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Tadano ATF 130G-5 - User Manual

Tadano ATF 130G-5
636 pages
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Translation of the original Operating Manual
ATF 130G-5
Superstructure
Vehicle identification number WFN5RUNMXE2146097
Head Office
TADANO LTD.
ko-34
Takamatsu
Phone: +81-87-839-5555
Fax: +81-87-839-5743
Overseas Service Dept
TADANO LTD.
Tadano Ryogoku Bldg.
Tokio, Japan
Phone: +81-3-3621-7765
Fax: +81-3-3621-7785

Table of Contents

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Summary

1 Preface

1.1 Superstructure Model Plate

Identifies the machine's key details via a plate on the superstructure cab.

1.2 In case of Damage

Instructions for reporting damage and specifying necessary information.

1.3 Warranty

Outlines warranty conditions and adherence to manual specifications.

1.4 Structure of the Operating Manual

Explains the content and organization of the operating manual chapters.

1.5 Using the Operating Manual

Guides users on safe and effective operation using the manual's structure and symbols.

2 General safety instructions

2.1 Basic Safety Information

Covers essential safety practices for operating the mobile crane, including proper use and personnel requirements.

2.2 Basic Safety Information for the Superstructure

Details specific safety instructions for operating the crane's superstructure components and systems.

3 Operation

3.1 Crane components of superstructure

Provides an overview of the superstructure's assemblies and components with installation place details.

3.2 Before starting work

Outlines crucial pre-operation checks for lights, fluid levels, and windshields.

3.3 Crane cab

Details the operation and adjustment of various cab features for operator comfort and safety.

3.4 Control & Service System CSS

Explains the functions and operation of the electronic Control & Service System (CSS).

3.5 Automatic safe load indicator

Covers the ASLI's functionality, setup, displays, and operational procedures for safe lifting.

3.6 Other safety devices

Describes essential safety features like the anti-twoblock device and limit switches.

3.7 Commissioning

Details necessary measures and checks before initial operation of the crane.

3.8 Outrigger

Explains preparations, alarm displays, and control methods for outrigger operation.

3.9 Functions of control levers and pedals

Provides instructions on actuating crane control levers and specific functions like superstructure lock.

4 Crane testing instructions

4.1 Periodic tests of cranes

Outlines mandatory periodic tests and inspections for crane safety and compliance.

4.2 Checking the load-bearing steel structures

Details inspection procedures for critical steel structures to ensure structural integrity.

4.3 Checking the bottom block

Specifies procedures for inspecting bottom blocks for defects to prevent load failure.

4.4 Checking the hoisting ropes

Covers inspection criteria, replacement states, and maintenance for hoisting ropes.

4.5 Service life of the hoisting gear

Discusses factors affecting hoisting gear service life and necessary checks.

4.6 Monitoring the slewing ring

Details checks for turntable fixing screws and slewing ring wear.

5 Rectifying the faults

5.1 Rectifying the faults

Provides a troubleshooting table for identifying and rectifying common faults in various crane systems.

6 Technical Specifications

6.1 Engine

Lists detailed technical specifications for the engine, including power and emissions.

6.2 Hydraulic system

Outlines specifications for the diesel-hydraulic system, pumps, and control units.

6.3 Hoisting gear

Details technical specifications for hoisting gears, including drum diameter and rope length.

6.4 Telescopic boom

Provides dimensions and telescoping time for the six-section telescopic boom.

6.5 Boom luffing gear

Specifies adjusting angle and time for the boom luffing gear.

6.6 Swing mechanism

Details specifications for the axial piston motor and transmission of the swing mechanism.

6.7 Safety equipment

Lists electronic safety devices like ASLI, anti-twoblock, and warning lamps.

6.8 Electrical system

Details the crane's DC system, batteries, beacon, and lighting specifications.

6.9 Superstructure cab

Describes the crane cab's construction, features, and installed systems like HVAC.

6.10 Counterweight

Specifies counterweight options, weight distribution, and vehicle transport capabilities.

6.11 Superstructure frame

Details the superstructure frame construction, slewing ring, and lubrication system.

