All Terrain Crane Carrier

Thank you for choosing our Tadano all terrain crane.

This booklet contains items considered important for
handling and maintenance of the carriers of all terrain cranes.
Use this booklet in conjunction with the instruction manual
provided to ensure that maximum performance is obtained
from the carrier over a long period of time.

SERVICE DIVISION
TADANO LTD.
 Faun Carrier Components for All Terrain Crane

Mercedes
Transfer Retarder
Benz Transmission Drop box Axles
box /Intarder
engine

Crane Carrier Manufacturer

Model Manufacturer
Manufacturer Manufacturer Manufacturer Model
and and
and and and Mounting
Maximum Number of
Model Model Model position
output axles
(Type)

OM-402LA ZF
AR-1000M RTF100-4 280 kW Telma
(381 PS) 6WG250 Kessler
F2000
OM-501LA Axles
Allison Steyr 4
GA-1000N RTF101-4 315 kW (electromagnetic)
HD4560P VG1600
(428 PS)

AR-1200M

RTF120-5
Kessler
GA-1500N Allison
OM-442LA 5
Allison Steyr Steyr CLBT755
370 kW
CLBT755 DR1600 VG2000 T/M internal
(503 PS)
AR-1600M RTF160-5 (hydrodynamic)

AR-2000M RTF100-4

ZF
16AS2602 Kessler
T/M internal
OM-502LA (hydrodynamic) 6
ZF
GA-3600N RTF300-6 448 kW
16AS2602 Telma
(609 PS)
F2000
Axles
(electromagnetic)

Allison
CLBT755
T/M internal
OM-402LA (hydrodynamic) Kessler
AR-4000M Allison Steyr
RTF600-7 405 kW
AR-5500M CLBT755 VG2000 Telma
(550 PS) 7
F2000
Axles
(electromagnetic)

Notes
T/M: Transmission
 Safety and Service News Contents

System Sheet No. Item Applicable carrier

General SV-A01 Maintenance All models

SV-B01 Engine Oil All models

SV-B02 Engine Oil Filter RTF100, 120, 160, 200, 600

SV-B03 Engine and Transmission Cooling Water All models

Engine SV-B04 Fuel Filter and Pre-filter RTF100, 120, 160, 200, 600

SV-B05 Fuel Tank RTF120, 160, 200, 600

SV-B06 Engine and Air Conditioner V-Belt

RTF100, 120, 160, 200, 600
SV-B07 Flywheel Damper

SV-C01 Transmission Oil RTF120, 160, 200, 600

SV-C02 Drop Box RTF120, 160, 200

SV-C03 Transfer Box RTF101, 120, 160, 200, 600

Power
transmission
SV-C04 Transfer Diff Lock RTF120, 160, 200, 600

SV-C05 Shift Lever RTF100

SV-C06 Accelerator Sensor RTF120, 160, 200, 600

SV-D01 Wheel Nut Torque

Travelling All models
SV-D02 Greasing Axle Hub Bearings

Steering gear SV-E01 Steering RTF120, 160, 600

SV-F01 Brake Linings

Brake All models
SV-F02 Brake Drum Inspection

Suspension SV-G01 Hydraulic Suspension All models

SV-H01 Pump Drive Transfer Box RTF120, 160, 200, 600

SV-H02 Central Lubrication Device

SV-H03 Main Fuses

Other
SV-H04 Air Conditioner All models

SV-H05 Tachograph

SV-H06 Torque Rods

 Tadano Safety and Service News
SV-A01

Maintenance
Neglecting maintenance and periodic replacement of parts invites serious malfunctions and unexpected
problems.
Always ensure that the carrier is checked before starting work, and periodically, and repairs made
immediately if a problem is found. Always ensure that items requiring periodic replacement (e.g. oil) are
replaced in accordance with the instruction manual.
When the crane is used under severe conditions, for example, frequently run in an overloaded condition,
or the foot brake used frequently (e.g. in urban environments), conduct inspections and replace parts in
a shorter cycle than noted in the instruction manual.
The primary periodic replacement parts are as follows.

