Tadano FAUN ATF 220G-5 Operating, Service And Maintenance Manual Download Page 690

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0450_EN_FA036_D1_01_00_00_FA029_AB106

2003-02

Summary of Contents for FAUN ATF 220G-5

Page 1: ...o WFN5 RUG R1 62036 Manufacturer After Sales Service FAUN GmbH Postfach 10 01 08 D 91205 Lauf a d Pegnitz Phone 49 0 9123 185 0 Fax 49 0 9123 7 53 20 TX 62 29 90 TADANO FAUN GmbH Postfach 10 02 64 D 91205 Lauf a d Pegnitz Phone 49 0 9123 955 0 Fax 49 0 9123 18 51 55 TX 62 29 90 ...

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Page 3: ...our crane with excessively hot water nor with excessive water pressure during the first 8 weeks Avoid steam jet units 2 When using the crane on construction sites when loading it with load take up equipment and wooden planks damage to the paint is inevitable Such damage will result in corrosion or rust and must therefore be repaired in an expert fashion without de lay 3 Damage may also be caused b...

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Page 5: ...0015_EN_ALLGE_I_00_00_00 TABLE OF CONTENTS ...

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Page 7: ...00_00 2002 12 1 22 P R E F A C E 1 How to use this Operating Manual 2 Technical data operation maintenance troubleshooting 3 Handling of this Operating Manual 4 Mounting locations of the vehicle identification number and of the nameplates ...

Page 8: ... data according to DIN 70020 2 Details of components chassis 2 1 Engine 2 2 Gearbox 2 3 Transfer box 2 4 Axles 2 5 Axle suspension 2 6 Power transmission 2 7 Wheels and tires 2 8 Brakes 2 9 Steering 2 10 Electrical equipment 2 11 Instruments 2 12 Driver s cab 2 13 Heating system 2 14 Frame 2 15 Outriggers 2 16 Fuel system 2 17 Standard equipment 2 18 Painting 2 19 Optional equipment ...

Page 9: ...ctrical equipment 3 9 Superstructure cabin 3 10 Counterweight 3 11 Heating system 3 12 Superstructure frame 3 13 Painting 3 14 Acceptance inspection 3 15 Optional equipment 3 16 Noise level when the engine is operating under load and at working speed 1 500 r p m 3 17 Vibration values in the crane cabin during crane work 4 Illustration of the vehicle 5 Notes referring to the load lifting capacity a...

Page 10: ...commended for communication between the crane operator and his assistant 2 8 Work in the vicinity of electrical overhead lines 2 9 How to behave in case of spark over if the crane has touched the power line 2 10 Grounding the crane and the load 2 11 Work in the vicinity of supply lines 2 12 Crane work with a load 2 13 Notes regarding work with two cranes 2 14 Instructions for crane operation 2 15 ...

Page 11: ...teering wheel 2 6 Actuation of the roller sun visor 2 7 Seat belts 2 8 Cab lighting 3 FAUN Cockpit Graphic Control System 3 1 Main screen 4 How to put the machine into operation 4 1 Steps to be taken and checks to be made before start up 4 2 Operation of the electrical equipment 4 3 Functional check of the electrical equipment of the vehicle before starting driving operation 4 4 Air distribution f...

Page 12: ...y outriggers 6 1 Control panel 6 2 Preparation for outrigger operation 6 3 Instructions regarding outrigger operation 6 4 Extending the outrigger beams 6 5 Extending the outrigger cylinders 6 6 Outriggers retracting the outrigger cylinders outrigger beams 6 7 Moving the vehicle with the complete counterweight mounted 7 Emergency control functions and elements 7 1 Hydraulic system 7 2 Centering the...

Page 13: ... engine pre heating 10 7 WEBASTO diesel heater unit 10 8 Eddy current brake 10 9 Checking the air accumulator retaining force on upward gradients vehicles equipped with trailer coupling device 10 10 Trailer Coupling Device 10 11 Starting the engine in the chassis with current supplied from an external power source 10 12 Battery charging plugbox 10 13 Switch Emergency OFF engine in chassis 10 14 Un...

Page 14: ...rol levers 2 9 Superstructure locking system 3 FAUN Cockpit Graphic Control System 3 1 Main screen 4 How to put the machine into operation 4 1 Steps to be taken and checks to be made before start up 4 2 Operation of the electrical equipment 4 3 Functional check of the electrical equipment of the vehicle before starting work 4 4 Blower fan heating air regulation 4 5 Start the engine 4 6 Monitoring ...

Page 15: ...unterweights 6 7 Work involving metallic ropes 6 8 Inspection of the safety equipment 6 9 Over overriding cutout device for auxiliary winch 7 Crane operation with a load fixed to the boom 7 1 Crane operation with the machine stabilized by outriggers 7 2 Crane operation free on wheels 7 3 Driving with a load 7 4 Moving the crane in full rig arrangement on construction sites 8 Emergency control func...

Page 16: ... lamp on the boom 11 9 Working floodlight on the hoist winch 11 10 Working floodlight electrical adjustment 11 11 Hook height indication auxiliary hoist winch 11 12 Air conditioning system 11 13 Mounting removal of the auxiliary winch 11 14 Switch Emergency OFF superstructure engine 11 15 Starting the engine with current supplied from an external power source 11 16 Battery charging plugbox 11 17 H...

Page 17: ...g 1 6 After having finished service and maintenance work 1 7 Configuration of electronic components 2 Maintenance intervals 2 1 Maintenance schedule 3 Engine 3 1 Oil level inspection 3 2 Oil change oil filter replacement 3 3 Inspection of hose clamps of the charge air hoses 3 4 Fuel tank 3 5 Coolant 3 6 Cleaning the radiator 3 7 Air cleaner 3 8 Exhaust system 4 Gearbox 4 1 Oil level inspection 4 2...

Page 18: ...klash 6 7 Checking screws and bolts on axles for tight fit check axle fastening drop arms thrust rod fastening etc 6 8 Preservation of axle and planetary gears 6 9 Checking the propeller shaft flange screws for tight fit 7 Propeller shafts 7 1 Inspection of backlash 7 2 Noise test 7 3 Checking the flange couplings 8 Eddy current brake 8 1 Service 9 Breather 10 Hydraulic system 10 1 Check the hydra...

Page 19: ...pressed air brake system 11 11 Test and setting values 11 12 Location of the measuring and test connectors 12 Electrical equipment 12 1 Batteries 12 2 Three phase generator 12 3 Starter 12 4 Lamps and lights 12 5 Fuse Relayarrangement 13 Wheels and tires 13 1 Measures to be taken to avoid accidents caused by the wheels 13 2 Checking the wheel nuts on the disc wheel for tight fit 13 3 Tightening to...

Page 20: ...g and maintenance 16 1 Other points of lubrication 16 2 Replacement of filter in the fuel pipe of the supplementary heater unit 16 3 Trailer coupling device 16 4 Sliding coupling 16 5 Steering 16 6 Suspension 16 7 Centralized lubrication system 16 8 Supplementary heater unit 24 Summary of oil types and filling capacities 25 Summary of lubricating grease types recommended grease types 26 Chart of a...

Page 21: ...7 Air cleaner 2 8 Exhaust system 3 Hydraulic system 3 1 Check the hydraulic oil level 3 2 Replacement of filter cartridges 3 3 Oil change in the hydraulic system 3 4 Changing the oil type 3 5 Replacement of filter insert of pressure filter 3 6 Checking and retightening the screw couplings of the hydraulic assemblies and pipes 3 7 Oil cooler supplementary oil cooler 3 8 Maintenance instructions for...

Page 22: ...raulic motor and the gearbox flange bolts for tight fit 4 11 Checking the slewing device for wear 5 Hoisting gear and auxiliary hoisting gear 5 1 Check for correct oil level and leakage 5 2 Oil change 5 3 Oil level inspection in motor coupling of hoisting gear motor 5 4 Oil change to motor coupling of hoisting gear motor 5 5 Check tooth face backlash on hoisting gear motor gearbox drive shaft 5 6 ...

Page 23: ...ade elements washing system 8 3 Supplementary heater unit 8 5 FAUN Cockpit Graphic Control System 8 6 Cleaning the recirculated air filter 9 Other points of lubrication servicing and maintenance 9 1 Telescopic boom 9 2 Boom elevation cylinder 9 3 Bottom block 9 4 Counterweight 9 5 Boom extension 9 6 Centralized lubrication system 9 7 Other points of lubrication 15 Summary of oil types and filling ...

Page 24: ...onnection diagram Slipring 99707782068 1 9 Emergency OFF Engine STOP stalling device 99707782491 1 10 Heater unit Webasto Thermo 90S 99707792167 1 11 Heater unit Webasto Air Top 3500 99707782214 2 Pneumatic diagrams 2 1 Compressed air system 99707784033_01 2 2 Compressed air system 99707784033_02 3 Hydraulic piping diagrams 3 1 Hydraulic system 99707017085 3 2 Steering 99707017084 3 3 Transfer box...

Page 25: ...07792040 1 6 Superstructure 99707792040 1 7 Telescope control 99707792040 1 8 Superstructure 99707792040 1 9 AML 99707792040 1 10 Jib 99707792040 1 11 Heavy lift fly jib single top 99707792040 1 12 Superstructure 99707792040 1 13 Webasto heating type Thermo 90 99707792040 1 14 Air conditioning system 99707792040 1 15 Superstructure 99707792040 1 16 Removal the boom 99707792040 1 17 Superstructure ...

Page 26: ...rosion 3 Inspection of lifting ropes 3 1 Lifting ropes Long lay Cross lay 3 2 Replacement state of repair of metallic ropes due to 3 3 Replacement of a metallic rope 3 4 Service and Maintenance 3 5 Elimination of elongation spin 4 Working life of the rope winch gear assemblies 4 1 Theoretical service life of the winch 4 2 Consumed portion of the theoretical service life 4 3 Determination of the co...

Page 27: ... mechanical section 5 2 Steering system hydraulic electrical section 5 3 Hydraulic system of suspension 5 4 Inclination adjustment and level control 5 5 Hydraulic system of outriggers 6 Brake system 7 Electrical equipment 8 Eddy current brake F 2 S u p e r s t r u c t u r e Troubleshooting 1 Engine 2 Hydraulic system of the superstructure in general 3 Slewing gear 4 Telescoping mechanism 5 Boom el...

Page 28: ...g instructions for ZF gearbox Operating instructions for ZF Intarder Chart of lubricants for ZF gearbox Centralized lubrication system G 2 S u p e r s t r u c t u r e Load Moment Limiter AML Centralized lubrication system Documents regarding heating ventilation and the air conditioning system superstructure cabin G 3 D o c u m e n t s o n v a r i o u s o p t i o n a l e q u i p m e n t s o f t h e...

Page 29: ...0025_EN_ALLGE_V_00_00_00 PREFACE ...

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Page 31: ...s be kept within easy reach of the operator s workplace i e in the driver s cab in the undercarriage or in the crane cab The Operating Manual is an integral part of the vehicle Before putting your FAUN crane carrier into operation please study the Operating Manual thoroughly Fa miliarize yourself with Part B 0 SAFETY INSTRUCTIONS and with Part E CRANE TESTING INSTRUC TIONS as well as with the inst...

Page 32: ...V 1 How to use this Operating Manual 2 2 2002 12 0030_EN_FA036_V_01_00_00_FA029 Memo ...

Page 33: ...After Sales Service Department of TADANO FAUN will be pleased to give you further information Parts D CIRCUIT AND PIPING DIAGRAMS and F TROUBLESHOOTING are intended to help you lo cate and eliminate faults and malfunctions more speedily Part G Annex contains documents supplied by subcontractors regarding vehicle components e g gear box operation of the Automatic Safe Load Indicator AML and specifi...

Page 34: ...V 2 Technical data operation maintenance troubleshooting 2 2 2002 12 0035_EN_FA036_V_02_00_00_FA029 Memo ...

Page 35: ...ally supplied They are still relevant however Your attention is also drawn to the additional brochures included with the set of vehicle documents In the Operating Manual the terms NOTE Attention and DANGER are used to draw your atten tion to particularly important information These terms have the following meaning NOTE This term is used whenever compliance with certain instructions is important fo...

Page 36: ...V 3 Handling of this Operating Manual 2 2 2002 12 0040_EN_FA036_V_03_00_00_FA029 Memo ...

Page 37: ... following locations The vehicle identification number 1 is stamped on the frame on the right side of the chassis between the 2nd and 3rt 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 VI...

Page 38: ...V 4 Mounting locations of the vehicle identification number and of the nameplates 2 2 2002 12 0045_EN_FA036_V_04_00_00 Memo ...

Page 39: ...0050_EN_ALLGE_A_00_00_00 Part A Technical Details ...

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Page 41: ...e moreover between the axle loads permitted by the road traffic regulations and the technically admissible axle loads When the technically admissible axle loads are exceeded a speed reduction is required depending on the actual extent by which the specified axle loads are exceeded The notes regarding tire load ratings and the maximum travelling speeds according to Part B0 1 Safety Instructions ite...

Page 42: ... km h is possible in the 1st gear off road at 800 rpm Tires 445 95 R 25 16 00R25 gross vehicle weight 60 t Gear step Off road on road gear Travelling speed at max engine power off road on road km h Gradability off road on road 1 3 6 61 47 2 3 7 47 39 3 4 8 37 31 4 4 10 30 25 5 5 12 24 20 6 7 15 19 16 7 8 18 16 14 8 9 21 13 11 9 11 26 11 9 10 14 31 8 7 11 17 38 7 6 12 20 46 5 4 13 24 56 4 3 14 30 6...

Page 43: ... Tronic 16 AS 2602 mechanical gearbox with integrated intarder Electronically pneumatically actuated dry clutch and fully automatic gearbox control The starting gear is selected manually or automatically If necessary semi automatic mode Tip Tronic possible with manual gear selection For extremely slow driving operation manoeuvring in 1st forward and reverse is possible In manoeuvring mode the vehi...

Page 44: ...the 2nd and 4th axles in transfer box and between 4th and 5th axles are lockable all inter wheel differentials are also lockable 10 x 6 drive for off road travel Inter axle and inter wheel differentials locked Drive variant 10x8 10 x 6 for on road travel 1st 4th and 5th axles are driven inter axle differentials between the 1st and 4th axles in transfer box and between the 4th and 5th axles 10 x 8 ...

Page 45: ...0 5 R 25 7 0 The tire inflating pressures are indicated on the instruction plate in the driver s cab 2 8 Brakes Air operated dual circuit brake system with air drier Parking brake acting on 2nd 4th and 5th axles as air accumulator brake Continuous service brake intarder and constant throttle system with exhaust flap brake On downhill gradients the Bremsomat function keeps a selected driving speed ...

Page 46: ...ring angles of the 1st and 4th axles so that a largely geometrically correct steering pattern results d Electronic tail swing suppression The 4th and 5th axles are steered automatically so that the swing out motion of the rear part of the vehicle is suppressed In the Federal Republic of Germany it is not admissible to drive on public roads with the steering acting independently on the rear axles a...

Page 47: ...14 Frame The frame of the five axle crane carrier is designed as a torsion resistant and rigid box type welded structure of high tensile fine grain steel incl the integrated outrigger casings Sliding coupling on the front Two access steps on each longitudinal side of the chassis Centralized lubrication system 2 15 Outriggers Hydraulic 4 point twin telescopic outriggers with deblockable check valve...

Page 48: ... Thermo 90S diesel operated A retrofit kit is additionally required if bio diesel fuel is used 3 Autonomous supplementary heater unit without engine pre heating and defroster nozzles for the windscreen warm air heater unit Webasto Airtop 3500 diesel operated not in combination with item 2 If bio diesel is used Webasto AT 2000 S 4 Air conditioning system 5 Refrigerator box in chassis cabin 6 ABS 7 ...

Page 49: ...power controlled axial piston twin pump hydraulically adjustable with accumulative power control for telescoping boom elevation and hoisting gear 1 axial piston pump for the swing mechanism and 1 geared pump for the supply with control oil 1 oil cooler 3 2 1 Control of the hydraulic system Two four position cross shift levers and electrically pre controlled 4 3 way valves which enable simultaneous...

Page 50: ...d prewarning system overload warning device safe load utilization indicator and work range limitation Digital displays for working radius actually lifted load and maximum allowable load tare indication boom length boom angle height of pulley head Hoist limitation for highest hook position Working range limitations for telescope boom angle and pulley head height and swing range limitation Further i...

Page 51: ...hnique integrated in the cab It features an adjustable hydraulically damped driver s seat with headrest mechanically adjustable lumbar support windshield wiping and washing system for windscreen and skylight windshield wipers with interval circuit hourmeter sun visor electric horn radio with CD player 12V and 24V Plugboxes Display to facilitate monitoring of e g fuel level and hydraulic oil temper...

Page 52: ...unterweight the width is 3 0m up to 47t the width is 3 6m up to 71t the width is 5 6m 12t can be carried along on the vehicle during transport travel technically speaking ASLI programming for 0t and 71t counterweights 3 10 1 Overview of all counterweight units which can be mounted 7 12 0t 6 12 0t 5 12 0t 4 11 5t 3 11 5t 2 10 0t 1 2 0t Load distribution for the various axle loads and rig arrangemen...

Page 53: ... 12 Superstructure frame Torsion resistant welded structure with single race ball bearing slewing device with external gearing rotating through 360 Central lubrication system for ball bearing slewing device boom elevation cylinder and boom basic bearing as well as main and auxiliary winch 3 13 Painting Single coloured painting telescopes black 3 14 Acceptance inspection Acceptance according to UVV...

Page 54: ...oads of more than 110t 9 AML extension feature for additional load chart variant of 12 0t 10 AML extension feature for additional load chart variant of 23 5t 11 AML extension feature for additional load chart variant of 35 0t 12 AML extension feature for additional load chart variant of 47 0t 13 Supported forces display in superstructure cab and the control boxes for the outriggers 14 10t hook tac...

Page 55: ...vel when superstructure cabin is open Noise at a distance of 7 m driver s ear driver s ear 73 dB A 77 dB A 73 dB A According to LNE French Environmental Protection Agency Valid until 31st December 2001 As of 01 01 2002 2000 14 EC 3 17 Vibration values in the crane cabin during crane work The measured vibration values do not exceed the limits of 0 5 m s according to the Machinery Directive 98 37 EC...

Page 56: ...A 3 Technical details of components superstructure 8 8 0065_EN_FA036_A_03_00_00 2003 01 Memo ...

Page 57: ...llustration of the vehicle A 4 0070_EN_FA036_A_04_00_00 2001 06 1 2 4 Illustration of the vehicle Lenkschema Steering pattern Strasse On road gear Baustelle Construction site durch Federung by suspension ...

Page 58: ...A 4 Illustration of the vehicle 2 2 0070_EN_FA036_A_04_00_00 2001 06 Memo ...

Page 59: ... is as close as possible to the actual working position It contains all the indications which are required for crane operation All the data required for the intended crane operation must be entered into the ASLI before starting to work The instructions given in the Notes referring to the load chart must also be observed 1 Working radius distance between the center of the ringgear and the center of...

Page 60: ...rt column the supporting forces charts contain the maximum supporting forces which might arise when the crane is supported by outriggers when the loads specified in the load charts are slewed through 360 The wheel loads occurring in the course of work with the crane on wheels to the rear are also listed if admissible observe the notes referring to the load charts ...

Page 61: ...0080_EN_ALLGE_B0_00_00_00 Part B0 Safety Instructions ...

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Page 63: ...ed on the front bumper cross member and secured as described in the Operating Manual Any national regulations differing from those mentioned above must be taken into consideration Additional bottom blocks and other items of equipment must be transported by an auxiliary vehicle Counterweights must have been removed and be transported by an auxiliary vehicle Any counterweights intermediate sections ...

Page 64: ...ort at the steering wheel The boom head must be marked on both sides with red and white diagonal section bars when the machine is operated in the darkness additional one type approved bordering light must be located on either side National registration requirements may differ from those mentioned and must be taken into consideration According to 41 14 StVZO German Federal Motor Vehicle Safety Stan...

Page 65: ...ave only a limited service life As the rims are important safety components of the crane they must be checked at regular intervals and these inspections must be recorded Given normal operation of the crane the normal service life to be expected of the rim is approx 80 000 to 100 000 km High jerky strains or e g driving with excessive axle loads which exceed the basic design data may reduce the spe...

Page 66: ...B0 1 Requirements and conditions for vehicles used in public road traffic 4 4 0085_EN_FA036_B0_01_00_00 2003 01 Memo ...

Page 67: ...hich steps are to be taken You must ask unauthorized persons to leave your vehicle and its working range If there is a risk to persons or equipment you must take all the steps you consider appropriate to eliminate the risk You must not perform any operations contrary to the regulations such as diagonal pulling of loads dragging of loads and working under troughs reservoirs or equipment that is inc...

Page 68: ...f bridges headroom of underpasses and road widths electrical overhead lines and their voltage If necessary request a police escort and obtain official permits The applicable travel or exception permits The appropriate paragraphs of the Federal Motor Vehicle Safety Standards in Germany StVZO and Road Traffic Regulations in Germany StVO of the country where the machine is to be registered must be ob...

Page 69: ...t suitable The outrigger cylinders must not be extended to their end positions Wooden planks should be placed underneath the outriggers leaving a clearance of approx 10 to 15 mm in the cylinders The vehicle must be aligned horizontally watch spirit levels The tires must be lifted clear off the ground if this is specified in the Operating Manual The tires must be checked for the specified inflating...

Page 70: ...een specified in the supporting forces charts Accordingly the corresponding wheel loads for work with the crane on wheels are specified in the wheel load charts For information regarding specific ground pressures please refer to the German DIN standard 1054 Admissible loads acting on the construction site The following table shows an excerpt of the admissible ground pressures Under certain circums...

Page 71: ... with a low cracking rate in good condition and position free from weathering in compacted strata in block or pillar form 15 30 Artificially compacted soil Asphalt Concrete B I Concrete B II 5 15 50 250 350 550 DANGER No thin boards lime sand brick or similar material may be used as supports for the outrigger floats Make sure that only sufficiently rugged material e g sufficiently thick wooden pla...

Page 72: ...fficient safety clearance must be provided between the outriggers and the edge of the excavation this safety clearance is measured from the base of the excavation DANGER In case of loose or back filled soil gradient of slope approx 30 the safety clearance twice the depth of excavation A 2 x T In case of natural soil which is not loose gradient of slope approx 45 the safety clearance once the depth...

Page 73: ...n their appropriate positions by insertion of locking pins so that they cannot slip If these instructions are not observed there is an i n c r e a s e d r i s k o f a c c i d e n t s The operator must extend the outrigger beams according to the selected load chart not only on the load side of the crane but also on the opposite side of the load If the outrigger beams on the opposite side of the loa...

Page 74: ...ANGER If the crane is not aligned horizontally and the boom is slewed towards the slope this increases the working radius which may cause the crane to tip over under certain circumstances A crane which is not aligned horizontally implies a r i s k o f a c c i d e n t s 2 4 Counterweight The size of the counterweight required is determined by the working radius required for the crane work in questi...

Page 75: ...rs or the hydraulic motor of the hoist winch may be damaged NOTE The annually consumed portion of the theoretical service life of the winch must be determined according to the amendment and the supplement to the regulation for the prevention of accidents VBG 8 Winches Hoisting and Towing Equipment If the theoretical service life of the winch has elapsed a general overhaul of the winch is necessary...

Page 76: ...nce felt when walking against the wind 8 gale 17 2 20 7 62 74 Tears boughs from trees walking outdoors is extremely difficult 9 gale force wind 20 8 24 4 75 88 Minor damage to houses chimney heads and roof tiles are blown off 10 severe gale 24 5 28 4 89 102 Uproots trees severe damage to houses 11 light hurricane 28 5 32 6 103 117 Extended storm damage in places occurs very rarely inland 12 hurric...

Page 77: ...ight of the load to be lifted G 20 t Prevailing wind area of the load to be lifted AWvorh 40 m2 1 According to diagram 1 Dynamic pressure at a wind speed of 12 m s 43 2 km h the resulting dynamic pressure amounts to 88 N m2 2 According to diagram 2 an admissible load wind area of AWZUl 23 m2 results for the load to be lifted Formula for calculation Fw q x Awzul 2024N 88 N m2 x 23 m2 Thus a load of...

Page 78: ...B0 2 Instructions for the crane operator 12 24 0090_EN_FA036_B0_02_00_00_FA029 2003 01 noch 2 6 1 Influence of and attention to the action of wind Diagram 1 Dynamic pressure Wind velocity km h or m s ...

Page 79: ...uctions for the crane operator B0 2 0090_EN_FA036_B0_02_00_00_FA029 2003 01 13 24 noch 2 6 1 Influence of and attention to the action of wind Diagram 2 Load wind area admissible load wind area Awzul incl cw ...

Page 80: ...Hand signals and special verbal expressions must be agreed between the crane operator and his assistant and observed precisely Any mistakes regarding the interpretation of the hand signals or verbal expressions may result in accidents The persons giving the hand signals must always be placed so that he can see the crane operator and keep at a safe distance from the hook or the load The following h...

Page 81: ...ppropriate safety clearances are indicated in the following table According to the German VDE directive 0105 the following safety clearances from live lines must be observed even in the most unfavourable crane positions and taking account of possible oscillations of the overhead line which may be due to the action of wind Rated voltage Minimum clearance to be observed up to 1000 V 1 kV 1 m over 1 ...

Page 82: ...ane Remove the crane from the danger zone by driving away or by slewing or adjusting the boom Request persons outside of the danger zone to shut off the power supply If it is indispensable to leave the crane cab never touch the crane and the ground at the same time Do not climb down but jump to the ground Leave the crane area making small steps 2 9 1 Inspection measures required after an electric ...

Page 83: ...om using a screw clamp or a vise grip wrench do not fasten to screwed down or bolted components Fasten the other end of the ground cable to a metal bar stuck into the soil Attention When slewing the crane make sure the ground cable can move without obstruction The ground cable must not be crushed or torn apart NOTE The ground cable and the ground spike are available as an assembly including the co...

Page 84: ... limit switches winch limit switches automatic safe load indicator etc must be in an operationally reliable condition The crane operator has to observe the following items Before the crane operator starts crane work he has to inform himself about the dimensions and the weight of the load The lifting capacities specified in the load chart have to be observed and must not be exceeded The crane must ...

Page 85: ...working range and be in constant eye contact with the crane operators 2 14 Instructions for crane operation The crane is ready to operate at ambient temperatures in the range from 25 C to 40 C During crane operation the gearshift lever must be set to neutral The hydraulic axle suspension must be locked for crane operation according to the operating manual before the outriggers are set and before d...

Page 86: ...te measures to avoid such risks 2 17 1 Causes for driving faults Overspeed of engine and or gearbox when driving on downward gradients The gearbox has not been shifted down in time before the vehicle enters a curve Make sure that the gearbox is never shifted to neutral before or while negotiating a curve as in this case the engine speed would drop suddenly to idling level thus impairing the hydrau...

Page 87: ...fe load indicator is not set to the actual rig arrangement of the crane The automatic safe load indicator and other safety devices are faulty or not in operation The admissible loads or the working radii specified in the load charts are exceeded During crane work diagonal tensile stress is applied to the boom especially in a lateral direction Any obstacles impeding the crane s movements are ignore...

Page 88: ...break suddenly Deficiencies in the hydraulic system e g frayed hoses Defective or unsatisfactorily operating safety devices e g load moment limiters or hoist limit or winch limit switches The brakes have to be checked for proper working order During this inspection the brake linings must be checked for wear Brake linings are subject to increased wear after installation they must be checked more fr...

Page 89: ...ed brake systems During the vehicle s service life recurrent pressure checks are only necessary if they are required by the regulations in force in your country The compressed air tanks must be checked visually in accordance to the maintenance instructions laid down in your country s regulations During the vehicle s service life the drainage valves installed in the compressed air tanks of the brak...

Page 90: ...B0 2 Instructions for the crane operator 24 24 0090_EN_FA036_B0_02_00_00_FA029 2003 01 Memo ...

Page 91: ... indicators must not be used for switching off the hoisting gear or the boom retracting mechanism during normal operation The crane operator has to make sure in all cases before such work that the lifting capacity is not exceeded by the load to be lifted Loads which exceed the lifting capacity of the crane must not be lifted in spite of the fact that the overload safety de vice is installed This d...

Page 92: ...rload safety device cannot become effective i e the drive assembly cannot be switched off quickly enough when the crane is operated incorrectly In this case accidents cannot be precluded completely in spite of the overload safety device being installed This applies particu larly to the following cases the hook or the load lifting equipment is fixed underneath the load excessive time lag forces are...

Page 93: ...0100_EN_ALLGE_B_00_00_00 Part B Operating Instructions ...

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Page 95: ...0105_EN_ALLGE_B1_00_00_00 Part B1 Operating Instructions Chassis ...

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Page 97: ... engine is started especially if the vehicle has been immobilized for an extended period of time it is necessary to check the fluid levels in the following components Engine oil level Oil level in hydraulic oil tank Engine coolant level The cooling system is filled correctly if the coolant reaches the rim of the filler socket on the expansion tank DANGER Do not check the coolant level while the en...

Page 98: ...on during drilling welding and grinding work Protect piping against battery acid temperature resistant in the range from 40 C to 100 C Apply the handbrake before you leave the driver s cab CAUTION Nobody is allowed to stay in the driver s cab during crane work STOP Access prohibited to unauthorized persons ATTENTION Vehicle may only be lowered while the engine is running ATTENTION RISK OF ACCIDENT...

Page 99: ...ENTIAL LOCKS must never be engaged while driving in curves but only briefly to overcome an obstacle Accelerate carefully when driving while the crane is mounted Wheel chocks Tires according to vehicle model Key actuated switch 99707754515 Oil level indicator Parking brake handbrake Oil dipstick Extension width 5 6 m Extension width 8 3 m Weight unit 150 kg Weight unit 50 kg ...

Page 100: ...e 4 14 0110_EN_FA036_B1_01_00_00 2003 01 cont d 1 1 Warning and instruction plates 24 V DC Instruction plate 12 V DC Instruction plate Plate Only in case of optional feature Emergency operation of the superstructure controlled from the chassis Weight unit 250 kg ...

Page 101: ...hicle B1 1 0110_EN_FA036_B1_01_00_00 2002 12 5 14 1 1 1 Drawing of chassis showing the location of warning and instruction plates The following diagram shows the position and the location of all the warning and instruction plates mounted to the chassis ...

Page 102: ...B1 1 General instructions concerning operation of the vehicle 6 14 0110_EN_FA036_B1_01_00_00 2001 06 Memo ...

Page 103: ...General instructions concerning operation of the vehicle B1 1 0110_EN_FA036_B1_01_00_00 2003 01 7 14 Memo ...

Page 104: ... Transfer box with emergency steering pump 20 Suspension cylinder 3rd axle 21 Eddy current brake 22 Compressed air tank 23 Brake cylinder 4th axle 24 Suspension cylinder 4th axle 25 Suspension cylinder 5th axle 26 Test connectors test panel compressed air system 27 Compressed air tank 28 Trailer coupling device 29 Sliding coupling 30 Outrigger rear left hand 31 Free 32 Access 33 5th driven axle 34...

Page 105: ...General instructions concerning operation of the vehicle B1 1 0110_EN_FA036_B1_01_00_00 2002 12 9 14 cont d 1 3 Components assemblies installation location and position ...

Page 106: ...B1 1 General instructions concerning operation of the vehicle 10 14 0110_EN_FA036_B1_01_00_00 2001 06 Memo ...

Page 107: ...nsported by an auxiliary vehicle The second hoist winch if available must be removed and transported by an auxiliary vehicle Additional bottom blocks and other items of equipment must be transported by an auxiliary vehicle DANGER When the boom is completely lowered it is not possible to slew the superstructure through 360 Collision of boom with engine cover or driver s cab The counterweights must ...

Page 108: ...oose components must be kept in a safe place or stowed in the tool box so that they cannot be lost The tool box cover must be locked Safety accessories warning triangles first aid kit warning lights and fire extinguishers must be stored in an easily accessible place and checked for proper working order and completeness at regular intervals or taken to authorized agencies for inspection The covers ...

Page 109: ... arranged on the left in the storage box of the driver s cab A tool box 3 is located at the rear of the vehicle The crank 1 used to mount the jib is located on the vehicle s platform The spare wheel 4 is either stowed safely on the vehicle platform or secured to the spare wheel holder The ladder 6 is arranged in the supports underneath the driver s cab Attention All covers must be closed before th...

Page 110: ...wheel chocks pursuant to the legal provisions The wheel chocks folding wheel chocks have been arranged on the left in the storage box of the driver s cab see item 1 4 1 Open wheel chocks to fit them to the vehicle Actuate the locking device 1 The wheel chock 2 opens automatically into working position DANGER Danger of crushing Fit opened wheel chocks 2 to the wheels 3 ...

Page 111: ...Driver s cab B1 2 0115_EN_FA036_B1_02_01_00_FA029 2002 12 1 10 Memo ...

Page 112: ... Fire extinguisher 18 First aid kit 19 Seat adjusting lever 20 Storage box for wheel chocks 21 Access plate 22 Accelerator pedal 23 Footbrake pedal 24 Steering wheel adjustment 25 Direction indicator 26 Air distributor side pane 27 Steering column switch direction indicators windshield wiper etc 28 Instrument panel 29 Steering wheel 30 Roller sun visor 31 Steering column switch engine brake etc 32...

Page 113: ...Driver s cab B1 2 0115_EN_FA036_B1_02_01_00_FA029 2002 12 3 10 Driver s cab X ...

Page 114: ...B1 2 Driver s cab 4 10 0115_EN_FA036_B1_02_01_00_FA029 2001 06 Memo ...

Page 115: ...id The lever used to unlock the front lid is installed on the left below the instrument panel Pull lever 1 down the front lid is unlocked 2 3 2 Opening and locking the front lid Fold the unlocked front lid 1 upwards and lock it in its position using the holding bar 2 DANGER When work is performed with the front lid open it must be definitely secured There is a risk of accidents should the front li...

Page 116: ...ge over flap for outside air circulating air 3 Change over flap for outside air circulating air 4 Air inlet heating ventilation 5 Electronic system engine ADM 6 Gearbox control system 7 Voltage transformer 24 12 V 8 Tank for windshield washing fluid 9 Steering computer 1 10 Intarder control 11 Steering computer 2 12 Windshield wiper motor 13 Multiway connector ...

Page 117: ...ure by means of an air assisted vertical adjusting device The driver s and the passenger s seats are equipped with identical control elements The following illustrations and descriptions refer to the adjustment of the driver s seat 1 Linkage longitudinal adjustment 2 Control lever inclination adjustment 3 Control lever height adjustment 4 Control lever quick lowering feature 5 Control lever backre...

Page 118: ...n be lowered entirely so that the driver can leave his cab easily Pull the control lever quick lowering feature 4 upwards The seat is lowered and remains in this position After returning to the cab the driver must push the control lever down The seat returns automatically to the position adjusted last 2 4 5 Backrest adjustment To adjust the backrest inclination in steps from approx 0 to 36 Actuate...

Page 119: ...r locking is also effected automatically after a few seconds DANGER Do not adjust the seat and the steering wheel while driving 2 6 Actuation of the roller sun visor Roller sun visors are installed on the windscreen to protect the driver and the passenger against dazzle This sun protection can be lowered approx to the middle of the windscreen Actuation of the roller sun visor Pick the tab 2 to pul...

Page 120: ... into the buckle 3 To release the belt push the button 4 of the buckle The belt retractor returns the belt automatically into its original position DANGER After an accident in which the seat belt was involved it must be ensured that it has not been damaged i e possibly elongated An inspection and possibly replacement by a specialist workshop are indispensable 2 8 Cab lighting Lamps are installed a...

