Tadano Faun GR-300EX Crane Technical Service Manual SN 561896 PDF

Description

Tadano Faun Rough Terrain Crane GR-300EX Service Manual SN 561896 – PDF DOWNLOAD

FILE DETAILS:

Tadano Faun Rough Terrain Crane GR-300EX Service Manual SN 561896 – PDF DOWNLOAD

Language : English
Pages : 352
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Tadano Faun Rough Terrain Crane GR-300EX Service Manual SN 561896 – PDF DOWNLOAD

GR-300EX-3 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 External view 7
3 Outline of specifications 8
4 Conversion table 9
5 Drawing method of illustrations in this service manual 11
6 Group index 12
7 Contents 13
B_Hydraulic Power Generating System 20
B-1 Hydraulic Power Generating System 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(elevating, telescoping, winch) 22
1 5 Sequence valve (pilot pressure) and solenoid valve (pilot pressure) 22
1 6 Pressure sensor (main 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 27
2 1 Regulation of flow rate by discharging pressure 27
2 2 Regulation of flow rate by external pilot(positive control) 29
3 Disassembly 32
3 1 Disassembly of the regulator 32
3 2 Disassembly of the pump main body 34
4 Assembly 35
4 1 Assembly of the pump main body 35
4 2 Assembly of the regulator 37
5 Maintenance standards 40
5 1 Replacement standards for parts subject to wear 40
5 2 Correction standards for parts subject to wear 40
5 3 Tightening torque 40
6 Test 41
6 1 Operation test 41
B-3 Hydraulic Pump (Double Gear Pump) 42
1 Structure 42
B-4 Hydraulic Pump (Gear Pump, Emergency Steering) (Option) 45
1 Structure 45
B-5 Hydraulic Valve (Emergency Steering Selection) (Option) 46
1 Structure 46
B-6 Center Joint 48
1 Structure 48
1 1 General view 48
1 2 Port size table 49
1 3 Swivel joint (hydraulics and pneumatics) 50
1 4 Swivel joint (heated water) 51
2 Slip ring 52
2 1 General view 52
2 2 Harness and connector 53
2 3 Maintenance of ring and brush 53
B-7 Hydraulic Pilot Control Valve (Elevating, Telescoping, Winch) 54
1 Structure 54
1 1 Hydraulic symbol 54
1 2 External view 55
1 3 General view 56
1 4 Winch selection assy 59
1 5 Telescoping selection assy 62
1 6 Elevating selection assy 63
1 7 Main relief valve assy 64
1 8 Overload relief valve assy 65
B-8 Sequence Valve (Pilot Pressure) 66
1 Structure 66
B-9 Solenoid Valve (Pilot Pressure) 69
1 Structure 69
B-10 Solenoid Valve (Positive Control) 71
1 Structure 71
B-11 Pressure Sensor (Main Pressure) 73
1 Structure 73
1 1 Internal section 73
1 2 Connection diagram 73
1 3 Specification 73
B-12 Check Valve (Gauge Isolator) 74
1 Structure 74
C_Outrigger System 75
C-1 Outrigger System 76
1 Function 76
1 1 Solenoid control valve (outrigger, suspension) 76
1 2 Solenoid valve (slide/jack) 76
1 3 Jack cylinder 76
1 4 Pilot check valve (jack cylinder retracting prevention) 76
1 5 Extension cylinder 76
1 6 Check valve (slide/jack extending prevention) 76
2 Hydraulic system description 76
2 1 Outrigger extension operation 76
2 2 Outrigger retraction operation 76
3 Electric system 77
3 1 Outrigger operation inside operation cab 77
C-2 Solenoid Control Valve (Outrigger, Suspension) 78
1 Structure 78
1 1 Control valve assy 79
1 2 Body assy (outrigger) 80
1 3 Body assy (suspension) 82
1 4 P cover assy 84
1 5 T cover assy 86
1 6 Tandem plate assy 88
C-3 Solenoid Valve (Slide/Jack) 89
1 Structure 89
2 Solenoid valve assy 90
2 1 Solenoid valve (Rexroth (UCHIDA)) 90
2 2 Solenoid valve (TOKIMEC) 91
2 3 Solenoid valve (NACHI) 92
C-4 Jack Cylinder 93
1 Structure 93
C-5 Pilot Check Valve (Jack Cylinder Retracting Prevention) 94
1 Structure 94
C-6 Extension Cylinder 95
1 Structure 95
C-7 Check Valve (Slide/Jack Extending Prevention) 96
1 Structure 96
D_Slewing System 97
D-1 Slewing System 98
1 Function 98
1 1 Slewing drive unit (hydraulic motor and slewing speed reducer) 98
1 2 Hydraulic pilot control valve (slewing) 98