Inspection
Location Replacement part Replacement interval Quantity
interval
Every 200 - 1,000 hours 21.5 - 37 L
Oil Every 10 hours
depending on brand (5.7-9.8 U.S.gal)

Oil filter When engine oil is replaced - 1

Fuel filter element Every 600 hours or 1 year - 2
Engine Coolant 60 - 82 L
(always ensure a 2 years As required (16-22 U.S.gal)
concentration of 50%) (total)
Every 2 years or upon
Air cleaner filter - 1
deterioration
V-belts (alternator, air
Every 2 years - 4
conditioner)
Every 1,000 - 1,200 hours 35 - 55 L
Oil Every 10 hours
Transmission or every 12 months (9-15 U.S.gal)
Oil filter Every 6 months - 1
6L
Drop box Gear oil Every 500 hours or 1 year Every 250 hours (1.6 U.S.gal)
(approx.)
9.5 L
Transfer box Gear oil Every 500 hours or 1 year Every 250 hours (2.5 U.S.gal)
(approx.)
2.2 L
Pump
Gear oil Every 500 hours or 1 year Every 10 hours (0.6 U.S.gal)
transfer box
(approx.)
Gear oil 20 L
Axles (differential, Every 2,000 hours Every 125 hours (5.3 U.S.gal)
planetary gears) (approx. per axle)
130 - 360 L
Hydraulic oil Hydraulic oil Every 2,000 hours Every 10 hours
(34-95 U.S.gal)
tank
Oil filter Every 2,000 hours - 2
Every 2,000 hours
Air dryer Cartridge - 1
or every 2 years
Central 2.7 L
Every 1 - 2 months
lubrication Grease replenishment - (0.7 U.S.gal)
depending on conditions
device (capacity)
Propeller Every 500 hours or after
Grease lubrication - -
shaft washing the vehicle etc.
• Some models may not be fitted with a particular part. The number of replacement parts may differ
with the model.
• Inspection and replacement of brake system consumables, and inspection of suspension accumulator
gas pressures, are also required. Inspect each part, and replenish or replace as necessary.
 Tadano Safety and Service News
SV-B01

Engine Oil

When did you last change the engine oil?

Replace the engine oil in accordance with oil performance and the hours of use of the carrier.
The timing with which engine oil should be replaced depends on the conditions of use.
Refer to the Faun carrier instruction manual, or contact a Tadano-approved service depot, for details.

Engine Manufacturer-specified Oils

Specified oils
Mercedes Benz
standards
API classification
Manufacturer Brand
SAE viscosity

Showa Shell Shell Rimula Plus 15W-40

Showa Shell Shell Rimula X 15W-40

228.3
Exxon Mobil Mobil Delvac MX 15W-40

Exxon Mobil Mobil Delvac HP 15W-40

Showa Shell Shell Rimula Ultra 10W-40

228.5 Exxon Mobil Mobil Delvac 1 5W-40

Exxon Mobil Mobil Delvac 1 SHC 5W-40

 Tadano Safety and Service News
SV-B02

Engine Oil Filter

Did you replace the engine oil filter with the engine oil?

Replace the oil filter when changing the engine oil.

The oil filter removes foreign matter and sludge from the engine oil.
Oil cools and lubricates the interior of the engine, and clogging of the oil filter will prevent sufficient
supply of oil, resulting in overheating and major damage, even if the engine oil is changed periodically.

Use genuine oil filters from the engine manufacturer.

The oil filters from the manufacturer are optimized for flow, filtering rate, pressure resistance,
resistance to acids, and thermal resistance etc.
They are manufactured of fine filter paper.

Carrier model Part No. Part name

RTF100-RTF600 997-047-86343 Engine oil filter
RTF101 997-073-08217 Engine oil filter
 Tadano Safety and Service News
SV-B03

Engine and Transmission Cooling Water

In Faun carriers, the cooling water is used to cool the engine and the transmission, and is also used in
the heater in the driver’s cab.

Are you using genuine coolant?

Use a genuine coolant from a reliable engine manufacturer to protect the engine, water pump, oil cooler,
radiator, radiator hoses, and cab heater etc. from rust and cavitation.

Are you using cooling water with the optimum coolant concentration?
Mix the same volumes of water and genuine coolant in a container to ensure a concentration of 50%.
Use drinking water. Do not use hard water, seawater, or distilled water.
Always mix equal volumes of water and genuine coolant beforehand, and then pour the mixture into the
water tank.

