Tadano Faun GR-300EX-1 Crane Repair Manual (SN 560678) PDF

Description

Tadano Faun Rough Terrain Crane GR-300EX-1 Service Manual SN 560678 – PDF DOWNLOAD

FILE DETAILS:

Tadano Faun Rough Terrain Crane GR-300EX-1 Service Manual SN 560678 – PDF DOWNLOAD

Language : English
Pages : 335
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Tadano Faun Rough Terrain Crane GR-300EX-1 Service Manual SN 560678 – PDF DOWNLOAD

GR-300EX-1/S1-1E 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 No 6
2 Separate service manual 6
3 Outline of specifications 7
4 Conversion table 8
5 Contents 11
(B) Hydraulic Power Generating System 18
B-1 Hydraulic Power Generating System 20
1 General 20
B-2 Hydraulic Pump (Double Variable Displacement Pump) 23
1 Structure 23
2 Theory of operating of regulator section 29
3 Air bleeding procedure 31
B-3 Hydraulic Pump (Double Gear Pump) 32
1 Structure 32
2 Air bleeding procedure 34
B-4 Hydraulic Pump (Gear Pump, Emergency Steering) (Option) 35
1 Structure 35
B-5 Hydraulic Valve (Emergency Steering) 36
1 Structure 36
B-6 Pressure Reducing Valve (Emergency steering) 38
1 Structure 38
B-7 Solenoid Control Valve (Outrigger, Suspension) 39
1 Structure 39
B-8 Rotary Joint 52
1 Structure 52
1 1 General view 52
1 2 Port size table 53
1 3 Swivel joint (Hydraulics • pneumatics) 55
1 4 Swivel joint (Heated water) 57
2 Slip ring 58
2 1 General view 58
2 2 Harness • Connector 59
2 3 Maintenance of Ring and Brush 59
B-9 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch) 60
1 Structure 60
B-10 Sequence Valve (Pilot Pressure) 71
1 Structure 71
B-11 Solenoid Valve (Pilot Pressure) 74
1 Structure 74
B-12 Check Valve (Gauge Isolator) 76
1 Structure 76
(C) Outrigger System 77
C-1 Outrigger System 78
1 General 78
C-2 Jack Cylinder 80
1 Structure 80
C-3 Pilot check Valve (Jack Cylinder Retracting Prevention) 81
1 Structure 81
C-4 Extension Cylinder 82
1 Structure 82
C-5 Solenoid Valve (Slide/Jack) (UCHIDA) 83
1 Structure 83
C-6 Solenoid Valve (Slide/Jack) (TOKIMEC) 84
1 Structure 84
C-7 Solenoid Valve (Slide/Jack) (NACHI) 85
1 Structure 85
C-8 Check Valve (Outrigger Extending Prevention) 86
1 Structure 86
C-9 Outrigger Operation Box 87
1 Structure 87
2 Connector diagram 88
3 Specifications 88
3 1 General 88
3 2 Bipolar toggle switch 88
3 3 Monopolar toggle switch 88
3 4 Push switch 88
3 5 Diode 88
3 6 Lamp assembly 88
(D) Swing System 89
D-1 Swing System 90
1 General 90
D-2 Swing Assembly 92
1 Structure 92
2 Swing bearing mounting bolt 93
2 1 Bearing Inner ring bolts 93
2 2 Bearing outer ring bolts 94
D-3 Hydraulic Pilot Control Valve (Swing) 95
1 Structure 95
D-4 Hydraulic Motor (Swing) 101
1 Structure 101
D-5 Swing Speed Reducer 103
1 Structure 103
2 Removing of hydraulic motor 104
3 Disassembly of reducer 104
4 Assembly of reducer 104
5 Installation of hydraulic motor 105
(E) Boom Elevating System 106
E-1 Elevating System 107
1 General 107
E-2 Elevating Cylinder 109
1 Structure 109
E-3 Counterbalance Valve (Elevating) 111
1 Structure 111
2 Function 113
2 1 When control valve is at the neutral position 113
2 2 While actuator is being pushed up 113
2 3 While actuator descends 113
(F) Winch System 114
F-1 Winch System 116