Page 121: ... switching on the ignition it can take up to 10 sec until the FAUN Control and Service System has been started A monitor 20 Cockpit Multi Vision and the appropriate control elements rocker tip switches 26 27 and 28 have been installed in the instrument panel of the chassis Cockpit Multi Vision 20 Put the crane carrier into operation as described in section B1 4 of the operating manual After the ba...

Page 122: ...ir pressure in brake circuit I Circuit II The indication in the top right corner of the main screen in the working and information menus shows the brake air pressure in brake circuit II If the brake air pressure in brake circuits I and or II decreases below 6 5 bar the symbol brake of the appropriate brake circuit is flashing in red If the brake air pressure in brake circuits I and or II decreases...

Page 123: ... coupled the symbol must not go on When the symbol goes on during traveling operation with a trailer this indicates a failure of the ABV trailer components However in this case the functional safety of the conventional air actuated brake system remains fully ensured Steering pump Symbol lights up In case of malfunction it may only light up during operation Emergency steering pump Symbol lights up ...

Page 124: ...s activated the symbol appears in blue and the numbers change from 0 to 1 If the leveling has been activated successfully the symbol appears in yellow and the numbers go out yellow level If the symbol remains blue the level position has not been reached The numbers indicate at which place in the vehicle an error has occurred 0 Position not reached 1 Position reached The proximity switches are inst...

Page 125: ...t to 4th axles is connected Inter axle differential lock 4th to 5th axles The symbol appears on the main screen while the inter axle differential lock of the 4th to 5th axles is connected Inter wheel differential locks The symbol appears on the main screen as long as the inter wheel differential locks are engaged The inter wheel differential locks remain locked for 10 seconds after actuation of th...

Page 126: ...ch 37 axle oscillation is being actuated Centralized lubrication system The symbol appears for approx 3 seconds on the monitor after system power up For further details refer to the enclosed operating manual of the manufacturer part G1 Chassis Operation from superstructure The symbol lights up as long as the connection to the superstructure is established Boom raised The symbol lights up if the bo...

Page 127: ...been actuated the selection menu appears on the monitor Symbols and meaning of the various selectable working menus Working menu drive Working menu brightness Working menu service Working menu axle suspension lock Working menu spirit level Working menu Rear area surveillance Information menu steering Information menu axle load Information menu Information Optional equipment ...

Page 128: ...tion menu Change over to the working screens Working operations can be performed via these screens Actuate the top or the lower part of the rocker tip switch 27 selection Select one of the working menus The selected menu is displayed visually Actuate the lower part of the rocker tip switch 26 Menu navigation Enter into a selected working menu ...

Page 129: ...gaged The circle is empty Differential locks are engaged A cross appears in the circle The 2nd axle drive is engaged The inter axle lock between the 1st and the 4th axles is connected The inter axle lock between the 4th and the 5th axles is connected Inter wheel differential locks are engaged Inter wheel differential locks remains engaged for another 10 seconds 10 s Actuate the upper part of the r...

Page 130: ... Actuate upper part of rocker switch monitor appears brighter Actuate lower part of rocker switch monitor appears darker The brightness value is indicated in Actuate lower part of rocker tip switch 28 Service the brightness value adjusted manually is saved SAVE appears backlit in red and the display changes automatically over into the selection menu SAVE NOTE The last brightness value which has be...

Page 131: ...in electric circuit diagram SC Short Cut Short Circuit CB Cable break 1 S437_SC 2 S437_CB Reset lifting of 3rd axle Should an error have occurred while the axle is lifted causing an undefined state the function can be reset by pressing the rocker tip switch 31 level control only in the working menu Service for 7 seconds DANGER Now the axle will fall down CAN Service data These error codes are used...

Page 132: ..._EN_FA036_B1_03_00_00_FA029 2003 01 cont d 3 1 1 3 Working menu Service CAN errors 1 OK 2 not on the CAN BUS D Designation of circuit diagram refer to electric circuit diagram D003 D006 D007 D017 D001 D015 CAN BUS STATE 5 OK 4 or 127 not OK D016 OW CGC ...

Page 133: ...he main screen as soon as the vehicle is supported by outriggers and all the axles are lifted 3rd axle lifted The symbol is lit as long as the 3rd axle is in its upper position lifted Moreover a green field appears next to the symbol suspension cylinders 3rd axle If the field appears empty the required position has not been reached Not blocked suspension activated Blocked Moreover a green or yello...

Page 134: ...correct Refer to item 3 1 1 3 The current vehicle inclination is visualized via the spirit level 3 and digitally via the x y coordinates Actuate the upper part of the rocker tip switch 26 Menu navigation Exit the working menu Return to the selection menu 3 1 1 6 Working menu Rear area surveillance After actuation and confirmation of the working menu the area to be monitored appears on the CMV moni...

Page 135: ...th axles is displayed digitally 3 1 1 8 Information menu axle load After actuation and confirmation the information menu axle load appears on the monitor NOTE The displayed axle loads are approximate values Vehicle is aligned horizontally leveled Symbol lights up Align the vehicle completely horizontally refer to part B1 4 item 4 7 1 2 An error has occurred The vehicle weight indications are incor...

Page 136: ...m 16 16 0125_EN_FA036_B1_03_00_00_FA029 2003 01 3 1 1 9 Information menu After selection and confirmation the information menu Info appears on the monitor In the information menu Info the software version and the hardware data are displayed ...

Page 137: ...Chassis Check the inflating pressure and the wear of the tires at regular intervals part C1 Service and Maintenance Chassis NOTE The tire inflating pressures specified in part A vehicle description apply to the original equipment of the vehicle When changing the tire brand adhere to the prescriptions of the tire manufacturer in question Check the vehicle s electrical equipment for proper working o...

Page 138: ...of the electrical equipment 4 2 1 Battery main switch Attention When the engine is running it is essential that the battery main switch is not turned OFF The current flow between the generator and the battery must not be interrupted destruction of the diodes of the generator Switching ON Unlock the rocker switch 7 battery main switch by actuating the lock handle down and push the rocker switch dow...

Page 139: ... on briefly and buzzer engine malfunction 21 is briefly activated In the FAUN Cockpit Graphic Control System refer to part B1 3 the following symbols generator steering pump emergency steering pump on road or off road gear 4 2 3 Rotary beacon The rotary beacon is switched on and off via the rocker switch 5 Rotary beacon Rocker switch pressed down rotary beacon ON Rocker switch pressed upwards rota...

Page 140: ... actuate the windshield washing system shift the switch ring 1 towards the steering column 4 2 7 Parking light dimmed light Actuate the rotary switch 8 light to switch the parking light or the dimmed light ON OFF Switch position 0 no lights ON Switch position I parking light Switch position II Parking light dimmed light I II 4 2 8 High beam light headlamp flashers To change over from dimmed light ...

Page 141: ... push button switch 2 at the end of the steering column switch 1 4 2 11 Mirror heating system The mirrors can be heated in order to prevent misting during the cold season Actuate the rocker switch 3 mirror heating the green function lamp in the switch goes on to indicate the heating process 4 2 12 Adjustment of rearview mirrors The mirror adjusting switch on the central bracket to the right of the...

Page 142: ... battery main switch and the ignition are switched ON The following items of the lighting system must be checked in particular Parking lights on the left and right front and rear Dimmed light high beam light on the left and right Direction indicators on the left and right front and rear Stop lights on the left and right Reversing lights on the left and right License plate illumination Rotary beaco...

Page 143: ...otary switch 3 from cold rotary switch turned to the left to warm rotary switch turned to the right 4 4 4 Air circulation 4 5 When the pushbutton switch 4 is actuated the supply of outside air into the driver s cabin is stopped The air intake and the air circulation is now only effected in a closed circuit within the driver s cab In ON condition pilot lamp 5 is lit 4 4 5 Air conditioning 6 7 Contr...

Page 144: ... not set the key switch to position 2 It is recommended that the key switch be removed during driving operation The rotary switch Gearbox is in N position gearbox in neutral Insert the ignition key into the ignition starter switch and turn it to position 2 now the ignition is switched ON Self check of the control system CH appears on the display Start the engine To do so turn the ignition key to i...

Page 145: ...32 Fuel level indicator 23 Engine temperature indicator 11 in the FAUN Cockpit Graphic Control System refer to part B1 3 Explanation of the pilot lamps and instruments while the engine is running refer to item 4 6 For further details please refer to the Operating Manual of the engine manufacturer 4 5 1 Stopping the engine Engage the parking brake handbrake Set rotary switch driving operation to ne...

Page 146: ...on 1 again the engine comes to a standstill or Actuate the push button 2 the engine comes to a standstill Starting the engine and increasing the engine speed The ignition in the chassis is ON and the engine is not running The gearbox is set to neutral position N Actuate push button 1 and keep it pressed the engine is started and runs at idle 3 seconds after the engine has started the engine speed ...

Page 147: ...tely leakage has occurred in the fuel system the fuel filter has been replaced filter replacement refer to part C1 Service and Maintenance Chassis Prerequisite a sufficient amount of fuel has been replenished any leakage has been eliminated the filter cartridge has been replaced as described in part C1 Service and Maintenance Chassis Bleeding and supplying fuel Open vent screw 1 actuate pump plung...

Page 148: ... if necessary repeat this procedure NOTE The oil level may only be checked while the engine is not running For further details please refer to the Operating Manual of the engine manufacturer 4 6 2 3 Function Engine steering In case of engine malfunction the warning lamp 13 engine malfunction goes on Eliminate the fault at the next opportunity if necessary take the machine to a specialist workshop ...

Page 149: ...ating The needle moves into the critical range Eliminate the fault at the next opportunity if necessary take the machine to a specialist workshop If the warning lamp 13 engine malfunction goes on and the buzzer 21 engine malfunction sounds stop the vehicle immediately stop the engine locate the reason for the malfunction and eliminate it immediately 4 6 2 6 Coolant level A sensor installed in the ...

Page 150: ...ne temperature indicator must not be in the critical range even during operation governed by the engine speed 4 6 2 8 Engine speed The engine speed is indicated by the revolution counter 24 The max engine speed is approx 2 000 r p m During thrust operation the maximum speed may be higher however it must not exceed 2 350 r p m 4 6 2 9 Operating hours An hourmeter has been integrated into the revolu...

Page 151: ...NGER When the hydraulic oil level symbol appears the rear axle steering is automatically set to malfunction The 4th and 5th axles must be centered via the emergency control refer to item B1 7 2 NOTE The hydraulic oil level symbol appears also when the outriggers are completely extended function test 4 6 3 3 Steering hydraulics dual circuit steering system The steering pump and the steering emergen...

Page 152: ...have the trouble eliminated 4 6 4 2 Gearbox display The Gearbox Display 25 indicates all the necessary information about the system e g gear step malfunction etc Attention It is essential to watch the malfunction indicators in the display Failure to comply with this instruction may result in damage to the gearbox and or the clutch Attention In the 1st gear manoeuvring mode the self protective func...

Page 153: ...tor system The red warning lamp goes out as from a brake air pressure of approx 5 5 bar NOTE If the red warning lamp 14 service brake goes on the air pressure gauges must be checked to see whether the needle exceeds the 5 5 bar indication If it does so in both air pressure gauges this indicates a malfunction in the air accumulator circuit FBA or in the auxiliary equipment circuit DANGER Whenever t...

Page 154: ...ccess to a mode in which internal settings can be changed 4 6 7 Modular tachograph electronic tachograph The modular tachograph refer to part B1 2 item 32 displays the current total mileage the current vehicle speed time the preset work groups and symbols of the inserted diagrams Malfunctions of the device or of one of the system components are displayed automatically The vehicle speed the distanc...

Page 155: ...adjustment If the inclination of the ground is to be compensated e g during off road operation with the vehicle in full rig arrangement or if the outriggers on one side of the vehicle are to be extended beyond an obstacle it is possible to correct the vehicle s inclination or to lift lower the machine only in one position DANGER Do not tilt the vehicle out of its horizontal alignment more than is ...

Page 156: ...efore leveling the vehicle for on road travel the axle suspension lock must be disengaged Deactivating the axle suspension lock Push the lock handle in the rocker switch 36 axle lock down actuate the rocker switch upwards now the axle suspension lock is disengaged The axle suspension lock symbol refer to part B1 3 FAUN Cockpit Graphic Control System goes out The lock handle automatically returns t...

Page 157: ...nd set to its lowest level position 4 7 3 Lowering the suspension In on road driving condition the vehicle s suspension is set to automatic level compensation 4 7 3 1 Lowering the suspension for leveling DANGER Make sure that nobody stays under or on the vehicle while it is being lowered Switch the ignition ON Unlock the rocker switch 36 axle suspension lock by actuating the lock handle down and p...

Page 158: ... 0 to 1 refer to part B1 3 FAUN Cockpit Graphic Control System Symbol normal level After the chassis has reached the predetermined level the leveling procedure is automatically terminated Moreover the yellow symbol normal level refer to part B1 3 FAUN Cockpit Graphic Control System appears Release the rocker tip switch 31 leveling Now the vehicle is positioned again so that all its sides are align...

Page 159: ...tralized lubrication system The machine is equipped with a centralized lubrication system This ensures optimum lubrication of all points of lubrication connected independently of the lubricating intervals indicated in the operating manual Only the lubricating points which are not connected still have to be supplied by hand 4 8 1 Function The system operates fully automatically in accordance with t...

Page 160: ...red warning lamp 15 Central warning CGC goes on in case of electronic faults of the control system of faults in the chassis CAN bus sensor faults or engine malfunctions Attention Observe the warning lamp 15 central warning CGC If it goes on the reason for the malfunction must be determined and eliminated without delay ...

Page 161: ...ion While the vehicle is at a standstill with the engine running and a gear engaged simply actuate the accelerator pedal to set the vehicle in motion Perform brake tests immediately after starting to drive As the vehicle must be stalled with the gearbox in neutral position and as no rigid connection exists between the engine and the axles the vehicle must be prevented from rolling away on stopping...

Page 162: ...e vehicle look for the fault and if it cannot be eliminated by means of the equipment available in or on the vehicle request specialist staff Before stopping the engine set the gearbox to neutral The 3rd gear has been programmed as starting gear However it may be useful to preselect a lower gear for starting Manoeuvring is only admissible in the 1st forward and reverse gears In case of extended st...

Page 163: ...ol on road gear see FAUN Cockpit Graphic Control System item B1 3 is lit Decelerate and stop the vehicle the engine must run at idle Engage the parking brake Set gearbox to neutral position N Actuate the rocker tip switch 45 off road on road gear downwards The symbol on road gear goes out and the symbol off road gear goes on if the off road gear is engaged correctly Set gearbox to the desired posi...

Page 164: ...n Never drive on a firm road while the differential locks and the 2nd axle drive are connected When the inter wheel differential locks are engaged only straight ahead driving is admissible Connect the differential locks only if this is absolutely indispensable The differential locks in the axles are only engaged correctly if the appropriate indicator lamps go on Drive 10x6 The locks should be enga...

Page 165: ...ive does not appear connected 5 4 2 Inter axle differential lock in transfer box Connection Actuate the rocker tip switch 46 Axle drive transfer box 2 x downwards The working menu drive appears on the monitor refer to FAUN Cockpit Graphic Control System part B1 3 item 3 1 1 1 After actuating the rocker tip switch the symbol Inter axle differential lock between 1st and 4th axles appears activated O...

Page 166: ... activated Once connection has been completed the symbol differential locks connected appears additionally At the same time the 2nd axle drive and the inter axle differential lock between the 1st and 4th axles is connected Disconnection Actuate the rocker tip switch 46 Axle drive transfer box upwards The 2nd axle drive the inter axle differential lock between the 1st and 4th axles and the inter ax...

Page 167: ...tion has been completed the 2nd symbol inter wheel differential locks connected appears additionally At the same time the 2nd axle drive the inter axle differential lock between the 1st and 4th axles and the inter axle differential lock between the 4th and 5th axles is connected Disconnection 1 Actuate the rocker tip switch 46 Axle drive transfer box upwards The 2nd axle drive the inter axle diffe...

Page 168: ...The vehicle moves to the upper level with the 3rd axle lifted When the 3rd axle has been lifted the symbol Lift 3rd axle and level motion goes out The symbol 3rd axle is lifted appears The construction site mode has been enabled Lowering the axle Actuate the rocker tip switch 30 lift lower 3rd axle downwards and keep it pushed The symbol Lower 3rd axle refer to item B1 3 is flashing on the main sc...

Page 169: ...ertain residual reduced braking effect can be reached 5 6 2 Auxiliary brake handbrake The auxiliary braking effect is achieved by the air accumulator cylinders via the handbrake In case of failure of the service brake foot brake or of a part of the service brake the vehicle can only be braked via the handbrake valve The warning lamp 17 parking brake goes on The handbrake can be actuated gradually ...

Page 170: ...trol lever from position 0 to position 1 Thus the engine brake has been actuated For control positions 2 to 5 refer to item 5 6 5 NOTE While the ABV control is activated the engine brake is automatically deactivated NOTE The lower the gear step selected in the gearbox the greater the resulting braking effect DANGER The engine brake is only operative while a gear is engaged Attention The engine bra...

Page 171: ...er sufficient to keep the speed constant on downhill gradients or if the vehicle is to be delayed additionally the vehicle can be braked additionally via the service brake by the driver Attention The engine brake Bremsomat is inoperative as long as the accelerator pedal is actuated NOTE While the ABV control is activated the engine brake Bremsomat is automatically deactivated However the Intarder ...

Page 172: ...trol switch to position 2 5 the intarder is actuated the symbol Intarder see part B1 3 is lit NOTE If the symbol Intarder is lit with the manual control switch actuated this indicates a malfunction Contact TADANO FAUN after sales service The braking effect of the intarder can be graduated The manual control switch has 6 positions Position Braking effect 0 0 1 Engine brake Bremsomat 2 40 Intarder e...

Page 173: ...ditions without having to actuate the accelerator pedal The Cruise Control can be adjusted as of 38 km h up to the vehicle s maximum speed DANGER Do not use the Cruise Control under winter time or skidding road conditions nor if the traffic conditions are not absolutely clear Risk of accidents NOTE Only use the Cruise Control if the traffic conditions allow driving at a constant speed When the Cru...

Page 174: ...f 2 km h each 5 7 2 Switching the Cruise Control OFF Actuate the service brake the Cruise Control function is interrupted To reactivate it refer to item 5 7 3 Actuate the rocker switch 53 Working speed the Cruise Control function is deactivated The speed must again be controlled by actuating the accelerator pedal The set speed will be deleted 5 7 3 Switching the Cruise Control ON again after actua...

Page 175: ...ng is enabled with minimum steering radii However this causes the rear part of the vehicle to swing out from its straight ahead position contrary to the steering direction of the front wheels when the steering is actuated to its maximum refer to the figure The steering angle of the rear axles increases along with the distance covered Swinging out is effected with a delay after approx 4 meters cove...

Page 176: ...d me chanically 4th and 5th axles connected steered electronically 4 Construction site mode Vehicle speed up to the 3rd gear 1st and 2nd axles are steered me chanically 4th and 5th axles connected steered electronically max angle Manual steering of the rear axles 3rd axle lifted For the steering mode minimum turning circle the 3rd axle need not be lifted 5 Construction site mode Vehicle speed up t...

Page 177: ...mum turning circle 5 9 2 Construction site mode The construction site mode is activated via the rocker switch Preselection of steering mode item 5 9 1 pos 1 and depending on the steering mode selected by lifting the 3rd axle In construction site mode the following steering options are available via the electronic control unit refer to item 5 9 1 Diagonal steering Electronic tail swing suppression ...

Page 178: ...s not possible to upshift the gearbox higher than to the 3th forward gear or 2nd reverse gear 2 Actuate rocker switch Preselection of steering mode The 3rd axle must be lifted The front axles should be set to straight ahead position Unlock the rocker switch Preselection of steering mode in the center console refer to item 5 9 1 pos 1 by actuating the locking handle and push the rocker switch to th...

Page 179: ... unit refer to item 5 9 1 pos 2 a bar appears which moves to the left or right depending on the motion of the rear axles NOTE It is not admissible to drive the vehicle on public roads with this steering variant Please observe any specific regulations of the country where the machine is to be used which might differ from the value mentioned before Deactivate diagonal steering mode The front axles s...

Page 180: ... item 5 9 1 pos 2 a bar appears which moves to the left or right depending on the motion of the rear axles NOTE It is not admissible to drive the vehicle on public roads with this steering variant Please observe any specific regulations of the country where the machine is to be used which might differ from the value mentioned before Deactivating Electronic tail swing suppression Prerequisites The ...

Page 181: ...appears which moves to the left or right depending on the motion of the rear axles NOTE It is not admissible to drive the vehicle on public roads with this steering variant Please observe any specific regulations of the country where the machine is to be used which might differ from the value mentioned before Deactivating the manual steering Prerequisites The front axles should be set to straight ...

Page 182: ...ing circle in the center console item 5 9 1 pos 10 The program minimum turning circle is activated The pilot lamp above the push button is lit The symbol turning circle activated must appear on the main screen refer to part B1 3 NOTE It is not admissible to drive the vehicle on public roads with this steering variant Deactivating the minimum turning circle Prerequisites The front axles should be s...

Page 183: ...there is no active error Ready appears in the display Provided that the error codes displayed so permit the following approach is possible Center the 4th and 5th axles via the emergency control Steering refer to item B1 7 1 1 B1 7 1 2 4 and B1 7 2 If necessary lower the 3rd axle To this effect Actuate the rocker tip switch 26 menu navigation downwards Call up the working menu Service refer to item...

Page 184: ... towing operation with due care and attention Comply with the directives regarding towing operation Setting the transfer box to Neutral position For towing the transfer box must be set to Neutral position The change over valve is located on the right side of the chassis behind the 5th axle Lever positions Move lever forward in driving direction 2 Neutral position Move lever backwards contrary to t...

Page 185: ...e compressed air is neither cleaned nor dried The pressure relief device of the pressure governor is bypassed 5 10 3 Towing the vehicle in case of damage to the engine or the air compressor The following measures must be taken before towing begins To make sure that during towing e g in case of damage to the air compressor at least the auxiliary brak ing effect of the service brake system is availa...

Page 186: ...can be filled via the filler socket K installed in the brake test panel via the spare wheel by means of a filler hose Minimum pressure required to release the air accumulators 6 5 bar To this effect all the measures specified above apply 5 10 5 Mechanical release of the air accumulator cylinders In order to be able to move the vehicle in case of failure of its compressed air system without filling...

Page 187: ... vehicle retains a reduced braking ability via the service brake or the circuit which is still in proper working order Set rotary switch gear range to neutral position N Set transfer box to Neutral position Comply with the instructions specified under item 5 10 5 10 7 Putting the air accumulator brake cylinders in operating condition Attention In order not to prejudice the traffic and operating sa...

Page 188: ...d under item 5 10 11 Set gearbox to neutral position N Set transfer box to Neutral position Make the engine run at idle to provide steering assistance and to ensure the compressed air supply Before towing remove the wheel chocks 5 10 9 Towing in the case of damage to the gearbox Shut off the engine Ensure the vehicle s braking ability Set transfer box to Neutral position Attention The towing speed...

Page 189: ... chocks and the parking brake and unless the propeller shafts are secured to prevent them from falling Set gearbox to Neutral Protect the vehicle against rolling away engage the parking brake The propeller shaft 1 connecting the 2nd axle to the transfer box and the propeller shaft 2 connecting the transfer box to the 4th axle must be removed Prop the propeller shafts 1 and 2 safely to obtain a suf...

Page 190: ...t not be exceeded Check and if necessary replace electrical cables hydraulic and compressed air lines Before release the fastening 3 For assembly of the propeller shafts proceed analogously by reversing the above sequence of operations 5 11 Engine speed regulation manual throttle working speed Under certain circumstances e g when actuating the outriggers it may be necessary to make the engine turn...

Page 191: ...e ignition ON ignition key in position 2 Actuate rocker switch 53 working speed Turn key actuated switch UW OW 50 to position 2 6 1 Control panel 6 1 1 Start screen The start screen appears automatically upon switching the ignition on Button no 1 active in each screen Æ Engine start Button no 2 active in each screen Æ Engine stop stalling device Button no 3 active in each screen Æ Reduce the engin...

Page 192: ...ts are switched on the symbol working floodlight appears inverse Actuate button no 18 Æ To the main menu Æ refer to item 6 1 2 Connection to CANBUS has been interrupted Outrigger functions are no longer available The error code is displayed by the Control and Graphic System installed in the driver s cab If necessary take the vehicle to the TADANO FAUN after sales service to have the troubles elimi...

Page 193: ...on when vehicle is aligned horizontally Button no 10 Æ Raising the vehicle Button no 11 Æ Lowering the vehicle Button no 12 Æ Change over to the screen Supporting pressure Æ refer to item 6 1 6 Button no 13 Æ Change over to the brightness contrast screen Æ refer to item 6 1 5 Button no 14 Æ Lifting the axles with the crane stabilized by outriggers NOTE Only perform this operation while the machine...

Page 194: ...ip switch 31 Leveling Symbol no 15 not inverse Æ Condition Axles not lifted Button no 16 Æ Change over to the screen extending retracting outrigger beams Æ refer to item 6 1 3 Button no 17 Æ Change over to the screen extending retracting outrigger cylinders Æ refer to item 6 1 4 Button no 18 Æ During outrigger operation the axles must be kept in horizontally aligned position Actuate button before ...

Page 195: ...Æ Function Extending the outrigger beams on the side where the operator is currently standing the symbol appears inverse while being actuated Button no 11 Æ Function Retracting the outrigger beams on the side where the operator is currently standing the symbol appears inverse while being actuated Inverse arrows indicate the current direction of movement of the corresponding outrigger beam Æ Digita...

Page 196: ...e outrigger cylinders Symbol Æ The corresponding outrigger cylinder is extended Symbol Æ The corresponding outrigger cylinder is retracted Button no 5 Æ Retracting all outrigger cylinders together Button no 6 Æ Extending all outrigger cylinders together Actuate button 1x and keep it pressed all outrigger cylinders are extended together Actuate button 2x and keep it pressed all outrigger cylinders ...

Page 197: ...rs Symbol above the spirit level Æ State Automatic leveling active The symbol appears inverse while leveling is active ÆState The crane is aligned horizontally leveled The symbol Spirit level OK appears Æ Digital display of the crane inclination in DEGREES ÆSuperstructure locked Button no 8 Æ Return to start screen Button no 7 Without function ...

Page 198: ...for contrast and brightness Button no 10 Æ Increase display contrast Button no 11 Æ Reduce display contrast Button no 12 Æ Increase display brightness Button no 13 Æ Reduce display brightness Button no 8 Æ Return to start screen Keep button no 8 pressed for about 6 seconds active in each screen Æ Function Standard adjustment for display contrast and brightness ...

Page 199: ...gers B1 6 0140_EN_FA036_B1_06_00_00_FA029 2003 01 9 20 6 1 6 Supporting pressure Button no 12 Æ The current supporting pressure of the individual outrigger cylinders is indicated Button no 8 Æ Return to start screen Optional equipment ...

Page 200: ... floats for stabilizing the vehicle The outrigger floats must be removed from their supports before the outrigger jacks can be extended Take the linch pin 3 out of the lock pin 4 and remove the lock pin Pull the outrigger float forward until the guide frame touches the cylinder rod and until the rear bore hole 5 of the guide frame can be fastened with lock bolts 4 and secured Attention Before outr...

Page 201: ...abilized by outriggers Lift the axles until all the tires are clear of the ground Do not prop the wheels with supporting material When the button Lifting the axles item 6 1 2 item 14 has been released the axles are kept in their current state The symbols lowering the axles and holding the axles item 6 1 2 button no 15 and no 18 appear inverse NOTE Only perform this operation while the machine is s...

Page 202: ...g material The third axle must not be lifted When changing the crane s rig arrangement for on road travel the axle suspension lock or to keep the previous level the function holding the axles may only be deactivated if the wheels have full ground contact due to the outrigger cylinders being retracted DANGER While outriggers are extended or retracted nobody is allowed to stay close to the outrigger...

Page 203: ... lock pins 6 and 9 are inserted in the locating bore holes of the four outrigger casings and the outrigger beam I and locked underneath the grooves of the pin holders 7 and 8 z The outrigger floats are fixed and locked in on road travel position item 6 2 1 6 4 2 First extension width Change position of outrigger floats to crane operation item 6 2 1 z If the first extension width is selected the lo...

Page 204: ...second extension width is reached if both the outrigger beams have been extended so that the mark for the second extension width reaches 5 6 m Extend all the other outrigger beams analogously in the same way Securing the extended outrigger beams at the second extension width with pins and locking them Remove lock pins 6 and 9 from the pin holders insert them into the bore holes of the outrigger ca...

Page 205: ...ders 7 and 8 Extend the outrigger beams as described under item 6 1 3 NOTE The third extension width is reached if both the outrigger beams have been extended so that the mark for the third extension width reaches 8 3 m Extend all the other outrigger beams analogously in the same way Securing the extended outrigger beams at the third extension width with pins and locking them Remove lock pins 6 an...

Page 206: ...n item 6 2 1 the outrigger beams are extended to the appropriate extension width item 6 4 The axles are being held in their present position as described under item 6 2 2 via the function Holding the axles or must be lifted while the vehicle is stabilized by outriggers via the function lifting the axles Extend the outrigger cylinder as described under item 6 1 4 Raise the machine until all the tir...

Page 207: ...thus the function lifting the axles is deactivated The button must no longer appear inverse Now the vehicle must be leveled as described under item B1 4 7 1 2 Retract the outrigger cylinder uniformly as described under item 6 1 4 6 6 2 Retracting the outrigger beams Attention Remove all lock pins from the outrigger beams outrigger casings and insert them in the bore holes of the pin holders Retrac...

Page 208: ...nterweight mounted is only admissible on firm horizontal ground which is as level as possible with the boom directed over rear the superstructure lock pin engaged and the swing brake actuated Driving must be effected at a low speed of max 1 4 km h at the specified tire pressure If possible the outrigger beams should be extended and the outrigger floats be located at a minimum distance from the gro...

Page 209: ... item 6 1 2 button n 18 again The button must no longer appear inverse DANGER The crane is unstable while the 3rd axle is being lifted and lowered Warning lamp 15 central warning Chassis is flashing while the axle is being lowered NOTE Lifting and lowering of the 3rd axle are only allowed when the vehicle is immobilized Moreover the conditions specified under item 5 9 Steering for lifting the 3rd ...

Page 210: ...Attention With the vehicle completely lowered driving operation is not admissible Otherwise the suspension cylinders being mechanically blocked might be damaged The axles have been actuated via the button holding the axles in the outrigger casing refer to item B1 6 1 2 As soon as the vehicle is in contact with the ground deactivate the function holding the axles by actuating the buttons item 6 1 2...

Page 211: ...gure NOTE To ensure the oil supply of the hydraulic system for outrigger operation the emergency control E of the solenoid valve 2 located on the valve block must be kept pressed down by an assistant at the same time Attention Make sure that emergency control devices with rubber caps are never actuated with sharp edged or pointed objects Should the rubber caps be damaged this may result in failure...

Page 212: ...to neutral position N Engage the parking brake handbrake Block the vehicle if necessary using wheel chocks 7 1 2 1 Retracting and extending the outrigger cylinders Solenoid valve 1 Tip switch A retract outrigger cylinders Tip switch C extend outrigger cylinders Solenoid valve 2 additionally Tip switch E oil supply 7 1 2 2 Retracting and extending the outrigger beams Solenoid valve 1 Tip switch B r...

Page 213: ...lems occur in the electronic system while the rear axle steering is actuated the rear axles can be centered via the emergency control The connectors are located below the front lid part B1 2 3 3 item 13 Release the connector X511 turn it by 180 and plug it onto the free connector X512 Center the 4th and 5th axles as described under item B1 7 1 and 7 1 2 4 in straight ahead position Remove connecto...

Page 214: ...B1 7 Emergency control functions and elements 4 4 0145_EN_FA036_B1_07_00_00 2003 01 Memo ...

Page 215: ...c i d e n t s DANGER In case of extremely low freezing temperatures do not touch metal surfaces with your naked hands danger of freezing to metal surfaces NOTE The recommendations regarding oil sorts provided in part C1 service and mainte nance chassis must be observed for the following assemblies Under extreme weather conditions it may be advisable to use snow chains The instructions of the snow ...

Page 216: ...w ambient temperatures For the steps to be taken and for further details please refer to the user manual of the engine manufacturer 8 2 Gearbox 8 2 1 Start up vehicle operation and parking the vehicle at low temperatures For information on operation in winter refer to the enclosed operating manual of the gearbox manufacturer For recommended oil types refer to ZF Chart of Lubricants in part G1 chas...

Page 217: ...vel as described in part C1 service and maintenance chassis Discharged batteries freeze already at temperatures as from 10 C Adhere to the instructions of the battery manufacturer 8 5 Adjustable air vents The supply of warm fresh air can be controlled by means of the adjustable air vents item 2 Pos 26 34 and 41 8 6 Windshield washing system During the winter months a certain amount of antifreeze a...

Page 218: ...B1 8 Operation in winter 4 4 0150_EN_FA036_B1_08_00_00_FA029 2003 01 Memo ...

Page 219: ...ely and comfortably Stationary ladder 5 on left side of vehicle facilitates refueling DANGER When climbing up ladders make sure that you grasp the side rails with your hands When climbing up the stationary ladders make sure that you grasp the handles in the access plates with your hands Otherwise there is a RISK OF ACCIDENTS DANGER Access devices and platforms must always be kept clean Dirt and ot...

Page 220: ...in its support on the access plate of the vehicle and secured The ladder 1 must be locked via the knob 3 of the support Swinging the ladder 1 to its access position The wheels must be aligned in straight ahead driving position Pull the knob 3 of the support until the ladder is released then swing the ladder outwards To swing the ladder 1 into its transport position proceed analogously by reversing...

Page 221: ...cle is listed and explained in this chapter The following list is an overview of the optional equipment which has been described and explained in other sections Optional equipment mentioned in other sections Pilot lamp direction indicators trailer Refer to part B1 4 item 4 2 9 Air conditioner Refer to part B1 4 item 4 4 5 Connecting the axle drive Refer to part B1 5 item 5 4 ...

Page 222: ...tively the sensor based monitoring of the wheels and axles as well as the other components of the ABV system The vehicle is equipped with the following instruments which ensure detection of the functions and the continuous monitoring of the ABV system Rocker tip switch 51 ABV system off road mode The ABV system can be switched over to an increased brake slip via the rocker tip switch 51 ABV OFF ro...

Page 223: ...d on the symbol must go on and go out again after 2 to 3 seconds If a trailer without ABV system is coupled the symbol must not go on When the symbol ABV trailer goes on during operation with trailer this indicates a failure of the trailer s ABV components However in this case the functional safety of the conventional air actuated brake system remains fully ensured 10 4 Electronc immobilizer FinTr...

Page 224: ...engine of the vehicle is running Before the engine is stopped the air conditioner must be switched off Start the engine Adjust the rotary switch 3 Cold warm air regulation as required Actuate the pushbutton switch 4 to connect the air circulation When the air circulation is switched ON the pilot lamp 5 is lit Actuate the pushbutton switch 6 to switch ON the air conditioner When the air conditioner...

Page 225: ...ressor or the air conditioner every week for a few minutes 10 6 WEBASTO Thermo 90 S with engine pre heating A heater unit type Thermo 90 S is installed in the chassis as supplementary heater unit The heating is programmed and operated via the timer Operation and maintenance of the heating are described in detail in the operating instructions of the heater unit s manufacturer which is supplied with...

Page 226: ...de Deaerate the heater unit Put the heater unit into operation 10 7 WEBASTO diesel heater unit When a supplementary diesel operated heating is installed the driver s cab can be heated independently of the engine fed warm water heating The operating element is provided for control and inspection of this unit Service operation and maintenance of the WEBASTO diesel operated heater unit are described ...