Do not use cooling water with a coolant concentration of 45% or less.

• Use of cooling water with a low concentration of coolant will
result in rust and cavitation, and water leaks.
Do not use cooling water with a coolant concentration of 55% or more.
• Use of cooling water with a high coolant concentration may result
in overheating.

When did you last change the cooling water?

Coolant has a service life of two years.

If it is used for more than two years, the cooling water may become acidic, leading to rusting and
cavitation.

Have you bled air from the cooling system?

Always bleed air from the

transmission oil cooler
after replacing the cooling
water.

Bleed air from the

transmission oil cooler
annually.

AR1000M

Part No. Part name Remarks

Engine manufacturer genuine 5L (1.32 U.S.gal)
997-035-17014
coolant (one bottle)
 Tadano Safety and Service News
SV-B04

Fuel Filter and Pre-filter

RTF100-200 fuel filter and pre-filter
Have you checked or replaced the fuel filter?

The fuel filter should be replaced every 600 hours or

annually.
Clogging of the filter may result in reduced engine output.
The filter should be replaced annually, even if the engine is
run infrequently.

Have you cleaned the fuel pre-filter?

Clean the fuel pre-filter when changing the fuel filter.

Undamaged metal fuel pre-filters may be washed and
reused.

Fuel pre-filter Fuel filter Manual feed pump

RTF 600 fuel filter and pre-filter

Is there any water in the fuel filter or pre-filter?

If water is found in the filter container when replacing
the fuel filter, or when cleaning the fuel pre-filter, check
for water in the fuel tank.
If water becomes mixed with the fuel, the fuel feed pump,
injection pump, and injection nozzles will be damaged.

• Bleed water from the fuel tank drain plug if water is

found in the filter container.

Fuel pre-filter with Fuel filter

Manual feed pump

Carrier model Part No. Part name Quantity Remarks

997-047-86344 Fuel filter 2
RTF100-600 997-000-56864 Center bolt packing 2 8 x 11.5
997-000-56864 Air bleed packing 1 8 x 11.5
 Tadano Safety and Service News
SV-B05

Fuel Tank

Is there any water in the fuel tank?

Drain water from the fuel tank every two years.

In carriers with five or more axles, part of the carrier frame is used as a fuel tank.
Water enters the tank due to condensation on the inside walls with changes in temperature, and
deterioration and cracking of seals around manholes, and collects at the bottom. This water will cause
problems if it reaches the engine with the fuel.

Always keep the fuel tank as full as possible to minimize the amount of air in the tank, and thus
prevent condensation.
If sludge or a jelly-like substance adheres to the fuel filter or pre-filter, it is possible that water has
collected in the fuel tank.
Mixture of water in the fuel may result in corrosion of the pre-filter.

• Repair the seals around the manhole if they are cracked.

• If the seals are cracked, or a jelly-like substance is found in the pre-filter, remove the drain plug from
the bottom of the fuel tank and drain water which has collected.

Part No. Part name Remarks

999-900-49041 Seal Sikaflex 221
 Tadano Safety and Service News
SV-B06

Engine and Air Conditioner V-Belt

Have you replaced the V-belts ?

The V-belts should be replaced every 600 hours or

every two years.
The engine and transmission will overheat if the water Belt tension
checker
pump drive V-belts break. Water pump
V-belt
• The V-belts should be replaced every two years, even
if the engine is run infrequently.

Is V-belt tension OK?

Measure the V-belt tension with the tension checker.
Adjust to the following values.
• New and following replacement: 392-441 N
(88-99 lbf, 40-45 kgf)
After 100 hours: 343-392 N (77-88 lbf, 35-40 kgf)
• In daily checks, and if loose: 343-392 N
(77-88 lbf, 35-40 kgf)

If V-belt tension is insufficient:

• V-belt and V-belt pulley wear is increased, and the
V-belts break. Air conditioner
V-belt
• The water pump bearing may be damaged, resulting in a
water leak.
• The alternator and bracket may be damaged.
• The air conditioner compressor and bracket may be damaged.