1 3 Solenoid valve (slewing brake release) 98
1 4 Slewing free function 98
2 Hydraulic system description 98
D-2 Hydraulic Pilot Control Valve (Slewing) 99
1 Structure 99
1 1 Hydraulic symbol 99
1 2 External view 100
1 3 Internal structural view 101
D-3 Hydraulic Motor (Slewing) 106
1 Structure 106
D-4 Slewing Speed Reducer 107
1 Structure 107
D-5 Slewing Assembly 108
1 Structure 108
2 Slewing bearing mounting bolt 109
2 1 Bearing inner ring bolts 109
2 2 Bearing outer ring bolts 110
E_Boom Elevating System 111
E-1 Elevating System 112
1 Function 112
1 1 Elevating cylinder 112
1 2 Counterbalance valve (elevating) 112
1 3 Pressure sensor 112
1 4 Proportional control valve (elevating slow stop) 112
2 Hydraulic system description 112
E-2 Elevating Cylinder 113
1 Structure 113
E-3 Counterbalance Valve (Elevating) 114
1 Structure 114
2 Function 115
2 1 When control valve is at the neutral position 115
2 2 While actuator is being pushed up 115
2 3 While actuator descends 115
E-4 Pressure Sensor 116
1 Structure 116
1 1 Internal section 116
1 2 Connection diagram 116
1 3 Specification 116
F_Winch System 117
F-1 Winch System 118
1 Function 118
1 1 Hydraulic motor 118
1 2 Counterbalance valve 118
1 3 Hydraulic valve (winch brake release) 118
2 Hydraulic system description 118
F-2 Winch 119
1 Structure 119
1 1 General view 119
F-3 Hydraulic Motor and Counterbalance Valve (Winch) 120
1 Structure 120
1 1 Hydraulic symbol 120
1 2 General view 121
1 3 Hydraulic motor assy 123
F-4 Hydraulic Valve (Winch Brake Release) 125
1 Structure 125
F-5 Accumulator (Winch Brake) 126
1 Structure 126
G_Boom Telescoping System 127
G-1 Telescoping System 129
1 Function 129
1 1 Telescoping cylinder 129
1 2 Counterbalance valve (telescoping) 129
1 3 Hose reel 129
1 4 Hydraulic valve 129
2 Boom telescoping mechanism 130
2 1 Order of boom extension 130
2 2 Order of boom retraction 130
3 System description 131
3 1 Extension circuit 131
3 2 Retraction circuit 131
G-2 Boom (Four-Section Boom) 132
1 Structure 132
2 Disassembly 135
2 1 Removing the 2nd – top boom sections 135
2 2 Removing the 3rd – top boom sections 136
2 3 Removing the top boom section 138
3 Check 138
3 1 Boom 138
3 2 Slide plate 138
3 3 Sheave 138
3 4 Boom telescoping wire rope 138
4 Reassembly 138
4 1 Greasing 138
5 Test 139
5 1 Operation Test 139
5 2 Boom lateral warp test 139
5 3 Other functional test 139
G-3 Jib 140
1 Structure 140
1 1 Location of Jib 140
1 2 Jib main body 142
G-4 Telescope Assy 144
1 Structure 144
1 1 Telescope assy 144
1 2 Telescoping cylinder 145
G-5 Counterbalance Valve (Telescoping) 146
1 Structure 146
2 Function 147
2 1 When control valve is at the neutral position 147
2 2 While actuator is being pushed up 147
2 3 While actuator descends 147
G-6 Hose Reel 148
1 Structure 148
2 Mounting 149
3 Disassembly 149
4 Reassembly 150
G-7 Hydraulic Valve 151
1 Structure 151
H_Safety System 153
H-1 Safety System 154
1 Function of safety devices 154
1 1 Moment detector (pressure sensor) 154
1 2 Boom length and angle detector 154
1 3 Slewing angle detector 154
1 4 Outrigger extension width detector 154
1 5 Other detectors and switches 154
1 6 AML (automatic moment limiter) main body 154
1 7 Anti-two-block device 154
1 8 Solenoid valve (AML vent) 154
2 System description 154
H-2 Boom Length and Angle Detector 155
1 Structure and function 155
2 Disassembly and reassembly 157
2 1 Disassembling boom length and angle detector 157
2 2 Reassembling boom length and angle detector 158
2 3 Replacing spiral spring 161
2 4 Disassembling the potentiometer(for boom length detector) 161
2 5 Reassembling potentiometer 161
2 6 Replacing the boom angle detector 162
3 Adjustment 162
H-3 Outrigger Extension Length Detector 163
1 Structure and function 163
2 Disassembly 164
3 Reassembly 165
H-4 Solenoid Valve (AML Vent) 167
1 Structure 167
K_Cab 169
K-1 Crane Cab Glass 171
1 Glass replacement procedure 171
