Description

Tadano FAUN ATF 160G 5 Technical Manual

You pull up to a crane with a load moment limiter acting up, and the aftermarket PDF you obtained tells you to “check the sensor.” Check it with what? I’ve seen guys chase ghosts for three billable hours because they trusted a generic wiring diagram. If you’re working on a Tadano FAUN ATF 160G 5, you don’t get to guess – not with AML thresholds and not with the superstructure hydraulics. This Technical Manual is the OEM document, straight from FAUN GmbH. No third-party rewrites. 82 pages of the same binder the factory techs use. That’s what I call a starting point.

Load Moment Limiter (AML) – The Brains of the Crane

The majority of this manual hammers on the AML system: the Automatic Safe Load Indicator. Page 3 walks you through the rocker tip switch actuation and what the monitor display shows when you toggle between tele indication and telescope selection mode. If you’ve ever had a 90% warning buzzer chirp at you and didn’t know why, this section tells you exactly what voltage drop triggers it. The AML stops you from flipping the crane when load ratio hits 100%. The manual spends 36 pages on AML-B operation alone. That’s not fluff – that’s the difference between a lift and a lawsuit.

What the Superstructure Annex Covers

You’re looking at Part G2, Annex – superstructure. That means the upper works: turntable, boom hoist cylinders, swing drive. Not the carrier. If your problem is in the truck transmission, you need Manual Transmission data, not this. But if the AML won’t calibrate or the boom tele doesn’t match the display, this Technical Manual has the OEM logic. The document ID 0695_EN_ALLGE_G2_01_00_00 tells you it’s the genuine article. I trust that string more than any reprint cover.

Tadano FAUN ATF 160G 5 Technical Manual: Inside the 82 Pages

The 82 pages break down into three main chunks: AML operation (function keys, display modes, warning thresholds), superstructure electrical schematics, and the annex notes for boom extension logic. You won’t find engine torque specs here. That’s in the base machine manual. What you do get is the factory procedure for the AML warning buzzer – page 3 shows the intermittent vs continuous tone behavior at 90% and 100% load. If you’ve ever swapped an AML board and got continuous alarm on startup, you’ll see the reset sequence here. No guesswork.

Verify the AML Settings Before You Lift

Page 3 of this Technical Manual is worth the price alone if you’re commissioning a used rig. It spells out the rocker tip switch 40 “tele indication” and how the monitor display (chapter B-2-2, item 39) switches between tele and telescope selection mode. I’ve watched techs skip this step and then wonder why the AML thinks the boom is 10 feet longer than it is. Don’t be that guy. Use the OEM diagram. For load chart verification on other FAUN models, grab FAUN RTF 40-3 Load Rating Charts. And if you’re doing a full crane teardown, you’ll want FAUN Part E Crane Testing Instructions alongside this manual.

AML Diagnostics: Factory Procedure for the 90% Warning

The AML section (60+ pages) includes the complete operation manual for the FAUN ATF 160G-5. The 2005-01 revision date is stamped on each page – that’s the latest factory release. When the load ratio crosses 90%, the buzzer sounds intermittently. At 100%, continuous. The manual tells you which AML output pin goes high and what the display should read. No third-party misinterpretation. For the carrier-side operator instructions, see Tadano FAUN ATF 80-4 2002 Operators Manual – 779 Pages of Factory Data. For drivetrain references, Manual Transmission covers that territory separately.

Source Validity – OEM vs Aftermarket

Every page in this PDF carries the FAUN GmbH header and the document number 0705_EN_FAUN99_G2_01_00_00. The watermark “FAUN” repeats. That’s how you spot a factory scan: the internal part numbering, the 2005 revision date, the FAUN-specific AML software flow. Aftermarket manuals strip those out and call it “universal.” Universal gets cranes tipped over. Stick with the OEM print.

Does this manual cover the entire ATF 160G-5 crane?

No, it covers the superstructure and AML system only.

What torque specs are listed for the AML mounting bolts?

This manual does not include fastener torque values. It focuses on AML operation, display logic, and warning thresholds. For mechanical torque specs on the superstructure, you need the separate FAUN superstructure service manual that covers hydraulic cylinder mounting and turntable bolts. The AML section here deals with electrical and functional testing – switch continuity, display mode sequencing, and load ratio calibration. If you’re bolting down the AML controller, refer to the FAUN standard torque chart for M6 or M8 hardware (typically 9-12 ft-lb), but that chart is not in this document.

You want the lift to go as planned? Access the Factory Manual from AutoRepairManuals and keep it open next to the AML display. Don’t trust a third-party summary. The OEM data sits on those 82 pages.