Use genuine V-belts from the manufacturer.

Belt tension
Faun carrier V-belts are under much greater tension than is commonly imagined. checker
Use of a non-genuine V-belt will result in the belt stretching immediately.

Water pump V-belts: Use genuine products from engine manufacturer

Air conditioner compressor V-belts: Use Faun genuine products

Carrier model Part No. Part name Remarks

RTF100,120,160,200 997-014-40598 L=1550mm (61 in)
RTF600 997-073-09731 Water pump V-belt L=1600mm (63 in)
RTF600 997-073-09727 L=1625mm (64 in)
RTF100,120,160,200 997-047-89267 L=1275mm (50.2 in)
Air conditioner V-belt
RTF600 997-070-05511 L=1300mm (51.2 in)
Common 001 589 69 21 00 Belt tension checker
 Tadano Safety and Service News
SV-B07

Flywheel Damper

Replace every four years.

Fit the rubber damper (2) to the engine flywheel clutch (1).
The rubber damper alleviates the variations in torque (vibration) from the engine.
Problems occur with transmission of power from the engine when cracking occurs in the rubber part of
the damper with age.

4 - 6-axle Vehicles (bolt length and number of bolts differs with 7-axle vehicles)

Metric U.S. Customary

65 N-m 47.9 ft-lbf
72 N-m 53.1 ft-lbf

When checking engine oil, check for cracking and distortion in the rubber damper (2), and replace if any
such deterioration is found.
If damage to the rubber damper is discovered early it may be possible to resolve the problem by simply
replacing the damper, however if cracking has progressed the bearings (6 and 7) will be damaged, and
the clutch (1) assembly will therefore require replacement.

Carrier model Code Part No. Part name

1 997-077-30228 Clutch
RTF100 - RTF200
2 997-047-84527 Rubber damper
1 997-070-05057 Clutch
RTF600
2 997-073-06909 Rubber damper
 Tadano Safety and Service News
SV-C01

Transmission Oil

Have you replaced the oil?

Models with five or more axles are fitted with an Allison automatic transmission.
The transmission is filled with engine oil prior to delivery.
• Replace the oil every 1,200 hours or every 12 months which ever occurs first.
• Replace the oil filter every six months.
The oil is drained from the oil pan beneath the transmission, and the oil cooler beneath the cab.

Transmission oil volume: 55 liters (14.5 U.S.gal.) (approx.)

Part No. Part name Quantity Remarks

997-032-39218 Oil filter 1 -
370-028-99610 Oil 20 liters (5.28 U.S.gal.) Shell Rimula, 15W-40
370-028-99614 Oil 200 liters (52.8 U.S.gal.) Shell Rimula, 15W-40
997-077-51473 Lockup switch 1 -
 Tadano Safety and Service News
SV-C02

Drop Box

Have you replaced the oil?

• Check the oil level every 250 hours.

• Replace the initially oil after 30 hours, and subsequently every 500 hours or 12 months, which ever
occurs first.
The drop box is connected directly to the transmission output shaft.
The drop box lubrication oil differs from transmission lubrication oil.
Fill with approximately six liters (1.59 U.S. gal.) of gear oil (HD80W-90).

Checking Hoses
Oil temperature increases when the drop box is run under conditions of excessive load, and hoses
connected to the oil cooler harden and crack, leading to oil leaks and lubrication problems, and
possible bearing seizure.

The air-cooled oil cooler is fitted beneath the drop box.

Check the hoses, and replace if any deterioration (e.g. hardening) is found, or if the hoses have been in
use for more than four years.
Damage to the drop box may also result in damage to the transmission output shaft, and may require
replacement of the shaft.

Part No. Part name Quantity Remarks

997-077-30575 Hose 2 Replacement parts may
997-077-30575 differ with the model and
Hose 1 each manufacturing number.
997-077-30790
370-028-99485 Gear oil 20 liters (5.28 U.S. gal.) HD80W-90
 Tadano Safety and Service News
SV-C03

Transfer Box

Have you replaced the oil?

• Check the oil level every 250 hours.

• Replace the oil initially after 30 hours and subsequently every 500 hours or 12 months which ever
occurs first.
The transfer box switches between low and high speed, and distributes drive power between the front
and rear axles on 5 and 6-axle vehicles. Fill with approximately 9.5 liters (2.5 U.S. gal.) of gear oil.