2 Bonding the joint between windshield glass and roof glass 172
K-2 Air Conditioner 173
1 Component parts 173
2 Layout 174
2 1 Overall layout (hydraulic) 174
2 2 Overall layout (heater and cooler) 175
2 3 Evaporator section 176
3 Compressor assy 177
4 Evaporator assy 178
5 Condenser assy 179
6 Electric 180
6 1 Electric circuit 180
6 1 1 Main harness A 181
6 1 2 Main harness B 182
7 Important points for assembly (layout) 183
7 1 Evacuation 183
7 2 Charging with refrigerant 183
7 3 Check for gas leakage and amount of refrigerant charge 184
7 4 Heated water circuit 184
7 5 Run-in operation 184
7 6 Bolt size and tightening torque 184
8 How to charge air conditioner gas 185
8 1 Charging gas in automatic operation 185
8 2 How to charge air conditioner gas 187
8 3 How to check air conditioner 188
9 Diagnosis table 189
9 1 Car air conditioner system diagnosis table I (Refrigeration circuit) 189
9 2 Car air conditioner system diagnosis table II (External causes other than insufficient cooling and abnormal pressure) 192
9 3 Car air conditioner system diagnosis table III (Electrical system) 194
9 4 Car air conditioner system diagnosis table IV (Electronic thermo system) 196
10 Compressor 198
10 1 Compressor abnormal sound diagnosis chart 198
10 2 Compressor diagnosis chart 199
11 Troubleshooting 201
12 Control table 207
K-3 Hydraulic Motor (Air Conditioner) 208
1 Structure 208
K-4 Solenoid Valve (Air Conditioner) 209
1 Structure 209
L_Control System 211
L-1 Control Device 212
1 Crane control system 212
1 1 Inside cab 212
2 Traveling system 215
2 1 Inside cab 215
2 2 Outside cab 218
3 Other controls 219
3 1 Inside cab 219
L-2 Shift Switch 221
1 Structure 221
2 Electric circuit 224
L-3 Remote Control Valve (Lever) 225
1 Structure 225
L-4 Remote Control Valve (Pedal) 227
1 Structure 227
L-5 Shuttle Valve (Lever/Pedal) 229
1 Structure 229
L-6 Solenoid Valve (Boom Telescoping/Aux Winch) 230
1 Structure 230
L-7 Proportional Control Valve (Elevating Slow Stop) 231
1 Structure 231
L-8 Solenoid Valve (Air) (2/4-Wheel Drive Shift) 233
1 Structure 233
N_Electric System 234
N-1 Combination Meter 235
1 System configuration 235
2 Display section 236
3 Specifications 238
3 1 Speedometer 238
3 2 Tachometer 238
3 3 Odo/trip meter, hour meter 238
3 4 Odometer 238
3 5 Trip meter 238
3 6 Hour meter 238
3 7 Fuel gauge 239
3 8 Coolant temperature gauge 239
3 9 Air pressure gauge 240
3 10 Torque converter oil temperature gauge 240
4 Electric circuit 241
N-2 Engine Control Unit 243
1 System configuration 243
2 Diagnosis function 244
2 1 Check for a failure in crane cab (with engine warning lamp) 245
2 2 How to call up fault code (in crane cab) 246
2 3 Check for a failure by the frame (with diagnosis lamp) 249
2 4 How to call up fault code (by the frame) 250
2 5 Error code table 253
N-3 Telecommunications Terminal 273
1 System configuration 273
2 ICF 274
2 1 External view 274
2 2 Connector (pin assignment) 274
3 SCT (satellite communications terminal) 275
3 1 External view 275
3 2 Connector (pin assignment) 275
4 GSMT (global system for mobile communications terminal) 276
4 1 External view 276
4 2 Connector (pin assignment) 276
R_Driving Power Transmission System 277
R-1 Driving Power Transmission System 278
1 Function 278
1 1 Engine 278
1 2 Torque converter 278
1 3 Transmission 278
1 4 Axles 278
2 System description 278
2 1 Torque converter circuit 278
2 2 PTO clutch 278
2 3 Lock up clutch 279
2 4 Shift of drive mode 279
3 Installation 280
3 1 Radiator 280
3 2 Torque converter 280
3 3 Power train 281
S_Steering System 283
S-1 Steering System 284
1 Function 284
1 1 Priority valve 284
1 2 Orbitrol 284
1 3 Steering cylinder 284
1 4 Solenoid valve (steering mode) 284
1 5 Pilot check valve(rear steering hydraulic lock) 284
2 Hydraulic system description 284
S-2 Priority Valve 285
1 Structure 285
2 Function 285
3 Principle of operation 286
3 1 Neutral state 286