1 General (2M2D) 116
2 General (1M1D) 118
F-2 Winch 120
1 Structure 120
1 1 General view 120
1 2 Reducer 121
F-3 Hydraulic Motor and Counterbalance Valve 122
1 Structure 122
1 1 Hydraulic symbol 122
1 2 General view 122
1 3 Hydraulic motor assy 123
2 Description of operation 125
2 1 Mechanical brake 125
2 2 Counterbalance valve 126
3 Troubleshooting 128
4 Disassembly procedure of motor 129
4 1 Washing hydraulic motor 129
4 2 Mounting hydraulic motor 129
4 3 Draining gear oil 129
4 4 Taking cover[113] out 130
4 5 Taking sun gear-1[104] out 130
4 6 Taking carrier assy out 130
4 7 Taking planetary gear-2[107] out 131
4 8 Taking counterbalance valve out 131
4 9 Taking rear flange[401] out 132
4 10 Taking out those parts attached to rear flange[401] 133
4 11 Disassembling internal counterbalance valve 134
4 12 Disassembling counterbalance valve section 134
4 13 Disassembling hydraulic motor 135
4 14 Taking spring[214] out of cylinder block[204] 137
4 15 Taking out pivot[267] 137
4 16 Taking out tapered roller bearing 138
4 17 Disassembling spindle[102] 138
4 18 Taking angular ball bearing out 139
4 19 Taking out those parts attached to spindle[102] 139
4 20 Primal washing 140
4 21 Final washing 140
5 Maintenance standards 141
5 1 Seal 141
5 2 Maintenance standards for parts subject to wear 141
6 Assembly 143
6 1 Preparation 143
6 2 General suggestion for work 143
7 Assembly procedure 143
7 1 Assembling hub[101] 144
7 2 Assembling spindle[102] 145
7 3 Assembling hydraulic motor parts 146
7 4 Assembling shaft[202] 146
7 5 Clearance adjustment for angular ball bearing 147
7 6 Clearance adjustment for tapered roller bearing 148
8 Performance confirmation test 149
8 1 Required measurement instruments 149
8 2 Test procedure 149
9 Classifications of clearance adjustment parts 150
F-4 Hydraulic Valve (Winch Brake Release) 151
1 Structure 151
(G) Boom Telescoping System 152
G-1 Telescoping System 154
1 General 154
2 Description of telescoping system (Refer to the circuit diagram in Chapter Z ) 156
2 1 Extension circuit 156
2 2 Retraction circuit 156
3 Boom telescoping mechanism 157
3 1 Extension 157
3 2 Retraction 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 164
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 169
G-4 Telescoping Cylinder 171
1 Structure 171
G-5 Counterbalance Valve (Telescoping) 173
1 Structure 173
2 Function 174
2 1 When control valve is at the neutral position 174
2 2 While actuator is being pushed up 174
2 3 While actuator descends 174
G-6 Hose Reel 175
1 Structure 175
2 Mounting 176
3 Disassembly 176
4 Reassembly 177
G-7 Hydraulic Valve 178
1 Structure 178
(H) Safety System 181
H-1 Safety System 182
1 General 182
1 1 Pressure sensor 182
1 2 Boom length and angle detector 182
1 3 Outrigger extension width detector 182
1 4 Other detectors and switches 182
1 5 AML (Load moment indicator) main body 182
1 6 Overwind cutout (Anti-twoblock) device 182
1 7 Solenoid valve 182
2 Description of system 182
H-2 Boom Length and Angle Detector 183
1 Structure and function 183
2 Disassembly and reassembly 185
2 1 Removing the cord 185
2 2 Installing the cord 185
2 3 Replacing spiral spring 187