Checking Hoses

An air-cooled oil cooler is fitted to the transfer box.

Oil temperature increases to an abnormal level when run under conditions of excessive load, and hoses
connected to the oil cooler harden, leading to oil leaks and lubrication problems, and bearing seizure.

Check the hoses, and replace if any deterioration (e.g. hardening) is found, or if the hoses have been in
use for more than four years.

Rear view of transfer box

Part No. Part name Quantity Remarks

997-077-30789 Hose 1
for 5 and 6 axle vehicles
997-077-30790 Hose 1
370-028-99485 Gear oil 20 liters (5.28 U.S. gal.) HD80W-90
 Tadano Safety and Service News
SV-C04

Transfer Diff Lock

Do not use the steering with transfer diff lock engaged!

Use the steering with transfer diff lock engaged only when the changeover switch is at ‘0’.
Axle loads on each drive axle, and wheel loadings, are particularly high in the on-site configuration, and
there is therefore almost no tire slip when moving with the diff lock engaged. Care is required in such
situations since this may result in damage to axle shafts and damage to the torque rods positioning the
axles.

Carriers with 5th and 6th axles are driven with the 1st, 4th and 5th axles on normal roads.
When the changeover switch is at ‘0’, the diff operates with normal steering when turning, and the
wheels on the front axles rotate faster than those on the rear axles.

Transfer drive changeover switch at other than ‘0’:

• Change from ‘0’ to ‘1’: Diff between 1st and 4th axles locked (wheels rotate at same speed).
• Change from ‘1’ to ‘2’: Additional drive with 2nd axle.
• Change from ‘2’ to ‘3’: Diff between 4th and 5th axles locked (wheels rotate at same speed).
• Diff lock switch held at ‘ON’: Diffs between left and right wheels on each drive axle also locked.

When diffs between axles are locked and the vehicle is steered, the tires on the front axles try to rotate
faster than those on the rear axles due to friction with the ground. When the diffs between the left and
right wheels are also locked, the system attempts to drive all four axle shafts (the drive transmission
shafts within the axles) at the same speed.
Torque therefore becomes unbalanced between input (from transfer box) and output (from tires) in the
axles, damaging the axle shafts.
Even if the axle shaft is not damaged immediately, the oil seals on the axle may be damaged, resulting
in oil leaks. Similarly, the transfer box input and output shaft bearings may be damaged, resulting in
oil leaks.
 Tadano Safety and Service News
SV-C05

RTF100-4 (AR-1000M) Shift Lever

Are the clutch and transmission operating normally?

Line Fuse

The power supply harness to the shift lever assembly incorporates a line fuse.
If the line fuse blows, the various solenoids in the transmission are not supplied with power when the
shift lever is operated, and the clutch and transmission do not operate.

• Check whether the low-line fuse has blown.

• Check for contact problems due to rust etc.

5A line fuse

Emergency measures:
• Remove the malfunctioning fuse.
• Replace with a commercially available line fuse holder and 5A fuse to obtain power.
A further solution is to obtain power by connecting a jumper to the 8A fuse on the chassis power supply.
 Tadano Safety and Service News
SV-C06

Accelerator Sensor

Are the retarder and exhaust brake operating?

Models fitted with the Alison transmission (vehicles with more than five axles) are also fitted with a
throttle position sensor (TPS) to detect the position of the accelerator. The TPS is used for a variety of
control functions.

• The exhaust brake and retarder operate when the accelerator is not depressed.
• The transmission gear-change timing is controlled based on the TPS detection signal.
• The exhaust brake and retarder do not operate if an abnormal TPS signal is detected.
• Transmission error ‘21’ is displayed if an abnormal TPS signal is detected.

Throttle position
sensor (TPS)

Accelerator
cylinder To engine stop lever

Idling adjuster knob

Part No. Part name

997-084-76394 Throttle position sensor (TPS)
 Tadano Safety and Service News
SV-D01

Wheel Nut Torque

Have the wheel nuts been tightened sufficiently?

Check wheel nut torque every 50 km up to 200 km.