6.12 Optional equipment

Lists various optional attachments and equipment available for the crane.

7 Service and Maintenance

General instructions

0.1 Before servicing and maintenance

Highlights cleanliness and planning prerequisites for all maintenance activities.

Maintenance intervals

1.1 Maintenance Schedule

Provides a detailed schedule for regular maintenance based on operating hours and time intervals.

Engine

2.1 Checking the oil level

Details the procedure for checking and replenishing engine oil levels using the sight glass.

2.2 Oil change; oil filter change

Provides instructions for changing engine oil and filter, including waste disposal.

2.3 Checking the hose clamps of the charge-air hoses

Specifies checking hose clamp torque and condition for charge-air system integrity.

2.4 Fuel tank

Covers procedures for draining condensed water and changing the fuel filter.

2.5 Coolant

Explains coolant specifications, checking levels, and replacing coolant, emphasizing safety.

2.6 Cleaning the cooler

Details methods for cleaning radiator fins of charge air and water coolers.

2.7 Air cleaner

Covers air cleaner maintenance, including checking housing, cartridge, and monitoring function.

2.8 Exhaust system

Provides instructions for maintaining the spark arrester and cleaning the exhaust pipe.

Hydraulic system

3.1 Checking the hydraulic oil level

Details how to check and replenish hydraulic oil levels using the sight glass.

3.2 Replacing the filter inserts

Provides instructions for replacing filter inserts and cleaning ventilation filters.

3.3 Oil change

Outlines procedures for changing hydraulic oil, including waste disposal and filter replacement.

3.4 Switching to another oil

Provides guidance on switching hydraulic oils, emphasizing VDMA Directives and additive use.

3.5 Replace the pressure filter insert

Details the process for removing, cleaning, and replacing the pressure filter insert.

3.6 Checking and tightening the screw couplings of the hydraulic units and pipes

Covers checking and tightening hydraulic screw couplings for leak tightness and proper fit.

Swing mechanism

4.1 Checking the oil level and leak tightness

Covers regular checks for swing mechanism oil level and leak tightness.

4.2 Oil change

Provides procedures for changing swing mechanism oil and checking ventilation filter.

4.3 Checking hydraulic oil in the working brake circuit of the swing mechanism

Details checking hydraulic oil in the working brake circuit and bleeding the system.

4.4 Checking the slewing engine - gear drive shaft, tooth profile play

Describes checks for the slewing engine, gear drive shaft, and tooth profile play.

4.5 Lubricating swing mechanism gear rings and pinions

Provides guidance on lubricating swing mechanism gear rings and pinions.

4.6 Lubricating the ball-bearing slewing ring

Explains the lubrication process for the ball-bearing slewing ring using a central system.

4.7 Greasing the swing mechanism - lock pins

Covers greasing procedures for swing mechanism lock pins.

4.8 Checking the functioning of the mechanical superstructure lock and proximity switch

Details checks for the superstructure lock and proximity switch functionality.

4.9 Lubrication of the swing mechanism multi-disc chamber

Provides instructions for lubricating the swing mechanism multi-disc chamber.

4.10 Checking the gear ring-joint screws, fastening screws of the hydro motor, gear flange screws for firm fit

Covers checking and tightening screws for the gear ring, hydro motor, and gear flange.

4.11 Checking the slewing ring for wear

Details how to check the slewing ring for wear and permissible clearance.

Hoisting gear; 2 nd hoisting gear*)

5.1 Checking the oil level and leak tightness

Covers regular checks for hoisting gear oil level and leak tightness.

5.2 Oil change

Provides procedures for changing hoisting gear oil, including safety precautions.

5.3 Checking the oil level in the hoisting gear motor-engine coupling

Details checking the oil level in the hoisting gear motor-engine coupling.

5.4 Changing the oil in the hoisting gear motor;engine coupling

Outlines the process for changing oil in the hoisting gear motor/engine coupling.

5.5 Checking the hoisting gear motor-gear drive shaft, tooth profile play

Describes checks for hoisting gear motor-gear drive shaft and tooth profile play.

