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

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 : 418
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 1
Safety 2
1 Fundamental cautions 3
2 Cautions in working 3
2 1 General 3
2 2 Dismounting & disassembling 4
2 3 Remounting & 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 Group index 10
6 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
B-4 Hydraulic Pump (Gear Pump, Emergency Steering) 35
1 Structure 35
B-5 Hydraulic Valve (Emergency Steering) (Option) 36
1 Structure 36
B-6 Pressure Reducing Valve (Pilot Pressure) 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 54
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 lsolator) 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 Control Box 87
1 Structure 87
2 Control box 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 105
5 Installation of hydraulic motor 105
(E) Boom Elevating System 106
E-1 Elevating System 107
1 General 107
1 1 Hydraulic pilot method 108
1 2 Max pressure setting 108
1 3 Slow stop function 108
1 4 Proportional control valve 108
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 on a workbench 129
4 3 Draining gear oil 129
4 4 Removing cover [113] 130
4 5 Removing sun gear-1 [104] 130
4 6 Removing carrier assy 130
4 7 Removing planetary gear-2 [107] 131
4 8 Removing counterbalance valve 131
4 9 Removing rear flange [401] 132
4 10 Removing rear flange [401] attachment 133
4 11 Disassembling internal counterbalance valve 134
4 12 Disassembling counterbalance valve section 134
4 13 Disassembling hydraulic motor 135
4 14 Removing spring [214] of cylinder block [204] 137
4 15 Removing pivot [267] 137
4 16 Removing tapered roller bearing 138
4 17 Disassembling spindle [102] 138
4 18 Removing angular ball bearing 139
4 19 Removing accessories 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
6 3 Assembly procedure 143
7 Performance confirmation test 149
7 1 Required measurement instruments 149
7 2 Test procedure 149
8 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 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 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 Structure 201
3 2 Conditions for air conditioning equipment 202
3 3 Refrigerant 203
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 206
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) 244
1 Structure 244
K-4 Solenoid Valve (Air Conditioner) (Option) (–560899) 246
1 Structure 246
K-5 Solenoid Valve (Air Conditioner) (Option) (560900–) 248
1 Structure 248
(L) Control System 250
L-1 Control System 251
1 General of hydraulic pilot system (2M2D) 251
2 General of hydraulic pilot system (1M1D) 252
3 General of pneumatic control devices 253
L-2 Remote Control Valve (Lever) 254
1 Structure 254
L-3 Remote Control Valve (Pedal) 257
1 Structure 257
L-4 Shuttle Valve (Lever / Pedal) 260
1 Structure 260
L-5 Solenoid Valve (Boom Telescoping / Aux Winch) 261
1 Structure 261
L-6 Solenoid Control Relief Valve (Elevating Slow Stop) 263
1 Structure 263
L-7 Accelerator Sensor 265
1 Structure 265
2 Adjustment 265
L-8 Solenoid Valve (2/4 Wheel Drive Shift) (Air) 266
1 Structure 266
(S) Steering System 268
S-1 Steering System 269
1 General 269
S-2 Priority Valve 270
1 Structure 270
2 Function 270
3 Principle of operation 271
3 1 Neutral state 271
3 2 Right steering 271
3 3 Right steering to the end 271
S-3 Orbitrol 272
1 Structure 272
2 Function 275
S-4 Steering Cylinder 276
1 Structure 276
S-5 Solenoid Valve (Steering Mode) 277
1 Structure 277
S-6 Pilot Check Valve (Steering Mode) 278
1 Structure 278
S-7 Solenoid Valve (Reverse Steering, Option) 279
1 Structure 279
(T) Brake System 280
T-1 Brake System 283
1 General 283
T-2 Brake (Service Brake) 284
1 Structure and function 284
1 1 Principle of operation 285
2 Checking the pad assy 285
3 Checking the disc plate 285