Wheel nut size Torque

M22 x 1.5 650 N-m (479 ft-lbf, 65 kgf-m)

Reduction of the torque on the wheel bolts loosens the nuts, and may result in a bolt breaking and a
wheel coming off. (It happened in the past.)
• Loose “nuts” on bolts on the wheels of drive axles may result in “play” in the wheels and consequent
wear of the periphery of the planetary gear housing (see photo).
• If the vehicle is continually run in this condition, the planetary gear housing may be damaged.

When wheel nuts are tightened during the initial check after delivery, at tire rotation, and at tire
replacement, torque on the bolts will be reduced due to settling-in of nuts, washers, wheel contact
surfaces after tightening, even if the nuts do not loosen with rotation.
 Tadano Safety and Service News
SV-D02

Greasing Axle Hub Bearings

Grease hub bearings every two years.

Hub bearings may seize or be damaged due to deterioration of grease with heat, and increased play.
Such damage results in leakage of oil into the brake linings, with hub runout and a dangerous condition
of the hub bearings.
When maintaining the vehicle, the hub assembly should therefore be removed and hub bearings
checked, and new apply grease applied.
If the vehicle travels frequently with the crane fitted, the hub bearings will always be subject to
considerable load. Compared to travelling with the carrier alone, heating is increased, with consequent
deterioration of the grease in the hub bearings.

Replace hub bearings damaged or discolored by heat.

During assembly, apply a suitable amount of pre-load to the hub bearings by adjusting the torque
applied to the locking nut.
 Tadano Safety and Service News
SV-E01

Steering

Cautions for steering

Avoid sudden and large steering loads at high axle weights.

Review the setup time for the central lubrication device.
With the RTF120-5, RTF160-5, and RTF200-6, there is possibility that, while the tires on the 1st and 2nd
axles are directed forward, the tires in the 3rd and subsequent axles are not.
This is due to “twisting” of the splines on the shaft (see diagram below) connecting the steering links on
the 1st and 2nd axles, and the steering links on the 3rd and subsequent axles.

Causes of shaft “twisting”:

• With high axle loads in the on-site configuration, the forces generated by the tires on the 3rd and
subsequent axles moving over the ground, and the forces on the steering wheel from the power
steering, are applied to the shaft as an excessive twisting torque.
• The shaft is greased from the central lubrication device, however in some cases grease may not be
applied depending on the setup time for this equipment. This is another cause of excessive twisting
torque being applied to the shaft.
 Tadano Safety and Service News
SV-F01

Brake Linings

Check the thickness of brake linings every 500 hours.

Inspect and replace brake linings earlier if the crane is recognized as being used under severe
conditions, for example, frequently run in an overloaded condition, or the foot brake used frequently in
urban environments.
Even when the thickness of the brake linings is sufficient, the surfaces may have become carbonized if
loud squeaking is heard when the brakes are applied while travelling.
Remove and inspect the brake drums if excessively loud noises are heard when the brakes are applied.
If the brakes are used in this condition the linings will become carbonized and hard, wearing the brake
drums.

An example of carbonization of brake linings on the AR-2000M.

Replace left and right brake linings on the same axle simultaneously, and with the same type of lining.
Replacing only one of the brake linings on an axle will not only result in unequal braking forces, but
will cause unequal wear.

• To minimize damage to brake linings and drums, avoid driving the vehicle in an extreme manner,
and avoid excessive use of the footbrake, and rapid braking.
• Select the bottom gear on the transmission, and use the engine brake and retarder effectively.

Optimum clearance between

0.4 - 1.2 mm (0.015 - 0.047 in)
brake drum and lining
 Tadano Safety and Service News
SV-F02

Brake Drum Inspection

Check for cracks in brake drums during brake maintenance.

Cracking occurs as shown in the photo, and at the points shown by the arrows in the diagram. These
cracks then propagate around the periphery of the brake drum, and may result in it splitting.
Splitting of brake drums results in reduction in the braking force available, and is extremely dangerous.

During vehicle inspections, remove the brake drums and check the contact surfaces of the brake linings,
and check for cracks in the brake drums.
Use a color check to inspect for cracking around the entire periphery as shown in the photo and at the
points noted by the arrows in the diagram.
Since any crack found will have propagated deeper than is apparent to the naked eye, replace the brake
drum.