5.6 Preserving the hoisting gear drive

Recommends procedures for preserving the hoisting gear drive during prolonged disuse.

5.7 Check the hoisting gear brake

Details the annual check of the hoisting gear brake, including free wheel.

5.9 Checking the anti-twoblock device function

Explains how to check the anti-twoblock device function for preventing sheave damage.

5.10 Check the over-unwind limit switch on the hoisting gear

Covers checking and setting the over-unwind limit switch for safe rope winding.

Hoisting rope

6.1 Check

Covers visual checks and legal regulations for hoisting rope inspection.

6.2 Cleaning and lubricating the hoisting rope

Details methods for cleaning and lubricating hoisting ropes to extend service life.

6.3 Laying the hoisting rope (rope change)

Provides step-by-step instructions for removing and installing hoisting ropes.

6.4 Checking the winch drum

Covers checks for the winch drum, including cleaning and oil level.

6.5 Laying a new hoisting rope

Guides on selecting and laying new hoisting ropes, emphasizing proper winding.

6.6 Servicing the hoisting rope

Highlights the importance of regular servicing for crane safety and hoisting rope service life.

Electrical system

7.1 Checking the batteries

Covers checking battery acid level, specific weight, and installing new batteries.

7.2 Three-phase generator

Details service life determination and periodic checks for the three-phase generator.

7.3 Starter

Advises to follow engine manufacturer's instructions for starter system.

7.4 Lamps and lights

Covers replacement of defective lamps and pilot lamps and their installation details.

7.5 Automatic Safe Load Indicator (ASLI)

Explains ASLI components, operator checks, and hydraulic pump feed verification.

7.6 Regular inspection of the automatic safe load indicator (ASLI) as per the legal regulations

Details regular system tests and re-adjustments for ASLI according to legal regulations.

7.7 Fuse and relay chart

Provides a chart listing functions, fuses, amperage, and locations for the electrical system.

7.8 Counterweight control relay chart

Lists relays associated with counterweight control functions.

Crane cab

8.1 Air conditioning system*)

Covers application, technical details, and functional checks of the air conditioning system.

8.2 Wiper-blade elements; windscreen washing system

Details replacing wiper blades and accessing the windscreen washing system tank.

8.3 Auxiliary heater

Provides instructions for operation, servicing, and maintenance of the auxiliary heater.

8.5 TADANO-Cockpit-Graphi7-Control System

Describes the monitor cleaning procedure for the TADANO-Cockpit-Graphi7-Control System.

8.6 Clean the circulating air filter

Explains how to clean the circulating air filter for the blower and air conditioning system.

Other greasing, maintenance and servicing points

9.1 Telescopic boom

Covers lubrication of telescope parts and locks, emphasizing safety during telescoping.

9.2 Derrick cylinder

Details lubrication of the derrick cylinder and cleaning of the piston rod.

9.3 Bottom block

Covers greasing procedures for the load hook traverse and bearing.

9.4 Counterweight

Details checking leak tightness of the locking cylinder and functioning of the lock.

9.5 Jib*)

Covers greasing of bearings, bushings, boltings, and adapter unit attachments.

9.6 Central lubricating system

Refers to manufacturer documents for operation, servicing, and specifications of the central lubricating system.

9.7 Other lubricating points

Lists general lubrication points like hinges, pins, and movable components.

Compressed air system

10.1 Drain valves in the pressure tanks

Details checking and draining water condensate from pressure tanks.

10.2 Air dryer

Covers function check and replacing the desiccating agent cartridge for the air dryer.

10.3 Pressure governor with tire inflation socket (integrated in air drier)

Explains setting the shut-off pressure of the pressure governor.

10.4 Test connectors for inspection of the compressed air system

Describes the location and use of test connectors for inspecting the compressed air system.

10.5 Test and setting values

Provides test and setting values for the compressed air system components.

Overview of the oil grades and capacities

Grease Overview (Grease Recommendations)

Selection table for lubricants and anti-friction agents

Annex;Manufacturers documents

8.1 Central lubricating system

Provides an overview of the central lubricating system and its lubrication points.