Page 227: ...rom approx 3 5 km h The various steps of the control device enable the driver to obtain the desired braking effect It is however necessary to make the switch lock in briefly for each step i e no switch position must be skipped in order to prevent the limits of adherence from being exceeded on slippery surfaces While the manual switch is being actuated the symbol eddy current brake active appears i...

Page 228: ...cedures even from a relatively high speed to save the wheel brakes Hilly terrain It is recommended to couple the effect of the eddy current brake with that of the engine brake by utilizing the correct reduction ratios Thus the appropriate speed for the existing slopes and routes can be reached as fast as possible On long downhill slopes As soon as the vehicle has been braked down to the desired sp...

Page 229: ... handbrake is engaged refer also to item B1 4 5 Push the handle 2 down and pull the lever 1 back to its stop Check whether the air accumulator retaining force is capable of holding the whole vehicle combination the whole tractor trailer combination does not move Return the lever 1 to its locking position braking position Lock position The check should be effected whenever the vehicle combination i...

Page 230: ...the hand lever 2 the coupling jaw must be placed centrally or be turned into one of its lateral end positions by hand NOTE The coupling can only be opened and locked in one of the above mentioned positions When the trailer s towing eyelet is moved in the automatic coupling mechanism is released as the coupling bolt 3 is lifted When the coupling bolt is in its lower position the second independent ...

Page 231: ...g bolster must not be braked NOTE When coupling a central axle trailer proceed as follows Back the tractor up carefully The towing eyelet must touch the coupling jaw in its center Attention Non observance of this instruction may result in damage to the coupling jaw the towing eyelet and the supporting device coupled Check After each coupling operation make sure that the coupling is checked for pro...

Page 232: ... supplied with power is installed on the left side of the vehicle on the battery box underneath the cover 3 refer to Fig The batteries of the vehicle supplying power should have the same or a higher capacity Ampere than those of the vehicle to be supplied with power To avoid damage to the generator make sure that the following sequence of operations is observed Vehicle to be supplied with power Ve...

Page 233: ...ugbox for starting via an external power source 1 is installed on the left side of the vehicle on the battery box underneath the cover 3 refer to Fig For further details refer to the brochures of the battery manufacturer Attention The charging plugbox 1 must not be used to start the vehicle via an external power source with the charging unit connected It is only used for charging the battery 10 13...

Page 234: ...e underride guard folded upwards is not admissible on public roads The underride guard must be mounted and pin fastened as shown in Fig 1 For folding down the underride guard proceed analogously by reversing the above sequence of operations Fig 2 NOTE If a trailer coupling device or various special attachments is are mounted the underride guard cannot be folded up 10 15 Rear area surveillance The ...

Page 235: ...copes are completely retracted The mechanical swing lock is engaged Fasten the spare wheel 3 with an appropriate securing device Release the securing bolts 1 and remove the holder 2 Remove the spare wheel from the spare wheel holder lifting it in the direction of the arrow and place it on the ground DANGER Secure the spare wheel against falling over To fasten the faulty wheel in the spare wheel ho...

Page 236: ...B1 10 Attachments optional equipment and accessories 16 16 0160_EN_FA036_B1_10_00_00 2003 01 Memo ...

Page 237: ...Instrument panel B1 11 0165_EN_FA036_B1_11_00_00_FA029 2002 12 1 4 Memo ...

Page 238: ...WS Mirror heating system 4 WS Fog lights 5 WS Rotary beacon 6 WT Rear fog light 7 WS Battery main switch 8 Rotary switch lighting equipment 26 WT Menu guidance 27 WT Selection 28 WT Service 29 free 30 WT 3rd axle lifting lowering 31 WT Leveling 32 WT Inclination adjustment VL 33 WT Inclination adjustment VR 34 WT Inclination adjustment HR 35 WT Inclination adjustment HL 36 WS Axle suspension lock ...

Page 239: ...Instrument panel B1 11 0165_EN_FA036_B1_11_00_00_FA029 2002 12 3 4 Instrument panel ...

Page 240: ...B1 11 Instrument panel 4 4 0165_EN_FA036_B1_11_00_00_FA029 2002 12 Memo ...

Page 241: ...Instrument panel B1 11 0165_EN_FA036_B1_11_00_00_FA029_AB106 2002 12 1 4 Memo ...

Page 242: ... 3 WS Mirror heating system 4 WS Fog lights 5 WS Rotary beacon 6 WT Rear fog light 7 WS Battery main switch 8 Rotary switch lighting equipment 26 WT Menu guidance 27 WT Selection 28 WT Service 29 free 30 WT 3rd axle lifting lowering 31 WT Leveling 32 WT Inclination adjustment VL 33 WT Inclination adjustment VR 34 WT Inclination adjustment HR 35 WT Inclination adjustment HL 36 WS Axle suspension lo...

Page 243: ...Instrument panel B1 11 0165_EN_FA036_B1_11_00_00_FA029_AB106 2002 12 3 4 Instrument panel ...

Page 244: ...B1 11 Instrument panel 4 4 0165_EN_FA036_B1_11_00_00_FA029_AB106 2002 12 Memo ...

Page 245: ...0170_EN_ALLGE_B2_00_00_00 Part B2 Operating Instructions Superstructure ...

Page 246: ......

Page 247: ... the superstructure is started the parking brake lever in the chassis must be set to braking position Before the engine is started especially if the vehicle has been immobilized for an extended period of time it is necessary to check the fluid levels in the following components Engine oil level Oil level in hydraulic Check coolant level for the engine The cooling system is filled correctly if the ...

Page 248: ...t Left hand control lever Multifunction Hubwerk ab auf Hoisting down up Wippen ab auf Lowering raising boom Standard equipment Right hand control lever Boom elevation and hoisting gear main winch Nobody is allowed to stay in the swing range Max fluid level in expansion tank Min fluid level in expansion tank Outriggers Hoist limit switch override feature Access prohibited to unauthorized persons Da...

Page 249: ...herlands Only in case of optional feature Emergency operation of the superstructure controlled from the chassis Instruction plate sound power Release hoisting gear brake Only in case of optional feature Emergency operation of the superstructure controlled from the chassis Operating prescription Only in Germany Hydraulic oil 99707782681 Display telescope emergency mode Display telescope emergency m...

Page 250: ...0 2003 01 cont d 1 1 Warning and instruction plates The brake system comprises plastic piping Caution during drilling welding and grinding work Protect piping against battery acid temperature resistant in the range from 40 C to 100 C Danger of crushing Weight unit 250 kg ...

Page 251: ... 8 1 2 Location of the warning and instruction plates The following diagram shows the position and location of all the warning and instruction plates mounted to the superstructure Specific requirement of the country where the machine is to be used or according to vehicle model ...

Page 252: ...B2 1 General information about operation 6 8 0175_EN_FA036_B2_01_00_00 2001 06 Memo ...

Page 253: ...ist cylinder counterweight 13 Hoist winch 14 free 15 Auxiliary hoisting gear 16 Hydraulic oil tank 17 Oil level indicator hydraulic oil 18 Supplementary oil cooler 19 Oil cooler 20 Fuel tank 21 Centralized lubrication system 22 Servicing lid 23 Servicing lid crane cab 24 Crane cab 25 Supplementary heater unit 26 Gearbox of swing mechanism 27 Ring gear slewing device 28 Boom elevation cylinder 29 C...

Page 254: ...B2 1 General information about operation 8 8 0175_EN_FA036_B2_01_00_00 2003 01 Memo ...

Page 255: ...Crane cabin B2 2 0180_EN_FA036_B2_02_00_00 2003 01 1 10 Memo ...

Page 256: ...ys 17 Diagnostic plug engine 18 Seat 19 Servicing lid 20 Superstructure locking pin 21 Control element heating ventilation air conditioner 22 Heated air fresh air vent 23 Free 24 Crane control lever 25 Ashtray 26 Free 27 Kick strip access 28 Working floodlight 29 Radio 30 Heated air fresh air vents 31 Locking mechanism windshield 32 Handhold 33 Accelerator pedal superstructure engine 34 Tank for w...

Page 257: ...Crane cabin B2 2 0180_EN_FA036_B2_02_00_00 2003 01 3 10 Crane cabin X ...

Page 258: ...B2 2 Crane cabin 4 10 0180_EN_FA036_B2_02_00_00 2003 01 Memo ...

Page 259: ...e bracket is tilted up when getting into and out of the crane cabin Otherwise there is a risk that crane movements might be triggered by touching of the control levers unintentionally This results in an increased R i s k o f a c c i d e n t s 2 2 1 Vertical adjustment of armrests Loosen the star grip 1 to set the armrests to the desired height 2 2 2 Adjustment of armrest inclination Turn adjusting...

Page 260: ...tage then lower it to its lowest position 2 2 9 Adjustment of backrest inclination Actuate handle 8 to set the backrest inclination 2 2 10 Adjustment of the lumbar support Turn adjustment wheel 9 the lumbar support is adjusted steplessly 2 2 11 Headrest The headrest 10 cannot be adjusted To remove the headrest pull it up 2 2 12 Electrical seat adjustment Actuate rocker tip switch 57 The inclinatio...

Page 261: ...shield unlocked Actuate rocker switch 56 The windscreen can be opened or closed steplessly Attention Unlock the windshield before opening it 2 5 Opening the rear window Actuate the rear window locking mechanism sect 2 item 8 and open the rear window 2 6 Cab lighting Switch positions 0 Lamp OFF 1 Lamp is permanently lit while the battery main switch is ON 2 No function ...

Page 262: ...n through the cabin door in case of an emergency open the windshield and leave the crane cabin in this way Opening the crane cabin 1 Actuate rocker tip switch 56 open windshield or 2 Remove spring clip 1 remove the adjusting cylinder 2 from the pin open windshield by hand Attention Unlock the windshield before opening it ...

Page 263: ...cker switch to the left 2nd winch slewing Right hand crane control lever 2 Right hand crane control lever forward bottom block of 1st winch down backwards bottom block of 1st winch up to the left boom is raised to the right boom is lowered Left hand crane control lever 1 Rocker switch 4 positioned to the right Left hand crane control lever forward telescopes are extended to the rear telescopes are...

Page 264: ... the superstructure is immobilized 2 9 1 Locking the superstructue Prerequisite The symbol superstructure can be rotated is lit Swing the superstructure in its position over rear Raise the locking pin by approx 10 mm turn it 45 to the left and lower it If necessary slew the superstructure slightly until the pin and the bore hole coincide After the slewing gear has been locked the symbol superstruc...

Page 265: ...rator puts the superstructure into operation he must have familiarized himself with the functionalities operation and the mode of function of the FAUN Cockpit Graphic Control System NOTE Reference to the following description is made in the sections of this operating manual which are marked refer to the Cockpit Graphic Control System The check or control functions described in these sections are p...

Page 266: ...en appears on the monitor after approx 3 sec Information is displayed via symbols Other screens can be selected by actuation of buttons Information and error messages on the main screen NOTE The error messages disappear automatically as soon as the error is eliminated Fuel level indicator A needle and a digital display show the filling level of the fuel tank The critical range is marked The symbol...

Page 267: ...isplay shows the current supporting pressure Superstructure locked The symbol lights up when the superstructure is locked Superstructure can be slewed The symbol lights up when the superstructure can be slewed unlocked The handbrake in the chassis is set to braking position symbol is lit The symbol parking brake in chassis engaged goes on when the vehicle is braked positively via the handbrake lev...

Page 268: ...e symbol appears Axles lifted The symbol appears as soon as the vehicle is supported by outriggers and all the axles are lifted Axle suspension lock symbol is lit The symbol axle suspension lock goes on if the key switch in the chassis is set to position 2 Axle suspension activated The symbol appears and flashes backlit Control elements of the main screen Change over to the working screens Actuate...

Page 269: ...ers Engine control system Control elements of the selection menu Change over to the working screens Working operations can be performed via these screens Actuate the arrow key up The working menu contrast brightness appears Actuate the arrow key right The working menu outriggers appears Actuate the arrow key left The working menu engine control appears Actuation of the key Quit Return to working m...

Page 270: ...cursor control keys Actuate arrow key right or left Setting the monitor s brightness within the specified limits Actuate arrow key up or down Setting the monitor s contrast within the specified limits Actuation of the F1 key All the contrast and brightness values set by hand are deleted The programmed initial settings are activated NOTE The last contrast and brightness values set in manual mode ar...

Page 271: ...d jointly When two three or four outriggers are selected only the selected outrigger cylinders can be actuated When all four outriggers are selected the vehicle can be aligned to horizontal position 3 1 1 2 1 Operation of the working menu outriggers The outrigger cylinders are selected via the cursor control system Actuate the arrow key up The front right hand outrigger has been selected Actuate t...

Page 272: ...ed positively via the handbrake lever in the chassis or when the brake air pressure of the parking brake in the chassis is no longer sufficient The handbrake in the chassis is not in braking position symbol goes on and flashes backlit Actuation of the key ENTER The selected outriggers are confirmed Actuation of the F1 key All the four outriggers are selected Actuation of the F2 key The outriggers ...

Page 273: ...rear left side of the vehicle The various actuation operations are selected via the cursor control system Actuate arrow key down and keep it pressed Extending the outrigger cylinders Actuate arrow key up and keep it pressed Retracting the outrigger cylinders Actuate arrow key left and keep it pressed Extending the outrigger beams Actuate arrow key right and keep it pressed Retracting the outrigger...

Page 274: ...dbrake in the chassis is set to braking position symbol is lit The symbol parking brake in chassis engaged goes on when the vehicle is braked positively via the handbrake lever in the chassis or when the brake air pressure of the parking brake in the chassis is no longer sufficient The handbrake in the chassis is not in braking position symbol goes on and flashes backlit Actuation of the key Quit ...

Page 275: ...rear right side of the vehicle The various actuation operations are selected via the cursor control system Actuate arrow key down and keep it pressed Extending the outrigger cylinders Actuate arrow key up and keep it pressed Retracting the outrigger cylinders Actuate arrow key right and keep it pressed Extending the outrigger beams Actuate arrow key left and keep it pressed Retracting the outrigge...

Page 276: ...ndbrake in the chassis is set to braking position symbol is lit The symbol parking brake in chassis engaged goes on when the vehicle is braked positively via the handbrake lever in the chassis or when the brake air pressure of the parking brake in the chassis is no longer sufficient The handbrake in the chassis is not in braking position symbol goes on and flashes backlit Actuation of the key Quit...

Page 277: ...be used to actuate 2 or 3 outriggers The various actuation operations are selected via the cursor control system Actuate arrow key down and keep it pressed Extending the outrigger cylinders Actuate arrow key up and keep it pressed Retracting the outrigger cylinders Indicates the outriggers being selected The electronic spirit level indicates the current inclination of the vehicle Symbol goes on wh...

Page 278: ...n symbol is lit The symbol parking brake in chassis engaged goes on when the vehicle is braked positively via the handbrake lever in the chassis or when the brake air pressure of the parking brake in the chassis is no longer sufficient The handbrake in the chassis is not in braking position symbol goes on and flashes backlit Actuation of the key Quit Return to working menu outriggers No functions ...

Page 279: ...cylinders Actuate arrow key up and keep it pressed Retracting the outrigger cylinders Indicates the outriggers being selected The display shows the current supporting pressure The electronic spirit level indicates the current inclination of the vehicle Symbol goes on when vehicle is aligned horizontally The handbrake in the chassis is set to braking position symbol is lit The symbol parking brake ...

Page 280: ...cont d 3 1 1 2 5 Working menu outrigger actuation in case of all four outriggers are selected Actuate the key F2 and keep it pressed The vehicle is aligned in horizontal position Actuation of the key Quit Return to working menu outriggers No functions are assigned to any of the other keys ...

Page 281: ...ation of the working menu engine functions The engine speed is regulated via the cursor control system Actuate the arrow key up The engine speed increases Actuate the arrow key down The engine speed is reduced Generator Insufficient voltage of vehicle battery If the vehicle voltage drops even briefly below 18V the symbol lights up for the duration of the voltage drop at least however for 20 second...

Page 282: ...braking position symbol is lit The symbol parking brake in chassis engaged goes on when the vehicle is braked positively via the handbrake lever in the chassis or when the brake air pressure of the parking brake in the chassis is no longer sufficient The handbrake in the chassis is not in braking position symbol goes on and flashes backlit No functions are assigned to any of the other keys ...

Page 283: ...4 1 1 NOTE When the key actuated switch in the chassis is set to position 2 the axle suspension is locked automatically The symbol axle suspension lock engaged in the FAUN Cockpit Graphic Control System refer to part B2 3 must be lit If the symbol is not lit the suspension is not locked or there is a fault in the axle suspension locking system The symbol Axles 1 5 lifted must go on during crane wo...

Page 284: ...ker switch upwards now the electrical equipment is de energized NOTE Whenever crane work is interrupted for an extended period e g at night the battery main switch must be turned OFF 4 2 2 Ignition starter switch While the ignition key is inserted the ignition starter switch 42 has the following positions Position P No function Position 0 Ignition OFF Position I Ignition ON Position II Engine star...

Page 285: ...cabin Top position OFF Central position Interval action Bottom position Wiper operation Rocker switch 53 Windshield wiper skylight Upper position OFF Central position Interval action Lower position Wiper operation 4 2 6 Windshield washing system Actuate the rocker tip switch 55 windshield washing system The windshield washing system for the windscreen and the skylight is actuated Both wipers move ...

Page 286: ... electrical equipment of the vehicle before starting work Before starting work the driver has to check the wipers the electric horn and the entire lighting system working floodlights for proper working order NOTE The inspection of the lighting system is only possible when the battery main switch and the ignition are switched ON DANGER z Any faulty operating elements and missing or defective lighti...

Page 287: ...evice 2 serves to progressively regulate the temperature of the inflowing air Rotary control device in left hand position cold Rotary control device in right hand position warm Air regulation 3 The rotary control device 3 serves to progressively regulate the relationship between external and recirculating air Rotary control device in left hand position outside air only Rotary control device in rig...

Page 288: ...r unit for engine preheating combined with heating of the superstructure cabin Only engine preheating Preheating of engine and of superstructure cabin zProgramming the timer refer to manufacturer s operating manual zSwitch on battery main switch 58 zSet blower fan refer to item 4 4 to step 1 zProgramming the timer refer to manufacturer s operating manual 4 4 1 2 Do it yourself troubleshooting in c...

Page 289: ... Do not actuate the starter for more than 20 seconds To save the batteries pause for approx 60 seconds between the various starting attempts While the engine is running the following instruments are in operation hourmeter FAUN Cockpit Graphic Control System refer to part B2 3 Explanation of the pilot lamps and instruments while the engine is running refer to item 4 6 For further details please ref...

Page 290: ...ton 1 again the engine comes to a standstill or Actuate the push button 2 the engine comes to a standstill Starting the engine and increasing the engine speed The ignition in the superstructure is ON and the engine is not running Actuate push button 1 and keep it pressed the engine is started and runs at idle 3 seconds after the engine has started the engine speed increases to max level Release th...

Page 291: ...een emptied completely leakage has occurred in the fuel system the fuel filter has been replaced filter replacement refer to part C2 Service and Maintenance Prerequisite a sufficient amount of fuel has been replenished any leakage has been eliminated the filter cartridge has been replaced as described in part C2 Service and Maintenance Bleeding and supplying fuel Open vent screw 1 actuate pump plu...

Page 292: ...Engine 4 6 2 1 Engine oil level The engine oil level is monitored by the symbol Engine oil level refer to part B2 3 FAUN Cockpit Graphic Control System and the warning lamp 3 Central warning CGC If the symbol appears stop all operations immediately stop the engine check the oil level and correct it For further details please refer to the Operating Manual of the engine manufacturer 4 6 2 2 Engine f...

Page 293: ...ontamination refer to part B2 3 FAUN Cockpit Graphic Control System and the warning lamp 3 Central warning CGC If the symbol goes on with the engine running replace the air cleaner cartridge refer to part C2 Service and Maintenance Superstructure 4 6 2 6 Operating hours The engine operating hours are monitored via an hourmeter sect B2 2 item 12 The hourmeter is activated as soon as the engine is s...

Page 294: ... A green pilot lamp in the switch goes on to indicate that lubrication is in progress To terminate the lubricating procedure turn the rocker switch OFF the pilot lamp in the switch goes out The lubrication time contact time and the duration of the regular lubri cation intervals depend on the frequency of working movements and can be determined by the operator However it is recommended to adhere to...

Page 295: ...sis ON in the superstructure Functions 2 OFF Ignition in chassis OFF only operation from superstructure possible 2 ON Ignition in chassis ON The engine in the chassis can be started from the superstructure outrigger operation is possible from the superstructure 5 1 1 Establishing the connection chassis superstructure in the super structure Switch on rocker switch 10 Ignition chassis ON function li...

Page 296: ...g level Actuate the push button F2 refer to part B2 3 item 3 1 1 3 Engine stop chassis until the engine in the chassis comes to a standstill or switch the rocker switch 10 ignition chassis OFF to stop the engine 5 2 2 Speed regulation of the engine in the chassis from the superstructure Actuate WT 12 Engine speed regulation chassis The speed of the engine in the chassis can be adjusted steplessly ...

Page 297: ...t the key actuated change over switch in the chassis to position 2 and switch on the rocker switch 10 in the superstructure ignition chassis ON The axle suspension is locked automatically The symbol axle suspension lock engaged must be lit in the superstructure refer to item B2 3 The position of the outrigger floats must be changed and the extended and retracted outrigger beams must be secured wit...

Page 298: ...ey refer to item B2 3 1 1 2 Actuate the ENTER key the selection is confirmed z Change of menu Extend the selected outrigger beam via the arrow keys refer to item B2 3 1 1 2 to the required extension width and secure it with a pin Select all the four outrigger beams in the way described above extend them to the required extension width and secure them with pins DANGER Make sure that the extended ou...

Page 299: ...o item B2 3 1 1 2 5 6 6 Retracting the outrigger beams Remove the lock pins from the four outrigger beams Select the desired outrigger beam using an arrow key refer to item B2 3 1 1 2 Actuate the ENTER key the selection is confirmed z Change of menu Retract the selected outrigger beam via arrow key item B2 3 1 1 2 and secure it with a pin Select retract and secure all the four outrigger beams in t...

Page 300: ...he superstructure and make it run at medium speed The red warning lamp 3 central warning CGC must not go on Before outrigger operation the operator must sound a warning signal actuate horn DANGER While outriggers are being extended or retracted nobody is allowed to stay close to the outrigger beams and the outrigger cylinders During extension and retracting the crane operator must constantly have ...

Page 301: ... outrigger beams are secured with pins as there is a risk of accidents otherwise 5 6 7 2 Extending the outrigger cylinders Comply with the information specified under item B1 6 3 Move rocker switch 7 preselection outriggers down To extend the outrigger cylinders on the left side of the chassis actuate the rocker tip switch 5 or 6 to the left and keep it pressed To extend the outrigger cylinders on...

Page 302: ...utriggers from its central position upwards Actuate rocker tip switches 5 and 6 to the right or rocker tip switches 8 and 9 to the left and retract the outrigger beams uniformly keep the rocker tip switches pressed until the outrigger beams have been retracted and can be secured using pins Reset rocker switch 7 preselection outriggers to their central position Slip the outrigger floats on as speci...

Page 303: ...st not be locked the icon Superstructure can be slewed is lit 6 1 Instructions regarding actuation of the crane control levers The actuation of the crane control levers described in the following text applies to the standard machine model Any differing special models have not been taken into account For the crane operator the instruction plates mounted in the cabin will be decisive in any case zTh...

Page 304: ...ned direction of motion is activated If several direc tions of motion are activated the high speed decreases 6 1 2 Rope winch rotation indicator D The integrated rotation indicator informs the crane operator about each motion of the rope drum When the right hand crane control lever is actuated to position hoisting gear raising lowering or the left hand crane control lever if the machine is equippe...

Page 305: ...is not lifted or lowered by jerks zIf the load is decelerated or accelerated too quickly this will cause an overload on the drive elements and the rope and may cause accidents such as overturning Attention The high speed for hoisting gear UP DOWN may only be connected at low or zero load If up to 3 rope falls are used the high speed must not be connected if the crane depending on the working radiu...

Page 306: ...l lever and work using the auxiliary hoisting gear Left hand crane control lever forward bottom block moves down to the rear bottom block moves up The hoisting gear speed can be controlled depending on the travel of the crane control lever see Fig 1 and by increasing the hoisting gear speed The auxiliary winch is mainly used during operation with a jib In case of failure of the main winch the rope...

Page 307: ...get slack on the rope drum Make sure that the load is not lifted or lowered by jerks If the load is decelerated or accelerated too quickly this will cause an overload on the drive elements and the rope and may cause accidents such as overturning 6 2 1 3 Switching off the auxiliary hoisting gear Change over rocker switch Fig 1 item 1 and rocker switch 25 now the auxiliary hoisting gear is switched ...

Page 308: ...tomatic safe load indicator AML switches off as soon as the maximum working radius is reached for a description of the AML please refer to part G2 superstructure After switching off only a movement tending to reduce the load moment boom elevation up can be performed Fast movements of the boom cause the load to swing out As the load swings away from the boom during the movement boom elevation down ...

Page 309: ...s and the hook height diagram The data for changing the counterweight variants or outrigger variants can only be entered while the telescopes are retracted NOTE The boom elements must be extended to the desired length in no load condition and subjected to load only afterwards During the telescoping process the boom elevation must not be actuated DANGER In case of a deficiency in the length transmi...

Page 310: ...or through the program in a user friendly fashion The AML must be programmed with the data determined previously as described in the operator manual Actuate the crane control lever The tele sections are automatically extended in the correct sequence starting from the smallest section until the required telescoping configuration is reached Telescoping sequence 6 5 4 3 2 and 1 NOTE The required boom...

Page 311: ...supported by outriggers as specified Before the telescopes are reset to their former arrangement in manual mode an attempt can be made whether the fault is eliminated automatically after a restart of the system To this effect the following steps must be taken Raise boom to 70 via the boom elevation If the jib is mounted raise boom to 75 via the boom elevation Shut off the engine Switch battery mai...

Page 312: ...Pilot lamp position tele cylinder in teles section 2 3 Pilot lamp position tele cylinder in teles section 3 4 Pilot lamp position tele cylinder in teles section 4 5 Pilot lamp position tele cylinder in teles section 5 6 Pilot lamp tele cylinder C pin locked 7 Pilot lamp tele cylinder C pin unlocked 8 free 9 Pilot lamp telescope B pin locked 10 Pilot lamp telescope B pin unlocked 11 Pilot lamp posi...

Page 313: ...ll control functions are effected in emergency mode All the automatic shut off features on overload are inoperative All crane motions must be performed with extreme caution Rocker tip switch 36 Emergency control locking unlocking telescope Actuate rocker tip switch upwards to unlock the telescope Actuate rocker tip switch downwards to lock the telescope Rocker tip switch 37 Emergency control locki...

Page 314: ... tele cylinder has left its initial position by approx 5 10 cm the pilot lamp in question i e tele cylinder in telescope goes out If the tele cylinder has been retracted until a distance of approx 5 10 cm from its final position is left the pilot lamp in question i e tele cylinder in telescope goes on not if tele section 1 is retracted Lock the telescope To do so actuate the rocker tip switch 36 d...

Page 315: ...switch 36 down The pilot lamp 9 goes on whereas pilot lamp 10 goes out Reset all other tele sections to their former rig arrangement as described above Switch OFF the rocker switch 35 Emergency control and if actuated the rocker switch 38 Interlock override tele control Switch OFF emergency control Remove the indicator element Subsequently an attempt can be made to find out whether the fault is el...

Page 316: ... swing brake is engaged while the crane control lever is not actuated The slewing speed can be controlled depending on the travel of the control lever and by increasing the engine speed DANGER If the superstructure is slewed and decelerated abruptly the load may start to oscillate The greater the load or the greater the boom length the lower the speed must be at which slewing is commenced decelera...

Page 317: ...uating the lock handle downwards and actuate the rocker tip switch downwards The lock handle automatically returns to its locking position The slow stop function has been bypassed override feature The preset slewing range can be exceeded The acoustical and visual warnings are still issued If the boom reaches the preset range the boom elevation movement is not decelerated but stops abruptly The aco...

Page 318: ...e ballast side while it is being slewed zCounterweights which are transported by an auxiliary vehicle must be located as close as possible to the supported chassis so that they can be picked up with the crane s bottom block To this effect a second crane may be used zThe legal regulations regarding ropes and hosting gear in force in the country where the crane is to be registered must be observed z...

Page 319: ...d lowered to the chassis they must neither be suspended aslant nor swing There is a risk of accidents and of damage to vehicle components The counterweights must be stowed safely and firmly in the counterweight rest Stowing counterweight elements in the counterweight rest of the chassis requires the help of another well instructed person The crane operator must be in constant eye contact with that...

Page 320: ...cylinders have been retracted the yellow indicator lamp 34 Counterweight unlocked is lit 28 34 Please refer also description AML item 8 counterweight status part G2 superstructure Swing the superstructure until the retracted ballast cylinders Fig 1 item 1 are located above the grooves of the counterweights However do not swing to its central position Actuate rocker tip switch 27 Counterweight up d...

Page 321: ...counterweight and lock the counterweight The green pilot lamp 30 Counterweight locked is lit the yellow indicator lamp 34 counterweight unlocked goes out Attention The counterweight can only be locked and unlocked if the ballast cylinders are completely retracted The red warning lamp 28 Counterweight not UP must not be lit 29 30 NOTE Before unlocking the counterweight it may be necessary to actuat...

Page 322: ... may indicate a fault e g leaky hoist cylinder No rotary movement can be performed Actuate rocker tip switch 31 Swing mechanism counterweight override Now the counterweight can be lifted again and the superstructure can be slewed DANGER To avoid damaging the chassis body components while the counterweight has not reached its upper stop position rotary motions must be performed with extreme caution...

Page 323: ...weight to the superstructure as described under item 6 6 2 1 Check visually NOTE Only the 12 0 t load chart data may be used to adjust the AML 6 6 2 4 Mounting the 23 5 t counterweight Attention Driving on public roads is prohibited with this counterweight distribution No EC approval DANGER Driving with mounted counterweight on the construction site refer to item 7 4 Picking up and fastening the 2...

Page 324: ...to item 7 4 Picking up and fastening the 35 0 t counterweight to the superstructure Prerequisite z The crane is supported by outriggers as specified z Fasten counterweight 1 to points 9 using appropriate securing devices and lift it to the counterweight rest Pick up counterweights 2 3 and 4 on points 10 and place them on the counterweight 1 Mount counterweight to the superstructure as described un...

Page 325: ...o item 7 4 Picking up and fastening the 47 0 t counterweight to the superstructure Prerequisite z The crane is supported by outriggers as specified z Fasten counterweight 1 to points 9 using appropriate securing devices and lift it to the counterweight rest Pick up counterweights 2 3 4 and 5 on points 10 and place them on the counterweight 1 Mount counterweight to the superstructure as described u...

Page 326: ... by outriggers as specified z Fasten counterweight 1 via points 9 using appropriate securing devices and lift it to the counterweight rest Pick up the counterweights 2 3 4 and 5 via points 10 and deposit them on counterweight 1 Pick up the counterweights 6 and 7 via points 10 and attach them to counterweight 5 Mount counterweight to the superstructure as described under item 6 6 2 1 Check visually...

Page 327: ... Rear montiert Auxiliary vehicle Remark with driver 25 t hook block attached Tires 445 95 R 25 16 00 R25 Drive 10 x 8 71000 71000 12t axle load EC homologation Counterweight kg Model total deposited on front end Rear montiert Auxiliary vehicle Remark with driver 25 t hook block attached Tires 445 95 R 25 16 00 R25 Drive 10 x 8 71000 2000 10000 12000 59000 Axle load exceeding 12 t no EC homologatio...

Page 328: ...ing Check ropes for wear breakage of wires and breakage of a strand Check the fastening of the rope socket Never use old cut off load lifting ropes as load securing ropes When attaching loads with sharp edges make sure that rope protective devices are used e g wooden devices to prevent the rope from being damaged DANGER Make sure that metallic ropes are not knotted Precise specifications concernin...

Page 329: ... Fig 2 DANGER Pin 3 must always be inserted in the direction of the arrow and be secured by the spring clip 4 Otherwise there is a risk of collision Attention With all rope reeving arrangements the rope end must be guided through the releasing weight of the hoist limit switch before it is secured to the rope socket Fig 2 6 7 2 Placing the rope in the bottom block NOTE The bottom block 1 comprises ...

Page 330: ...ponents a winch rope with steel wire rope clamp 1 and a rope socket 2 are provided In the case of an even number of rope falls the rope socket is fastened to the boom head in the case of an odd number of rope falls it is fastened to the bottom block refer to item 6 7 1 The steel wire rope clamp of the winch rope is attached in the rope socket as shown in the illustration If the locking pin is inse...

Page 331: ...nction is provided The following important instructions must be observed Insert the rope always so that the pulling rope moves in the traction axis of the rope socket Fig item A Should the rope be inserted incorrectly it would be subject to kinking breaking and premature wear The free rope end must be locked using a rope clamp 1 It is not admissible to use implements as securing devices by means o...

Page 332: ...ould be arranged in the bottom block especially if few rope falls are used so that the bottom block is suspended vertically as far as possible refer to example with four rope falls Bottom block 1 pulley Bottom block 1 pulley Bottom block 1 pulley Bottom block 3 pulleys arrangement with 1 rope fall arrangement with 2 rope falls arrangement with 3 rope falls arrangement with 4 rope falls Bottom bloc...

Page 333: ... 7 pulleys arrangement with 9 rope falls arrangement with 10 rope falls arrangement with 11 rope falls arrangement with 12 rope falls Bottom block 7 pulleys Bottom block 7 pulleys Bottom block 7 pulleys Bottom block 9 pulleys arrangement with 13 rope falls arrangement with 14 rope falls arrangement with 15 rope falls arrangement with 16 rope falls Bottom block 9 pulleys arrangement with 17 rope fa...

Page 334: ...sit the basic mast in its end position while winding up the winch rope 6 slowly and carefully until the two load securing ropes 4 are positioned horizontally and the winch rope is no longer slack Attention To prevent damage to the bumper cross member do not tighten the rope more than absolutely necessary If necessary have the procedure watched by an assistant 6 7 7 Detaching the bottom block for c...

Page 335: ...ulting cases of damage i e accidents 6 8 3 Hoist limit switch The hoist limit switch serves as a shut off device to prevent the bottom block from knocking against the boom head The shut off function must be checked before each crane operation by the working movement bottom block UP The bottom block can be lowered as the control lever is actuated to bottom block DOWN Remark The expression hoist lim...

Page 336: ...ain on the rope drum The rope can be wound up again by actuation of the control lever bottom block UP 6 9 Over overriding cutout device for auxiliary winch DANGER When the bottom block has been removed the winch rope may be wound up only until its end reaches the hoist winch If the winch rope is wound over the hoist winch without a load being fastened the setting of the dead windings on the rope d...

Page 337: ...n this case the boom must be retracted or deposited and crane operation must be stopped immediately Attention During traveling operation the anemometer must be decommissioned or removed Removal of the anemometer refer to item 6 10 1 6 10 1 Removal of the anemometer Remove the plug 5 from the plugbox 4 Remove the spring clip 1 Remove the anemometer 2 with its retaining device 3 To mount the anemome...

Page 338: ...B2 6 Crane movements in no load condition 36 36 0200_EN_FA036_B2_06_00_00 2003 01 Memo ...

Page 339: ...levels The wheels must be clear of the ground Make sure that the applicable load chart and the appropriate values are entered into the ASLI if the outrigger beams are extended to half their supporting base The weight of the load to be lifted must have been determined The bottom block and the arrangement of rope falls must be dimensioned sufficiently The admissible values specified in the load char...

Page 340: ... all crane work with due care and attention 7 2 Crane operation free on wheels Not admissible observe the notes referring to the load charts 7 3 Driving with a load Not admissible observe the notes referring to the load charts 7 4 Moving the crane in full rig arrangement on construction sites For the conditions for driving the crane in full rig arrangement on construction sites refer to item 7 4 1...