Thermal expansion and contraction of the brake drum during braking is considerable. Repetition of this
process results in metal fatigue and consequent cracking. Rusting and corrosion on the periphery of the
brake drum occurs as well.

If the vehicle travels frequently with the crane fitted, large braking forces are required constantly,
resulting in generation of considerable heat.

Cracking as shown by color check Cross-section of brake

Note
Inside diameter of brake lining contact
Brake drum use limit
surface: 504 mm (19.84 in)
 Tadano Safety and Service News
SV-G01

Hydraulic Suspension
Using the suspension
Level the hydraulic suspension before moving off.
1. Lower the vehicle to minimum height with the suspension locked.
2. Release the suspension lock and level the vehicle.
The vehicle cannot be leveled properly at maximum height.
Running with the suspension cylinders at maximum or minimum stroke is prohibited whether the
suspension is locked or free. Running in this condition will interfere with absorption of shocks from the
road, and damage the suspension system.
When it is anticipated that the crane will need to be moved slightly following placement, first lock the
suspension (particularly during leveling), and then extend the outriggers.

Check hydraulic gas pressure.

The suspension circuit incorporates a pressurized nitrogen gas accumulator.
If the vehicle is leveled (height adjusted) with low nitrogen gas pressure in the accumulator, it will not
operate normally and pressure will become abnormal, resulting in damage to the accumulator.
Leakage of hydraulic fluid at the point indicated by the arrow in the photo below is a symptom of this
problem.
Ensure that gas pressure is checked at least annually at a Tadano-approved service depot.

Accumulator
Hydraulic fluid leak here

After leveling the carrier (prior to mounting the upper structure) and locking the suspension, the
balance between axle mass and accumulator pressure may be lost when the vehicle is raised on the
jacks, and the axles may drop. This is not a malfunction.
1. After fitting the upper structure to the carrier, lock the suspension during leveling.
2. Jack-up the vehicle.
If the axles still drop, there is a problem with the accumulator, a suspension valve, or a suspension
cylinder. Contact your Tadano-approved service depot for repairs.
 Tadano Safety and Service News
SV-H01

Pump Drive Transfer Box

Have you replaced the oil?

Replace the oil every 500 hours or every 12 months which ever occurs first.
The pump drive transfer box fitted at the rear of the engine transmits engine output to the hydraulic
pumps.
The transfer box drives the hydraulic pumps constantly while the engine is running.
It holds approximately 2.2 liters (0.58 U.S. gal.) of gear oil.

Metric U.S. Customary

80 N-m 59 ft-lbf

Checking mounting bolts

Check that none of the pump transfer box mounting bolts are loose.
• Loose mounting bolts will result in excessive force being applied to the damper, and consequent
damage.
• Drive for the hydraulic pump and radiator cooling fan will also be interrupted, and the engine may
overheat.

Part No. Part name Quantity Remarks

370-028-99485 Gear oil 20 liters (5.28 U.S. gal.) HD80W-90
 Tadano Safety and Service News
SV-H02

Central Lubrication Device

Ensuring sufficient supply of grease

The central lubrication device automatically supplies grease to the various components of the carrier at
fixed intervals.
At delivery, the controller is pre-set to supply grease at six-hour intervals.

Greasing times are calculated based on the cumulative running time after the starter switch is turned
ON.
If the switch is OFF continuously for 48 hours, the cumulative running time is reset to zero.

If the vehicle is left unused for long periods of time, components requiring lubrication will not be
greased, resulting in unexpected problems while running.
• Vary the greasing interval in accordance with use of the vehicle.
• The greasing interval may be set in 12 steps from 0.5 to 11 hours on the controller inside the front
cover.

To check the lamp bulb, and to detect any abnormality in the equipment, the Auto-greaser Warning
Lamp (on the dashboard) is lit for approximately three seconds when the starter switch is turned ON,
and then extinguished.
An abnormality in the central lubrication device is indicated if the lamp is not extinguished.
• Take the appropriate measures (e.g. refill the grease tank), and press the button to the left of the
equipment to reset the abnormality and the cumulative greasing time. Greasing then commences.

