air leak test 427
7 Maintenance standards 427
7 1 1200-hour or 1-year check 427
T-6 Solenoid Valve (Air) (Parking Brake) 428
1 Structure 428
(U) Suspension System 430
U-1 Suspension System 431
1 Function 431
1 1 Suspension lock cylinder 431
1 2 Pilot check valve 431
1 3 Solenoid valve (suspension lock) 431
1 4 Pressure reducing valve 431
2 System description 431
3 Suspension lock 432
4 Installation 434
U-2 Suspension Lock Cylinder 436
1 Structure 436
U-3 Pilot Check Valve (Suspension Lock Cylinder) 437
1 Structure 437
U-4 Solenoid Valve (Suspension Lock) (Free/Lock) 438
1 Structure 438
History of revision 440

DESCRIPTION:

Tadano Faun GR-300EX-2 Rough Terrain Crane Service Manual SN 561378 – PDF DOWNLOAD

Safety:

Most accidents that occur during machine operation and maintenance are caused by failure to observe basic safety rules and precautions. Before operating your machine or performing maintenance, read and become familiar with all the safety precautions and recommendations given in this section.

• Remember that failure to observe even a single precaution could involve you and the people around the machine in a serious accident.
• Foreseeing potential dangers is vital for preventing accidents. All personnel working with the machine, including the supervisor, machine operator and oiler, should be sensitive to potentially dangerous situations and take the necessary measures to prevent accidents.
• Safety precautions and recommendations are outlined in this section and are also included in the operation and maintenance instructions given in subsequent sections. Warning labels are also provided on the machine.

1. Fundamental cautions
Servicemen inexperienced in the units of this machine should be cautious about safety operations. They must acquire sufficient knowledge about the equipment before dismounting and disassembling it. Before dismounting each component, a serviceman should read this service manual thoroughly and find out the weight of the component, then lift it by proper means.

The following are cautions to be observed all the time.

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