8.2 Superstructure cab

References documents related to the superstructure cab's operation and maintenance.

8.3 MTU Tier4 i-Inducement-Concept

Details the MTU Tier4i-Inducement-Concept, likely related to engine emissions.

8.4 Dolly traveling operation

Covers procedures and requirements for operating the crane with a dolly for transportation.

8.5 Fall protection system

Explains the proper use and installation of the fall protection system for safety.

Summary

1 Preface

1.1 Superstructure Model Plate

Identifies the machine's key details via a plate on the superstructure cab.

1.2 In case of Damage

Instructions for reporting damage and specifying necessary information.

1.3 Warranty

Outlines warranty conditions and adherence to manual specifications.

1.4 Structure of the Operating Manual

Explains the content and organization of the operating manual chapters.

1.5 Using the Operating Manual

Guides users on safe and effective operation using the manual's structure and symbols.

2 General safety instructions

2.1 Basic Safety Information

Covers essential safety practices for operating the mobile crane, including proper use and personnel requirements.

2.2 Basic Safety Information for the Superstructure

Details specific safety instructions for operating the crane's superstructure components and systems.

3 Operation

3.1 Crane components of superstructure

Provides an overview of the superstructure's assemblies and components with installation place details.

3.2 Before starting work

Outlines crucial pre-operation checks for lights, fluid levels, and windshields.

3.3 Crane cab

Details the operation and adjustment of various cab features for operator comfort and safety.

3.4 Control & Service System CSS

Explains the functions and operation of the electronic Control & Service System (CSS).

3.5 Automatic safe load indicator

Covers the ASLI's functionality, setup, displays, and operational procedures for safe lifting.

3.6 Other safety devices

Describes essential safety features like the anti-twoblock device and limit switches.

3.7 Commissioning

Details necessary measures and checks before initial operation of the crane.

3.8 Outrigger

Explains preparations, alarm displays, and control methods for outrigger operation.

3.9 Functions of control levers and pedals

Provides instructions on actuating crane control levers and specific functions like superstructure lock.

4 Crane testing instructions

4.1 Periodic tests of cranes

Outlines mandatory periodic tests and inspections for crane safety and compliance.

4.2 Checking the load-bearing steel structures

Details inspection procedures for critical steel structures to ensure structural integrity.

4.3 Checking the bottom block

Specifies procedures for inspecting bottom blocks for defects to prevent load failure.

4.4 Checking the hoisting ropes

Covers inspection criteria, replacement states, and maintenance for hoisting ropes.

4.5 Service life of the hoisting gear

Discusses factors affecting hoisting gear service life and necessary checks.

4.6 Monitoring the slewing ring

Details checks for turntable fixing screws and slewing ring wear.

5 Rectifying the faults

5.1 Rectifying the faults

Provides a troubleshooting table for identifying and rectifying common faults in various crane systems.

6 Technical Specifications

6.1 Engine

Lists detailed technical specifications for the engine, including power and emissions.

6.2 Hydraulic system

Outlines specifications for the diesel-hydraulic system, pumps, and control units.

6.3 Hoisting gear

Details technical specifications for hoisting gears, including drum diameter and rope length.

6.4 Telescopic boom

Provides dimensions and telescoping time for the six-section telescopic boom.

6.5 Boom luffing gear

Specifies adjusting angle and time for the boom luffing gear.

6.6 Swing mechanism

Details specifications for the axial piston motor and transmission of the swing mechanism.

6.7 Safety equipment

Lists electronic safety devices like ASLI, anti-twoblock, and warning lamps.

6.8 Electrical system

Details the crane's DC system, batteries, beacon, and lighting specifications.

6.9 Superstructure cab

Describes the crane cab's construction, features, and installed systems like HVAC.

6.10 Counterweight

Specifies counterweight options, weight distribution, and vehicle transport capabilities.

6.11 Superstructure frame

Details the superstructure frame construction, slewing ring, and lubrication system.

6.12 Optional equipment

Lists various optional attachments and equipment available for the crane.