3 2 Right steering 286
3 3 Right steering to the end 286
S-3 Orbitrol 287
1 Structure and function 287
1 1 Housing 287
1 2 Spool and sleeve 288
1 3 Drive 288
1 4 Rotor set 288
2 Operation 289
2 1 Neutral state 289
2 2 Right steering 290
2 3 Left steering 291
3 Disassembly 292
3 1 Rotor section 292
3 2 Control section 293
4 Check 294
5 Reassembly 294
5 1 Control section 294
5 2 Rotor section 296
S-4 Steering Cylinder 298
1 Structure 298
S-5 Solenoid Valve (Steering Mode) 299
1 Structure 299
2 Solenoid valve (steering mode) 300
3 Pilot check valve (rear steering hydraulic lock) 301
T_Brake System 302
T-1 Brake System 304
1 Function 304
1 1 Service brake 304
1 2 Brake valve 304
1 3 Booster 304
1 4 Air dryer 304
1 5 Brake chamber 304
1 6 Parking brake 304
1 7 Solenoid valve (air) (parking brake) 304
1 8 Solenoid valve (exhaust brake) 304
1 9 Pressure regulator 304
2 System Description 305
2 1 Service brake 305
2 2 Parking brake 305
2 3 Exhaust brake 305
T-2 Brake Valve 306
1 Structure and function 306
2 Description of operation 307
2 1 Generation of air pressure 307
2 2 Stabilization of air pressure 307
2 3 Release of air pressure 308
2 4 Operation under piping rupture 309
3 Dismounting and remounting 309
4 Disassembly 310
4 1 Disassembly of the mount plate 310
4 2 Disassembly of the body 310
5 Cleaning and checking 311
5 1 Cleaning 311
5 2 Checking 312
6 Reassembly 312
6 1 Reassembly of the secondary side 312
6 2 Reassembly of the primary side 312
6 3 Reassembly of the mount plate 314
7 Test 314
7 1 Air leakage through supply valve and exhaust valve 314
7 2 Air leakage in other parts 314
7 3 Operation test 314
7 4 Performance test 314
8 Maintenance standard 315
8 1 600-hour check 315
8 2 1200-hour or 1-year check 315
T-3 Booster 316
1 Structure 316
2 Function 317
2 1 Air cylinder 317
2 2 Oil cylinder 317
3 Operation of cylinder 318
3 1 Booster not in operation 318
3 2 Booster in operation 318
3 3 Brakes released 318
4 Removing of booster 318
5 Disassembly 319
5 1 Disassembly of cylinder 319
6 Check 320
6 1 Rubber parts 320
6 2 Air cylinder 320
6 3 Oil cylinder 320
7 Reassembly 321
8 Test 322
8 1 Testing equipment 322
8 2 Performance diagram 322
8 3 Test method 322
9 Maintenance standards 323
9 1 Daily check 323
9 2 1200-hours or one year check 323
9 3 Maintenance standards 323
T-4 Air Dryer 324
1 Structure 324
2 Function 328
2 1 Dehumidification 328
2 2 Regeneration 329
2 3 Intake position 330
2 4 Release position 330
3 Precautions for handling 331
4 Maintenance and inspection 331
4 1 Daily inspection 331
4 2 Inspection and part replacement every 1 year or 100,000 km (62,140 mi) of driving 332
5 Disassembly 332
5 1 Removing DU-3 332
5 2 Disassembly of cartridge 332
6 Reassembly 334
6 1 Cartridge (lower) 334
6 2 Tamping the desiccant 335
6 3 Cartridge (upper) 335
7 Troubleshooting 336
T-5 Brake Chamber 339
1 Structure 339
2 Function 340
3 Disassembly 340
4 Cleaning and checking 341
4 1 Cleaning 341
4 2 Checking 341
5 Reassembly 342
6 Test 342
6 1 Air leak test 342
7 Maintenance standards 342
7 1 1200-hour or 1-year check 342
T-6 Solenoid Valve (Air) (Parking Brake and Exhaust Brake) 343
1 Structure 343
U_Suspension System 344
U-1 Suspension System 345
1 Function 345
1 1 Suspension lock cylinder 345
1 2 Pilot check valve (suspension lock cylinder) 345
1 3 Solenoid valve (suspension lock)(free/lock) 345
1 4 Pressure reducing valve 345
2 System description 345
3 Installation 346
U-2 Suspension Lock Cylinder 348
1 Structure 348
U-3 Pilot Check Valve (Suspension Lock Cylinder) 349
1 Structure 349
U-4 Solenoid Valve (Suspension Lock) (Free/Lock) 350
1 Structure 350
1 1 General view 350
1 2 Solenoid valve 351
History of revision 352

DESCRIPTION:

Tadano Faun Rough Terrain Crane GR-300EX Service Manual SN 561896 – 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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