4 Replacing the pad assy 286
5 Disassembly 287
6 Washing and checking 287
6 1 Washing 287
6 2 Checking 287
7 Reassembly 288
8 Maintenance standards 288
T-3 Brake Valve 289
1 Structure and function 289
2 Description of operation 291
2 1 Generation of air pressure 291
2 2 Stabilization of air pressure 291
2 3 Release of air pressure 292
2 4 Operation under piping rupture 293
3 Dismouting and remounting 293
4 Disassembly 294
4 1 Disassembly of the mount plate 294
4 2 Disassembly of the body 294
5 Cleaning and checking 295
5 1 Cleaning 295
5 2 Checking 296
6 Reassembly 296
6 1 Reassembly of the secondary side 296
6 2 Reassembly of the primary side 296
6 3 Reassembly of the mount plate 298
7 Test 298
7 1 Air leakage through supply valve and exhaust valve 298
7 2 Air leakage in other parts 298
7 3 Operation test 298
7 4 Performance test 298
8 Maintenance standard 299
8 1 600-hour check 299
8 2 1200-hour or 1-year check 299
T-4 Booster 300
1 Structure 300
2 Function 301
2 1 Air cylinder 301
2 2 Oil cylinder 301
3 Operation of cylinder 302
3 1 Booster not in operation 302
3 2 Booster in operation 302
3 3 Brakes released 302
4 Removing of booster 302
5 Disassembly 303
5 1 Disassembly of cylinder 303
6 Check 304
6 1 Rubber parts 304
6 2 Air cylinder 304
6 3 Oil cylinder 304
7 Reassembly 305
8 Test 306
8 1 Testing equipment 306
8 2 Performance diagram 306
8 3 Test method 306
9 Maintenance standards 307
9 1 Daily check 307
9 2 1200-hours or one year check 307
9 3 Maintenance standards 307
T-5 Air Dryer 308
1 Structure 308
2 Function 312
2 1 Dehumidification 312
2 2 Regeneration 313
2 3 Intake position 314
2 4 Release position 314
3 Precautions for handling 315
4 Maintenance and inspection 315
4 1 Daily inspection 315
4 2 Inspection and part replacement every 1 year or 100,000 km (62,140 mi) of driving 316
5 Disassembly 316
5 1 Removing DU-3 316
5 2 Disassembly of cartridge 316
6 Reassembly 318
6 1 Cartridge (lower) 318
6 2 Tamping the desiccant 319
6 3 Cartridge (upper) 319
7 Troubleshooting 320
T-6 Brake (Parking Brake) 323
1 Structure and function 323
2 Replacing pad 324
3 Remounting 325
3 1 Connecting parking brake to spring chamber 325
3 2 Adjusting parking brake clearance 325
4 Check 326
T-7 Brake Chamber 327
1 Structure 327
2 Function 328
3 Disassembly 328
4 Cleaning and checking 329
4 1 Cleaning 329
4 2 Checking 329
5 Reassembly 330
6 Test 330
6 1 Air leak test 330
7 Maintenance standards 330
7 1 1200-hour or 1-year check 330
T-8 Solenoid Valve (Exhaust, Parking Brake) (Air) 331
1 Structure 331
(U) Suspension System 333
U-1 Suspension System 334
1 General 334
U-2 Spring Lock Cylinder 335
1 Structure 335
U-3 Pilot Check Valve (Spring Lock Cylinder) 336
1 Structure 336
U-4 Solenoid Valve (Spring Lock Check Release) 337
1 Structure 337
(Y) Data, Adjusting and Checks 339
Y-1 Hydraulic Pressure Setting Table 342
1 Winch 342
2 Telescoping and Elevating 343
3 Steering 344
4 Swing 345
5 Outrigger 346
6 Pilot pressure 347
7 Torque converter oil pressure 348
8 Pressure reducing valve [for Europe] 348
Y-2 Air Pressure Setting Table 349
1 Air pressure setting table 349
Y-3 Air Bleeding Procedure 350
1 Starting pump 350
1 1 Before starting the engine 350
1 2 Shakedown of the pump 350
1) Steering, winch brake pilot pressure pump (double gear pumps) 350
2) Main pump 350
3) Others 350
2 Service brake circuit 351
3 Swing circuit 351
3 1 Swing motor 351
3 2 Swing hydraulic pilot control valve 351
4 Winch circuit (main and aux ) 352
4 1 Winch motor 352
4 2 Winch brake 352
5 Hydraulic pilot circuit 353
5 1 Swing 353
5 2 Elevating 353
5 3 Telescoping 353
5 4 Winch (main and aux ) 353
6 Steering circuit 353
7 Air conditioner motor (option) 353
Y-4 Electric Switch Adjustment 354
1 3rd/top boom full retraction detection switch (CN859) 354
2 Jib stowed detection proximity switch (CN572) 354