7 Service and Maintenance

General instructions

0.1 Before servicing and maintenance

Highlights cleanliness and planning prerequisites for all maintenance activities.

Maintenance intervals

1.1 Maintenance Schedule

Provides a detailed schedule for regular maintenance based on operating hours and time intervals.

Engine

2.1 Checking the oil level

Details the procedure for checking and replenishing engine oil levels using the sight glass.

2.2 Oil change; oil filter change

Provides instructions for changing engine oil and filter, including waste disposal.

2.3 Checking the hose clamps of the charge-air hoses

Specifies checking hose clamp torque and condition for charge-air system integrity.

2.4 Fuel tank

Covers procedures for draining condensed water and changing the fuel filter.

2.5 Coolant

Explains coolant specifications, checking levels, and replacing coolant, emphasizing safety.

2.6 Cleaning the cooler

Details methods for cleaning radiator fins of charge air and water coolers.

2.7 Air cleaner

Covers air cleaner maintenance, including checking housing, cartridge, and monitoring function.

2.8 Exhaust system

Provides instructions for maintaining the spark arrester and cleaning the exhaust pipe.

Hydraulic system

3.1 Checking the hydraulic oil level

Details how to check and replenish hydraulic oil levels using the sight glass.

3.2 Replacing the filter inserts

Provides instructions for replacing filter inserts and cleaning ventilation filters.

3.3 Oil change

Outlines procedures for changing hydraulic oil, including waste disposal and filter replacement.

3.4 Switching to another oil

Provides guidance on switching hydraulic oils, emphasizing VDMA Directives and additive use.

3.5 Replace the pressure filter insert

Details the process for removing, cleaning, and replacing the pressure filter insert.

3.6 Checking and tightening the screw couplings of the hydraulic units and pipes

Covers checking and tightening hydraulic screw couplings for leak tightness and proper fit.

Swing mechanism

4.1 Checking the oil level and leak tightness

Covers regular checks for swing mechanism oil level and leak tightness.

4.2 Oil change

Provides procedures for changing swing mechanism oil and checking ventilation filter.

4.3 Checking hydraulic oil in the working brake circuit of the swing mechanism

Details checking hydraulic oil in the working brake circuit and bleeding the system.

4.4 Checking the slewing engine - gear drive shaft, tooth profile play

Describes checks for the slewing engine, gear drive shaft, and tooth profile play.

4.5 Lubricating swing mechanism gear rings and pinions

Provides guidance on lubricating swing mechanism gear rings and pinions.

4.6 Lubricating the ball-bearing slewing ring

Explains the lubrication process for the ball-bearing slewing ring using a central system.

4.7 Greasing the swing mechanism - lock pins

Covers greasing procedures for swing mechanism lock pins.

4.8 Checking the functioning of the mechanical superstructure lock and proximity switch

Details checks for the superstructure lock and proximity switch functionality.

4.9 Lubrication of the swing mechanism multi-disc chamber

Provides instructions for lubricating the swing mechanism multi-disc chamber.

4.10 Checking the gear ring-joint screws, fastening screws of the hydro motor, gear flange screws for firm fit

Covers checking and tightening screws for the gear ring, hydro motor, and gear flange.

4.11 Checking the slewing ring for wear

Details how to check the slewing ring for wear and permissible clearance.

Hoisting gear; 2 nd hoisting gear*)

5.1 Checking the oil level and leak tightness

Covers regular checks for hoisting gear oil level and leak tightness.

5.2 Oil change

Provides procedures for changing hoisting gear oil, including safety precautions.

5.3 Checking the oil level in the hoisting gear motor-engine coupling

Details checking the oil level in the hoisting gear motor-engine coupling.

5.4 Changing the oil in the hoisting gear motor;engine coupling

Outlines the process for changing oil in the hoisting gear motor/engine coupling.

5.5 Checking the hoisting gear motor-gear drive shaft, tooth profile play

Describes checks for hoisting gear motor-gear drive shaft and tooth profile play.

5.6 Preserving the hoisting gear drive

Recommends procedures for preserving the hoisting gear drive during prolonged disuse.

