Operating, Service and

Maintenance Manual
ATF 80-4

Vehicle identification no: WFN4 RTY R5 62043158

Manufacturer After-Sales Service:

FAUN GmbH TADANO FAUN GmbH
Postfach 10 01 08 Postfach 10 02 64
D - 91205 Lauf a. d. Pegnitz D - 91205 Lauf a.d. Pegnitz
Tel: (09123) 185 - 0 Tel: (09123) 955 - 0
Fax: (09123) 7 53 20 Fax: (09123) 18 51 55
TX: 622990 TX: 62 29 90

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 TABLE OF CONTENTS

PREFACE

1 Mounting locations of the vehicle identification number and of the nameplates

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 Mounting locations of the vehicle identification number and of the nameplate V-1

4 Mounting locations of the vehicle identification number and of

the nameplate:

These plates are provided on the vehicle in the following locations:

The vehicle identification number (1) is stamped on the frame, on the right side of the vehicle, between the
1st and 2nd axles.
The nameplates bearing all the relevant vehicle data are located in the driver's cabin in the undercarriage (3)
to the right of the passenger's seat, next to the cab door, and on the rear outside of the superstructure cabin
(2).

1 = Vehicle identification number

2 = Nameplate, superstructure
3 = Nameplate, chassis

0045_EN_FA043_V_04_00_00
2003-01 2/11

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 TABLE OF CONTENTS

ChapterA)TechnicalDetails

1 Specification sheet

1.1 Specification sheet

2 Load rating chart

2.1 Notes to the load rating chart

2.2 Boom
2.3 Fly jib
2.4 Counterweight configuration

3 Moving on construction site

3.1 Distribution of counterweight

3.2 Front and rear axle loads for moving the crane in full rig arrangement

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ChapterB)Construction&Operation&Circuits

B1)Chassis
1 Construction & Operation & Circuit(Chassis)

1 System construction

2 Layout of components

2.1 Over-view
2.2 Driver’s cab
2.3 Electric system
2.4 Hydraulic system
2.5 Penumatic system
2.6 Others

3 Circuit diagrams

3.1 Key for diagrams

3.2 Assumption in electrical circuit diagrams
3.3 Electrical circuit
3.4 Hydraulic circuit
3.5 Pneumatic circuit

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ChapterB)Construction&Operation&Circuits

B2)Superstructure

1 System construction（from #2043135~)

1.1 Monton telescoping system

1.2 I-Flex operation
1.3 I-Flex information & data

1 System construction (from #2043101~#2043134)

2 Layout of components (From #2043135~)

2.1 Over-view
2.2 Crane’s cab
2.3 Electric system
2.4 Hydraulic system

2 Layout of components (from #2043101~#2043134)

3 Circuit diagrams

3.1 Key for diagrams

3.2 Assumption in electrical circuit diagrams
3.3 Electrical circuit
3.4 Hydraulic circuit

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 TABLE OF CONTENTS

ChapterC)ServiceandMaintenance

C1)Chassis
1 General information

2 Maintenance intervals

3 Engine

4 Gearbox

5 Transfer box

6 Axles

7 Propeller shafts

8 Eddy-current brake

9 Breather

10 Hydraulic system

11 Brake system

12 Electrical equipment

13 Wheels and tires

14 Outriggers

15 Driver’s cab

16 Miscellaneous; other points of lubrication, servicing and maintenance

24 Summary of oil types and filling capacities (Recommended oil types)

25 Summary of lubricating grease types (recommended grease types)

26 Chart of approved consumables and lubricants

27 Inspection scheme/8x8 drive (before start-up, daily)

28 Inspection and cleaning scheme/8x8 drive

29 Oil/coolant level inspection and change scheme/8x8 drive

30 Lubricating scheme/8x8 drive

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ChapterC)ServiceandMaintenance

C2)Superstructure
1 Maintenance intervals

2 Engine

3 Hydraulic system

4 Swing mechanism

5 Hoisting gear and auxiliary hoisting gear

6 Winch rope

7 Electrical equipment

8 Crane cabin

9 Other points of lubrication, servicing and maintenance

15 Summary of oil types and filling capacities

16 Summary of lubricating grease types (recommended grease types)

17 Chart of approved consumables and lubricants

18 Inspection scheme (before start-up, daily)

19 Inspection and cleaning scheme

20 Oil/coolant level inspection and change scheme

21 Lubricating scheme

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ChapterD)Troubleshooting

D1)Chassis
1 Simple Troubleshooting

1.1 Engine
1.2 Gearbox
1.3 Transfer box
1.4 Axle differential locks and drive assemblies
1.5 Hydraulic system in general
1.6 Brake system
1.7 Electrical equipment
1.8 Eddy current brake

2 Emergency operation

2.1 Towing the vehicle

2.2 Emergency control features

3 Error Code List

3.1 Transmission (ZF AS-Tronic)

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 TABLE OF CONTENTS

ChapterD)Troubleshooting

D2)Superstructure
1 Simple troubleshooting

1.1 Engine
1.2 Hydraulic system in general
1.3 Swing mechanism
1.4 Telescoping mechanism
1.5 Boom elevation
1.6 Hoisting gear
1.7 Counterweight
1.8 Electrical equipment

2 Emergency operation

2.1 Emergency operation

2.2 Emergency control of superstructure via hydraulic motor in the chassis
2.3 Manual telescoping operation

3 Error code list

3.1 PDC #2043101~# 2043134

3.2 I-Flex # 2043135~# 2043225

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ChapterE)Dis./Assembly&Adjustment

E ) chassis

E1 01 Adjustment (chassis)

1.1 Pressure adjustment

ChapterE)Dis./Assembly&Adjustment

E)Superstructure

E2 02 Adjustment (superstructure)

2.1 Pressure adjustment

2.2 Electric adjustment

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Components/SpecialTool

The service manual of this machine consists of this manual and following separate component manuals.
Separate component Manual Information No.

1 Engine(Daimler Chrysler)
Maintenance and Repair (1511120902-1stedition) ........ (W556-0011E)
Electronical Engine Control (1511121002-1stedition) .... (W556-0021E)
ADM2-FRO ..................................................................... (W556-0031E)

2 Transmission(ZF AS-Tronic)
Operating manual (1328_758_104) ................................ (W562-0021E)
Installation manual (1327_754_106)............................... (W562-0031E)
Repair manual (1327_751_101a) .................................. (W562-0041E)
Preparation for the clutch installation ............................. (W562-0051E)
ZF_Sachs_clutch_information ........................................ (W562-0061E)

3 Axle(Kessler)
Service manual (51_61_71_81) ..................................... (W563-0101E)

4 Central lubricating system(Beka-Max)

Repair instructions (PDQ8939000406D7GB) ................ (W590-0031E)
Central Lubricating System ............................................ (W590-0041E)

5 Air conditioning(Wolfle)
Operating Instructions .................................................... (W701-0251E)
Air conditioning system .................................................. (W701-0261E)

6 Anti-Lock Braking System for Commercial Vehicles (ABV)(Wabco)

Anti-Lock Braking System
for Commercial Vehicles (ABV) ....................................... (W577-0231E)

7 Brake(Kontt)
Maintenance and Repair Instructions TM 89/03 ............ (W577-0241E)

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 ｃ2008
◯
PRINTED IN JAPAN
0801 E

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