Greasing interval setting dial

Cumulative greasing time

reset button

Auto-greasing controller

Part No. Part Name

999-900-49600 Genuine grease
 Tadano Safety and Service News
SV-H03

Main Fuses

The main fuses (five blade fuses, 25 - 250 A) are located in the fuse box within the carrier battery box.
Fuse boxes are of either the small or large type.

Corrosion of the fuse mounts will result in unsatisfactory electrical contact, with consequent problems.
• Unsatisfactory contact with the 250 A fuse may cause problems with operation of the
electromagnetic retarder.
• Unsatisfactory contact with the 80 A fuse may result in problems with battery charging, and
consequent rapid deterioration of the battery.

Check the fuses when checking the battery (every 125 hours, or at least monthly) noted in the
instruction manual.

Inside of battery box Inside of battery box with fuse box covers removed

Large: 250A (at top), 50A, 80A

Part No. Capacity (A) Use Fuse box

Electromagnetic retarder (only on
997-077-30226 250
vehicles fitted with retarder)
997-009-45696 50 Other circuits (each circuit) Large

997-000-14787 *80 For charging circuit from alternator

997-016-60003 25 Tire light power supply (optional)
Small
- 50 Unused

* The following fuses are used in place of the 80A fuse in the RTF101-4 (differs with manufacturing
number).

Part No. Capacity (A) Use Fuse box

997-002-71652 100
For charging circuit from alternator Large
997-070-13442 120
 Tadano Safety and Service News
SV-H04

Air Conditioner

If the air conditioner does not provide enough cooling in summer, it is possible that it does not contain
enough coolant.
• Check the sight glass on the receiver (liquid tank) to verify the condition of the ball and whether or
not bubbles are present. The sight glass is located to the left of, and below, the passenger seat. The
air conditioner is normal if the ball is floating (see diagram below).

Ball

Sight glass

Sight glass in receiver

Coolant is insufficient if the sight glass contains bubbles.

• Check for coolant leaks, and make repairs as necessary.
• Replenish coolant with two R-134a Service cans (200 g) to one can of compressor oil (coolant R-134a:
60g, oil 10g).

If the air conditioner is operated without compressor oil, the compressor will be insufficiently lubricated,
it will become overloaded, and the magnetic clutch may seize.

When the system contains the correct volume of coolant, the engine cooling water circulates through the
heater, and may provide a heating effect.
• Move the Low/High temperature selector lever firmly to Low.

If cooling water circulates despite the lever being moved to Low, the cooling water valve is probably not
completely closed.
• Check and repair as necessary.

Some models employ two balls (blue and white). Water in the coolant is indicated by the blue ball
changing to red.
• Replace the receiver tank.

Part No. Part name Remarks

- R-134a Service can (200g) Use commercially
- Compressor oil can (coolant R-134a: 60g, oil: 10g) available products.
997-073-02332 Receiver tank
 Tadano Safety and Service News
SV-H05

Tachograph

• The tachograph continues operating in accordance with the internal clock even when the engine is
stopped.
• The tachograph employs two recording sheets (to allow for two drivers).
• The recording sheets last for 24 hours, and are replaced daily.
• When there is only one driver, a plastic dummy sheet is fitted in place of the second recording sheet.
• Fit two dummy sheets if it is anticipated that the vehicle will be out of use for a week or more,

If the same recording sheet is used for a long period of time, the recoding needle may catch on the paper,
resulting in a malfunction.

Sheet for Sheet for

second driver primary driver

Part No. Part name

999-900-49890 Recording sheets (x 100)
997-077-51670 Plastic dummy sheet
 Tadano Safety and Service News
SV-H06

Torque Rods

Are the torque rod mounting bolts loose?

• The chassis frame is held in position by the four or five torque rods (including lateral rods) fitted
to each axle.
• The torque rods and lateral rods are fixed to the axles and chassis frame by bolts, or nuts and
bolts.
• If these mounting bolts become loose, the axles will lose their alignment, possibly resulting in a
serious accident.
• Check for loose mounting bolts annually.

As shown in the diagram above, all axles are held in position (i.e. suspended) relative to the
chassis frame by the torque and lateral rods.