2 4 Disassembling the potentiometer (for boom length detector) 187
2 5 Reassembling potentiometer 188
2 6 Replacing the boom angle detector 188
3 Adjustment 188
H-3 Outrigger Extension Length Detector 189
1 Structure and function 189
2 Disassembly 190
3 Reassembly 191
H-4 Solenoid Valve (Auto Stop) 193
1 Structure 193
(K) Cab 195
K-1 Crane Cab Glass 197
1 Glass replacement procedure 197
2 Bonding the joint between windshield glass and roof glass 198
K-2 Air Conditioner 199
1 Component parts 199
2 Introduction to air conditioning 200
2 1 Principle of air conditioning 200
3 Basic refrigeration cycle 201
3 1 Construction 201
3 2 Conditions for air conditioning equipment 202
3 3 Refrigerant 202
3 4 Refrigeration cycle of a car air conditioner 204
3 5 Comparison with a household air conditioner 204
3 6 Receiver functions 205
3 7 Reheat method 205
3 8 Components 207
4 Layout 209
4 1 Overall layout 209
4 2 Overall layout 210
4 3 Evaporator section 211
5 Compressor Assy 212
6 Evaporator Assy 213
7 Condenser Assy 214
8 Electric 215
8 1 Electric circuit 215
8 2 Main harness A 216
8 3 Main harness B 217
9 Important points for assembly (Layout) 218
9 1 Evacuation 218
9 2 Charging with refrigerant 218
9 3 Check for gas leakage and amount of refrigerant charge 219
9 4 Heated water circuit 219
9 5 Run-in operation 219
9 6 Bolt size and tightening torque 219
10 How to charge air conditioner gas 220
10 1 Charging gas in automatic operation 220
10 2 How to charge air conditioner gas 222
10 3 How to check air conditioner 224
11 Diagnosis table 225
11 1 Car air conditioner system diagnosis table I (Refrigeration circuit) 225
11 2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure) 228
11 3 Car air conditioner system diagnosis table III (Electrical system) 230
11 4 Car air conditioner system diagnosis table IV (Electronic thermo system) 232
12 Compressor 234
12 1 Compressor abnormal sound diagnosis chart 234
12 2 Compressor diagnosis chart (1/2) 235
13 Troubleshooting 237
14 Control table 243
K-3 Hydraulic Motor (Air Conditioner) (Option) 244
1 Structure 244
K-4 Solenoid Valve (Air Conditioner) (Option) 246
1 Structure 246
(L) Control System 248
L-1 Control System 249
1 General of hydraulic pilot system (2M2D) 249
2 General of hydraulic pilot system (1M1D) 250
3 General of pneumatic control devices 251
L-2 Remote Control Valve (Lever) 252
1 Structure 252
L-3 Remote Control Valve (Pedal) 255
1 Structure 255
L-4 Shuttle Valve (Lever / Pedal) 258
1 Structure 258
L-5 Solenoid Valve (Boom Telescoping / Aux Winch) 259
1 Structure 259
L-6 Solenoid Control Relief Valve (Elevating Slow Stop) 261
1 Structure 261
L-7 Accelerator Sensor 263
1 Structure 263
2 Adjustment 263
L-8 Solenoid Valve (Air) 264
1 Structure 264
(S) Steering System 266
S-1 Steering System 267
1 General 267
S-2 Priority Valve 268
1 Structure 268
2 Function 268
3 Principle of operation 269
3 1 Neutral state 269
3 2 Right steering 269
3 3 Right steering to the end 269
S-3 Orbitrol 270
1 Structure 270
2 Function 273
S-4 Steering Cylinder 274
1 Structure 274
S-5 Solenoid Valve (Steering Mode) 275
1 Structure 275
S-6 Pilot Check Valve (Steering Mode) 276
1 Structure 276
S-7 Solenoid Valve (Reverse Steering, Option) 277