Page 341: ...th 30 20 52 28 55 36 59 42 23 49 31 52 40 55 49 58 65 65 without 60 19 41 27 45 36 48 44 51 53 54 30 19 55 27 58 47 23 50 31 53 40 57 48 60 66 66 5 4 13 2 laterally in transport position 60 18 43 27 46 36 49 44 52 53 55 47 22 50 31 53 39 57 48 60 66 66 5 4 mounted to boom head 60 18 43 26 46 35 49 44 52 52 55 50 22 51 31 54 39 57 48 60 66 66 13 2 mounted to boom head 60 17 44 26 47 35 50 43 53 52 ...

Page 342: ...ites Note Boom over rear and superstructure lock pin inserted swing brake engaged solid resistant level and horizontal ground suspension locked specified tire pressure max 1 4 km h at creeping speed if possible with the outrigger beams extended and the outrigger floats as close as possible above the ground With the 3rd axle lowered 12 t the front rear axle loads are reduced by approx 6t 5t ...

Page 343: ... control elements must never be used instead of the controls for normal operation Any damage to the control and operating elements must be eliminated immediately If the superstructure is moved via the emergency controls no unauthorized persons are allowed in the area of movement The operator must be able to see the area of movement Otherwise another person must be designated to act as signal perso...

Page 344: ...m 2 9 6 Release swing brake while 8 slewing to the right or 9 slewing to the left and 7 actuating arm rest override feature simultaneously 8 1 1 3 Hydraulic pumps for crane control B When the pump control fails the hydraulic pumps can be connected via the emergency control Now crane motions are possible NOTE Before actuating the control valves 1 and 2 make sure to remove the connectors and once ac...

Page 345: ...lubrication in case the vehicle is to be started at low ambient temperatures the viscosity of the engine oil must be selected according to the ambient temperatures prevailing at the time when the engine is started The specifications of the engine manufacturer supplied in a separate brochure must be adhered to 9 1 2 Coolant Attention The engine must be filled with anti corrosion anti freeze agent a...

Page 346: ...em is filled e g with hydraulic oil HLP 68 or HLP 46 the oil type must be replaced by the specified pressure fluids at low ambient temperatures 9 3 Batteries Well charged batteries are a prerequisite for cold starting the engine At ambient temperatures lower than 30 C when the machine has been standing in the open air for an extended period of time without being operated e g at night the batteries...

Page 347: ...the optional equipment which has been described and explained in other sections 11 1 Optional equipment mentioned in other sections 11 1 1 Assignment of functions to the left crane control lever in case of operation with a 2nd winch auxiliary hoisting gear Refer to item B2 6 2 1 2 11 1 2 Connecting disconnecting the auxiliary hoisting gear 2nd hoist winch Refer to item B2 6 2 1 11 1 3 Over overrid...

Page 348: ... the ladder 1 into the rear part of the angular supports 2 NOTE The struts 3 on the movable end of the supports must be in full contact with a rung of the ladder to prevent the ladder from slipping sideways Attach eyelets of turnbuckle a in the locating cramps b fold turnbuckles 4 down and secure them using the catch lever Fasten one of the two catch levers with the padlock supplied with the machi...

Page 349: ...with the threaded pins of the spindle 3 Insert the crank in the threaded pin of the spindle 3 and turn the pin until the pin sections are completely inserted in the bore holes on the boom DANGER The colored mark F on the spindle must be completely visible Remove the crank from the threaded pin Fasten the base section 1 using pin 4 and lock it by means of spring clips Fasten the top jib 2 using the...

Page 350: ... over which the jib will swing Anyone standing in this area could be injured Also check the neighboring area for any structure or other obstruction that may present a problem when moving the jib DANGER Whenever performing work on the jib use the double ladder supplied with the crane DANGER Picking up loads which are resting on the ground by raising the boom via the boom elevation may result in ove...

Page 351: ...easing the pins Remove the winch rope from the rope socket Pull the winch rope out of the releasing weight of the hoist limit switch Remove the winch rope falls from the bottom block and the rope sheaves on the boom head Wind up the winch rope Make sure that the winch rope is not dragged on the ground Rest the winch rope on an appropriate surface as shown in the illustration NOTE In case of crane ...

Page 352: ...op jib Remove the upper spring clip and pins 30 and 31 Remove the lower spring clip and pins 32 and 33 DANGER The securing pins of the top jib must be inserted and remain locked NOTE Insert pins in supports 50 and lock them using the spring clips Shift the top jib in the direction of the arrow using a ratchet 35 until the bracket 34 touches the stop A Now the base section is disconnected from the ...

Page 353: ...ted in the bore holes of the bearing brackets DANGER The colored mark F on the spindle must be completely visible Remove the crank from the spindle Detaching the jib base section from the boom To this effect turn the threaded pin of the spindle 11 using the crank 10 until the top and the bottom pin sections are completely moved out of the bore holes of the bearing brackets NOTE The colored mark F ...

Page 354: ...lip on fixed point by means of the spring clip and pin 47 and 48 Wind up the winch rope carefully putting it under tension Remove spring clip and pin 42 and 43 from the bore hole X Unwind the winch rope carefully Remove the rope locking sheave and the spring clip 44 and 45 Fold rope sheave carrier 41 down to its stop Pin fasten rope sheave carrier 41 by inserting and locking it in its position Y b...

Page 355: ... switch Insert the pins 21 securing the rope and lock them using spring clips Mount the rope securing sheave and the spring clip 44 and 45 Attach the bottom block 22 to the winch rope 20 using the rope socket Insert the connectors St into the plugboxes on the boom head and the jib base section Thus the electrical connection of the AML for the hoist limit switch on the jib base section is establish...

Page 356: ... winch rope on the central rope pulley as shown in the illustration Mount the rope securing sheave and the spring clip 44 and 45 Fasten the rope socket 46 to the winch rope Fasten the rope socket 46 to the bracket 49 central clip on fixed point by means of the spring clip and pin 47 and 48 Wind up the winch rope carefully putting it under tension until the direct rope control raises the head of th...

Page 357: ...gle always raise the basic boom mast enough to make sure that the head of the jib does not touch the ground Check that all pins and plugs are locked and that the cable connectors for the hoist limit switch are correctly connected Winding up the winch rope while actuating the boom elevation up is not admissible The data of the jib rig arrangement in question must be entered into the AML Remove the ...

Page 358: ...hanged The crane must not be moved while the offset angle of the jib is being reset The jib has been mounted as described under item 11 4 2 Make sure that a sufficient length of winch rope is available to pass the winch rope over the head of the jib and back to the fixed point 49 of the jib Lower the telescopic boom via the elevating mechanism until the head of the jib is placed just above the gro...

Page 359: ...up the winch rope until the jib has reached its initial position Do not wind up the rope more than necessary Remove the spring clip and pull out both offset pins 51 Insert both offset pins 51 on the left and right into the bore holes for the initial position and lock them using spring clips Wind off the winch rope carefully until the jib has reached the desired initial position When the jib has re...

Page 360: ...key tip switch 43 set to ON the anti two block overwind cutout function is disabled Operate carefully and only without a load Set the key tip switch 43 hoist limit switch override for anti two block function to ON and hold it in this position Deposit the bottom block 22 on the ground and remove the winch rope 20 together with the rope socket Remove the rope securing pin 21 Remove pin 21 of the rop...

Page 361: ...spindle must not be visible The spindle pins must touch NOTE If the upper locking pin is hard to remove or even cannot be removed from the bracket on the telescopic boom at all the jib base section must be raised as described under item 11 4 2 1 Swing the jib base section via the lifting strap until it touches the stop at the boom The bore holes of the spindle 11 are aligned with the bore holes on...

Page 362: ...the bore holes of the bearing brackets DANGER The colored mark F on the spindle must not be visible Remove the crank 10 from the spindle 9 Swing jib base section in the direction of the arrow to its stop on the ramp Fasten the jib base section by means of pin and spring clip 36 and 37 to the base section and secure it Fasten the top jib to the base section by means of pins Shift the top jib in the...

Page 363: ...g lock is engaged While mounting the jib make sure that there are no obstacles in the area of movement The crane must not be moved during assembly The steps described under item 11 14 1 have been accomplished The base section and the top jib are interconnected by pins and mounted on the boom Folding out the ramp If the base section and the top jib are mounted together the ramp must be folded out a...

Page 364: ...rstructure Swing jib base section and top jib in the direction of the arrow to its stop To mount the jib to the boom head proceed analogously as described under item 11 4 2 Exception If the upper pin section cannot be inserted in the bore hole proceed as described under item 11 4 6 1 To disassemble the jib proceed analogously as described under item 11 4 5 All lock pins which have been removed for...

Page 365: ...apter section and of the bearing bracket must be aligned the top pin section must be turned in until the colored mark F on the inner fine spindle is visible completely Carefully unwind the winch rope and remove it 11 4 6 2 Changing the jib offset angle To change the jib offset angle proceed analogously as described under item 11 4 3 and 11 4 4 Attention When changing the jib offset angle or when c...

Page 366: ...sections and the top jib to the jib make sure that there are no obstacles in the area of movement The crane must not be moved during assembly The base section is mounted and set to an offset angle of 40 as described under item 11 4 1 to 11 4 3 or the top jib and the base section is mounted to the boom head as described under item 11 4 6 If a top jib is mounted it must be detached from the base sec...

Page 367: ... this effect insert and lock the pins 65 66 NOTE Always insert the pins from the inside to the outside and lock them Continue to raise boom via the boom elevation Fasten and lock further intermediate sections and the top jib as described above Insert the connector in the plugboxes The electrical connection of the AML for the hoist limit switch on the top jib is prepared Move the jib into the offse...

Page 368: ...ate sections are mounted proceed as follows Lower the boom carefully until the jib rests on the ground and pins 51 are set free NOTE To achieve the desired offset position lower the vehicle via the rear outriggers if necessary extend tele section 1 up to 50 and fasten it with pins Remove both pins 51 on the left and right and insert them into the desired position A B or C and lock them Remove the ...

Page 369: ...m 11 4 7 and is returned to its initial position as described under item 11 4 8 For removal proceed analogously by reversing the sequence of mounting operations described under item 11 4 7 If work is to be performed now using the base section proceed as follows Fasten the releasing weight to the hoist limit switch Fold down rope sheave 41 in working position pin fasten and lock it Pull the winch r...

Page 370: ...falls required must be arranged as follows NOTE The rope should be arranged in the bottom block especially if few rope falls are used so that the bottom block is suspended vertically as far as possible refer to example with four rope falls Bottom block 1 pulley Bottom block 1 pulley Bottom block 1 pulley arrangement with 1 rope fall arrangement with 2 rope falls arrangement with 3 rope falls Botto...

Page 371: ...opes cannot be ruled out 11 5 2 Mounting the heavy lift sheave up to a hoisting capacity of 140t Release bolts 18 remove washers 17 and sleeves 13 Stow sleeves 13 so as to prevent them from being lost Mount sheave carriers 15 16 as shown using the washers 17 and bolts 18 Remove spring clip 20 and cotter pin 19 Reeve the rope 12 as shown between the bottom block 11 the sheave carrier 15 16 and the ...

Page 372: ...1 Attachments optional equipment and accessories 26 40 0220_EN_FA036_B2_11_00_00 2003 01 11 5 2 1 Rope reeving Fasten the winch rope falls in the sheaves as shown in the illustration Bottom block 9 pulleys ...

Page 373: ...tom blocks 11 21 the sheave carriers 1 2 15 16 and the top block 10 Fasten the ropes 12 22 and the rope sockets 7 23 as shown using the pin 9 25 Lock pin 9 25 using the spring clip 8 24 Secure ropes 12 22 using the cotter pins 5 19 and the spring clips 6 20 For disassembly reverse assembly procedure For rope reeving refer to item 11 5 3 1 Attention For the maximum admissible hoisting load refer to...

Page 374: ...oads which are resting on the ground by raising the boom via the boom elevation may lead to overload of the single top or the winch rope or result in the crane overturning thus this procedure is prohibited This movement boom elevation up is not stopped by the overload safety device Attention The load and radius data appearing in the AML deviate slightly from the actual values as the AML does not t...

Page 375: ...to its initial state 11 6 3 Rope fall arrangement for operation with the main and auxiliary winch Place the winch rope item 6 of the 1st hoist winch over the boom head and lock it using the securing yokes item 7 Pass winch rope of the 1st hoist winch through the releasing weight item 13 and secure the hoist limit switch item 14 Place the winch rope item 12 of the 2nd hoist winch over the single to...

Page 376: ... jib which are admissible in this case correspond to the maximum lifting capacities indicated in the appropriate load charts for the jib The total load incl hook block and all the load securing equipment must not exceed the lifting capacities specified for the rig arrangement of the crane DANGER The number of rope falls attached to the boom head must never be smaller than the number of rope falls ...

Page 377: ... is suspended on both hook blocks the telescopic boom must on no account be lowered via the derricking gear All crane work must be performed with the required care Ö 1 Use the 2nd winch to lift the load clear of the ground 2 Use the main winch to hoist the load 1 Use the second winch to lower the load 2 Use the main winch to deposit the load ...

Page 378: ... 9 Working floodlight on the hoist winch Actuate the rocker switch 48 working floodlight hoist winch down to switch the lights ON OFF 11 10 Working floodlight electrical adjustment Actuate the rocker tip switch 50 working floodlight The working floodlight on the boom is adjusted 11 11 Hook height indication auxiliary hoist winch Actuate the rocker tip switch 24 Hook height indication auxiliary hoi...

Page 379: ...actory and must not be adjusted In case of problems please contact the TADANO FAUN After Sales Service Pick up counterweight as described Fasten the auxiliary winch To this effect insert pins 6 and lock them using the spring clips 7 Connect the electrical 10 and hydraulic 8 connec tors and the line of the centralized lubrication system 9 Detach and place the winch rope For removal of the auxiliary...

Page 380: ... right side of the vehicle on the battery box below the cover The batteries of the vehicle supplying power should have the same or a higher capacity Ampere than those of the vehicle to be supplied with power To avoid damage to the generator make sure that the following sequence of operations is observed Vehicle to be supplied with power Vehicle supplying power 1 The ignition is switched off The ig...

Page 381: ...r source 1 is installed on the right side of the vehicle on the battery box underneath the cover For further details refer to the brochures of the battery manufacturer Attention The charging plugbox 1 must not be used to start the vehicle via an external power source with the charging unit connected It is only used for charging the battery 11 17 Hourmeter hoist winch A separate hourmeter part B2 2...

Page 382: ...lisation of the emergency control feature oil supply to the emergency control system must be ensured before such work begins At the same time all possible procedures for resetting the superstructure to its former rig arrangement must be checked for proper function When slewing the superstructure pay attention to any connected hydraulic hoses DANGER Only hoisting gear 1 can be reset to its former r...

Page 383: ...r cock and the plug engine cooling system are used for change over in the emergency position and must be returned or inserted to their initial position once work is finished In the superstructure Establishing the connection of the hydraulic hoses between the chassis and the superstructure Prerequisite The three hose pipes in the chassis are safely connected to the quick locking coupling devices Op...

Page 384: ... display remains visible and should be used to assess the risk DANGER If there is a failure of the electrical power supply of the superstructure the AML information is no longer available The prevailing risk must be judged on the basis of other information Even if the electrical power supply is still available in superstructure emergency mode a dangerous motion increasing the load moment will not ...

Page 385: ...trol cocks 20 21 to enable slewing of superstructure to the right left actuate control cocks 17 or 18 to slew the superstructure to the right or left To return the superstructure to its former rig arrangement proceed as follows Switch on the pressure oil supply by actuation of the control cock 11 Perform the desired crane function by actuation of the appropriate control cock 12 21 In the case of e...

Page 386: ...B2 11 Attachments optional equipment and accessories 40 40 0220_EN_FA036_B2_11_00_00 2003 01 Memo ...

Page 387: ...WS rocker tip switches WT 5 WT Extending retracting outriggers VL 6 WT Extending retracting outriggers HL 7 WS Outrigger preselection 8 WT Extending retracting outriggers HR 9 WT Extending retracting outriggers VR 10 WS Ignition chassis ON 11 free 12 WT Engine speed regulation chassis 13 17 free Pilot lamps gn green Indicator lamps ge yellow or orange bl blue Warning lamps rt red UW Chassis WS Roc...

Page 388: ...weight override feature crane control 32 WS Hoist winch rotation indicator 35 WS Emergency control tele 36 WT Emergency control tele section s tele section s locked unlocked 37 WT Emergency control tele section s cylinder locked unlocked 38 WS Lock override feature tele control 39 WT Lift adjuster 40 WT Monitor Tele 41 WT Engine stalling device 44 free 45 WS Aircraft warning lamp 46 WS Mirror heat...

Page 389: ...0230_EN_ALLGE_C_00_00_00 Part C Service and Maintenance ...

Page 390: ......

Page 391: ... cloth for all work to be carried out in particular at the hydraulic system Check oil levels only while the machine is standing in horizontal position NOTE During oil level inspections the safety prescriptions according to 6 Regulation for the prevention of accidents to drive assemblies must be observed Please observe any specific regulations of the country where the machine is to be used which mi...

Page 392: ...supporting components are absolutely prohibited refer to part E 1 item 1 As high tensile steels are used there is a risk that the material properties might be lost due to inexpert welding work thermal treatment or straightening work 1 3 Inspection of screw couplings Check all connecting and securing bolts including those of the assemblies and all hose clamps for tight fit at regular 3 month interv...

Page 393: ...imum pressure of cleaning units 80 bar Preferably fan nozzles should be used 1 6 After having finished service and maintenance work After having finished these operations re install the protective equipment properly Check the machine for proper operation Attention When disposing of oil grease detergents or components containing oil e g filters observe the provisions for pollution control Used oil ...

Page 394: ...C1 1 General information 4 4 0235_EN_FA036_C1_01_00_00_FA029 2001 06 Memo ...

Page 395: ...0240_EN_ALLGE_C_01_00_00 Part C1 Service and Maintenance Chassis ...

Page 396: ......

Page 397: ...nance work which must be performed daily or before commissioning the vehicle has been marked by an X in the maintenance schedule in the column Daily before start up The number of operating hours expiry of which calls for the specified maintenance work to be performed repeatedly have been marked by an X in the columns Regular maintenance every 125 250 500 1000 2000 operating hours e g every 500 ope...

Page 398: ...C1 2 Maintenance intervals 2 16 0245_EN_FA036_C1_02_00_00_FA029 2003 01 Memo ...

Page 399: ...s for tight fit and tightness 3 X Oil level inspection 3 1 X Oil change oil filter replacement 3 2 600 operati ng hours Once per year Every 40 000 km traveled every 600 operating hours at least however once per year Inspection of tight fit of the hose clamps of the charge air hoses 3 3 X Drain condensed water 3 4 1 X Once per year If necessary earlier Fuel tank check ventilation filter 3 4 2 X Onc...

Page 400: ...ing 3 7 1 Simultaneously with each maintenance of the air cleaner If necessary earlier depending on dust collected Check air intake pipes and hoses 3 7 3 X Servicing switch Air cleaner monitoring check for proper working order 3 7 4 X Once per year and if the indicator lamp in the CGC does not go on in spite of contamination of the air cleaner Cleaning the louvred grill coarse filter 3 7 5 Simulta...

Page 401: ...est with each oil change Check breather if necessary clean 5 1 1 9 X Simultaneously with each oil level inspection at the latest with each oil change Inspection for leakage 5 1 1 X Daily simultaneously with each oil level inspection and each oil change Oil level inspection check visually 5 1 5 1 1 X Every 3 months Oil change 5 2 1 000 to 1 500 km Once per year At regular intervals of 10 000 km tra...

Page 402: ...wheel bearing backlash 6 6 100 oper ating hours Once per year Check screws and bolts on axles drop arms thrust rods etc for tight fit if necessary re tighten 6 7 50 operating hours then after reaching 100 op hrs X Once per year Preservation of axle and planetary gearings 6 8 When the vehicle is inoperative for an extended period of time Check flange screws of propeller shafts for tight fit if nece...

Page 403: ...ue of screws and bolts 8 X Once per year Check shaft packing rings on axle 8 X Once per year Check insulating sleeves cabling fasteners and supports for good condition 8 X Once per year Check terminals pole units and pole shoes for corrosion 8 X Once per year Check cable lugs and ground connection for proper fastening and tight fit 8 X Once per year Check contacts in relay box for good condition 8...

Page 404: ...t holes on the brake cylinders 9 X If necessary earlier Check clean and if neces sary replace silencers breathers on the brake valves 9 X If necessary earlier Hydraulic system Check hydraulic system for leakage 10 C2 3 6 X Oil level inspection 10 1 X Replace filter cartridges 10 2 125 operating hours X Once per year simultaneously with each hy draulic oil change and if the symbol indicating contam...

Page 405: ... leakage 10 5 4 X Hydraulic system of suspension Hydraulic oil change 10 6 1 Simultaneously with each hydraulic oil change Check for proper working order and leakage 10 6 2 X Check the preload pressure of the hydraulic accumu lators 10 6 3 50 operating hours then once more after 4 months X Once per year And if necessary more fre quently during the winter months Hydraulic system of outriggers Hydra...

Page 406: ...spection according to the legal regulations of the country where the machine is to be registered Inspection and cleaning of the diaphragm cylinders 11 4 3 X And whenever the spreading device is checked Inspection according to the legal regulations of the country where the machine is to be registered Checking wheel brakes for proper working order and wear 11 5 X Inspection according to the legal re...

Page 407: ...operation and or while driving check the pilot lamps for proper working order Check mechanical compo nents of ABV system 11 8 X Check the entire ABV system 11 8 X In a specialist workshop Checking function and setting of engine brake and exhaust flaps 11 9 11 9 1 X Observe specifications of engine manufacturer Inspection of the compressed air system 11 10 X Inspection according to the legal regula...

Page 408: ...d 200 km X Subsequently after 500 1000 and every 5000 km or after 50 100 and every 500 operating hours Check tire inflating pressure 13 4 X Interchanging wheels in case of tire wear 13 6 Every 5 000 to 10 000 km Depending on wear pattern Outriggers Cleaning and lubrication of sliding surfaces of outrigger beams 14 X Once per month And after every crane cleaning operation using the high pressure st...

Page 409: ...n Warm water heating unit lubricate shaft bearings articulations of levers and all movable parts 15 1 X Twice per year Warm water heating unit Clean heat exchanger 15 1 X every 3 years Simultaneously with a replace ment of the coolant in the engine Warm water heating unit Heat exchanger Clean air fins Blower fan Clean electric motor and fan wheel 15 1 2 X Twice per year Warm water heating unit Ins...

Page 410: ... conditioning system Replenish compressor oil filling 15 3 10 Whenever performing work on the air conditioner Miscellaneous other points of lubrication service and maintenance Other points of lubrication Oil grease joints and pins hinges and other movable components 16 1 X Every two weeks And after every crane cleaning operation using the high pressure steam jet blower Supplementary heater unit Re...

Page 411: ...ease coupling bolt 16 3 2 X And after each vehicle cleaning operation using a high pressure steam jet unit If necessary earl ier depending on dust collected Check compressed air coupling heads 16 3 3 X And simultaneously with each inspection of the brake system Sliding coupling Checking the sliding coupling 16 4 X Steering Grease bearing points on guide levers supplied via central lubrication 16 5...

Page 412: ...C1 2 Maintenance intervals 16 16 0245_EN_FA036_C1_02_00_00_FA029 2001 06 Memo ...

Page 413: ...Vee belt for good condition Checking the tappet clearance Performing troubleshooting etc have been described in the Operating Manual of the engine manufacturer which has been supplied with the machine Check engine for leakage at regular intervals 3 1 Oil level inspection NOTE The oil level is checked and oil is added through the servicing port in the engine cover For oil level inspection and oil f...

Page 414: ...instead of the oil drain plug During subsequent oil changes only the cap 1 of the drain valve 2 needs to be removed and replaced by the oil drain hose 3 which is also supplied with the tool kit As the hose is fastened the drain valve opens and the oil can be drained through the hose into the collect vessel provided to this effect After these operations have been finished remove the drain hose clea...

Page 415: ...r check and clean sealing element 4 if necessary replace it 3 4 3 Fuel strainer 3 4 3 1 Draining condensation water Open the drain valve 1 and allow the collected condensation water to drain into an appropriate vessel NOTE Before the cold season begins the condensate must be drained If necessary repeat this step several times 3 4 3 2 Replacement of fuel filter Drain the entire filter contents as d...

Page 416: ...over for proper working order A defective valve may cause excess pressure in the coolant circuit and consequently leakage 3 5 2 Drainage of coolant NOTE Before the coolant is renewed the vehicle s warm water heating must be open Two drain cocks are installed in the cooling system The coolant contained in the two radiators can be drained via the drain cock 1 The entire contents of the cooling syste...

Page 417: ...29 2003 01 5 8 3 6 Cleaning the radiator Clean the cooler fins of the intercooler water cooler 1 and of the water cooler 2 at regular intervals according to the maintenance schedule by blowing out with compressed air or using a painter s brush ...

Page 418: ... air cleaner is serviced 3 7 1 Removal installation of the air cleaner cartridge Unscrew cover 4 Remove the cover 3 from the air cleaner housing Pull the air cleaner cartridge 2 carefully and comple tely out of the air cleaner housing turning it slightly Clean air cleaner housing and sealing surfaces of air cleaner housing and cover carefully using a lint free damp cloth Attention Do not blow clea...

Page 419: ...o the bottom of the cartridge Clean air cleaner cartridge carefully by blowing from the inside to the outside using dry compressed air max 5 bar by moving the tube in the air cleaner cartridge up and down repeatedly until no more dust is raised Attention The tip of the tube must not get too close to the filter paper Attention Before reinstalling the cleaned air cleaner cartridge check it carefully...

Page 420: ...leaner icon lights up Attention Once the air cleaner icon is lit the intake opening must not be reduced further Risk of damage NOTE The air intake duct the air cleaner housing and the filter cartridge are located on the radiator housing on the right side of the vehicle 3 7 5 Cleaning the fin type grill coarse filter Clean fin type grill Fig item 3 7 4 pos 1 Unscrew plate Fig item 3 7 4 pos 2 from ...

Page 421: ...heel chocks NOTE Check the gearbox for leakage during each inspection Locate and eliminate any leakage immediately Replenish any possible amounts of oil which may have been lost In case of leakage at the gearbox also check the breather installed on the upper side of the gearbox for correct function For information on the oil level inspection refer to the enclosed documents of the gearbox manufactu...

Page 422: ...or information regarding oil types oil changes replacement of oil filters pouring in oil and oil level inspection please refer to the enclosed operating instructions and the gearbox manufacturer s list of approved lubricants Part G1 chassis NOTE Dirt particles Whenever changing the oil check the drained oil for traces of dirt Any deposits of sludge or soft mud collected in the oil sump must be eli...

Page 423: ...on tube 4 Pour in oil 5 until it escapes at the oil level inspection tube 4 drain in an appropriate vessel Clean the sealing surfaces Screw fasten the oil filler plug 5 with a new packing ring tightening torque 60 Nm Close the oil level inspection tube 4 Start the engine and perform a test run 2 to 5 km Attention During and after the test run and until after the next oil level measurement the inta...

Page 424: ...level inspection Park the vehicle and secure it as described under item 4 1 Open the oil level inspection tube 4 Allow any oil existing in the tube to drain in an appropriate vessel Drain excess oil in an appropriate vessel or add oil as described above until it escapes through the oil level inspection tube 4 Close oil level inspection tube 4 and if necessary the oil filler plug 5 Used oil and oil...

Page 425: ...e must be unscrewed Remove the oil filler and inspection plugs 2 The oil level must reach the lower edge of the bore hole If necessary add oil through the oil filler and inspection plug 2 To this effect proceed as described under item 5 2 Oil change Fasten oil filler and inspection plug 2 safely after having fitted a new seal 5 1 1 Visual check during each oil level inspection Check housings and s...

Page 426: ...plug 1 safely with new packing rings and reconnect hydraulic line to the oil cooler item 5 3 pos 5 Pour in new oil via the oil filler plug 4 For the correct oil quantity refer to item C1 24 After pouring in the required quantity of oil install the oil filler plug 4 using a new seal Clean breather item 5 1 1 pos 3 and re tighten it refer to item C1 9 Start the engine and set gearbox to D Select hig...

Page 427: ...f the planetary gears the oil drain port 2 item C1 6 2 1 and C 1 6 2 2 must be in its lowest position To this effect lock the axle suspension support the vehicle by outriggers and place it in horizontal position Turn the wheels so that the oil drain port is placed in its lowest position Protect the vehicle against rolling away Remove the plugscrews 1 item C1 6 2 1 and C1 6 2 2 of the oil level ins...

Page 428: ...n oil via the filler ports 4 until the oil leaves through the oil level inspection and filler ports 1 5th axle Add oil via the oil level inspection and filler port 1 until overflow occurs Wait a few minutes then add oil if necessary until the oil level remains constant The oil level must reach the rim bottom edge of the inspection and filler ports 1 Check the sealing elements for damage clean and ...

Page 429: ...03 01 3 8 cont d 6 2 1 Drive 10x6 2nd driven axle 4th driven axle 5th driven axle 2nd 4th and 5th axles Planetary gears in wheel hubs Item 1 Oil level and inspection port Item 2 Oil drain port Item 3 Breather Item 4 Filler ports Driving direction ...

Page 430: ...orts 4 until the oil leaves through the oil level inspection and filler ports 1 5th axle Add oil via the oil level inspection and filler port 1 until overflow occurs Wait a few minutes then add oil if necessary until the oil level remains constant The oil level must reach the rim bottom edge of the inspection and filler ports 1 Check the sealing elements for damage clean and if necessary replace t...

Page 431: ...cont d 6 2 2 Drive 10x8 1st driven axle 2nd driven axle 4th driven axle 5th driven axle 1st 2nd 4th and 5th axles Planetary gears in wheel hubs Item 1 Oil level and inspection port Item 2 Oil drain port Item 3 Breather Item 4 Filler ports Driving direction ...

Page 432: ...Lubricators Grease filling in the wheel hubs NOTE The twin propeller shafts in the driven axles are maintenance free 6 4 1 Replacement of grease filling in the wheel hubs of the non driven axles In case of the 10 x 6 drive configuration the wheel hubs of the 1st and 3rd axles are filled with grease In case of the 10 x 8 drive configuration the wheel hubs of the 3rd axle are filled with grease Thes...

Page 433: ...t Check securing bolts of steering and track rods and if necessary re tighten them observe specified tightening torques Re tighten thrust rod fasteners of axle suspension systems observe specified tightening torque Screws locked by means of Loctite must not be re tightened 6 8 Preservation of axle and planetary gears In order to maintain the operating safety of the vehicle corrosion is not admissi...

Page 434: ...C1 6 Axles 8 8 0265_EN_FA036_C1_06_00_00_FA029 2003 01 Memo ...

Page 435: ... of the gudgeon assemblies and the splined shaft connections at regular intervals Attention If a noticeable backlash is detected replace the propeller shaft repair 7 2 Noise test Perform a noise test at regular intervals If the noise is different from that noise known from normal operation look for the reason and repair any possible deficiency Check the balancing plates or the counter balancing pi...

Page 436: ...C1 7 Propeller shafts 2 2 0270_EN_FA036_C1_07_00_00_FA029 2003 01 Memo ...

Page 437: ...ate grease and dirt The cleaning may only be effected when the machine has cooled down and when the electrical equipment is switched off Clean rotors of the retarder at regular intervals on the outside using a steam jet unit to remove grease and dirt and to ensure heat dissipation Attention Do not use detergents or solvents To avoid damaging the insulation of the electrical cables do not direct th...

Page 438: ...EN_FA036_C1_08_00_00_FA029 2003 02 8 1 1 Test and setting values Air gap A 1 35 1 5 mm Tightening Torque B 90 Nm 18 Nm C 250 Nm 50 Nm D 60 Nm 12 Nm E 60 Nm 12 Nm Tightening Torque A 5 Nm 1 Nm B 4 Nm 0 8 Nm C 6 Nm 1 2 Nm D 12 Nm 2 4 Nm ...

Page 439: ...inated breathers on the outside Vent breather holes on the wheel brake cylinders must be free from contamination The breather cap must be easy to turn not in the case of venting devices on the brake valves Check breathers for tight fit Replace breathers if they have been loosened or lost or if they are faulty If it is suspected that the oil especially the oil of the axles of gearbox and transfer b...

Page 440: ...er to item C1 6 For an illustration and indication of the mounting location of the breather to the transfer box refer to item C1 5 1 1 For an illustration and the mounting location of the breather on the fuel tank refer to item C1 3 4 2 chassis and item C2 2 4 2 1 superstructure For an illustration and the mounting location of the breather on the hydraulic oil tank refer to item C1 10 2 1 chassis ...

Page 441: ...ers and the suspension are supplied from a common hydraulic oil tank Check hydraulic oil level when the engine is at a standstill while the outriggers are retracted The hydraulic oil level is indicated at the sight glass 2 The hydraulic oil level depends on the hydraulic oil temperature refer to plate 3 Oil is poured in via the port of the filter cap 1 Unscrew the filter cap 1 and pour in hydrauli...

Page 442: ... the maintenance schedule Do not clean filter cartridges Unscrew the two filter covers 1 Fold the clips 2 of the filter cartridges 3 up Turn the filter cartridge to the left by 90 and unlock it Remove the filter cartridges 3 allow the residual oil to drip Insert new filter cartridges carefully into the housing Lock them by a 90 rotation and fold down the clip 2 Clean check and if necessary replace...

Page 443: ...commended to have the oil analysed by the supplier before carrying out a scheduled hydraulic oil change or at regular intervals to see whether a hydraulic oil change is necessary The purity degree must comply with ISO 4406 grade 18 16 13 Only clean hydraulic oil must be poured in during the oil changes Depending on the degree of contamination and the thermal load the hydraulic oil is subject to sh...

Page 444: ...laced Check the miter gear for leakage at regular intervals according to the maintenance schedule 10 5 3 Pressure check NOTE The test connectors measuring connectors M and the measured values of the entire hydraulic system of the chassis are listed up under item 10 9 In case of an operating malfunction in the steering system the set point pressure can be checked by screw fastening a hydraulic pres...

Page 445: ...ower the vehicle completely The pre load pressure of the hydraulic accumulators must be set and checked especially during the winter months and after every installation or repair work The inspection intervals specified in the maintenance schedule must absolutely be observed The first inspection must be performed already after 50 operating hours Check the pressure of each individual hydraulic accum...

Page 446: ...ers 10 7 1 Hydraulic oil change After having changed the hydraulic oil in the hydraulic oil tank with the outrigger and extension cylinders retracted no hydraulic oil change is required in the outriggers The cylinders are automatically supplied with new hydraulic oil When replacing a cylinder or after repair work extend the appropriate outrigger cylinder while the engine is running at idling speed...

Page 447: ...draulic pressure gauge to the measuring connector M 3 2 Actuate the desired hydraulic circuit to its mechanical stop while the engine is running at idling speed Pressure check of the fan drive Connect a hydraulic pressure gauge to the measuring connector M 3 2 at an engine speed of 1000 rpm fan I 530 rpm fan II 470 rpm connector 1 remains inserted at an engine speed of 1800 rpm fan I 2100 rpm fan ...

Page 448: ...supplied with 24V Fan I 530 rpm Fan II 470 rpm Setting on pump controller of fan pump 30 bar 5 bar M3 1000 min 1 Level and inclination position Set point Tolerance Measuring connector Engine speed Level control and inclination adjustment 270 bar 10 bar M3 at idle Lift axles 1 5 270 bar 10 bar M3 at idle Lift 3rd axle 270 bar 10 bar M3 at idle Axle load of 3rd axle at driving level 12000 kg Procedu...