3 Main winch drum rotation detection proximity switch (CN591) (option) 354
4 Aux winch drum rotation detection proximity switch (CN592) (option) 354
5 Over-front detection proximity switch (CN521) 355
6 Control lever stand position detection switch (swing control and boom telescoping/aux winch) (CN529) 355
7 Straight ahead detection proximity switch (CN408) 356
8 Over-rear detection proximity switch [for Europe] 356
Y-5 Adjustment and Checks 357
1 Service brake adjustment 357
1 1 Adjusting the brake pedal 357
1 2 Tightening the cap of reserve tank of service brake fluid 357
2 Accelerator adjustment 358
2 1 Accelerator pedal 358
2 2 Accelerator sensor assembly and adjustment 358
3 Parking brake adjustment 360
3 1 Adjusting the parking brake clearance(between pad and disc plate) 360
3 2 Connecting the parking brake and spring chamber 360
4 Tire steering angle adjustment 360
4 1 Tire air pressure 360
4 2 Adjusting the tire Steering angle 360
5 Engine speed (and governer setting) 361
6 Torque converter and transmission 361
6 1 Maximum allowable speed 361
6 2 Adding oil to the torque converter and transmission 361
7 Braking force 362
7 1 Parking brake force 362
7 2 Service brake force 362
8 Adjusting the headlight light axes 362
9 Adjusting boom telescoping wire ropes 363
Y-6 Check (Crane Operation) 365
1 Outrigger status indicator 365
2 Spring lock 365
3 Hoisting 366
4 Backward stability control 366
5 Outrigger emergency setting 366
6 Jib 366
7 Boom Telescoping Control 367
8 Alarms 368
9 Outrigger slide plate adjustment 368
Y-7 Check (Driving Devices) 369
1 Exhaust brake (EXB) 369
2 Automatic transmission 369
3 Steering mode change 370
4 Overshift prevention 371
5 Warnings 371
6 Speed limiter (For Europe) 372
7 Reverse steering (For Europe) 372
Y-8 Oil and Grease Table 373
Y-9 Mass Table 374
Y-10 Specifications 375
1 Engine speed 375
1 1 Idling speed 375
1 2 MAX speed (unload) 375
1 3 Stall speed 375
2 Hydraulic pump (for crane)(Double Variable Displacement Pump) 375
2 1 Pump speed 375
2 2 Pump displacement 375
3 Hydraulic pump (for steering)(Double Gear Pump) 375
3 1 Pump speed 375
3 2 Pump displacement 375
4 Charging pump(for torque converter) 375
4 1 Pump speed 375
4 2 Pump displacement 375
5 Emergency steering pump(option) 375
5 1 Pump speed 375
5 2 Pump displacement 375
6 Winch motor 375
7 Swing driving unit 375
7 1 Swing motor 375
7 2 Swing speed reducer 375
Y-11 Boom Connecting Pin and Thread Size Table 376
(Z) System Diagrams 377
Z-1 Hydraulic Circuit 379
1 For Europe 379
2 For general export 381
Z-2 Torque Converter Circuit 383
Z-3 Brake Circuit (Pneumatic Circuit) 384
Z-4 Electric Circuit (AML, Crane) 385
Z-5 Electric Circuit (MDT, Carrier/Upper) 387
Z-6 Electric Circuit (MDT, Carrier/Lower) 389
Z-7 Location of Hydraulic Parts (Upper) 391
Z-8 Location of Hydraulic Parts (Lower) 392
Z-9 Location of Air Parts 393
Z-10 Location of Electric Parts (Inside cab) 394
Z-11 Location of Electric Parts (Swing Table, Boom, AML) 395
Z-12 Location of Electric Parts (Relay Assembly/Upper) 396
Z-13 Location of Electric Parts (Lower) 397
Z-14 Location of Electric Parts (Box Assembly/Lower) 398
Z-15 Harness (Connector No Table) 399
Z-16 Harness (Inside Cab) 402
1 –#561005 402
2 #561006– 403
Z-17 Harness (Swing Table, Left) 404
Z-18 Harness (Swing Table, Right) 405
Z-19 Harness (Boom) 406
Z-20 Harness (AML, Upper) 407
Z-21 Harness (Overwind) 408
Z-22 Harness (Lower, Main) 409
1 –#560789 409
2 #560790– 410
Z-23 Harness (Lower, Electronic Governor) 411
Z-24 Outdoor Temp (Minus 25°C or Less) Detection Device 412
1 Structure 412
2 Harness 413
Z-25 Anemometer 414
1 Structure 414
2 Harness 415
3 Cord reel 416
1 –#561022 416
2 #561023– 417
History of revision 418

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.

IMAGES PREVIEW OF THE MANUAL:

Need help? Contact: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V