1 Structure 277
(T) Brake System 278
T-1 Brake System 280
1 General 280
T-2 Brake (Service Brake) 281
1 Structure and function 281
1 1 Principle of operation 282
2 Checking the pad assy 282
3 Checking the disc plate 282
4 Replacing the pad assy 283
5 Disassembly 284
6 Washing and checking 284
6 1 Washing 284
6 2 Checking 284
7 Reassembly 285
8 Maintenance standards 285
T-3 Brake Valve 286
1 Structure and function 286
2 Description of operation 288
2 1 Generation of air pressure 288
2 2 Stabilization of air pressure 288
2 3 Release of air pressure 289
2 4 Operation under piping rupture 290
3 Dismouting and remounting 290
4 Disassembly 290
4 1 Disassembly of the mount plate 291
4 2 Disassembly of the body 291
5 Cleaning and checking 292
5 1 Cleaning 292
5 2 Checking 293
6 Reassembly 293
6 1 Reassembly of the secondary side 293
6 2 Reassembly of the primary side 293
6 3 Reassembly of the mount plate 295
7 Test 295
7 1 Air leakage through supply valve and exhaust valve 295
7 2 Air leakage in other parts 295
7 3 Operation test 295
7 4 Performance test 295
8 Maintenance standards 296
8 1 600-hour check 296
8 2 2000-hour or 1-year check 296
T-4 Booster (Brake) 297
1 Structure 297
2 Function 298
2 1 Air cylinder 298
2 2 Oil cylinder 298
3 Operation of cylinder 299
3 1 Booster not in operation 299
3 2 Booster in operation 299
3 3 Brakes are released 299
4 Removing of booster 299
5 Disassembly 300
5 1 Disassembly of cylinder 300
6 Check 301
6 1 Rubber parts 301
6 2 Air cylinder 301
6 3 Oil cylinder 301
7 Reassembly 302
8 Test 303
8 1 Testing equipment 303
8 2 Performance diagram 303
8 3 Test method 303
9 Maintenance standards 304
9 1 Daily check 304
9 2 2000-hours or one year check 304
9 3 Maintenance standards 304
T-5 Air Dryer 305
1 Structure 305
2 Function 309
2 1 Dehumidification 309
2 2 Regeneration 310
2 3 Intake position 311
2 4 Release position 311
3 Precautions for handling 311
4 Maintenance and inspections 312
4 1 Daily inspection 312
4 2 Inspection and part replacement every 1 year or 100,000 km (62140mi) of driving 313
5 Disassembly 313
5 1 Removing DU-3 313
5 2 Disassembly of cartridge 313
6 Reassembly 315
6 1 Cartridge (lower) 315
6 2 Tapping 315
6 3 Cartridge (upper) 316
7 Troubleshooting 317
T-6 Brake (Parking Brake) 320
1 Structure and function 320
2 Replacing pad 321
3 Remounting 322
3 1 Connecting parking brake to spring chamber 322
3 2 Adjusting parking brake clearance 322
4 Check 323
T-7 Brake Chamber 324
1 Structure 324
2 Function 325
3 Disassembly 325
4 Cleaning and checking 326
4 1 Cleaning 326
4 2 Checking 326
5 Reassembly 327
6 Test 327
6 1 Air leak test 327
7 Maintenance standards 327
7 1 2000-hour or 1-year check 327
T-8 Solenoid Valve (Air) 328
1 Structure 328
(U) Suspension System 330
U-1 Suspension System 331
1 General 331
U-2 Spring Lock Cylinder 332
1 Structure 332
U-3 Pilot Check Valve (Spring Lock Cylinder) 333
1 Structure 333
U-4 Solenoid Valve (Spring Lock Check Release) 334
1 Structure 334
to Data and Diagrams-section 0

DESCRIPTION:

Tadano Faun Rough Terrain Crane GR-300EX-1 Service Manual SN 560678 – 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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