Page 449: ... actuated to the right 90 bar 5 bar M1 at idle Circuit II Hydr steering limitation with washer steering actuated to the left 60 bar 5 bar M2 at idle Circuit II Hydr steering limitation with washer steering actuated to the right 60 bar 5 bar M2 at idle Circuit I max check using a 15 mm washer steering actuated to the left and right not adjustable 150 bar 15 bar M1 at idle Circuit II max check using...

Page 450: ...hicle The locations of the measuring connectors on the vehicle are shown in the following illustration Designation and function of the measuring connectors M 1 Measuring connector steering circuit I M 2 Measuring connector steering circuit II M 3 Measuring connector hydraulic pressure fan drive and outriggers M 4 Measuring connector steering 4th rear axle M 5 Measuring connector steering 5th rear ...

Page 451: ...iggers and the suspension are supplied from a common hydraulic oil tank Check hydraulic oil level when the engine is at a standstill while the outriggers are retracted The hydraulic oil level is indicated at the sight glass 2 The hydraulic oil level depends on the hydraulic oil temperature refer to plate 3 Oil is poured in via the port of the filter cap 1 Unscrew the filter cap 1 and pour in hydra...

Page 452: ... in the maintenance schedule Do not clean filter cartridges Unscrew the two filter covers 1 Fold the clips 2 of the filter cartridges 3 up Turn the filter cartridge to the left by 90 and unlock it Remove the filter cartridges 3 allow the residual oil to drip Insert new filter cartridges carefully into the housing Lock them by a 90 rotation and fold down the clip 2 Clean check and if necessary repl...

Page 453: ... recommended to have the oil analysed by the supplier before carrying out a scheduled hydraulic oil change or at regular intervals to see whether a hydraulic oil change is necessary The purity degree must comply with ISO 4406 grade 18 16 13 Only clean hydraulic oil must be poured in during the oil changes Depending on the degree of contamination and the thermal load the hydraulic oil is subject to...

Page 454: ...replaced Check the miter gear for leakage at regular intervals according to the maintenance schedule 10 5 3 Pressure check NOTE The test connectors measuring connectors M and the measured values of the entire hydraulic system of the chassis are listed up under item 10 9 In case of an operating malfunction in the steering system the set point pressure can be checked by screw fastening a hydraulic p...

Page 455: ...m lower the vehicle completely The pre load pressure of the hydraulic accumulators must be set and checked especially during the winter months and after every installation or repair work The inspection intervals specified in the maintenance schedule must absolutely be observed The first inspection must be performed already after 50 operating hours Check the pressure of each individual hydraulic ac...

Page 456: ...iggers 10 7 1 Hydraulic oil change After having changed the hydraulic oil in the hydraulic oil tank with the outrigger and extension cylinders retracted no hydraulic oil change is required in the outriggers The cylinders are automatically supplied with new hydraulic oil When replacing a cylinder or after repair work extend the appropriate outrigger cylinder while the engine is running at idling sp...

Page 457: ... hydraulic pressure gauge to the measuring connector M 3 2 Actuate the desired hydraulic circuit to its mechanical stop while the engine is running at idling speed Pressure check of the fan drive Connect a hydraulic pressure gauge to the measuring connector M 3 2 at an engine speed of 1000 rpm fan I 530 rpm fan II 470 rpm connector 1 remains inserted at an engine speed of 1800 rpm fan I 2100 rpm f...

Page 458: ... valve supplied with 24V Fan I 530 rpm Fan II 470 rpm Setting on pump controller of fan pump 30 bar 5 bar M3 1000 min 1 Level and inclination position Set point Tolerance Measuring connector Engine speed Level control and inclination adjustment 270 bar 10 bar M3 at idle Lift axles 1 5 270 bar 10 bar M3 at idle Lift 3rd axle 270 bar 10 bar M3 at idle Axle load of 3rd axle at driving level 12000 kg ...

Page 459: ...ing actuated to the right 90 bar 5 bar M1 at idle Circuit II Hydr steering limitation with washer steering actuated to the left 60 bar 5 bar M2 at idle Circuit II Hydr steering limitation with washer steering actuated to the right 60 bar 5 bar M2 at idle Circuit I max check using a 15 mm washer steering actuated to the left and right not adjustable 150 bar 15 bar M1 at idle Circuit II max check us...

Page 460: ... vehicle The locations of the measuring connectors on the vehicle are shown in the following illustration Designation and function of the measuring connectors M 1 Measuring connector steering circuit I M 2 Measuring connector steering circuit II M 3 Measuring connector hydraulic pressure fan drive and outriggers M 4 Measuring connector steering 4th rear axle M 5 Measuring connector steering 5th re...

Page 461: ...pressed air system for leakage at regular intervals Locate and eliminate any leakage immediately 11 2 Air drier 11 2 1 Functional check Actuate the drainage valves as described under item C1 11 1 If no condensed water is blown off the desiccant cartridge of the air drier may only be replaced when condensed water escapes several times successively during the regular inspections of the air tank valv...

Page 462: ...erating safety of the vehicle make sure that the adjustment and maintenance operations on the entire brake system also in the wheel brake system as specified below are only performed by well trained specialist staff in an authorized specialist workshop brake repair service DANGER Prior to all types of work on the brake system protect the vehicle against rolling by means of wheel chocks The pressur...

Page 463: ...eleased 11 4 2 Establishing the braking function of the air accumulator section Ventilate the air accumulator section min 6 bar Screw in the releasing bolts and tighten them safely tightening torque approx 45 Nm Check braking function if necessary re adjust 11 4 3 Cleaning the diaphragm brake cylinders Even if the diaphragm cylinders operate perfectly response pressure does not exceed 0 5 bar no l...

Page 464: ...e It is essential that only original TADANO FAUN spare parts are used 11 5 2 Inspection of air gap Check the air gap between the brake drum and the brake lining using a feeler gauge During the inspection make sure that both brake shoes are applied evenly to the brake drum For that purpose actuate the service brake The air gap for each brake shoe must be 0 4 to 1 2 mm The max air gap must not excee...

Page 465: ...mit the rear axle pressure item 15 in the brake system Whenever the brake and compressed air system is examined or on replacing valves the setting value of the pressure limiting valve must be checked When the valve is replaced the pressure must be set to the specified value For setting and measured values refer to item 11 11 The correct setting value can be obtained on valve 1 by turning the setsc...

Page 466: ...tion work A Supply line connecting the air compressor to the four circuit protection valve feed line B Brake air pressure service brake circuit I BBA I C Brake air pressure service brake circuit II BBA II D Brake air pressure auxiliary and parking brake HBA FBA E Brake air pressure auxiliary equipment NVA F Control line pressure service brake circuit I BBA I 3rd 4th and 5th axles upstream the pres...

Page 467: ...essure is reached Reduce pressure in brake system until it is replenished Test connector on air drier Test connector on air drier 11 7 12 3 bar 10 0 11 0 bar Pressure limitation Service pressure 1st and 2nd circuits 3rd and 4th circuits Test panel connectors B and C D and E 9 8 10 2 bar 8 1 8 5 bar Pressure switch Operating pressure Fill empty brake system The warning lamp service and parking brak...

Page 468: ...esignations and functions of the measuring and test connectors 1 Test panel connectors A X behind the 5th axle on the right assignment see item C1 11 10 2 Test connector auxiliary equipment 20l compressed air tank between 1st and 2nd axles on the right 3 Test connector brake cylinders of 2nd axle right hand and left hand 4 Test connector brake cylinders of 3rd axle right hand and left hand 5 Test ...

Page 469: ...r intervals visual inspection The acid level must be approx 10 to 15 mm above the top edge of the cells Only top up distilled or demineralized water After replenishing wait approx 30 minutes then check the acid The acid density in the individual cells must be measured using an acidimeter NOTE Discharge batteries freeze at 10 C 12 1 1 Specific gravity and charge condition of the battery at an acid ...

Page 470: ... of the discharged battery The other end of the cable must be connected to the negative terminal of the battery of the vehicle supplying power The plus and minus signs are marked on the battery Now start the engine of the vehicle to be started by an external power source as described under item B1 4 4 5 After starting the engine disconnect the jumper cables again DANGER Do not touch the metallic p...

Page 471: ... 5W Front flasher lamps 72601 P25 1 24V 21W Rear flasher lamps 72601 P21W 24V 21W Stop lights 72601 P21W 24V 21W Rear fog light 72601 P21W 24V 21W Reversing light 72601 P21W 24V 21W Fog lights 72601 YC 24V 70W Rear lamps 72601 R10W 24V 10W Lateral lights rear 72601 R10W 24V 10W Cab roof bordering lights 72601 R19 10 24V 10W Driver s cab ceiling lamp 72601 K 24V 10W Instrument panel switch lighting...

Page 472: ...C1 12 Electrical equipment 4 8 0295_EN_FA036_C1_12_00_00_FA029 2003 01 Memo ...

Page 473: ...ng light Lateral light crane F046 ABV Trailer F009 Stop lights Air drier F028 Dimmed light left hand Relay fog light F047 Immobilizer Tachograph F010 Reversing light Centralized lubrication system F029 Dimmed light right hand F048 Tachograph Radio Voltage reduction device 24 12 V F011 Indicator lamps Relays Tachometer F030 High beam light left hand F049 Supplementary heater unit F012 Heater fan Su...

Page 474: ... Working speed K 040 Holding circuit NES K 532 Malfunction steering 5th axle K 731 Lighting from super structure V 004 CMV supply K 531 Power supply steering computer 5th axle K 730 Lighting from super structure K 015 Eddy current brake K 521 Buzzer V 711 Ignition chassis V 506 Group of diodes K 511 Speed limitation 4th axle K 101 ABV shut off feature K 316 Engine brake K 514 Front axle steering l...

Page 475: ...Electrical equipment C1 12 0295_EN_FA036_C1_12_00_00_FA029 2001 06 7 8 cont d 12 5 Fuse relay arrangement Belegung der Sicherungsdosen Fuse arrangement Sonderausrüstung optional equipment ...

Page 476: ..._12_00_00_FA029 2001 06 12 5 2 Fuses in battery box 1 Eddy current brake 250 A 2 F 061 Fuse charging plugbox 25 A 3 F 058 Fuse chassis frame 25 A 4 F 059 Fuse superstructure 25 A 5 F 060 Fuse driver s cabin 50 A 99707793307 A 1105 Optional equipment ...

Page 477: ...ular intervals visual inspection The acid level must be approx 10 to 15 mm above the top edge of the cells Only top up distilled or demineralized water After replenishing wait approx 30 minutes then check the acid The acid density in the individual cells must be measured using an acidimeter NOTE Discharge batteries freeze at 10 C 12 1 1 Specific gravity and charge condition of the battery at an ac...

Page 478: ...nal of the discharged battery The other end of the cable must be connected to the negative terminal of the battery of the vehicle supplying power The plus and minus signs are marked on the battery Now start the engine of the vehicle to be started by an external power source as described under item B1 4 4 5 After starting the engine disconnect the jumper cables again DANGER Do not touch the metalli...

Page 479: ...24V 5W Front flasher lamps 72601 P25 1 24V 21W Rear flasher lamps 72601 P21W 24V 21W Stop lights 72601 P21W 24V 21W Rear fog light 72601 P21W 24V 21W Reversing light 72601 P21W 24V 21W Fog lights 72601 YC 24V 70W Rear lamps 72601 R10W 24V 10W Lateral lights rear 72601 R10W 24V 10W Cab roof bordering lights 72601 R19 10 24V 10W Driver s cab ceiling lamp 72601 K 24V 10W Instrument panel switch light...

Page 480: ...C1 12 Electrical equipment 4 8 0295_EN_FA036_C1_12_00_00_FA029_AB106 2003 01 Memo ...

Page 481: ...nal bordering light Lateral light crane F046 ABV Trailer F009 Stop lights Air drier F028 Dimmed light left hand Relay fog light F047 Immobilizer Tachograph F010 Centralized lubrication system F029 Dimmed light right hand F048 Radio Voltage reduction device 24 12 V F011 Indicator lamps Relays Tachometer F030 High beam light left hand F049 Supplementary heater unit F012 Heater fan Supplementary heat...

Page 482: ...8 Reversing light K 532 Malfunction steering 5th axle K 731 Lighting from super structure K 040 Holding circuit NES K 531 Power supply steering computer 5th axle K 730 Lighting from super structure V 004 CMV supply K 521 Buzzer V 711 Ignition chassis K 015 Eddy current brake K 511 Speed limitation 4th axle K 101 ABV shut off feature V 506 Group of diodes K 514 Front axle steering left hand V010 Re...

Page 483: ...Electrical equipment C1 12 0295_EN_FA036_C1_12_00_00_FA029_AB106 2001 06 7 8 cont d 12 5 Fuse relay arrangement Belegung der Sicherungsdosen Fuse arrangement Sonderausrüstung optional equipment ...

Page 484: ..._00_00_FA029_AB106 2001 06 12 5 2 Fuses in battery box 1 Eddy current brake 250 A 2 F 061 Fuse charging plugbox 25 A 3 F 058 Fuse chassis frame 25 A 4 F 059 Fuse superstructure 25 A 5 F 060 Fuse driver s cabin 50 A 99707793307 A 1105 Optional equipment ...

Page 485: ...boreholes Re paint rim to prevent the development of corrosion and tension cracks The surface protection of the rim must be checked and if necessary renewed at certain intervals and when a tire is mounted Whenever tires are mounted clean the rims to remove corrosion dirt and rubber residues and provide the rims with a new protective paint DANGER In order to avoid severe accidents make sure that on...

Page 486: ...hub bolts nuts and contact surfaces of wheel check them for wear and deficiencies Replace defective components Use only genuine TADANO FAUN spare parts NOTE To facilitate mounting the wheel can be lifted to the level of the wheel hub by means of appropriate equipment e g a forklift truck Check new wheel for proper working order then position it on the hub Do not damage the threads of the wheel bol...

Page 487: ...utrigger beam is extended and retracted speedily without getting seized 14 2 2 Outrigger beam C The outrigger beam B has been adjusted The outrigger beam C is adjusted via one slideway liner 3 and two slide pieces 4 The outriggers are extended completely the engine in the chassis has been stopped the parking brake is engaged Check dimension S2 if the backlash exceeds 3 mm it must be readjusted Rel...

Page 488: ...ioned The readjustment must be performed on the cup spring package 8 after having loosened the cup spring package 9 Cup spring package 9 Release the locknut 7 To release the cup spring package 9 release the tightening nut 5 by approx three turns this corresponds to approx 6 mm Hold tightening nut 5 and lock it using locknut 7 Cup spring package 8 Release the locknut 7 Tighten the tightening nut 6 ...

Page 489: ... must be extended and retracted for checking Check the setting dimension D E and F in case of cup spring package 8 and if necessary correct Mount covers again Retract and secure outriggers as described under item B1 6 Move outrigger flats into on road driving condition and pin fasten them Covers to be removed for service and maintenance work I Cover rear right hand II Cover front right hand III Co...

Page 490: ...C1 14 Outriggers 4 6 0305_EN_FA036_C1_14_00_00_FA029 2003 03 Memo ...

Page 491: ...Outriggers C1 14 0305_EN_FA036_C1_14_00_00_FA029 2002 12 5 6 cont d 14 Outriggers ...

Page 492: ...C1 14 Outriggers 6 6 0305_EN_FA036_C1_14_00_00_FA029 2002 12 cont d 14 Outriggers ...

Page 493: ...fins should be blown out at regular intervals of 500 service hours using compressed air in the direction opposite to the air supply This can be performed while the heat exchanger remains mounted However the air cleaner and the blower fan must be removed previously 15 1 2 Blower fan The blower fan slide in module can be pulled out to the back after the rear panel has been removed To reach an optimu...

Page 494: ...n and filling stations recovery stations electronic leak detectors and special tools which are only available in specialist workshops Correct disposal of fluids is also only ensured in a specialized workshop In the scope of the maintenance operations which are to be performed at least twice per year by the vehicle s operator all movable parts such as shaft bearings and articulations of levers must...

Page 495: ...sure that chalk and iron deposits are removed For cleaning of heat exchanger fins refer to item 15 3 3 Evaporator 15 3 5 Blower fan To reach an optimum service life the electric motor and the fan wheel must be blown out gently with compressed air at regular intervals of 500 service hours Attention Make sure that the position of any balancing clips on the impeller is not changed 15 3 6 Air cleaner ...

Page 496: ...e filling If parts have been replaced during repair then the quantities specified for the replaced component must be added additionally adhere to the current information by the various manufacturers 15 4 Supplementary heater unit For instructions on operation service and maintenance of the heater unit please refer to the documents of the unit s manufacturer Make sure that the manufacturer s instru...

Page 497: ...ponents are e g Threads of the star shaped handles which serve to lock the lateral coverings Hinges of the lateral coverings Hinges of the engine servicing lid Hinges and pin securing devices of the tool kit 16 2 Replacement of filter in the fuel pipe of the supplementary heater unit The supplementary heating is supplied with fuel from the fuel tank of the chassis It is recommended to replace the ...

Page 498: ...klash Move the coupling head not the coupling jaw funnel with both hands in longitudinal direction Make sure that no longitudinal backlash is noticeable 16 3 1 4 Inspection of the vertical bearing backlash Open the coupling hand actuated lever in 1st locking position Insert a bent tire lever so that the top side of the lever touches the coupling jaw and its underside rests against the coupling bod...

Page 499: ...n the coupling hand actuated lever in 1st lock Loosen the screws at the bottom part Push the coupling jaw to the right left until the release lever is engaged Tighten the screws tightening torque 49 Nm To engage press the hand lever into the 2nd lock position 16 3 1 10 Inspection Close the coupling device hand lever down Push the coupling jaw slightly to the left or right Open the coupling hand ac...

Page 500: ...hem 16 7 Centralized lubrication system For instructions on operation service and maintenance along with the data regarding lubricants and the lubricating points please refer to the information supplied by the unit s manufacturer see Part G1 Chassis Make sure that the manufacturer s instructions are observed 16 8 Supplementary heater unit For instructions on operation service and maintenance of th...

Page 501: ...blies Maintenance point Oil type Filling type Filling capacity Engine Engine oils according to the DC consumables specification Initial filling with SAE 15W 40 Refer to DC Operating Manual Coolants anti freeze agents Coolants according to the DC Operating Manual Anti freeze agents according to the DC fuel specifications approx 90 l Fuel tank Diesel fuel EN 590 approx 530 l Gearbox For oil types an...

Page 502: ...3 l each Axle drive assembly 2nd axle approx 21 0 l Planetary gears 4th axle approx 1 3 l each Axle drive assembly 4th axle approx 22 0 l Planetary gears 5th axle approx 1 3 l each Axle drive assembly 5th axle approx 19 0 l Hypoid gear oil SAE 90 according to MIL L 2105 B API GL 5 Hypoid gear oil with multigrade properties according to MIL L 2105 C D API GL 5 SAE 90 or multigrade oils at normal ou...

Page 503: ...pray Extension and retracting chain Preservation lubricant specification BB DIN 51513 or bituminous cogwheel spray for ring gears as required Sliding surfaces Lubricating paste containing MoS2 Cu or Al Outrigger floats Makroflon HSII Centralized lubrication system Grease tank Lubricating grease lithium saponified according to DIN 51825 KP2K 20 as required Batteries Terminal grease as required Spre...

Page 504: ...C1 25 Summary of lubricating grease types recommended grease types 2 2 0325_EN_FA036_C1_25_00_00_FA029 2003 03 Memo ...

Page 505: ...F CROWN Grease No 2 243 K to 393 K Engrenage 3 263 K to 393 K GULF LUBCOTE No 2 253 K to 333 K Aralub HL 2 243 K to 393 K MOBILUX 2 243 K to 403 K Aralub LFZ 1 253 K to 403 K MOBILTAC 81 243 K to 393 K BP Energrease LS 2 243 K to 393 K Alvania Fett R 2 243 K to 403 K BP Energol WRL 243 K to 353 K Cardium Fluid C 255 K to 333 K Castrol Spheerol AP 2 253 K to 393 K Glissando FL 20 253 K to 393 K Cas...

Page 506: ...C1 26 Chart of approved consumables and lubricants 2 2 0330_EN_FA036_C1_26_00_00_FA029 2003 03 Memo ...

Page 507: ...ore start up daily C1 27 0335_EN_FA036_C1_27_00_00 2002 12 1 2 27 Inspection scheme before start up daily Check before start up Refer to Part C1 item Inspection K Coolant Check before start up Illustration of version 10 x 8 ...

Page 508: ...C1 27 Inspection scheme before start up daily 2 2 0335_EN_FA036_C1_27_00_00 2001 06 Memo ...

Page 509: ... to main tenance schedule Cleaning replacement refer to maintenance schedule Refer to Part C1 item F Cleaning and or re placement of filters refer to maintenance schedule E Breathers Inspection Cleaning Inspection refer to main tenance schedule Cleaning replacement refer to maintenance schedule Illustration of version 10 x 8 ...

Page 510: ...C1 28 Inspection and cleaning scheme 2 2 0340_EN_FA036_C1_28_00_00 2001 06 Memo ...

Page 511: ...evel inspection refer to maintenance schedule Refer to Part C1 item F Filter change refer to maintenance schedule Engine oil Hypoid gear oil Hydraulic oil Refrigerator oil and refrigerant Corrosion protective anti freeze agent coolant Use the recommended oil types Oil change refer to main tenance schedule Oil level inspection refer to maintenance schedule Illustration of version 10 x 8 ...

Page 512: ...C1 29 Oil coolant level inspection and change scheme 2 2 0345_EN_FA036_C1_29_00_00 2001 06 Memo ...

Page 513: ...0 Lubricating scheme Lubrication refer to maintenance schedule Refer to Part C1 Item Universal grease Special grease Use recommended grease types Clean lubricators before greasing Grease all the other parts using an oil can Lubrication refer to maintenance schedule ...

Page 514: ...C1 30 Lubricating scheme 2 2 0350_EN_FA036_C1_30_00_00 2001 06 Memo ...

Page 515: ...0355_EN_ALLGE_C_02_00_00 Part C2 Service and Maintenance Superstructure ...

Page 516: ......

Page 517: ... column Daily before start up The number of operating hours expiry of which calls for the specified maintenance work to be performed repeatedly have been marked by an X in the columns Regular maintenance every 125 250 500 1000 2000 operating hours e g every 500 operating hours i e after 500 1000 1500 etc operating hours have been reached every 2000 operating hours i e after 2000 4000 6000 etc oper...

Page 518: ...C2 1 Maintenance intervals 2 12 0360_EN_FA036_C2_01_00_00 2003 01 Memo ...

Page 519: ...r replacement 2 2 900 oper ating hour s Once per year Inspection of tight fit of the hose clamps of the charge air hoses 2 3 X Fuel tank drain condensed water 2 4 1 X Once per year If necessary earlier Fuel tank clean fuel strainer in the filler socket 2 4 2 X If necessary earlier Fuel tank check ventilation filter 2 4 2 1 X Once per year If necessary earlier Fuel strainer drain condensed water 2 ...

Page 520: ...imultaneously with each maintenance of the air cleaner Replacement of air cleaner cartridge 2 7 1 X And when the indicator air cleaner in the CGC goes on Check air intake pipes and hoses 2 7 3 X Check electrical vacuum switch on the air cleaner housing 2 7 4 If the indicator air cleaner in the CGC does not go on in spite of contamination of the air cleaner Monitoring the air cleaner 2 7 4 X During...

Page 521: ...3 2 1 1 As required Replace sinter filters if installed refer to hydraulic piping diagrams 3 2 2 If an operating malfunction occurs Oil change 3 3 X Every 2 years Take and analyse an oil sample at regular intervals Replacement of filter insert of pressure filter 3 5 X Oil cooler supplementary oil cooler clean cooler fins 3 7 X Oil cooler supplementary oil cooler check fan and thermostatic valve fo...

Page 522: ... on swing motor gearbox drive shaft 4 4 Once per year Grease ring gear and pinion of swing mechanism 4 5 X If necessary at shorter intervals depending on slewing frequency Grease ball bearing slewing device of race system supp lied via central lubrication 4 6 X If necessary at shorter intervals depending on slewing frequency Grease the lock pin 4 7 X Check mechanical super structure lock and proxi...

Page 523: ... change Check tooth face backlash 5 5 X Once per year Grease drum bearings supp lied via central lubrication 5 6 X Twice per year And after each cleaning operation using a steam jet unit Hoisting gear brake check disc package and free wheeling 5 8 X Once per year Check hoist limit switch for proper function 5 9 X During operation Check rope limit switch for proper function 5 10 X and simultaneousl...

Page 524: ...age 7 4 X If necessary earlier in case of contamination Check the automatic safe load indicator for proper working order 7 5 X Check automatic safe load indicator 7 6 X Crane cab Lubricate oil joints pins hinges and all movable components 8 X Every two weeks And after every crane cleaning operation using the high pressure steam jet blower Treat door locks closing cylinders 8 X Once per year Air co...

Page 525: ...ation service and maintenance Telescopic boom Oil grease slide pieces slideway linings slide bars crossheads and guide rollers 9 1 X Grease slideway linings of boom on top 9 1 1 Once per week Grease slideway linings of boom at the bottom 9 1 1 Once per week Grease boom laterally and at the bottom 9 1 1 Once per month Every 100 operating hours Grease telescope cylinder locks 9 1 1 Once per month Ev...

Page 526: ...r leakage 9 4 X Check locking cylinders for leakage 9 4 X Jib Grease and lubricate rope pulley support bearings and bolt securing mechanisms 9 5 X Centralized lubrication system Check fluid level in supply tank if necessary replenish 9 6 As required Check pipes and screw couplings for damage 9 6 X Other points of lubrication Lubricate joints pins hinges and all movable components 9 7 X Every two w...

Page 527: ...Maintenance intervals C2 1 0360_EN_FA036_C2_01_00_00 2003 01 11 12 Memo ...

Page 528: ...C2 1 Maintenance intervals 12 12 0360_EN_FA036_C2_01_00_00 2003 01 Memo ...

Page 529: ...ll The following general inspection servicing and maintenance operations at the engine such as Engine oil level inspection Engine oil change Replacement of lubricating oil filter Replacement of fuel filter cartridges Cleaning of fuel prefilter cartridges Inspection of Vee belt for good condition Checking the tappet clearance Performing troubleshooting etc have been described in the Operating Manua...

Page 530: ... installed as standard equip ment can be removed during the first oil change and replaced by a drain valve provided with the tool kit To this effect first drain the used oil then mount the drain valve with packing ring instead of the oil drain plug During subsequent oil changes only the cap 1 of the drain valve 2 need be removed and replaced by the oil drain hose 3 which is supplied with the took ...

Page 531: ... replace Insert plugscrew 1 together with the sealing element 2 and tighten it 2 4 2 Clean fuel strainer in the filler socket The filler socket for fuel is located on the left side behind the superstructure cabin Open the cover remove the fuel strainer 5 and clean it in a clean vessel using a cleaning agent or diesel fuel check and if necessary replace it Subsequently blow the fuel strainer 5 out ...

Page 532: ...ensate must be drained If necessary repeat this step several times 2 4 3 2 Replacement of fuel strainer Drain the entire filter contents as described under item 2 4 3 1 Disconnect the filter 4 from the filter top 5 together with the filter base 2 Disconnect the filter base from the filter clean the filter base e g using diesel fuel Clean the sealing surfaces Grease new sealing elements with diesel...

Page 533: ...he expansion tank 3 If necessary add or replace the anti freeze agent approved by the engine manufacturer Check the anti freeze protection using a test instrument The components must be frost proof down to 37 C all the year round When the coolant is replaced or the cooling system has to be refilled after repair the whole cooling system must be bled NOTE In case of possible leakage at the radiator ...

Page 534: ...rain plug and pour in coolant mix via the overflow tank Start the engine make it run at various speed levels for approx 1 minute Stop the engine and check the coolant level in the overflow tank if necessary top up Coolant must be disposed of in an environmentally responsible fashion NOTE For instructions how to drain the entire coolant from the engine refer to the engine manufacturer s operating m...

Page 535: ...below the air cleaner fairing Open servicing lid 1 after having released the lock 2 The air cleaner 3 is accessible for maintenance purposes 2 7 1 Removal installation of the air cleaner cartridge Open the retaining clips 1 of the cover Remove the cover 2 from the air cleaner housing Pull the air cleaner 3 out of the air cleaner housing Clean the air cleaner housing and the sealing surfaces of the...

Page 536: ...ng procedures 2 7 2 2 Disposal Air cleaner cartridges must be disposed of in an environmentally responsible fashion 2 7 3 Check air intake pipes and hoses Check all hose connections between the air cleaner and the engine and the charge air hoses for tight fit Use screw type hose clamps only Check hoses and pipes for porosity and cracks 2 7 4 Inspection of electric vacuum switch on the clean air en...

Page 537: ...e any particular service or maintenance 2 8 1 Servicing the silencer spark arrester Cleaning the soot collector To remove the soot particles collected in the soot collector 1 remove the cap 2 To ensure that the spark arrester is always in proper working order the soot recipient must be emptied at regular intervals Optional equipment ...

Page 538: ...C2 2 Engine 10 10 0365_EN_FA036_C2_02_00_00 2003 01 Memo ...

Page 539: ...aulic oil is poured in from clean vessels 3 2 Replacement of filter cartridges DANGER Replace the filter cartridges only while the engine is at a standstill NOTE The individual components installed in the valves pumps and hydraulic motors have deliberately narrow tolerances Even very small impurities penetrating the hydraulic system may cause malfunctions The filter cartridge must be replaced simu...

Page 540: ...il hydraulic oil is leaving Drain the hydraulic oil completely into a suitable container Close the drain plug Reposition the cap Replace the filter cartridge as described under item 3 2 Eliminate any impurities after having removed the cover 9 Rinse the tank using diesel petroleum etc Make sure that no impurities remain in the tank Eliminate rinsing liquid completely Clean sealing surfaces clean s...

Page 541: ...ance schedule In case of leakage of the adjustable screw couplings and assemblies proceed as follows first release the cap nuts on the piping systems or hose pipes then tighten the adjustable screw couplings in the assemblies safely finally fasten the cap nuts of the piping systems and hose pipes again Perfectly sealing condition is only ensured if the above sequence of operations is observed and ...

Page 542: ...t to neutral the engine in the chassis is at a standstill the parking brake has been engaged The boom is directed over front and stowed in its rest all tele sections are retracted Remove the cover 1 Start the engine in the superstructure as described have it run at increased speed level Put the tele section emergency control into operation as described under item B2 6 4 3 1 Release vent screws 1 4...

Page 543: ...ck in the hydraulic system of the superstructure In the case of an operating malfunction of the hydraulic system of the superstructure the set point pressures of the various pressure ranges can be checked at max engine speed by unscrewing the pipes from the measuring connectors on the valves and control blocks which are marked with M in the figure and by fastening hydraulic pressure gauges to thes...

Page 544: ... pressure reduction extending I 145 bar M12 Max Boom elevation secondary down 30 bar M12 Max Boom elevation secondary up 345 bar M12 Max Triple control block tele section 2 winch auxiliary winch primary II 350 bar M6 Max Winch secondary down III 110 bar M11 Max Auxiliary winch secondary down III 100 bar M11 Max Control block counterweight up 210 bar M5 Max Counterweight secondary down 100 bar M5 a...

Page 545: ...oil level once more if necessary replenish Attention Different oil types even if from the same manufacturer must not be mixed Moreover mineral and synthetic oil must not be mixed 4 2 Oil change Perform the oil change at regular intervals according to the maintenance plan when the system has its service temperature DANGER Risk of scalding Drain oil into an appropriate vessel through the drain port ...

Page 546: ... motor and the brake should be removed and the splined shaft connections on the drive end checked at regular intervals No excessive tooth face backlash is admissible After the running in period the tooth faces show a smooth bright surface in case of normal wear If there are other phenomena such as scrub marks seizing pits flaking blistering cracks and plastic deformations the gear wheels must be r...

Page 547: ...whole circumference of the bearing grooves To achieve uniform grease distribution support the crane by outriggers and slew the superstructure while re greasing DANGER CAUTION during slewing operation Nobody is allowed to stay on the chassis For slewing it is essential that the crane is supported by outriggers 4 7 Greasing the swing lock pin The lock pin of the superstructure locking system must al...

Page 548: ...gearbox flange bolts for tight fit according to the maintenance schedule if necessary re tighten Attention It is essential to use a torque wrench for checking or re tightening the screws and bolts Tightening torques of ring gear connecting bolts M 30 1805 95 Nm hydraulic motor securing bolts M 12 89 Nm 5 Nm gearbox flange bolts M 20 546 Nm 14 Nm 4 11 Checking the slewing device for wear During the...

Page 549: ...ked visually inside and outside at intervals of three years 5 1 Check for correct oil level and leakage Check the hoisting gear for leakage at regular intervals according to the maintenance schedule Defective seals may affect the service life of the hoisting gear considerably Loss of oil or an insufficient oil level in the gearbox may result in damage Check oil level at regular intervals according...

Page 550: ...of scalding If e g coarse impurities are detected they may be due to excessive stress or improper operation Determine the cause and eliminate it Dismantle the hoisting gear check it for damage If necessary have a general overhaul be performed by the manufacturer Check oil for possible blackening and foreign matter if necessary reduce oil change intervals 5 3 Oil level inspection in motor coupling ...

Page 551: ...o be decommissioned for an extended time preservation of the hoisting gear is recommended Drain the used oil and pour in half the quantity of preservative oil Actuate the hoisting gear for approx 5 to 10 minutes winding and unwinding the rope without load using a high number of rope falls On re commissioning the machine drain the preservative oil and pour in the specified oil type Only such types ...

Page 552: ...rane movements are possible again 5 10 Checking the hoist limit switch on the hoisting gear The rope limit switch is set so that at least three safety rope windings remain on the drum Extend the telescopes and wind off the rope until at least three rope windings remain on the drum Now the hoisting gear must shut off NOTE Before winding up the rope check the rope drum and the rope grooves for wear ...

Page 553: ...es 6 2 Cleaning and lubrication of the winch rope To prolong the service life of the winch ropes wash severely soiled winch ropes down with clear water at regular intervals and grease them after drying To protect the winch ropes against humidity and corrosion grease them at regular intervals using an adhesive grease It is not sufficient to grease the winch rope only on the outside The lubricant mu...

Page 554: ...e moved under moderate load and the load must be increased gradually to its maximum rating so that the winch rope is allowed to run in to settle and to lengthen 6 6 Care to the winch rope Regular care to the winch rope helps ensure safety during crane operation and is essential for enhancing the winch rope s service life considerably Metallic winch ropes must be re greased at regular intervals dep...

Page 555: ...ately with ample quantities of tap water and if necessary consult a doctor Attention Used batteries must be disposed of in an environmentally responsible fashion The batteries are installed on the right side of the superstructure viewed in driving direction on the front end below the cover For battery maintenance open the servicing lid 1 by unlocking the square head bolt 2 and remove the battery c...

Page 556: ...on immediately governor or alternator 7 1 2 Installation of new batteries When installing new batteries first connect the positive cable and then the negative cable For removal reverse sequence of installation operations 7 2 Three phase generator The service life of the three phase generator depends considerably on the bearings Thus make sure that the Vee belts have always the proper tension refer...

Page 557: ...c components of modular design which must be serviced exclusively by qualified service staff Every time before the crane operator puts the machine into operation he must make sure that the ASLI is not restricted in its functionality by external destruction the hoist limit switch its weight and chain are correctly mounted the electric cable connections are inserted the cables are correctly wound up...

Page 558: ...C2 7 Electrical equipment 4 10 0390_EN_FA036_C2_07_00_00 2003 01 Memo ...

Page 559: ...ctric horn F827 Working floodlight on boom electrically adjustable 25 A F846 Length transmitter angle transmitter anemometer F809 Crane control hoist winches F828 free F847 AML Valve SCK buzzer Equipment according to the country where the ma chine is to be registered F810 Crane control swing brake high speed F829 Working floodlight hoisting gear F848 LCD Monitor F811 Crane control F830 Aircraft wa...

Page 560: ...lescope K 982 Crane control emergency mode V 914 Crane control emer gency mode swing brake K 954 Crane control emergen cy mode boom elevation up K 970 Tele control emergency mode V 907 AML override actuated K 952 Crane control emer gency mode hoisting gear down K 972 Tele control emergency mode K 817 Generator D V 913 Crane control emergency mode V 803 CGC supply K 919 AML shut off feature K 961 C...

Page 561: ...Electrical equipment C2 7 0390_EN_FA036_C2_07_00_00 2001 06 7 10 7 7 Fuse relay arrangement cond t ...

Page 562: ...quipment 8 10 0390_EN_FA036_C2_07_00_00 2001 06 7 7 1 Fuses in battery box 1 F 863 Fuse charging plugbox 25 A 2 F 862 Fuse battery 25 A 3 F 861 Fuse battery battery main switch 50 A 99707792061 0 0705 Optional equipment ...

Page 563: ...Electrical equipment C2 7 0390_EN_FA036_C2_07_00_00 2003 01 9 10 Memo ...

Page 564: ...C2 7 Electrical equipment 10 10 0390_EN_FA036_C2_07_00_00 2003 01 Memo ...

Page 565: ...stations recovery stations electronic leak detectors and special tools which are only available in specialist workshops Correct disposal of fluids is also only ensured in a specialized workshop Oil level inspection of air conditioning compressor The oil level in the compressor can only be checked after a repair or every time before the air conditioning system is filled with new refrigerant No refr...

Page 566: ...se disassembly procedure 2 1 3 8 2 2 Windshield washing system The tank of the windshield washing system is accessible after opening of the windshield 8 3 Supplementary heater unit For instructions on operation service and maintenance of the heater unit please refer to the documents of the unit s manufacturer Make sure that the manufacturer s instructions are observed 8 3 1 Replacement of the fuel...

Page 567: ...tor has been designed for a temperature range from 20 C to 70 C 8 6 Cleaning the recirculated air filter The recirculated air filter 3 for the fan and the air conditioning is located between the protective grille 2 in the floor assembly 1 behind the seat If the recirculated air filter 3 is visibly clogged by relatively big particles it must be cleaned The cleaning intervals required depend greatly...

Page 568: ...C2 8 Crane cab 4 4 0395_EN_FA036_C2_08_00_00_FA029 2003 01 Memo ...

Page 569: ... boom the boom must be directed forward in driving direction and max 2 tele sections may be extended simultaneously During telescoping operations or during boom elevation up down persons are not allowed to stay in the work range NOTE To grease the telescopes select the boom state maintenance as described in the AML operation manual Attention If telescoping is required to get access to the points o...

Page 570: ...rizontally Grease the lubricators lock cylinder according to the maintenance schedule Repeat the process until all lubricators have been greased Telescope position points of lubrication The tele sections are retracted completely The points of lubrication 1 can be greased Tele section 1 is extended 100 The points of lubrication 3 and 9a for tele section 1 and 9b for tele section 2 can be greased Te...

Page 571: ...ls depend on the number of service operating under extreme operating conditions lubrication may have to be effected earlier than specified in the maintenance schedule DANGER Welding on any components of the bottom block is not admissible 9 4 Counterweight Check counterweight cylinders for leakage according to the maintenance schedule Check the cylinders for correct fastening Check locking cylinder...

Page 572: ...lubrication Grease joints pins and all movable components such as hinges of the engine servicing lid hinges of the servicing lid for the air cleaner and the batteries hinges of the working floodlight adjusting device etc by means of lubricating oil Make sure that these parts move unrestrictedly and are easy to operate ...

Page 573: ...ti freeze agents according to the DC fuel specifications approx 25 l Fuel tank Diesel fuel EN 590 approx 250 l Hydraulic system Ambient temperature Mineral oils according to DIN 51524 2 Biodegradable oils according to VDMA 24568 approx 1 050 l over 30 C HVLP 68 HEES 68 Oil tank from 5 C to 25 C HLP 46 HEES 46 approx 920 l below 5 C to 15 C HLP 32 HEES 32 from 15 C to 25 C HLP 22 HEES 22 below 25 C...

Page 574: ...C2 15 Summary of oil types and filling capacities 2 2 0405_EN_FA036_C2_15_00_00 2003 03 Memo ...

Page 575: ...cy grade 2 DIN 51818 as required Tele section slide pieces slideway liners Long term lubricant We recommend FAUN LUB Slide bars slide jaws Guide elements from 40 C to 125 C NLGI grade no 1 Penetration 310 340 Dropping point 180 C from 30 C to 150 C NLGI grade no 2 Penetration 265 295 Dropping point 185 C as required Telescopic boom Locking mechanism for boom elevation cylinder and boom Lithium sap...

Page 576: ...C2 16 Summary of lubricating grease types recommended grease types 2 2 0410_EN_FA036_C2_16_00_00_FA029 2003 03 Memo ...

Page 577: ...F CROWN Grease No 2 243 K to 393 K Engrenage 3 263 K to 393 K GULF LUBCOTE No 2 253 K to 333 K Aralub HL 2 243 K to 393 K MOBILUX 2 243 K to 403 K Aralub LFZ 1 253 K to 403 K MOBILTAC 81 243 K to 393 K BP Energrease LS 2 243 K to 393 K Alvania Fett R 2 243 K to 403 K BP Energol WRL 243 K to 353 K Cardium Fluid C 255 K to 333 K Castrol Spheerol AP 2 253 K to 393 K Glissando FL 20 253 K to 393 K Cas...

Page 578: ...C2 17 Chart of approved consumables and lubricants 2 2 0415_EN_FA036_C2_17_00_00_FA029 2003 03 Memo ...

Page 579: ...tion scheme before start up daily C2 18 0420_EN_FA036_C2_18_00_00 2002 12 1 2 18 Inspection scheme before start up daily Check before start up Refer to Part C2 item Inspection K Coolant Check before start up ...

Page 580: ...C2 18 Inspection scheme before start up daily 2 2 0420_EN_FA036_C2_18_00_00 2001 06 Memo ...

Page 581: ...Inspection refer to maintenance schedule Cleaning replacement refer to maintenance schedule Refer to Part C2 Item F Cleaning and or re placement of fil ters refer to main tenance schedule E Breathers Inspection Cleaning Inspection refer to maintenance schedule Cleaning replacement refer to maintenance schedule ...

Page 582: ...C2 19 Inspection and cleaning scheme 2 2 0425_EN_FA036_C2_19_00_00 2001 06 Memo ...

Page 583: ...intenance schedule Oil level inspection refer to maintenance schedule Refer to Part C2 Item F Filter change refer to maintenance schedule Engine oil Hydraulic oil Refrigerator oil and refrigerant Corrosion protective anti freeze agent coolant Use the recommend ed oil types Oil change refer to maintenance schedule Oil level inspection refer to maintenance schedule ...

Page 584: ...C2 20 Oil coolant level inspection and change scheme 2 2 0430_EN_FA036_C2_20_00_00 2001 06 Memo ...

Page 585: ...1 Lubricating scheme Lubrication refer to maintenance schedule Refer to Part C2 Item Universal grease Special grease Use recommended grease types Clean lubricators before greasing Grease all the other parts using an oil can Lubrication refer to maintenance schedule ...

Page 586: ...C2 21 Lubricating scheme 2 2 0435_EN_FA036_C2_21_00_00 2001 06 Memo ...

Page 587: ...0440_EN_ALLGE_D_00_00_00 Part D Circuit and piping diagrams ...

Page 588: ......

Page 589: ... Loudspeaker right hand B809 Timer heating B902 AML buzzer B904 Rotation transmitter hoisting gear 1 B905 Buzzer ASLI shut off feature B908 Rotation transmitter hoisting gear 2 B909 Anemometer B909 Connector anemometer B909 Connector anemometer B911 Rotation pulse transmitter hoisting gear 1 B912 Rotation pulse transmitter hoisting gear 2 B913 Buzzer swing mechanism active B916 Displacement sensor...

Page 590: ...3 Relay battery main switch time delayed K015 Relay eddy current brake K016 Relay box K023 Relay eddy current brake K024 Relay eddy current brake K025 Relay eddy current brake K026 Relay eddy current brake K027 Relay eddy current brake shut off K030 Relay working speed K033 Relay heater unit 58 K036 Relay CGC supply K037 Relay air conditioner K038 Relay clutch air conditioner K039 Relay condenser ...

Page 591: ... Light switch S007 Steering column switch Intermittent wiper action Washer S008 Steering column switch High beam dimmed light horn S009 Steering column switch direction indicators S010 Rocker switch super tone horn S011 Rocker switch fog light S012 Hazard warning flasher switch hazard warning flashers with indicator lamp S013 Key actuated change over switch chassis superstructure S013 Key actuated...

Page 592: ... limit switch top jib S981 Hoist limit switch single top S981 Hoist limit switch single top S985 Hoist limit switch heavy lift fly jib S990 Rocker switch rope winch rotation transmitter S993 Rocker tip switch monitor S994 Rocker switch with indicator lamp lockout of swing range limitation S996 Rocker switch indication of hook height hoisting gear 1 S997 Rocker switch indication of hook height hois...

Page 593: ...r beams Y801 Fuel pump Y901 Solenoid valve crane control control pressure Y902 Solenoid valve boom elevation down Y903 Solenoid valve hoisting gear 1 down Y904 Solenoid valve hoisting gear 1 up Y905 Solenoid valve extending tele Y906 Solenoid valve hoisting gear 2 down Y907 Solenoid valve hoisting gear 2 up Y908 Solenoid valve retracting tele Y909 Solenoid valve boom elevation up Y910 Solenoid val...

Page 594: ...Swing mechanism Drehwinkel Swing angle Ein on entr entriegeln Unlocked unlocking EURO Steuerung EURO control Fahrersitz Driver s seat Fahrschalt Gear selector switch Fahrtrichtung Driving direction FAUN Steuerung FAUN control system FBA Federspeicherbremsanlage Air accumulator brake system Federung Suspension Federungszylinder Suspension cylinder Folientastatur CGC Membrane keypad CGC Funktion Fun...

Page 595: ...tracting rear outrigger beams left hand Stützträger hi re ausfahren Extending rear outrigger beams right hand Stützträger hi re einfahren Retracting rear outrigger beams right hand Stützträger vo li ausfahren Extending front outrigger beams left hand Stützträger vo li einfahren Retracting front outrigger beams left hand Stützträger vo re ausfahren Extending front outrigger beams right hand Stütztr...

Page 596: ... clutch and gearbox NV Connector or auxiliary equipment Re Chapter D1 2 page 1 2 List of functionalities not for materials planning Functions of valves according to designation of electr connector Item Designation Qty Y002 Transfer box off road gear 001 3 2 way valve 5 Y006 Connection of 2nd axle 002 3 2 way valve 2 Y007 Inter wheel differential lock in axles 003 5 2 way valve 1 Y008 Diff transfer...

Page 597: ...0445_EN_ALLGE_D1_00_00_00 Part D1 Circuit and piping diagrams Chassis ...

Page 598: ......

Page 599: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 34 1 Electric circuit diagrams 1 1 Chassis 99707782035 ...

Page 600: ...D1 1 Electric circuit diagrams 2 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 601: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 3 34 ...

Page 602: ...D1 1 Electric circuit diagrams 4 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 603: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 5 34 ...

Page 604: ...D1 1 Electric circuit diagrams 6 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 605: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 7 34 ...

Page 606: ...D1 1 Electric circuit diagrams 8 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 607: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 9 34 ...

Page 608: ...D1 1 Electric circuit diagrams 10 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 609: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 11 34 ...

Page 610: ...D1 1 Electric circuit diagrams 12 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 2 ABV 99707782035 ...

Page 611: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 13 34 1 3 Gearbox control 99707782035 ...

Page 612: ...D1 1 Electric circuit diagrams 14 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 613: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 15 34 1 4 Chassis 99707782035 ...

Page 614: ...D1 1 Electric circuit diagrams 16 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 615: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 17 34 ...

Page 616: ...D1 1 Electric circuit diagrams 18 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 617: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 19 34 ...

Page 618: ...D1 1 Electric circuit diagrams 20 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 619: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 21 34 ...

Page 620: ...D1 1 Electric circuit diagrams 22 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 621: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 23 34 ...

Page 622: ...D1 1 Electric circuit diagrams 24 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 623: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 25 34 ...

Page 624: ...D1 1 Electric circuit diagrams 26 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 ...

Page 625: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 27 34 ...

Page 626: ...D1 1 Electric circuit diagrams 28 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 5 CAN connections 99707782035 ...

Page 627: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 29 34 1 6 Chassis 99707782035 ...

Page 628: ...D1 1 Electric circuit diagrams 30 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 7 Eddy current brake 99707782035 ...

Page 629: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 31 34 1 8 Connection diagram Slipring 99707782068 ...

Page 630: ...D1 1 Electric circuit diagrams 32 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 9 Emergency OFF Engine STOP stalling device 99707782491 ...

Page 631: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029 2003 02 33 34 1 10 Heater unit Webasto Thermo 90S 99707792167 ...

Page 632: ...D1 1 Electric circuit diagrams 34 34 0450_EN_FA036_D1_01_00_00_FA029 2003 02 1 11 Heater unit Webasto Air Top 3500 99707782214 ...

Page 633: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 34 1 Electric circuit diagrams 1 1 Chassis 99707782035 ...

Page 634: ...D1 1 Electric circuit diagrams 2 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 635: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 3 34 ...

Page 636: ...D1 1 Electric circuit diagrams 4 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 637: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 5 34 ...

Page 638: ...D1 1 Electric circuit diagrams 6 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 639: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 7 34 ...

Page 640: ...D1 1 Electric circuit diagrams 8 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 641: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 9 34 ...

Page 642: ...D1 1 Electric circuit diagrams 10 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 643: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 11 34 ...

Page 644: ...D1 1 Electric circuit diagrams 12 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 2 ABV 99707782035 ...

Page 645: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 13 34 1 3 Gearbox control 99707782035 ...

Page 646: ...D1 1 Electric circuit diagrams 14 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 647: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 15 34 1 4 Chassis 99707782035 ...

Page 648: ...D1 1 Electric circuit diagrams 16 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 649: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 17 34 ...

Page 650: ...D1 1 Electric circuit diagrams 18 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 651: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 19 34 ...

Page 652: ...D1 1 Electric circuit diagrams 20 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 653: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 21 34 ...

Page 654: ...D1 1 Electric circuit diagrams 22 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 655: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 23 34 ...

Page 656: ...D1 1 Electric circuit diagrams 24 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 657: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 25 34 ...

Page 658: ...D1 1 Electric circuit diagrams 26 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 ...

Page 659: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 27 34 ...

Page 660: ...D1 1 Electric circuit diagrams 28 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 5 CAN connections 99707782035 ...

Page 661: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 29 34 1 6 Chassis 99707782035 ...

Page 662: ...D1 1 Electric circuit diagrams 30 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 7 Eddy current brake 99707782035 ...

Page 663: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 31 34 1 8 Connection diagram Slipring 99707782068 ...

Page 664: ...D1 1 Electric circuit diagrams 32 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 9 Emergency OFF Engine STOP stalling device 99707782491 ...

Page 665: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 33 34 1 10 Heater unit Webasto Thermo 90S 99707792167 ...

Page 666: ...D1 1 Electric circuit diagrams 34 34 0450_EN_FA036_D1_01_00_00_FA029_AB104 2003 02 1 11 Heater unit Webasto Air Top 3500 99707782214 ...

Page 667: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 34 1 Electric circuit diagrams 1 1 Chassis 99707782035 ...

Page 668: ...D1 1 Electric circuit diagrams 2 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 669: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 3 34 ...

Page 670: ...D1 1 Electric circuit diagrams 4 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 671: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 5 34 ...

Page 672: ...D1 1 Electric circuit diagrams 6 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 673: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 7 34 ...

Page 674: ...D1 1 Electric circuit diagrams 8 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 675: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 9 34 ...

Page 676: ...D1 1 Electric circuit diagrams 10 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 677: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 11 34 ...

Page 678: ...D1 1 Electric circuit diagrams 12 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 2 ABV 99707782035 ...

Page 679: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 13 34 1 3 Gearbox control 99707782035 ...

Page 680: ...D1 1 Electric circuit diagrams 14 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 681: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 15 34 1 4 Chassis 99707782035 ...

Page 682: ...D1 1 Electric circuit diagrams 16 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 683: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 17 34 ...

Page 684: ...D1 1 Electric circuit diagrams 18 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 685: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 19 34 ...

Page 686: ...D1 1 Electric circuit diagrams 20 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 687: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 21 34 ...

Page 688: ...D1 1 Electric circuit diagrams 22 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 689: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 23 34 ...

Page 690: ...D1 1 Electric circuit diagrams 24 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 691: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 25 34 ...

Page 692: ...D1 1 Electric circuit diagrams 26 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 ...

Page 693: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 27 34 ...

Page 694: ...D1 1 Electric circuit diagrams 28 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 5 CAN connections 99707782035 ...

Page 695: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 29 34 1 6 Chassis 99707782035 ...

Page 696: ...D1 1 Electric circuit diagrams 30 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 7 Eddy current brake 99707782035 ...

Page 697: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 31 34 1 8 Connection diagram Slipring 99707782068 ...

Page 698: ...D1 1 Electric circuit diagrams 32 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 9 Emergency OFF Engine STOP stalling device 99707782491 ...

Page 699: ...Electric circuit diagrams D1 1 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 33 34 1 10 Heater unit Webasto Thermo 90S 99707792167 ...

Page 700: ...D1 1 Electric circuit diagrams 34 34 0450_EN_FA036_D1_01_00_00_FA029_AB106 2003 02 1 11 Heater unit Webasto Air Top 3500 99707782214 ...

Page 701: ...Pneumatic diagrams D1 2 0455_EN_FA036_D1_02_00_00 2003 02 1 2 2 Pneumatic diagrams 2 1 Compressed air system 99707784033_01 ...

Page 702: ...D1 2 Pneumatic diagrams 2 2 0455_EN_FA036_D1_02_00_00 2003 02 2 2 Compressed air system 99707784033_02 ...

Page 703: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 1 14 3 Hydraulic piping diagrams 3 1 Hydraulic system 99707017085 ...

Page 704: ...D1 3 Hydraulic piping diagrams 2 14 0460_EN_FA036_D1_03_00_00 2003 02 Memo ...

Page 705: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 3 14 ...

Page 706: ...D1 3 Hydraulic piping diagrams 4 14 0460_EN_FA036_D1_03_00_00 2003 02 Memo ...

Page 707: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 5 14 ...

Page 708: ...D1 3 Hydraulic piping diagrams 6 14 0460_EN_FA036_D1_03_00_00 2003 02 3 2 Steering 99707017084 ...

Page 709: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 7 14 Memo ...

Page 710: ...D1 3 Hydraulic piping diagrams 8 14 0460_EN_FA036_D1_03_00_00 2003 02 ...

Page 711: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 9 14 3 3 Transfer box 99707783346 ...

Page 712: ...D1 3 Hydraulic piping diagrams 10 14 0460_EN_FA036_D1_03_00_00 2003 02 3 4 Front outriggers 99707791175 ...

Page 713: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 11 14 3 5 Rear outriggers 99707791176 ...

Page 714: ...D1 3 Hydraulic piping diagrams 12 14 0460_EN_FA036_D1_03_00_00 2003 02 3 6 Oil tank 99707793659 ...

Page 715: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00 2003 02 13 14 3 7 Motor 99707783371 ...

Page 716: ...D1 3 Hydraulic piping diagrams 14 14 0460_EN_FA036_D1_03_00_00 2003 02 3 8 Emergency control 99707785508 ...

Page 717: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 1 14 3 Hydraulic piping diagrams 3 1 Hydraulic system 99707017085 ...

Page 718: ...D1 3 Hydraulic piping diagrams 2 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 Memo ...

Page 719: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 3 14 ...

Page 720: ...D1 3 Hydraulic piping diagrams 4 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 Memo ...

Page 721: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 5 14 ...

Page 722: ...D1 3 Hydraulic piping diagrams 6 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 3 2 Steering 99707017084 ...

Page 723: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 7 14 Memo ...

Page 724: ...D1 3 Hydraulic piping diagrams 8 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 ...

Page 725: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 9 14 3 3 Transfer box 99707783346 ...

Page 726: ...D1 3 Hydraulic piping diagrams 10 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 3 4 Front outriggers 99707791175 ...

Page 727: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 11 14 3 5 Rear outriggers 99707791176 ...

Page 728: ...D1 3 Hydraulic piping diagrams 12 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 3 6 Oil tank 99707793659 ...

Page 729: ...Hydraulic piping diagrams D1 3 0460_EN_FA036_D1_03_00_00_AB104 2003 02 13 14 3 7 Motor 99707783371 ...

Page 730: ...D1 3 Hydraulic piping diagrams 14 14 0460_EN_FA036_D1_03_00_00_AB104 2003 02 3 8 Emergency control 99707785508 ...

Page 731: ...0465_EN_ALLGE_D2_00_00_00 Part D2 Circuit and piping diagrams Superstructure ...

Page 732: ......

Page 733: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 1 42 1 Electric circuit diagrams 1 1 Chassis control system 99707792040 ...

Page 734: ...D2 1 Electric circuit diagrams 2 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 735: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 3 42 ...

Page 736: ...D2 1 Electric circuit diagrams 4 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 737: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 5 42 1 2 Superstructure 99707792040 ...

Page 738: ......

Page 739: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 7 42 ...

Page 740: ...D2 1 Electric circuit diagrams 8 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 741: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 9 42 ...

Page 742: ...D2 1 Electric circuit diagrams 10 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 743: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 11 42 ...

Page 744: ...D2 1 Electric circuit diagrams 12 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 745: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 13 42 ...

Page 746: ...D2 1 Electric circuit diagrams 14 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 747: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 15 42 ...

Page 748: ...D2 1 Electric circuit diagrams 16 42 0470_EN_FA036_D2_01_00_00 2003 02 1 3 AML 99707792040 ...

Page 749: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 17 42 1 4 Crane control 99707792040 ...

Page 750: ...D2 1 Electric circuit diagrams 18 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 751: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 19 42 ...

Page 752: ...D2 1 Electric circuit diagrams 20 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 753: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 21 42 ...

Page 754: ...D2 1 Electric circuit diagrams 22 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 755: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 23 42 ...

Page 756: ......

Page 757: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 25 42 ...

Page 758: ...D2 1 Electric circuit diagrams 26 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 759: ......

Page 760: ......

Page 761: ......

Page 762: ...D2 1 Electric circuit diagrams 30 42 0470_EN_FA036_D2_01_00_00 2003 02 1 7 Telescope control 99707792040 ...

Page 763: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 31 42 ...

Page 764: ...D2 1 Electric circuit diagrams 32 42 0470_EN_FA036_D2_01_00_00 2003 02 ...

Page 765: ......

Page 766: ...D2 1 Electric circuit diagrams 34 42 0470_EN_FA036_D2_01_00_00 2003 02 1 9 AML 99707792040 ...

Page 767: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 35 42 1 10 Jib 99707792040 ...

Page 768: ...D2 1 Electric circuit diagrams 36 42 0470_EN_FA036_D2_01_00_00 2003 02 1 11 Heavy lift fly jib single top 99707792040 ...

Page 769: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 37 42 1 12 Superstructure 99707792040 ...

Page 770: ...D2 1 Electric circuit diagrams 38 42 0470_EN_FA036_D2_01_00_00 2003 02 1 13 Webasto heating type Thermo 90 99707792040 ...

Page 771: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 39 42 1 14 Air conditioning system 99707792040 ...

Page 772: ...D2 1 Electric circuit diagrams 40 42 0470_EN_FA036_D2_01_00_00 2003 02 1 15 Superstructure 99707792040 ...

Page 773: ...Electric circuit diagrams D2 1 0470_EN_FA036_D2_01_00_00 2003 02 41 42 1 16 Removal the boom 99707792040 ...

Page 774: ...D2 1 Electric circuit diagrams 42 42 0470_EN_FA036_D2_01_00_00 2003 02 1 17 Superstructure 99707792040 ...

Page 775: ...Hydraulic piping diagrams D2 3 0475_EN_FA036_D2_03_00_00 2003 02 1 6 3 Hydraulic piping diagrams 3 1 Hydraulic system 99707785519 ...

Page 776: ...D2 3 Hydraulic piping diagrams 2 6 0475_EN_FA036_D2_03_00_00 2003 02 Memo ...

Page 777: ...Hydraulic piping diagrams D2 3 0475_EN_FA036_D2_03_00_00 2003 02 3 6 ...

Page 778: ...D2 3 Hydraulic piping diagrams 4 6 0475_EN_FA036_D2_03_00_00 2003 02 Memo ...

Page 779: ...Hydraulic piping diagrams D2 3 0475_EN_FA036_D2_03_00_00 2003 02 5 6 ...

Page 780: ...D2 3 Hydraulic piping diagrams 6 6 0475_EN_FA036_D2_03_00_00 2003 02 3 2 Emergency control 99707785508 ...

Page 781: ...0480_EN_ALLGE_E_00_00_00 Part E Crane testing instructions ...

Page 782: ......

Page 783: ...g text contains a few important instructions which are to be observed in the scope of the recurrent inspections However we should like to point out that this text does not specify all items pertaining to the extent of inspection 1 Inspection of supporting steel structures All supporting steel structures such as boom superstructure rotary platform with the screws and bolts of the ball bearing slewi...

Page 784: ...lding work must be effected on the mobile crane the following measures must be taken before work is commenced in order to protect the electronic control units Turn the battery switch in chassis and superstructure OFF disconnect battery cables in chassis and superstructure from the negative terminal then disconnect the battery cables from the positive terminal and connect them remove the connectors...

Page 785: ...l welding work the ground terminal of the welding unit must be connected directly to the part to be welded If this instruction is not observed the current flow may cause damage to loose connections e g tooth faces bearings slide pieces shafts the electronic system the ASLI etc DANGER Make sure that the welding instructions are observed Once welding work is finished all plug and socket connectors m...

Page 786: ...E 1 Inspection of supporting steel structures 4 10 0485_EN_FA036_E1_01_00_00_FA029 2003 01 Memo ...

Page 787: ...Inspection of supporting steel structures E 1 0490_EN_FA036_E1_01_01_00 2001 06 5 10 1 1 Guidelines for areas to be checked 1 1 1 Superstructure frame ...

Page 788: ...E 1 Inspection of supporting steel structures 6 10 0490_EN_FA036_E1_01_01_00 2001 06 1 1 2 Boom ...

Page 789: ...Inspection of supporting steel structures E 1 0490_EN_FA036_E1_01_01_00 2001 06 7 10 1 1 3 Chassis frame ...

Page 790: ...E 1 Inspection of supporting steel structures 8 10 0490_EN_FA036_E1_01_01_00 2001 06 1 1 4 Boom extension jib Optional equipment ...

Page 791: ...Inspection of supporting steel structures E 1 0490_EN_FA036_E1_01_01_00 2001 06 9 10 1 1 4 Boom extension jib cont d Optional equipment ...

Page 792: ...E 1 Inspection of supporting steel structures 10 10 0490_EN_FA036_E1_01_01_00 2001 06 Memo ...

Page 793: ...at the deficiencies have been eliminated 2 1 Inspection for widening of the hook mouth The hook mouth has to be checked for deforma tion at regular intervals as required depending on the operating conditions of the crane at least however once per year The widening of the hook mouth must not ex ceed 10 referred to the original dimension y or y1 and y2 The original dimensions are specified on the lo...

Page 794: ...E 2 Inspection of the hook blocks 2 2 0495_EN_FA036_E2_00_00_00_FA029 2003 01 Memo ...

Page 795: ... for working applications are recorded in the following text The ropes must be checked regularly taking account of the prevailing operating conditions of the crane The rope must be observed more attentively at shorter intervals especially in the time just after it has been placed after a lifting rope has ben replaced and after extraordinary stress situations or if internal damage is suspected whic...

Page 796: ...fers to the direction of the helical line of the outer strands A distinction is made between right laid ropes symbol Z and left laid ropes symbol S CROSS LAY The direction of turning of the wires in the strands is opposite to the direction of turning of the strands in the rope cross lay right laid DIN designation s Z cross lay left laid DIN designation z S LONG LAY The wires in the strands and the...

Page 797: ...After the first wire breaks have been detected the test intervals must be shortened to ensure timely detection of the replacement state of wear It may be useful to record the occurrence of wire breaks via time In this case an increasing number of wire breaks in the course of of time helps the user determine the expected time when the rope should be dis carded 3 2 2 Replacement state of wear of met...

Page 798: ...e metallic rope must be discarded as soon as basket shaped deformations appear Loop shaped deformations In this case single wires or wire groups resem bling hairpins protrude from the rope structure on the opposite side of the rope groove If the rope structure is changed substantially the rope must be dis carded Loosening of single wires or strands In this case the outer wires or single strands of...

Page 799: ...allic ropes must be discarded 3 2 8 Service life Provided that operating conditions are identical and the same metallic rope is used the persons in charge of a crane can estimate approximately the time when a metallic rope is to be replaced in the scope of preven tive maintenance of the crane to the extent that they dispose of sufficient knowledge and experience in the operation of a rope drive Al...

Page 800: ...ets When a new lifting rope is mounted it is essential to ensure that the new rope is spooled up on the winch without being twisted and dam aged A rope supplied as a ring or on a reel should be spooled up preferably using a rotary table or a trestle When the rope is spooled from the reel to the drum the bending direction must not changed The rope windings must definitely not be pulled off the ring...

Page 801: ...drum with excessive play the upper layers may be squeezed between the loose lower rope windings when subject to load This may cause serious damage to the rope The pre load should be produced by braking the reel flange using a board or using a brake disc mounted to the reel by means of brake strings It is absolutely inadmissible to produce the required pre load by clamping the metallic rope between...

Page 802: ...and lengthening of the rope after an extended period of use and after a new rope has been placed Due to this elongation spin the outer strands of the metallic rope can become loose and may even form baskets under certain circum stances To eliminate this elongation spin the following steps should be taken 1 Deposit the hook block on the ground to this effect make sure that a maximum rope length is ...

Page 803: ...h The actual real service life is affected additionally by a number of external influences e g a Overload if the crane is used for purposes not included within its intended fields of application b Insufficient maintenance e g neglect of the specified oil change intervals c Operating errors extreme decelerations or loads dropping in the rope d Maintenance faults e g incorrect oil type or filling vo...

Page 804: ... Drive assemblies or parts of drive assemblies which are rather fre quently subject to maximum load which however are subject to light stress on a routine basis 1 6 of operating time with max load dead load 1 1 payload 1 6 of operating time with dead load 2 3 payload 1 6 of operating time with dead load 1 3 payload 50 of operating time with dead load only Km 0 25 Load Service life heavy Q 3 L 3 Dr...

Page 805: ...ice hours of the su perstructure is to be estimated by the operator NOTE If a mobile crane is used for assembly work a value of 20 can normally be assumed for the portion of service hours of the winch referred to the service hours used for superstructure operation as a whole 4 2 5 One combined hour meter provided for crane and driving operation The actual portion of the service hours of the winch ...

Page 806: ...y the hoist winch manufacturer or by persons authorized by the hoist winch manufacturer the overhaul must be re corded accordingly in the crane inspection booklet After the general overhaul has been performed a new theoretical service life D is specified by the hoist winch manufacturer or by persons authorized by him This new theoretical service life D must be recorded in the crane inspection book...

Page 807: ...various inspec tion intervals once per year as described below First inspection after the first year of operation A separate hour meter is provided on the superstructure The crane has been used exclusively for assem bly work in the past 12 months The load ensemble is L 1 i e Km1 0 125 The hour meter of the superstructure indicates 800 h the portion of service hours used for the winch is esti mated...

Page 808: ...y the remaining theoretical service life amounts to D2 D1 S2 3040 h 1920 h D2 1120 h These values must also be recorded in the crane documentation see Table Third inspection after the third year of operation During the past 12 months the crane has been used mainly for assembly work and occasionally for unload ing work in a port The load ensemble is L 2 i e Km3 0 25 The hour meter of the superstruc...

Page 809: ...tion no according to nameplate abc Last general overhaul effected on Drive assembly group M 3 Load ensemble L 1 Load ensemble factor Km 0 125 Theoretical service life 3200 h Inspec tion no Date of initial op eration in spec tion Operat ing condi tions since the last in spec tion load en semble Load en semble factor Km Service hours of the whole crane h Service hours of su per struc ture h Service ...

Page 810: ... service life of the hoisting winch is calculated using the various inspection intervals once per year as described below 1 inspection after the first year of operation The hoisting winch is equipped with a separate hourmeter The crane has been used exclusively for assembly work during the past 12 months The load ensemble is L 1 i e Km1 0 125 The hoisting winch hourmeter indicates 160 hours i e T1...

Page 811: ... 1920 h Thus the remaining theoretical service life amounts to D2 D1 S2 3040 h 1920 h D2 1120 h These values must also be recorded in the crane inspection booklet refer to Table 3 inspection after the 3rd year of operation During this year the crane has been used mainly for assembly work and occasionally for unloading work in a port The load ensemble is L 2 d h Km3 0 25 The hourmeter of the supers...

Page 812: ...ntification no according to nameplate abc Last general overhaul effected on Drive assembly group M 3 Load ensemble L 1 Load ensemble factor Km 0 125 Theoretical service life 3200 h Inspec tion no Date of initial op eration in spec tion Operat ing condi tions since the last in spec tion load en semble Load en semble factor Km Service hours of the whole crane h Service hours of su per struc ture h S...

Page 813: ... Operating Manual The first inspection of the securing pins is to be effected after approx 100 service hours The ring gear pins must be checked at regular intervals depending on the actual operating conditions of the crane at least however every 500 service hours If the crane has been subjected to an inadmissible load during operation e g a high shock load caused by a load dropping in the rope or ...

Page 814: ...E 5 Monitoring the slewing device 2 2 0510_EN_FA036_E5_00_00_00_FA029 2003 01 Memo ...

Page 815: ...0515_EN_ALLGE_F_00_00_00 Part F Troubleshooting ...

Page 816: ......

Page 817: ...0520_EN_ALLGE_F1_00_00_00 Part F1 Troubleshooting Chassis ...

Page 818: ......

Page 819: ... malfunctions of the machine Of course this table cannot cover all causes of malfunctions The hydraulic piping diagrams brake system diagrams and electric circuit diagrams also help you locate and eliminate malfunctions A troubleshooting guide is no substitute for a specialist If the cause of the malfunction cannot be determined or eliminated by means of the table please contact the After Sales Se...

Page 820: ...F1 0 Troubleshooting in the chassis 2 2 0525_EN_FA036_F1_00_00_00_FA029 2003 01 Memo ...

Page 821: ... to neutral N No electrical connection between battery and consumers Battery main switch is not set to ON Key actuated switch is set to wrong position Set key switch to position I chassis Engine operates irregularly or with an insufficient power output Air cleaner clogged Replace filter element clean filter bowl Leakage in air intake lines Check air intake system for leakage re tighten hose clamps...

Page 822: ...drain cocks open Clean fins by blowing out with compressed air or a steam jet unit Check cocks Coolant level too low the inidcator in the CGC display is lit Leakage in coolant hose connections Re tighten hose clamps Pressure relief valve on expansion tank faulty Check pressure relief valve for proper working order replace it if necessary Coolant hoses attacked by porosity Replace Engine cannot be ...

Page 823: ...r of the gearbox manufacturer How to read out the error codes The vehicle is parked The engine is stopped The gearshift lever is in neutral position The parking brake is engaged The battery main switch is turned ON The ignition is ON Actuate the service brake Push jogging lever to the left The gearbox display refer to item B1 4 6 4 2 indicates the error codes ...

Page 824: ...F1 2 Gearbox 2 2 0535_EN_FA036_F1_02_00_00_FA029 2003 01 Memo ...

Page 825: ...r tip switch or electrical connectors faulty or loosened Replace rocker tip switch check connections Solenoid valve faulty Replace valve Change over valve in neutral position Set change over valve to on road gear The vehicle cannot be set into motion Change over valve in neutral position Set change over valve to on road gear Transfer box is overheating Insufficient oil level Wrong oil type Inspect...

Page 826: ...F1 3 Transfer box 2 2 0540_EN_FA036_F1_03_00_00_FA029 2003 01 Memo ...

Page 827: ...icient Brake air pressure of brake system min 6 bar Rocker tip switch or electrical connectors faulty or loosened Replace rocker tip switch check connections Solenoid valve faulty Replace valve Drive assemblies produce a roaring sound Insufficient oil level Wrong oil type Balancing plates on propeller shafts are missing Check for leakages replenish oil Observe recommendations regarding oil types R...

Page 828: ...F1 4 Axle differential locks and drive assemblies 2 2 0545_EN_FA036_F1_04_00_00_FA029 2003 01 Memo ...

Page 829: ...bolts Leaks in suction pipe Re tighten screw couplings replace seals Oil in tank is foaming Check hydraulic oil level Pump pressure Check pressure at test connector Valve block or solenoid valves or pressure limiting valves on valve block defective Repair valve block or replace valves on block Cylinders worn or damaged Replace cylinder s Hydraulic system does not reach full power output Control pr...

Page 830: ...umn loosened Check rocker tip switches on steering wheel actuate them Excessive wear of tires wheels are fluttering Incorrect wheel toe Set wheel toe to 0 Incorrect tire pressure Check and if necessary readjust tire inflating pressure Wheel bearings defective Check and if necessary replace bearings Lateral or vertical movement of rim or disc wheel Check in specialist workshop if necessary Replace ...

Page 831: ...ges in steering block Check screw couplings and seals Pilot lamp of a steering circuit goes on Flowmeter defective Replace Flow limiting valve defective Replace Hose pipe leaking Replace hoses Screw coupling in pipe system loosened loss of oil Check screw couplings for tight fit and seals for perfect condition Steering pump produces excessive noise Pump defective Repair or replace pump Pump sucks ...

Page 832: ... pilot lamp is lit Valve block or solenoid valves in valve block defective blocking valve on each cylinder Replace valve block or exchange solenoid valves if necessary check electrical components Suspension block defective Replace valve block Front axle transverse oscillation does not operate Fuse defective Replace fuse Electro hydraulic ball cock defective front axle Replace ball cock Lock pin in...

Page 833: ...NGER The oil bearing end of the accumulator must be depressurized before the pressure check Check pressure via the test connector at the valve block of each cylinder Air inclusions in the suspension system Bleed suspension system by lowering the vehicle several times while actuating the leveling valve Hydraulic hoses attacked by porosity Replace hoses Suspension too stiff Insufficient pressure of ...

Page 834: ...ace valve if necessary No flow in return line Check return flow at hydraulic oil tank also bleeding function Leveling not possible Axle suspension still locked via rocker switch Unlock axle locking assembly via the rocker switch Symbol must not be lit Rocker tip switch defective Replace rocker tip switch Leveling valve defective Replace valve Valve block defective or pressure control valve in valv...

Page 835: ...still inserted Remove pins from beams Electronic system of outriggers is faulty Have the fault eliminated Fuse defective Replace fuse Relay change over beams cylinders defective Replace relay Solenoid valve outrigger beams cylinders defective Replace valve Diode defective Replace diode Insufficient pump pressure Check pressure at test connector Pump defective Replace pump Pressure limiting valve i...

Page 836: ... moves downwards without being actuated Stop valve at cylinder leaky or clogged Clean and check valve replace if necessary Line or hose leaky Check and re tighten screw couplings if necessary replace hose Solenoid valve defective Replace valve Outriggers can only be extended retracted very slowly Insufficient engine speed Increase engine speed Insufficient pump pressure Check pressure at test conn...

Page 837: ...p is lit although the indicator in the CGC display indicates more than 5 5 bar Pressure switch in BBA I or BBA II defective Replace switch Brake cylinders air accumulator section are not completely vented Handbrake is not completely released Deficiency in air accumulator circuit functionality of valves Check Insufficient braking effect despite correct supply pressure Brake linings worn or dirty oi...

Page 838: ...ke cylinders clogged Clean Pedal plate valve adjusted incorrectly Check and correct setting The wheel sensor warning lamp does not go out after the ignition has been switched on Sensors are not fitting correctly cable connections faulty Electrical cables damaged Check and if necessary repair Replace damaged components Electronic system faulty Take the machine to a specialist workshop ...

Page 839: ...sened Insulate or fasten Governor defective Replace governor Generator defective Check or replace No current available when ignition is switched ON No connection between negative battery terminal and ground Turn battery main switch ON actuate rocker switch in the dashboard Ground strap loose Secure strap safely Engine cannot be started Ignition starter switch defective Replace switch Relay defecti...

Page 840: ...F1 7 Electrical equipment 2 2 0560_EN_FA036_F1_07_00_00_FA029 2003 01 Memo ...

Page 841: ... defective Replace fuse Bad braking effect in all gearsteps Insulation and condition of cabling or ground connection loosened Check replace cabling if necessary Excessive backlash rotor stator excessive air gap wear of silent blocks Have measured checked and repaired Coils of stator defective Check or replace Excessive current consumption of batteries while vehicle or engine is not running consequ...

Page 842: ...F1 8 Eddy current brake 2 2 0565_EN_FA036_F1_08_00_00_FA029 2003 01 Memo ...

Page 843: ...0570_EN_ALLGE_F2_00_00_00 Part F2 Troubleshooting Superstructure ...

Page 844: ......

Page 845: ...of the machine in a short time Of course this table cannot cover all causes of malfunctions The hydraulic piping diagrams and the electric circuit diagrams also help you locate and eliminate malfunctions A troubleshooting guide is no substitute for a specialist If the cause of the malfunction cannot be determined or eliminated by means of the table please contact the After Sales Service of TADANO ...

Page 846: ...F2 0 Troubleshooting 2 2 0575_EN_FA036_F2_00_00_00_FA029 2003 01 Memo ...

Page 847: ...k plug and socket connectors Engine operates irregularly or with an Air cleaner clogged Replace filter elements clean filter bowl observe servicing indicator insufficient power output Leakage in air intake lines Check air intake system for leakage re tighten hose clamps Function of the injection system Have checked in a specialist workshop Excessive coolant temperature although the engine is not s...

Page 848: ...F2 1 Engine 2 2 0580_EN_FA036_F2_01_00_00_FA029 2003 01 Memo ...

Page 849: ...efective Check pump check setting of controller or repair it Oil of incorrect viscosity grade Fill in the oil specified according to the prevailing ambient temperature Pumps produce excessive noise Pumps suck in air Stop engine immediately check suction pipes for leakage check hydraulic oil level Pumps defective Repair or replace the pumps Stop cock closed Open stock cock Hydraulic system of super...

Page 850: ...F2 2 Hydraulic system of the superstructure in general 2 2 0585_EN_FA036_F2_02_00_00_FA029 2003 01 Memo ...

Page 851: ...valve defective Replace valve Check valves in triple control block defective Replace valves Slewing gear cannot be braked completely Multiple discs worn Replace complete disc package Solenoid valve defective Replace solenoid valve Slewing gear does not operate in spite of actuation of the manual control valve Brake is not released Check hydraulic pressure Manual control valve faulty Replace Pilot ...

Page 852: ...F2 3 Slewing gear 2 2 0590_EN_FA036_F2_03_00_00_FA029 2003 01 Memo ...

Page 853: ...to lubricating scheme readjust slideway linings replace if necessary Bleed cylinder Telescopes do neither extend nor retract Fuses in telescope control defective Relay of telescope control defective Solenoid valve defective Replace fuses Replace relay Replace solenoid valve see electrical circuit diagrams Fast speed not available when telescopes are extended Fast speed valve in valve block defecti...

Page 854: ...F2 4 Telescoping mechanism 2 2 0595_EN_FA036_F2_04_00_00_FA029 2003 01 Memo ...

Page 855: ...Control piston in double control block defective Brake valve defective Sinter filter in brake valve clogged Readjust Replace valve Replace brake valve Replace filter Lowering via boom elevation no longer possible Brake valve defective Pressure limiting valve defective Sinter filter clogged Replace valve Replace valve Replace filter Fast speed not available for lifting via the boom elevation Fast s...

Page 856: ...F2 5 Boom elevation 2 2 0600_EN_FA036_F2_05_00_00_FA029 2003 01 Memo ...

Page 857: ...ficient control oil pressure Continued suction valve leaking Sinter filter clogged Check pressure at test connector Replace valve Replace filter Hoisting gear does not operate AML in shut off condition Hoist limit switch is in shut off condition or defective Manual control valve defective Valve in simple control block defective Winch motor defective Set AML into operating condition Lower bottom bl...

Page 858: ...F2 6 Hoisting gear 2 2 0605_EN_FA036_F2_06_00_00_FA029 2003 01 Memo ...

Page 859: ...fective Replace cylinder seals replace cylinder s if necessary Bleed cylinder s Replace valve Ballast cylinders are not evenly lowered Nozzle in flow divider clogged Clean nozzle Weight units cannot be lifted or lowered Valve in triple control block defective Replace valve Ballast cylinders are extended or retracted too slowly Insufficient hydraulic pressure Insufficient pilot pressure Check press...

Page 860: ...F2 7 Counterweight 2 2 0610_EN_FA036_F2_07_00_00 2003 01 Memo ...

Page 861: ...gine in superstructure cannot be started Fuse faulty Starter defective Ignition starter switch defective Replace the fuse Overhaul or replace starter Replace switch Excessive hydraulic oil temperature the symbol in the CGC display is lit Temperature switch radiator motor defective Relay radiator control defective Cooler engine or fuse defective Replace switch Replace relay refer also to part C2 Re...

Page 862: ...F2 8 Electrical equipment 2 2 0615_EN_FA036_F2_08_00_00_FA029 2003 01 Memo ...

Page 863: ...0630_EN_ALLGE_F4_00_00_00 Part F4 Connection diagram Chassis ...

Page 864: ......

Page 865: ...Connection diagram Chassis F4 4 0635_EN_FA036_F4_01_00_00_FA029 2001 06 1 4 4 Connection diagram Chassis key to drawing refer to page 4 ...

Page 866: ...F4 4 Connection diagram Chassis 2 4 0635_EN_FA036_F4_01_00_00_FA029 2001 06 cont d 4 Connection diagram Chassis key to drawing refer to page 4 ...

Page 867: ...Connection diagram Chassis F4 4 0635_EN_FA036_F4_01_00_00_FA029 2001 06 3 4 cont d 4 Connection diagram Chassis key to drawing refer to page 4 ...

Page 868: ...ut dummy Anschlussplan Transmitter Tadano D700 Connection diagram Tadano D700 transmitter Knotenanordnung im FH Node arrangement in the driver s cab nur bei Option Telma Bremse only in case of optional equipment eddy current brake Telma Eddy current brake Batt h sch Battery main switch Anschlußplan Sicherung Connection diagram fuses Ladesteckdose Charging plugbox Frankreich France frei free R Sig ...

Page 869: ...0640_EN_ALLGE_G_00_00_00 Part G Annex ...

Page 870: ......

Page 871: ...0645_EN_ALLGE_G1_00_00_00 Part G1 Annex Chassis ...

Page 872: ......

Page 873: ...0650_EN_ALLGE_G1_01_00_00 Operating instructions for ZF gearbox ...

Page 874: ......

Page 875: ...12AS 2301 16AS 2601 ZF Standard 1328 758 104 ...

Page 876: ...any form either wholly or in part especially as a reproduction photomechanical or electronic copies or storage in data processing equipment or data networks without the approval of the legal owner is expressly prohibited and any violation will be pursued vigorously in the civil and criminal courts Printed in Germany Edition 2000 09 ...

Page 877: ... all the information you require to be able to make full use of the advanced technical features of the ZF AS TRONIC To ensure operating safety please note the maintenance specifications Specialists employed by ZF After Sales Service are always available to help with maintenance work on the transmission and are there to assist you should any other problems occur The relevant addresses can be obtain...

Page 878: ...ng agents must not be allowed to enter the ground the water table or the sewage system Request safety information for the products concerned from your local environmental protection authority and follow any instructions herein at all times Always collect used oil in a suitably large container Always dispose of used oil clogged filters lubricants and cleaning agents in accordance with environmental...

Page 879: ...pes 2 4 2 5 Changing between manual and automatic mode 2 4 2 6 Changing gear 2 5 2 6 1 Changing gear in automatic mode 2 5 2 6 2 Changing gear in manual mode 2 5 2 7 Reversing 2 7 2 7 1 Changing direction of travel 2 7 2 8 Engine brake 2 8 2 9 Stopping 2 8 2 10 Switching off engine parking vehicle 2 9 2 11 Towing 2 9 2 12 Tow starting 2 9 2 13 Clutch protection 2 10 2 14 Overspeed protection 2 11 ...

Page 880: ...le at low temperatures 2 17 3 Maintenance 3 1 3 1 Transmission oil 3 1 3 1 1 Oil grade 3 1 3 1 2 Oil quantities 3 1 3 2 Oil changes 3 1 3 2 1 Oil change intervals 3 1 3 2 2 Draining oil 3 2 3 2 3 Oil fill 3 3 3 3 Oil level check 3 4 3 4 Transmission ventilation 3 4 3 5 Type plate 3 5 3 6 Visual inspection of wiring 3 5 3 7 Pneumatic system maintenance 3 5 4 List of errors 4 1 4 1 Key to error list...

Page 881: ...16 AS 2601 with Intarder 1 1 013165 ...

Page 882: ...transmission is shifted using constant mesh gears The splitter and planetary group are synchronized A display in the dashboard shows the driver all the system information required e g gear stage fault etc The transmission actuator and the clutch actuator are the components most crucial to complete transmission automation The transmission actuator consists of the transmission electronics shift valv...

Page 883: ... 7 8 1 6 4 2 3 5 017179 Key 1 Console range selector 2 Display 3 E module 4 Transmission actuator with integrated electronic transmission control unit 5 Clutch actuator 6 Transmission 7 Accelerator 8 Brake pedal 017179 1 2 Overview ...

Page 884: ...ct gears and change operating mode Whenever actuated the tip lever always springs back into its original position Upshifts and downshifts covering several stages can be performed by toggling the tip lever several times Upshift through one stage Upshift through two stages Downshift through one stage Downshift through two stages Mode changes Press tip lever to the left to switch between manual mode ...

Page 885: ...e ZF AS TRONIC 1 6 Automatic mode Rotary switch in D position The shift system automatically selects the most appropriate gear for starting off The ZF AS TRONIC shift system automatically performs upshifts and downshifts during travel Change from automatic to manual mode is always possible Description of system 1 5 013 585 4th gear selected in transmission 4th gear selected in transmission Transmi...

Page 886: ...he driver must avoid over revving the engine The engine stall if the accelerator is depressed in too high gear 1 8 ZF auxiliary units Depending on the vehicle version the ZF AS TRONIC can be equipped with the following auxiliary units ZF Intarder ZF PTO clutch dependent ZF emergency steering pump Please refer to the Operating Manual to find out how to operate and maintain the auxiliary equipment D...

Page 887: ...e vehicle when the engine is running and a gear is selected 2 1 Starting the engine ð Engage parking brake ð Rotary switch is pointing to N transmission in neutral setting ð Switch on ignition Ä Self check of shift system CH display ð Start the engine Ä Self check is complete N appears on the display transmission is in neutral setting NOTE Gear shifts are not possible when the engine is at a stand...

Page 888: ...sengaged ð Depress accelerator and at the same time release the parking brake DANGER The vehicle may roll away even if the accelerator is not depressed Ä Vehicle sets off clutch closes automatically 2 2 1 Correcting the starting gear The driver may correct the starting gear selected by the system How to make a correction ð Press tip lever in the or direction Ä The display shows the starting gear s...

Page 889: ...aneuvering mode the vehicle accelerator is more responsive and clutch actuation is different from normal status DANGER Depending on the accelerator position and vehicle roadspeed the system switches from maneuvering to startup mode The vehicle can accelerate RISK OF ACCIDENT Unlimited maneuvering time In the event of clutch overload the dis play shows CL Whenever clutch overload occurs the display...

Page 890: ...cle rolls forwards with transmission in neutral once the brake is released and the driver shifts from N to D then the system selects a gear suitable for the roadspeed The driveline is then fully engaged 2 5 Changing between manual and automatic mode Always possible even while the vehicle is in motion Changing from manual to automatic mode ð tip lever to the left Changing from automatic to manual m...

Page 891: ...elerator position ä speed ä engine speed The gear indication appears as a digit in the display during travel 2 6 2 Changing gear in manual mode ðPush tip lever in or direction When a shift is performed manually the shift system automatically exits automatic mode If the driver moves the tip lever to the left automatic mode is reactivated 2 5 Operation 013586 014 290 ...

Page 892: ...at any time This shift process always takes priority ä ä The position of the accelerator must not be changed during the shift process because the engine is automatically controlled ä ä A shift command is not carried out if this shift would lead to the maximum engine speed being exceeded DANGER The driver may shift to Neutral during travel If the driver does shift to Neutral the driveline is interr...

Page 893: ...e same time release brake clutch closes automatically Ä Vehicle moves backwards 2 7 1 Changing direction of travel Changing from reverse R to forwards travel D and vice versa ð Turn rotary switch from R to D DANGER A change in the direction of travel performed by moving the rotary switch from R to D and vice versa D to R may only be undertaken when the vehicle is at a standstill otherwise the tran...

Page 894: ...complete stop ä The clutch opens automatically before the vehicle comes to a complete stop preventing the engine from stalling ä If ever the vehicle is stationary for extended periods ZF advises you to select transmission neutral DANGER äIf ever the vehicle is stationary with the engine run ning and the gear engaged you only have to press the accelerator pedal for the vehicle to set off unless the...

Page 895: ...al whenever the engine is switched off The vehicle may roll away if brakes are not actuated 2 11 Towing Vehicle manufacturer instructions must be observed when towing CAUTION For towing purposes always disconnect the propeller shaft flange from the rear axle before setting off If it cannot be disconnected remove both stub shafts Avoid polluting the environment in the event of oil loss 2 12 Tow sta...

Page 896: ...ading This may cause the engine to stall and if on an incline it is possible that the vehicle will roll backwards The clutch opens again when speed is reduced ä To conserve the mechanical components of the clutch release device the transmission should be shifted to neutral if the vehicle stops for long periods of time for more than approx 1 to 2 min for example in traffic jams at railway crossings...

Page 897: ...xceed the permitted speed range ä If the vehicle accelerates on downhill slopes there is no automatic upshift into a higher gear CAUTION The engine may be damaged if the vehicle is accelerated on downhill gradients and the engine thereby enters the overspeed range 2 14 2 Automatic mode DANGER The vehicle may accelerate on downhill slopes The system will undertake upshifts to protect the engine fro...

Page 898: ...isplay then shows e g i e PTO 1 is activated setting off gear 3 is enga ged Also refer to Chapter entitled Displays 2 15 2 Stationary operation When the PTO is in stationary mode no gear can be selected The transmission remains in neutral position 2 16 Roller test rig Having driven onto the roller test rig brake test rig shift transmission into neutral ä When the roller is activated the system rec...

Page 899: ...ll DANGER If shifts are undertaken when pneumatic pressure is too low the transmission may remain in neutral to ensure that there is no direct drive and that the engine brake is ineffective u FP drive pedal accelerator u Bring accelerator to idling position u If the display does not go out there is a system error The vehicle cannot be driven u CL clutch clutch u Alternates with the normal display ...

Page 900: ... facing upwards PTO 1 is activated u st P3 PTO 1 2 transmission in 3rd gear u PTOs 1 and 2 are activated The trans mission is in its 3rd setting off gear s Arrow facing upwards PTO 1 is activated t Arrow pointing downwards PTO 2 is activated PTO Power Take Off u Manual mode u 4th gear selected in transmission u Manual mode u Downshift option from 8th gear into 5th gear one gear per bar 008 122 008...

Page 901: ...le NOTE When certain system error occurs automatic mode is deactivated and the transmission system remains in manual mode u STOP spanner serious system error u Stop the vehicle Vehicle may no longer be driven and must be taken to works hop DANGER If possible do not stop the vehicle when it is in a danger zone ä Also refer to chapter 2 18 008 027 008 026 ...

Page 902: ... out once the ignition has been turned Off use the battery isolator to switch off the system Switch the ignition back on If the error message is still in place the vehicle will have to be taken to a service point Please specify the error number s when the service point is contacted Calling up error numbers ð Switch on ignition ð Turn rotary switch to N ð Hold tip lever in position Console range se...

Page 903: ...w 20 C the transmission will require a warming up phase once the engine is started The engine must be operated for at least 10 minutes with the vehicle at a standstill until the transmission oil has warmed up u At outside temperatures of below 30 C warm air must be used to heat transmission up to a temperature above 30 C before the engine is started 2 19 1 Using the vehicle when the outside temper...

Page 904: ......

Page 905: ...F subsidiaries or via Internet http www zf com zf n 3 1 2 Oil quantities To ensure correct oil quantities when changing oil always conduct the oil filling process as specified refer to chapter 3 2 2 with intarder 3 2 Oil changes NOTE Vehicle should be on horizontal ground when oil is changed 3 2 1 Oil change intervals To safeguard reliable operation of the transmission compliance with the oil chan...

Page 906: ... burning upon contact with parts and with the transmission oil ðRemove oil drain plugs from transmission Figs 1 1 and 1 2 items 1 and 2 and collect transmission oil in a suitable container Dispose of in an environmentally friendly manner ðClean oil drain plug with magnetic plug and replace seal ðTighten oil drain plugs to the specified torque Maintenance 3 2 ...

Page 907: ...ment point There is a notice on this screw indicating the oil gra des and oil change intervals tightening torque TA 60 Nm 3 2 3 Oil filling ðTop up with oil through the oil filling point Figs 1 1 and 1 2 item 3 ÄThe oil level is correct once the top of the oil has reached the bottom of the filling point or once oil has already started to escape from the filling point 1 2 3 Maintenance 3 3 010 768 ...

Page 908: ...l has fallen below the oil filling point it will have to be topped up section 3 2 2 NOTE Each time you check the oil also watch out for any leakages on the transmission 3 4 Transmission ventilation The transmission oil heats up during travel This causes excess pressure which is continually reduced by a breather valve Ensure that the breather valve is always functioning correctly The breather item ...

Page 909: ...ction of wiring ðCheck wiring for damage ðEnsure that connectors are seated correctly connec tors must be fitted with tension relief 3 7 Pneumatic system maintenance ðThe maintenance instructions of the vehicle manufacturer must be observed ðThe compressed air reservoir must be drained every week every day in winter NOTE When the compressed air reservoir is drained the compressed air cleaner and w...

Page 910: ......

Page 911: ...tio gears 7 12 range change group With 16 ratios Low ratio gears 1 8 or High ratio gears 9 16 range change group PTO Power Take Off RESET Switch off ignition while vehicle is stationary and wait until display goes out Then switch on the ignition If there is an error in the system visit a workshop without delay 4 1 List of errors ...

Page 912: ...Stationary automatic neutral shift System not available Section 3 Errors which even if they occur frequently do not have to lead to impaired availability of the system 11 Warning buzzer permanently active 12 44 Activation of reversing light not possible 13 14 45 46 59 60 63 64 PTO 1 or 2 not available No other system limitations 23 Continuous activation of warning lamp 25 89 Display EE No system r...

Page 913: ...range selector 150 System not available Subsequent GV shift attempts are possible 151 Motion automatic gear correction or neutral shift Stationary setting off gear only selectable using speed range selector 153 155 156 Motion and stationary automatic neutral selection Subsequent shifts using speed range selector 154 Motion clutch closes Next shift attempt using speed range selector Stationary set ...

Page 914: ...0660_EN_ALLGE_G1_02_00_00 Operating instructions for ZF Intarder ...

Page 915: ......

Page 916: ...6085 758 102a The integrated retarder for trucks and buses with ZF transmissions ECU 42 control unit Operating Manual ...

Page 917: ...ed by copyright Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Printed in Germany ZF Friedrichshafen AG MC C 2004 03 Edition 2004 03 ...

Page 918: ...S 251 IT Ecomid 9 S 109 IT 16 S 109 IT AS Tronic 12 AS 2301 IT 16 AS 2601 IT New Ecosplit 16 S 1621 TD 16 S 1821 TO 16 S 1921 TD 16 S 2221 TO 16 S 2221 TD 16 S 2521 TO 16 S 2721 TO 12 AS 1631 TD 12 AS 1931 TD 12 AS 1931 TO 12 AS 2131 TO 12 AS 2331 TO 16 AS 2231 TD 16 AS 2631 TO ...

Page 919: ... horizontal on the right and heat exchanger on the right 10 AS 2010 B IT 10 AS 2310 B IT 12 AS 2000 B IT 12 AS 2300 B IT 8 S 2101 BD 8 S 2101 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 10 AS 2001 BD 10 AS 2001 BO 10 AS 2301 BD 10 AS 2301 BO 10 AS 2701 BO 12 AS 2001 BO 12 AS 2301 BO 12 AS 2701 BO ...

Page 920: ...ment are available to you for maintenance work and if any problems arise on the transmission and ZF Intarder You can find the individual addresses in the ZF directory of companies order no 0000 762 703 which we would be more than happy to send out to you on request NOTE This operating manual deals with the standard version Customer specific modifications are possible We wish you a pleasant journey...

Page 921: ...ry or death THREATS TO THE ENVIRONMENT Lubricants and cleaning agents must not be allowed to enter the soil ground water or sewage system Ask your local environment agency for safety information on the relevant products and adhere to their requirements Collect used oil in a suitably large container Dispose of used oil dirty filters lubricants and cleaning agents in accordance with environmental pr...

Page 922: ... Bremsomatic Function 20 3 6 1 ZF Brake Step Lever Bremsomatic 21 3 7 Flash Code Output 22 3 8 Flash Code Error List 24 4 Maintenance 27 4 1 Oil Level Check 27 4 2 Instruction Plate on Oil Overflow Plug 28 4 2 1 Instruction Plate on Oil Drain Plug 28 4 3 Type Plate 29 4 4 Draining Oil 30 4 5 Truck Oil Drain Oil Overflow and Oil Fill Plugs 31 4 6 Bus Oil Drain Oil Fill and Oil Overflow Plugs 34 4 7...

Page 923: ...o change gear the Intarder s braking force remains in place and is not reduced If your vehicle has an engine brake this can be engaged in addition to the Intarder CAUTION Before and while travelling downhill ensure that your engine speed does not fall to below n 1600 rpm Only briefly depress the clutch to change gear Do not travel down hill in idling mode or with the clutch depressed otherwise suf...

Page 924: ...der is conducive to more consistent and more cost effective driving styles The advantages of the ZF Intarder are high braking power short response times shares oil supply with the transmission and therefore one common oil change low weight low constant transmission operating temperatures due to integrated constant cooling Fig 1 Structure of the ZF Intarder taking the example of a ZF Ecosplit trans...

Page 925: ...elow 20 C a warm up phase is needed for the transmission once the engine has been start ed The engine must be run at low speed in the partial load range until the transmission oil has warmed up At outside temperatures of below 30 C warm air should be used to warm up the transmission to a temperature of at least 30 C before the engine is started Ensure that a temperature of 150 C is not exceeded on...

Page 926: ...ights up during Bremsomat operations if the Intarder is active and when in constant brake steps NOTE Check whether the Intarder functions match the light displays described below When the ignition has been switched on and when the Intarder master switch is in the ON position the In tarder system automatically checks that the monitoring display is functioning Monitoring display lights up for 3 sec ...

Page 927: ... 758 102 2004 03 For error code output via flash code refer to 3 7 In addition to its normal function the Intarder monitoring display is used to output the flash code error number refer to section 3 7 Flash Code Output ...

Page 928: ...cle braking relieves the service brake system Activating constant brake step mode Move the brake step lever to a position between 1 and max The vehicle is constantly braked in accordance with the position selected in Position 1 slight braking to in Position max high level braking Constant Brake Step Mode 0 1 2 3 4 5 B 012 899 B Bremsomat 1 5 Constant brake step mode max 0 1 2 3 4 B 021 624 B Brems...

Page 929: ...ns depends on the vehicle manufacturer NOTES If the braking power needed is greater than the maxi mum braking power of the Intarder the engine or ser vice brake should also be activated See section 1 General Intarder Safety Notice Constant Brake Step Mode 0 1 2 3 4 5 B 012 899 B Bremsomat 1 5 Constant brake step mode max 0 1 2 3 4 B 021 624 B Bremsomatic 1 4 Constant brake step mode max ...

Page 930: ...d is set once the accelerator is released again NOTES If when travelling downhill the braking power needed is greater than the maximum braking power of the Intarder the engine or service brake should also be activated If the current roadspeed is less than the speed set the Intarder remains off Once the roadspeed returns to the value saved the Intarder is again activated CAUTION When programming th...

Page 931: ...nction only operates in step B NOTE If the brake step lever is returned to position B once con stant brake step mode has been activated then automatic speed control takes effect using the current roadspeed Cancelling the Bremsomat function Move brake step lever either into position 0 or into position 1 5 constant brake step mode into position B and depress accelerator as soon as the accelerator is...

Page 932: ...mat in position B but the cur rent roadspeed is set once the accelerator brake pedal or engine brake is released Advantages of the Bremsomatic Cruise control and Bremsomatic cannot work against one another The brake step lever remains in position B Constant manual interventions on the brake step lever are not needed Bremsomatic Function ...

Page 933: ...c function only operates in step B NOTE If the brake step lever is returned to position B once con stant brake step mode has been activated then automatic speed control takes effect using the current roadspeed Cancelling the Bremsomat function Move brake step lever either into position 0 or into position 1 4 constant brake step mode Changing roadspeed and saving new value Change the roadspeed by d...

Page 934: ...seconds Example taking error number 23 4 Move the brake step lever to two steps below the max brake step in this case position 3 and then move it back to the position one step below the max brake step in this case position 4 within the next 5 seconds 5 Wait for the flash code output refer to Functions of the Intarder monitoring display In addition to its normal function the Intarder monitoring dis...

Page 935: ...to position 0 5 All errors to be displayed via flash code output are deleted for flash code output Only those errors from the control unit which impair function can be called up using the flash code output Errors which have no impact whatsoever on control unit functions can only be called up using an external diagnosis unit Deleting the error memory with the aid of the brake step lever makes the e...

Page 936: ...rge valve 12 El defect engine brake activation 13 El defect Intarder monitoring display activation 14 El defect Reduced power warning light activation 15 El defect brake lights activation 16 El defect fault lamp activation 17 El defect cruise control deactivation during constant brake step operation 18 El defect brake step lever supply 19 El defect proportional solenoid AIP activation 21 El defect...

Page 937: ...t engine speed sensor 41 CAN message EEC2 defective 42 CAN message TSC1 defective 43 Send error CAN messages 44 CAN BUS off 45 CAN message EBC1 defective 46 Communication error CAN messages 47 CAN message EEC1 defective 48 CAN message TCO1 49 CAN message CCVS defective 51 Engine brake CAN message ERC1 defective 52 CAN message ETC1 defective 53 CAN message ETP defective 54 On board computer CAN mes...

Page 938: ... CAN message FMR2 defective IES ID 593 62 CAN message EPS1 defective IES ID 556 63 CAN message BC_DR 64 ExtensionBox CAN message TSC1 65 Adaptive Cruise Control ACC CAN message TSC1 66 Transmission 2 CAN message ETC1 defective 67 CAN message EPS2 defective IES ID 557 71 Open circuit term 30 72 Undervoltage overvoltage term 15 81 Parameter setting defective 82 Loss of operating hours counter 83 Los...

Page 939: ...asurements the oil level on transmissions fitted with a ZF Intarder must be checked with the vehicle horizontal the engine off cooled transmission oil 40 C Regularly check the oil level During the check look out for leaks on the transmission Intarder oil water heat exchanger associated coolant pipes CHECK Stop and park the vehicle without activating the Intarder The oil overflow plug item 4 should...

Page 940: ...tion Warning synthetic oil fill oil change interval has changed This plate may only be removed from the oil drain plug if synthetic oils are no longer being used Warning Other oil change intervals then apply depending on the lubricant classes for transmissions fitted with a ZF Intarder in accordance with List of Lubricants TE ML 02 OIL CHANGE List of Lubricants TE ML 02 1 FILL UP TO OVERFLOW 2 TES...

Page 941: ...king enquires placing orders or undertaking repair work 1 Type of transmission 2 Intarder parts list no 3 Serial no of Intarder 4 Oil volume 5 List of lubricants Example of type plate Maintenance ZF FRIEDRICHSHAFEN AG MADE IN GERMANY MODEL PARTS LIST NO SERIAL NO CUSTOMER SPEC NO TOTAL RATIO P T O N OILCAPACITY IN LTS SPEEDO RATIO n OIL GRADE SEE LUBRIC LIST TE ML xn ENGINE 1 5 4 3 2 ...

Page 942: ... the transmission oil is still warm and thin Stop vehicle in horizontal position and switch off engine To drain the oil the drain plug on the transmission item 1 and the drain plug on the oil filter housing item 2 should be unscrewed DANGER Hot transmission oil RISK OF BURNING Once the oil has been drained the drain screws solenoids must be cleaned and the seals replaced Insert new filter Then scr...

Page 943: ...e heat exchanger in truck transmissions may be fitted horizontally at the bottom Oil maintenance points depend on the transmission type 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 41 1 2 3 004 702 4 9 004 703 009 ...

Page 944: ...e bottom Oil maintenance points depend on the transmission type 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 41 Truck Maintenance Oil Drain Oil Fill and Oil Overflow Plugs 1 019 457 3 019 456 9 4 2 019 484 ...

Page 945: ... maintenance points depend on the transmission type 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 41 Truck Maintenance Oil Drain Oil Fill and Oil Overflow Plugs 3 2 1 004 512 4 9 004 511 Viewed from below 009 552 ...

Page 946: ...RDER 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 42 Bus Maintenance Oil Drain Oil Fill and Oil Overflow Plugs 1 3 2 004 705 4 9 004 714 ...

Page 947: ...1 BO 6 S 1901 BO 1 Transmission oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 42 Bus Maintenance Oil Drain Oil Fill and Oil Overflow Plugs 009 413 4 1 3 150 9 013907 ...

Page 948: ...O 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 42 Bus Maintenance Oil Drain Oil Fill and Oil Overflow Plugs 019 459 4 2 3 9 1 019 432 ...

Page 949: ...on 10 AS 2301 BO 10 AS 2310 B IT 1 Transmission oil drain point 2 Intarder housing oil drain point 3 Intarder housing oil filter cover 4 Oil overflow plug and oil filling after oil change 9 Oil fill plug after repairs For tightening torques refer to table on page 42 013 610 013 609 1 2 9 4 3 013 742 ...

Page 950: ...er grease the O ring 7 Use screws 10 to fit cover 3 For tightening torques refer to table on pages 41 and 42 004 467 10 3 5 6 7 019 485 3 004 707 6 8 004 467 Remove cover 3 with filter attached Take oil filter off filter cover Unscrew plug 10 from oil filter housing cover 3 Remove cover 3 and pull filter out of filer housing Securely attach solenoid 5 to the new filter Insert new filter 6 in filte...

Page 951: ...nd if necessary top up oil until it overflows Use new seal to close oil overflow plug 4 again Fill transmission until oil overflows Screw in oil overflow plug 4 with new seal Test run Do NOT activate Intarder Test run Activate Intarder BRIEFLY ONCE at the start max stage and return to position 0 Screw in oil fill plug 9 with new seal NOTE Only fill transmission and Intarder when vehicle is station...

Page 952: ...ifreeze corrosion protection agent Basic fluid ethylene glycol with corrosion protection inhibitors Fresh water pH value of 6 5 8 0 total hardness 3 10 dH Interval for changing oil coolant max 2 years mix liquids before filling NOTE If sludge starts to form or if the concentration suddenly falls the coolant must be replaced immediately 4 10 Bleeding the Transmission Differences in pressure are rec...

Page 953: ...ce with List of Lubricants TE ML 02 corresponding to trans mission type with ZF Intarder oil change approx 11 0 dm3 12 0 dm3 12 5 dm3 12 0 dm3 12 5 dm3 12 0 dm3 13 0 dm3 repairs approx 18 5 dm3 21 5 dm3 22 0 dm3 21 0 dm3 22 0 dm3 21 0 dm3 23 0 dm3 Filter no 1 M 38 120 or M 24 60 120 60 2 60 60 60 4 60 60 60 9 60 60 60 10 23 46 23 Oil volume after Tightening torque Nm for position 6085 298 026 1 Tr...

Page 954: ...heat exch right 6 S 1901 BO 10 AS 2010 B IT 10 AS 2001 BD 10 AS 2310 B IT 10 AS 2001 BO 10 AS 2301 BD 10 AS 2301 BO 10 AS 2701 BO 12 AS 2000 B IT 12 AS 2001 BO 12 AS 2300 B IT 12 AS 2301 BO 12 AS 2701 BO Oil grade In accor dance with List of Lubricants TE ML 02 Oil change intervals In accordance with List of Lubricants TE ML 02 corresponding to trans mission type with ZF Intarder oil change approx...

Page 955: ...0670_EN_ALLGE_G1_03_00_00 Chart of lubricants for ZF gearbox ...

Page 956: ......

Page 957: ...tive 4 02A 02B x New Ecomid truck ZF Ecofluid M 02E 02D 02L NewEcosplit NewEcosplit with NMV truck 1 ZF Ecofluid M 02E 02A 02B 02C 02D 02H 02L ZF Ecofluid M 02E 02C 02D 02H 02L truck 2 ZF Ecofluid M 02E alternative 6 02A 02B 02D 02H 02L ZF Ecofluid M 02E alternative 6 02D 02H 02L Classic Line truck bus ZF Ecofluid M 02E 02A 02B 02C 02D 02H 02L x Transmatic 02C 5 _ Warning Note continuation of tabl...

Page 958: ...on has reached a total of 2 500 km This also applies to repairs 4 Product groups VAN Ecolite In moderate climate zones shift quality is impaired if oils of the lubricant classes 02A 02B 02C 02D 02H 02L are used 5 Lubricants marked on the following pages must not be used 6 Lubricant classes can only be used after a total transmission mileage of 540 000 km 3 years long haul coach operation or 360 00...

Page 959: ...O 6AS1000TO 6S710BO 6AS710BO 6S710BD 6AS710BD 6S810BO 6AS810BO 6S810BD 6AS810BD 6S1010BO 6AS1010BO NewEcomid truck 9S1110 9S1310 NewEcosplit NewEcosplit with NMV truck 1 8S1620 16S1620 8S1820 16S1820 8S1920 16S1920 16S2020 8S2220 16S2220 16S2520 16S2720 truck 2 16S2320 Classic Line truck 8S1350 16S1650 16S1950 bus S6 1550 6S1380 Transmatic Ecosplit with WSK NewEcosplit with WSK 16S151 16S221 16S25...

Page 960: ...uses x 90 000 kmx 1 year x 160 000 kmx 1 year x 300 000 km 2 years With dry room breather 7 x 540 000 km 3 years _ Hydraulic actuators No oil change needed 7 These intervals only apply to a hose breather in a dry room If there is no hose breather in the dry room the oil change intervals specified for lubricant classes 02D 02L apply 8 Oil change required depending on what occurs first x Low tempera...

Page 961: ...R IPIRGEROL EP 80W CONDAT LUBRIFIANTS CHASSE SUR RHONE F GEAR A 80W DE OLIEBRON B V ZWIJNDRECHT NL TOR MULTIPURPOSE GEAR OIL SAE 80W90 EKOPROM UFA RUS EKOIL ECO TRANS SAE 80W EKOPROM UFA RUS EKOIL ECO TRANS SAE 80W 85 ENI S P A REFINING MARKETING DIVISION ROME I ROTRA HY 80W 90 ENI S P A REFINING MARKETING DIVISION ROME I ROTRA HY DB 80W EXXON MOBIL CORPORATION FAIRFAX VIRGINIA USA ESSO GEAR OIL G...

Page 962: ...SPIRAX MA 80W SRS SCHMIERSTOFF VERTRIEB GMBH SALZBERGEN D WINTERSHALL WIOLIN MEHRZWECK GETRIEBEÖL 80 SRS SCHMIERSTOFF VERTRIEB GMBH SALZBERGEN D WINTERSHALL WIOLIN MEHRZWECK GETRIEBEÖL 80W 90 TOTAL ISU OIL CO LTD SEOUL ROK TOTAL EP 80W 90 TOTAL LUBRIFIANTS S A PARIS F ANTAR EP 80W TOTAL LUBRIFIANTS S A PARIS F ANTAR EP 80W 90 TOTAL LUBRIFIANTS S A PARIS F FINA PONTONIC N 80W 85 TOTAL LUBRIFIANTS S...

Page 963: ...AIRFAX VIRGINIA USA MOBILUBE 1 SHC 75W 90 EXXON MOBIL CORPORATION FAIRFAX VIRGINIA USA MOBILUBE S 80W 90 FALCON OIL COMPANY LTD SHARJAH UAE FALCON SUPER EP GEAR OIL 80W 90 GL 4 FUCHS PETROLUB AG MANNHEIM D TITAN SUPERGEAR MC 80W 90 GENOL GMBH CO WIEN A GENOL GEAR SYN 80W 90 GINOUVES GEORGES SA LA FARLEDE F YORK 896 GULF OIL INTERNATIONAL PITTSBURG USA GULF GEAR TDL 80W 90 GULF OIL INTERNATIONAL PI...

Page 964: ...COMP LTD LONDON GB SHELL SPIRAX MX 80W 90 SRS SCHMIERSTOFF VERTRIEB GMBH SALZBERGEN D WINTERSHALL GETRIEBEFLUID SML 80W 90 SRS SCHMIERSTOFF VERTRIEB GMBH SALZBERGEN D WINTERSHALL WIOLIN RSG 80 STATOIL LUBRICANTS STOCKHOLM S GEARWAY G4 80W STRUB CO AG REIDEN CH STRUB MULTIGEAR SGO 80W 90 STRUB CO AG REIDEN CH VULCOGEAR SYNT SGX 75W 90 TEDEX PRODUCTION SP Z O O TOMASZOW MAZOWIECKI PL TEDEX SUPER GEA...

Page 965: ...ACO GHENT B URSA SUPER LA 40 FUCHS LUBRICANTS UK PLC HANLEY GB TITAN TXE 30 FUCHS PETROLUB AG MANNHEIM D TITAN UNIVERSAL HD 30 GENOL GMBH CO WIEN A GENOL MULTI TURBO 30 HINO MOTORS LTD HINO SHI TOKYO J BLUE RIBBON BIG SUPER 30 SAE 30 HUILES BERLIET S A SAINT PRIEST F RTO PREXIMA 40 IGOL FRANCE SA AMIENS F TRANS TURBO 4 SAE30 INA MAZIVA RIJEKA RIJEKA HR INA GORGONELA S 30 INA MAZIVA RIJEKA RIJEKA H...

Page 966: ... POWER D SAE 30 TOTAL LUBRIFIANTS S A PARIS F ANTAR TRAXOLIA Z 40 TOTAL LUBRIFIANTS S A PARIS F ELF PERFORMANCE SUPER D 30 TOTAL LUBRIFIANTS S A PARIS F ELF PERFORMANCE SUPER D 40 YACCO ST PIERRE LES ELBEUF F YACCO TRANSPRO MAS3 SAE 30 Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 10 of 17 ...

Page 967: ... 80 IGOL FRANCE SA AMIENS F TRANS GEAR ZF 75W80 KUWAIT PETROLEUM R T B V EUROPOORT RT NL Q8 T 60 SAE 75W 80 MAZIVA ZAGREB D O O ZAGREB HR INA TRANSMOL HD 75W 80 MOTUL SA AUBERVILLIERS CEDEX F MOTUL MOTYLGEAR 75W 80 OEL BRACK AG HUNZENSCHWIL CH MIDLAND CRYPTO GEAR OMV REFINING MARKETING GMBH WIEN A OMV GEAR OIL LDI SAE 75W 80 PAKELO MOTOR OIL S R L SAN BONIFACIO VR I PAKELO GOLDENGEAR LD SAE 75W 80...

Page 968: ...licable for Intarder x x Manufacturer 02E Trade name 02E CASTROL INTERNATIONAL PANGBOURNE READING GB CASTROL SYNTRANS MAX 75W 80 ZF FRIEDRICHSHAFEN AG FRIEDRICHSHAFEN D ZF ECOFLUID M Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 12 of 17 ...

Page 969: ... TRANS ALL EHP AUTOMATIC TRANSMISSION FLUID MAZIVA ZAGREB D O O ZAGREB HR INA ATF DX IID MORRIS LUBRICANTS SHREWSBURY GB LIQUIMATIC SUPER ATF OMV REFINING MARKETING GMBH WIEN A OMV ATF III PANOLIN AG MADETSWIL CH PANOLIN ATF DEXRON III PETRO CANADA LUBRICANTS MISSISSAUGA CDN HEAVY DUTY SYNTHETIC BLEND ATF PETRO CANADA LUBRICANTS MISSISSAUGA CDN MERCON V ATF H 36007 PETRO CANADA LUBRICANTS MISSISSA...

Page 970: ...applicable for Intarder x x Manufacturer 02G Trade name 02G CHEVRONTEXACO GHENT B MULTIGEAR MTF LT FUCHS PETROLUB AG MANNHEIM D TITAN EG 75 ZF FUCHS PETROLUB AG MANNHEIM D TITAN GEAR ZF Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 14 of 17 ...

Page 971: ...licable for Intarder x x Note In moderate climate zones shift quality is impaired if viscosity grades higher than SAE 80W are used x Manufacturer 02H Trade name 02H FL SELENIA S P A VILLASTELLONE I TUTELA TRUCK ZC 90 SAE80W 90 Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 15 of 17 ...

Page 972: ... Hydraulic fluid x Manufacturer 02K Trade name 02K DEUTSCHE PENTOSIN WERKE GMBH WEDEL D PENTOSIN CHF 11S HYDRAULIC FLUID 70W 75 Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 16 of 17 ...

Page 973: ... 02L Trade name 02L BP INTERNATIONAL PANGBOURNE READING GB BP ENERGEAR SHX 30 CASTROL INTERNATIONAL PANGBOURNE READING GB CASTROL SYNTRANS COGNIS DEUTSCHLAND GMBH MONHEIM D EMGARD 2924 VEEDOL INTERNATIONAL PANGBOURNE READING GB VEEDOL SYNMESH Continued ZF Friedrichshafen AG List of lubricants TE ML 02 edition 01 04 2006 Page 17 of 17 ...

Page 974: ...0680_EN_ALLGE_G1_04_00_00 Centralized lubrication system ...

Page 975: ......

Page 976: ... Front drop arm Lenkhebel hinten Rear drop arm Ausgleichzylinder unten Lower compensation cylinder Ausgleichzylinder oben Upper compensation cylinder Schmierstellen Lubricating points Hochdruckschlauch High pressure hose Polyamidrohr Polyamid tube EP 1 24V 1 9kg PE 120 und integrierter Steuerung S EP4 EP 1 24V 1 09 kg PE 120 and integrated control S EP4 Schmierzeit Lubrication time Pausenzeit Paus...

Page 977: ...G1 4 Overview of lubricating points 2 2 0685_EN_FA029_G1_04_00_00_SCHMIERSUEBERS 2003 01 Memo ...

Page 978: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 1 12 ...

Page 979: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 2 12 Beschreibung_EN_G1 doc 2003 01 ...

Page 980: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 3 12 ...

Page 981: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 4 12 Beschreibung_EN_G1 doc 2003 01 ...

Page 982: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 5 12 ...

Page 983: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 6 12 Beschreibung_EN_G1 doc 2003 01 ...

Page 984: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 7 12 ...

Page 985: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 8 12 Beschreibung_EN_G1 doc 2003 01 ...

Page 986: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 9 12 ...

Page 987: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 10 12 Beschreibung_EN_G1 doc 2003 01 ...

Page 988: ...Central Lubricating System Method of operation of the central grease lubrication system G1 4 Beschreibung_EN_G1 doc 2003 01 11 12 ...

Page 989: ...G1 4 Central Lubricating System Method of operation of the central grease lubrication system 12 12 Beschreibung_EN_G1 doc 2003 01 Memo ...

Page 990: ...0695_EN_ALLGE_G2_00_00_00 Part G2 Annex Superstructure ...

Page 991: ......

Page 992: ...0700_EN_ALLGE_G2_01_00_00 Load Moment Limiter AML ...

Page 993: ......

Page 994: ...onitor chap B 2 2 item 39 changes between the tele indication and the telescope selection mode refer to the Operating Manual of the Automatic Safe Load Indicator Part G2 superstructure The warning buzzer 4 AML sounds intermittently if the AML s load ratio reaches 90 If the load ratio reaches 100 the buzzer sounds continuously ...

Page 995: ...G2 1 AML 2 2 0705_EN_FA036_G2_01_00_00_FA029 2003 01 Memo ...

Page 996: ...Function keys and displays 0710_EN_FA036_G2_01_01_00_AML 2003 01 1 38 AML B Operation Manual for FAUN ATF 220G 5 FAUN GmbH ...

Page 997: ...of boom jib state 2 3 2 Registration of jib set 2 4 Registration of rope falls and hook displacement display 3 Telescopic boom operation and LCD graphics 3 1 Telescopic boom selection and operation 3 2 Jib set operation 3 3 Emergency mode operation 4 Work range limit function 4 1 Item selection registration and cancellation 4 2 Work range limit function display 4 3 Display example 4 4 Saving the v...

Page 998: ...and displays 0710_EN_FA036_G2_01_01_00_AML 2003 01 3 38 1 Function keys and displays Fig 1 shows the AML control panel and graphic display AML control panel Graphic display Fig 1 AML control panel and graphic display ...

Page 999: ...election When this key is used for menu selection the menu cursor moves down or right Boom Use this key for boom or jib operation selection Jib set Use this key for jib set operation Outrigger left Use this key for left hand outrigger condition selection Outrigger right Use this key for right hand outrigger condition selection Counterweight Use this key for counterweight condition selection Work r...

Page 1000: ... Use this key to activate or deactivate the TARE function When this key is pressed the TARE function is activated and the load display value is reset to zero Moreover the load values are saved before this key is pressed While the TARE function is activated the saved values are subtracted from the load display When this key is pressed again the TARE function is deactivate Check Use this key to star...

Page 1001: ...top condition is present It is also lit if the override key or the overwind cancel key is ON Pre warning LED This LED goes on if the load ratio enters the pre warning range 90 102 5 Work range limit function LEDs These 6 LEDs indicate the current work range function status in question LED status Meaning OFF The work range function is deactivated ON The work range function is activated Flashing The...

Page 1002: ...isplay Normally displays the boom length While the work range limit function is being registered or cancelled it displays the registered height limit information Work Radius Display Normally displays the work radius In some display modes ex jib set operation appears While the work range limit function is registered or cancelled it displays the registered work radius limit information Jib Angle Dis...

Page 1003: ...x indicates the number of rope falls If the hook displacement switch is on the hook displacement is displayed While the work range limit function is registered or cancelled it displays the registered boom upper angle limit information Counterweight Display Displays counterweight information Wind speed display Displays the wind speed Outrigger Length Display 1 4 no use for ATF 220G 5 Note The numer...

Page 1004: ... Shows that the work radius is displayed on the work radius display 8 Jib angle symbol Shows that the jib angle is displayed on the jib angle display 9 Jib length symbol Shows that the jib length is displayed on the jib length display 10 Hook symbol This symbol appears if the rope falls or the hook displacement appears on the jib length display 11 Upper angle limit symbol This symbol shows that th...

Page 1005: ...s Shows the outrigger condition The outer symbol designates the maximum outrigger length and the inner symbol shows the selected outrigger status 20 Swing position symbol Shows the swing position by 20 segments 21 26 no use for ATF 220 5 1 2 3 Character Display The character display shows 16 characters x 2 lines Normally the load ratio bar graph appears in the first line and hook displacement or p...

Page 1006: ...d information of auxiliary winch also appears on the graphic display And it shows the information of counterweight on the right side This information shows mounted dismounted condition of counterweight and permission prohibition state of operation Graphic display is used for telescoping speed pre selection and maintenance These operations are instructed in other chapters ...

Page 1007: ...er conditions With the AML in normal display state press Outrigger right or Outrigger left then the AML goes to the outrigger registration state and shows the LCD panel as follows If the Outrigger right key is pressed the right hand outrigger state symbols start to flash For each actuation of Outrigger right Back or Forward the state of the right hand outrigger changes to the next condition Then p...

Page 1008: ...AML goes to the counterweight registration state and shows the LCD panel as follows Whenever the keys Counterweight Back or Forward are pressed the counterweight value changes to the next condition If the desired condition is reached press Set to register the counterweight condition If Initial display is pressed the AML exits the counterweight registration state Counterweight key Set key Flashing ...

Page 1009: ...et angle condition appears e g 5 4m 20 0 degrees After all offset angle conditions have appeared then next jib length condition with first offset angle condition appears Load Display Flashes to display Rated Load Display Flashes to display Work Radius Display Flashes to display Press Set to register the selected boom jib condition in the AML If Initial display is pressed the AML exits the boom jib...

Page 1010: ...appears on character display Jib Length Display While the jib symbol appears this indicator flashes to display the jib length condition Jib Angle Display While the jib symbol is appearing it flashes to display the jib angle condition Load Display Flashes to display Rated Load Display Flashes to display Work Radius Display Flashes to display If the Set key is pressed the selected jib set condition ...

Page 1011: ...l number is also used for capacity control for wire cut protection 2 Hook Displacement Display If the hook displacement switch is on the AML displays the main hook or sub hook displacement height from their reset position The main or sub hook information can be changed using the hook select switch During boom or single top operation the displacement value is displayed on the jib length display Dur...

Page 1012: ...or Back and the select boom condition Actuating Plus or Minus changes the menu page If the boom condition menu is displayed on the graphic the character display also shows the boom condition menu Box cursor to select boom condition Cursor moves by Forward or Back If cursor reaches bottom then the next menu page appears Pressing Plus or Minus changes the menu page The mark appears on the currently ...

Page 1013: ...shed press the telescope display on off switch Now the graphic turns off If the telescope display on off switch is not actuated the graphic remains visible If the boom status graphic is displayed on the graphic LCD the character display also shows the boom length Target boom condition Current boom status Boom connection pin B pin status graphic Green locked Circle not filled unlocked Red detector ...

Page 1014: ...0 0m 0 0 46 46 46 46 17 34 1m 0 46 46 46 46 46 18 38 3m 46 46 46 46 46 46 19 42 5m 92 46 46 46 46 46 20 42 5m 46 46 46 46 46 92 21 46 7m 46 46 46 46 92 92 22 50 9m 92 46 46 46 92 92 23 46 7m 92 92 46 46 46 46 24 50 9m 92 92 92 46 46 46 25 55 0m 92 92 92 92 46 46 26 55 0m 46 92 92 92 92 46 27 59 2m 92 92 92 92 92 46 28 68 0m 100 100 100 100 100 100 29 17 4m 0 46 0 0 0 0 30 21 6m 46 46 0 0 0 0 31 25...

Page 1015: ... the control panel without inputting the telescoping code that appears on LCD graphic screen Top boom can be extended by control lever During telescopic operation the boom status graphic also appears Graphic display Character display Current cylinder length Telescopic menu number fixed on 99 Telescopic menu number fixed on 99 Current cylinder length ...

Page 1016: ...1 38 3 3 Emergency mode operation When emergency control switch is on the display may differ in some cases from the normal boom telescope In emergency mode B pin and C pin operation should be effected while symbol is displayed E02 indicates emergency mode indicates cylinder position ...

Page 1017: ...Height During item selection the AML flashes to display the selected limit symbol while the other limit symbols not selected are turned on If the key Set is pressed the AML registers if already registered it cancels the current position as the selected limit function value and terminates the work range limit registration and cancellation mode Pressing Set inverts the item registration states If th...

Page 1018: ...ed The boom height symbol flashes thus indicating that the height limit is selected The boom length display flashes while showing the current boom height Flashing means that the value is not registered The other parts of the numerical display show as no other items are selected and registered Fig 4 3 1 A Display example of LCD panel when height limit function is selected The height value is not ye...

Page 1019: ...ver the swing position symbols in this area flashes Fig 4 3 2 A Display example of the LCD panel when boom upper angle limit function is selected The jib length display shows the boom upper angle limit information When the limit function is not registered the current boom angle is displayed Fig 4 3 3 A Display example of an LCD panel when the left hand swing angle limit function is selected In thi...

Page 1020: ...anel when the left hand swing angle limit function is selected In this example only the left hand swing limit is registered and the right hand swing limit is not yet registered If only the left hand swing limit is registered if the crane enters this area by left hand swing the AML s auto stop function is applied However if the crane enters this area by right hand swing the AML s auto stop function...

Page 1021: ...n state 2 Limit symbols Flashing Item is now selected On Item is not selected 3 LEDs Off The work range function has been cancelled On The work range function is activated Flashing The work range function is activated and auto stop control is being performed 4 Numerical Displays Value turned on The work range function is registered Value flashing The work range function is cancelled and the curren...

Page 1022: ...d up boom lowering and extending operations are deactivated If the key Initial display is pressed the AML display returns to normal display state 6 Speed pre selection and maintenance When the Check key is pressed for more than 3 seconds icons for Speed pre selection Boom maintenance and Hook position initialize are displayed on the graphic display Speed pre selection icon Boom maintenance Icon Ho...

Page 1023: ...on elevating up lowering can be adjusted independently Main winch up down can be adjusted independently Aux winch up down can be adjusted independently When the Speed pre selection menu is selected the adjustable actuator menu appears on the graphic display Move cursor by Forward or Back to select actuator for speed pre selection Swing speed pre selection icon Elevation speed pre selection icon Ma...

Page 1024: ... during right swing operation only the right swing speed changes Pressing Plus or Minus during left swing operation the left swing speed changes Other actuators are same Forward Select the actuator Move the cursor Back Select the actuator Move the cursor Plus Increase value of speed pre selection max 100 Minus Decrease value of speed pre selection min 10 Set Register the pre selection value Return...

Page 1025: ...raphic display The displayed special telescopic configuration are all intended for maintenance purpose only and not for lifting the load Table Boom condition of maintenance mode No Boom Tele 1 Tele 2 Tele 3 Tele 4 Tele 5 Tele 6 M00 13 2m 0 0 0 0 0 0 M01 22 0m 0 0 0 0 0 100 M02 31 3m 100 0 0 0 0 100 M03 22 3m 0 0 0 0 100 0 M04 31 6m 0 100 0 0 100 0 M05 22 5m 0 0 0 100 0 0 M06 31 7m 0 0 100 100 0 0 ...

Page 1026: ...n Boom Status Graphic The character M appears on target boom configuration number To exit the Boom maintenance use telescope display on off switch Use the Boom maintenance only when maintaining the booms Actual load and rated load display are showing in this mode Do not lift anything other than hook block Overload prevention system is not functioning in this state M indicates maintenance telescope...

Page 1027: ...erformed 1 Procedure Make sure rope fall setting and Boom configuration setting of AML at normal display state Lowering the hook until it slightly touches the ground The boom angle and boom length conditions are freely selectable Select the Hook position initialization icon The following display appears Press the Set the initialization is performed and exit menu To exit the menu press Initial disp...

Page 1028: ...or during telescoping operation after long interval from the boom extended In this condition telescopic speed becomes slowly for correct telescoping Such the condition is called slow telescoping mode When tortoise symbol appearing with the temperature more than 0 degree centigrade you can cancel slow telescoping mode In slow telescoping mode one icon is added on Speed pre selection and maintenance...

Page 1029: ...ter of hook block should be set at center of gravity of the load Add the tension slightly to the sling wire of the load Setting the number of part line is very important for accurate control of Lift Adjuster Check the condition of number of part line and confirm for other setting of AML Note If the hook block is not set at the center of gravity of the load properly sway of the load is large Note D...

Page 1030: ...the operation Note If following conditions occur Lift Adjuster operation is automatically shut off Overloaded Over winding the winch Press the Lift adjuster switch Elevating cylinder is reached to the end of the stroke Operate other control except hoisting or swing levers Note If winch lever is returned to the neutral position before the Lift Adjuster operation finishes hoisting up and elevating u...

Page 1031: ...osition symbol Green Counterweight cylinders are retracted fully Without counterweight Graphics of cylinders retract fully Yellow Counterweight cylinders are middle position Without counterweight Graphics of cylinders extend according to actual length Green Counterweight cylinders are retracted fully With counterweight Graphics of cylinders retract fully Yellow Counterweight cylinders are middle p...

Page 1032: ...w the swing positions of counterweight cylinders that can operate Left side symbol right side symbol Green Swing positions that can extend retract cylinders Extension is possible only without counterweight Not filled Swing positions than cannot extend cylinders Circle symbol Superstructure locking pin condition Green Swing positions that can extend retract cylinders Over rear with superstructure l...

Page 1033: ...Counterweight status 38 38 0710_EN_FA036_G2_01_01_00_AML 2003 01 Memo ...

Page 1034: ...AML Warning and Error Codes 0715_EN_FA036_G2_01_03_00_ERROR_CODE 2003 01 1 14 AML Warning and Error Codes for FAUN ATF 220G 5 FAUN GmbH ...

Page 1035: ...er boom angle limit Cancel work range function or lower the boom W0027 Stopped due to working area limit lower boom angle limit Cancel work range function or elevation up the boom W0028 Stopped due to working area limit height limit Cancel work range function or lower the boom W0029 Stopped due to working area limit work radius limit Cancel work range function or elevate the boom up W0034 Stopped ...

Page 1036: ...degree W0095 Automatic telescope is impossible because the boom connection pin B pin speed is very slow Retry again with full lever and full engine revolution If the temperature is more than 0 degree centigrade it is possible to use Slow telescoping mode cancel function see operation manual chapter 6 4 W0102 This message appears when Slow telescoping mode cancel is selected W0106 Elevating speed i...

Page 1037: ... Communication line between Transmitter and AML is interrupted or connected incorrectly AML receive circuit fault Transmitter s transmit circuit fault E1012 Outrigger state transmitter type in data received is wrong Outrigger state transmitter fault Wrong connection of communication line E1021 AML detects data error in data received from Display Unit Display Unit fault Wrong connection of communic...

Page 1038: ...ngth detector error The input value from detector is out of normal range Normal range is 1 1 21mA Inside of transmitter convert to voltage 0 25 4 75V Detector fault Detector wire interrupted or short circuit Outrigger state transmitter circuit fault E2011 Front left outrigger length detector error The input value from detector is out of normal range Normal range is 1 1 21mA Inside of transmitter c...

Page 1039: ...is 0 25 4 75V Note Lever 1 operation is not possible Another operation is possible via AML override key Lever fault Wire fault interrupted or short circuit AML circuit fault E2042 Crane control lever 2 error analogue The input value from lever 2 is out of normal range Normal range is 0 25 4 75V Note Lever 2 operation is not possible Another operation is possible via AML override key Lever fault Wi...

Page 1040: ...in neutral range Note Lever 3 operation is not possible Another operation is possible via AML override key Lever fault Wire fault interrupted or short circuit AML circuit fault E2051 Crane control lever 4 error mismatch When operation detect switch of lever 4 is off analog input value from crane control lever 4 is not in neutral range Note Lever 1 operation is not possible Another operation is pos...

Page 1041: ...sible Another operation is possible via AML override key Hydraulic circuit fault Solenoid fault Swing angle detector fault AML circuit fault E2082 Main winch motion error When AML does not activate the main winch valve but winch motion up is detected Note Main winch up operation is not pos sible Another operation is possible via AML override key Hydraulic circuit fault Solenoid fault Main winch po...

Page 1042: ...ector fault Wire fault AML circuit fault E2089 Boom section detector error While telescopic cylinder is not connected to the boom telescopic cylinder length value exceeds the normal range when boom section detector becomes on Cylinder length and boom section detector status does not match Note Telescope operation is not possible Another operation is possible via AML override key Cylinder length de...

Page 1043: ...is possible Execute tele reset menu E2095 Lever 1 operation detect switches are both turned on Note Lever 1 operation is not possible Another operation is possible Lever 1 fault Wire fault AML circuit fault E2096 Lever 2 operation detect switches are both turned on Note Lever 2 operation is not possible Another operation is possible Lever 2 fault Wire fault AML circuit fault E2097 Lever 3 operatio...

Page 1044: ... override key Hydraulic circuit fault Solenoid fault Telescopic cylinder length detector fault AML circuit fault E2107 Elevating motion error When AML does not activate the elevating valve but elevating down motion is detected Note Elevation down operation is not possible Another operation is possible via AML override key Hydraulic circuit fault Solenoid fault Boom angle detector fault AML circuit...

Page 1045: ...ation is possible via AML override key Tele section 3 or 4 or 5 detector fault Wire fault AML circuit fault E2117 Tele section 5 detector ID sensor does not work Tele section 6 4 detector ID sensor works after tele 4 6 without tele 5 Note Telescope operation is not possible Another operation is possible via AML override key Tele section 4 or 5 or 6 detector fault Wire fault AML circuit fault E2119...

Page 1046: ...03 CPU or DMAC address error E3004 Illegal instruction E3005 Undefined exception is called Hardware fault due to external noise Re write program and data AML circuit fault E3006 Applied voltage to analog detector 5V is out of range Wire fault Circuit fault E3007 Adjustment data in flash memory is not correct Hardware fault due to external noise AML circuit fault Note Erase error log This message r...

Page 1047: ... error is detected Memory fault Hardware fault due to external noise Display unit circuit fault E4003 CPU or DMAC address error E4004 Illegal instruction E4005 Undefined exception is called Memory fault Re write program and data Hardware fault due to external noise Display unit circuit fault E4010 Receive timeout error Cannot receive data from Main Unit Wire fault Main Unit is updating flash Displ...

Page 1048: ...0720_EN_ALLGE_G2_02_00_00 Centralized lubrication system ...

Page 1049: ......

Page 1050: ...UEBERS_FA029 2003 01 1 2 Overview of lubricating points Ausleger Boom Drehkranz Ring gear Hochdruckschlauch High pressure hose Hubwinde 1 Hoist winch 1 Hubwinde 2 Hoist winch 2 Kabine Cabin Polyamidrohr Polyamid tube Schmierstellen Lubricating points Wippzylinder Cylinder ...

Page 1051: ...G2 2 Overview of lubricating points 2 2 0725_EN_FA036_G2_02_00_00_SCHMIERSUEBERS_FA029 2003 01 Memo ...

Page 1052: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 1 12 ...

Page 1053: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 2 12 Beschreibung_EN_G2 doc 2003 01 ...

Page 1054: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 3 12 ...

Page 1055: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 4 12 Beschreibung_EN_G2 doc 2003 01 ...

Page 1056: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 5 12 ...

Page 1057: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 6 12 Beschreibung_EN_G2 doc 2003 01 ...

Page 1058: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 7 12 ...

Page 1059: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 8 12 Beschreibung_EN_G2 doc 2003 01 ...

Page 1060: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 9 12 ...

Page 1061: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 10 12 Beschreibung_EN_G2 doc 2003 01 ...

Page 1062: ...Central Lubricating System Method of operation of the central grease lubrication system G2 2 Beschreibung_EN_G2 doc 2003 01 11 12 ...

Page 1063: ...G2 2 Central Lubricating System Method of operation of the central grease lubrication system 12 12 Beschreibung_EN_G2 doc 2003 01 Memo ...

Page 1064: ...0735_EN_ALLGE_G2_03_00_00_00 Documents regarding heating ventilation and the air conditioning system superstructure cabin Optional equipment ...

Page 1065: ......

Page 1066: ...00 g Refrigerating oil PAG Air conditioning expansion kit Rated voltage Cooling capacity in connection with heater unit 910154 4 5 kW 10 Condenser unit 964081 Rated voltage 24 V Max air throughput 2100 m h Thermal output approx 13 kW Fan stages 1 Max power consumption 11 A Weight approx 9 7 kg Compressor 359213 Model Seltec TM 15HD Rated voltage 24 V Max speed 6000 rpm Delivery 147 cm Sense of rot...

Page 1067: ...WÖLFLE GmbH Operating Instructions 2 These data are partially given without being established by measurements and thus should only be considered as approximate values ...

Page 1068: ...Thermostat in the electric case next to the MB engine control unit Compressor on the engine or in case of a hydraulic drive in the hydraulic drive unit Filter drier on the condenser unit Pressure switch on the filter drier Inspection glass on the filter drier Condenser unit on the ballast Compressor Evaporator Condenser Thermostat Temperature Expansion valve Filter drier Pressure switch Inspection...

Page 1069: ...enser fan is running For maximum cooling effect turn thermostatic switch to the right to its stop turn the temperature switch to the left to its stop OFF position set fan to stage 3 set flap to circulating air close the door and the windows open all air vents An individual conditioning comfort range can be adjusted for each crane operator via the air vents which can be varied independently of one ...

Page 1070: ... performed at the beginning in the middle and at the end of a cooling period Check Vee belt tension and fastening of the compressor Check refrigerant filling To this effect the refrigerant must pass the inspection glass of the liquid tank free of bubbles when the engine is running and the air conditioning system is operating at maximum capacity Cleaning the condenser The discs of the condenser mus...

Page 1071: ...ace sensor Condenser soiled Visual inspection Clean condenser do not bend discs Vee belt loosened Hissing sounds Check Vee belt tension Condenser fan is not running Visual inspection Check fuse F843 Check electrical connections if necessary replace fan Compressor damage Abnormal sounds Replace compressor Increased compressor temp Replace compressor Lubricant has soiled belt pulley Clean Insufficie...

Page 1072: ...g Instructions 7 Relay faulty Replace component Thermostat faulty Replace component Pressure switch faulty Replace component Thermostatic switch faulty Replace component No refrigerant Repair leakage and fill system again ...

Page 1073: ...le cranes Moreover the unit is used for defrosting the vehicle s window panes 2 Technical Details Design Air heater unit with water heat exchanger Thermal output so far no measured data Rated voltage 24 V Service voltage 20 28V Service overpressure 1 bar Blower fan 1060 m3 h blowing free 3 stage Long Life Motor Heater unit The heater unit is installed below the seat bracket ...

Page 1074: ...ge fan switch Actuation of fresh recirculating air flap Actuation of water valve The water valve and the flap are actuated via Bowden cables Towards foot compartment Recirculating air Fresh air induction Towards windscreen Towards head room Towards rear window Fan Heat exchanger Fresh recirculating air flap Filter Water valve ...

Page 1075: ...h The temperature controller in conjunction with the 3 stage fan switch enables individual variation of the inside cabin temperature For maximum heating effect turn temperature switch to the right to its stop set fan to stage 3 set flap to recirculating air close the door and the windows open all air vents Defrosting of window panes as above however only open the air vents concerned example for wi...

Page 1076: ...nts Other components The heater unit has been equipped as standard with a filter category F7 In case of a considerable reduction of the capacity during fresh air operation the filter must be replaced Malfunctions Malfunction Error location elimination Reduced air throughput Replace filter Fan inoperative Check fuse F823 Check fan switch Check fan This kind of work may only be performed by speciali...

Page 1077: ...0750_EN_ALLGE_G3_01_00_00 Part G3 Annex Documents on various optional equipments of the vehicle ...

Page 1078: ......

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