5.7 Check the hoisting gear brake

Details the annual check of the hoisting gear brake, including free wheel.

5.9 Checking the anti-twoblock device function

Explains how to check the anti-twoblock device function for preventing sheave damage.

5.10 Check the over-unwind limit switch on the hoisting gear

Covers checking and setting the over-unwind limit switch for safe rope winding.

Hoisting rope

6.1 Check

Covers visual checks and legal regulations for hoisting rope inspection.

6.2 Cleaning and lubricating the hoisting rope

Details methods for cleaning and lubricating hoisting ropes to extend service life.

6.3 Laying the hoisting rope (rope change)

Provides step-by-step instructions for removing and installing hoisting ropes.

6.4 Checking the winch drum

Covers checks for the winch drum, including cleaning and oil level.

6.5 Laying a new hoisting rope

Guides on selecting and laying new hoisting ropes, emphasizing proper winding.

6.6 Servicing the hoisting rope

Highlights the importance of regular servicing for crane safety and hoisting rope service life.

Electrical system

7.1 Checking the batteries

Covers checking battery acid level, specific weight, and installing new batteries.

7.2 Three-phase generator

Details service life determination and periodic checks for the three-phase generator.

7.3 Starter

Advises to follow engine manufacturer's instructions for starter system.

7.4 Lamps and lights

Covers replacement of defective lamps and pilot lamps and their installation details.

7.5 Automatic Safe Load Indicator (ASLI)

Explains ASLI components, operator checks, and hydraulic pump feed verification.

7.6 Regular inspection of the automatic safe load indicator (ASLI) as per the legal regulations

Details regular system tests and re-adjustments for ASLI according to legal regulations.

7.7 Fuse and relay chart

Provides a chart listing functions, fuses, amperage, and locations for the electrical system.

7.8 Counterweight control relay chart

Lists relays associated with counterweight control functions.

Crane cab

8.1 Air conditioning system*)

Covers application, technical details, and functional checks of the air conditioning system.

8.2 Wiper-blade elements; windscreen washing system

Details replacing wiper blades and accessing the windscreen washing system tank.

8.3 Auxiliary heater

Provides instructions for operation, servicing, and maintenance of the auxiliary heater.

8.5 TADANO-Cockpit-Graphi7-Control System

Describes the monitor cleaning procedure for the TADANO-Cockpit-Graphi7-Control System.

8.6 Clean the circulating air filter

Explains how to clean the circulating air filter for the blower and air conditioning system.

Other greasing, maintenance and servicing points

9.1 Telescopic boom

Covers lubrication of telescope parts and locks, emphasizing safety during telescoping.

9.2 Derrick cylinder

Details lubrication of the derrick cylinder and cleaning of the piston rod.

9.3 Bottom block

Covers greasing procedures for the load hook traverse and bearing.

9.4 Counterweight

Details checking leak tightness of the locking cylinder and functioning of the lock.

9.5 Jib*)

Covers greasing of bearings, bushings, boltings, and adapter unit attachments.

9.6 Central lubricating system

Refers to manufacturer documents for operation, servicing, and specifications of the central lubricating system.

9.7 Other lubricating points

Lists general lubrication points like hinges, pins, and movable components.

Compressed air system

10.1 Drain valves in the pressure tanks

Details checking and draining water condensate from pressure tanks.

10.2 Air dryer

Covers function check and replacing the desiccating agent cartridge for the air dryer.

10.3 Pressure governor with tire inflation socket (integrated in air drier)

Explains setting the shut-off pressure of the pressure governor.

10.4 Test connectors for inspection of the compressed air system

Describes the location and use of test connectors for inspecting the compressed air system.

10.5 Test and setting values

Provides test and setting values for the compressed air system components.

Overview of the oil grades and capacities

Grease Overview (Grease Recommendations)

Selection table for lubricants and anti-friction agents

Annex;Manufacturers documents

8.1 Central lubricating system

Provides an overview of the central lubricating system and its lubrication points.

8.2 Superstructure cab

References documents related to the superstructure cab's operation and maintenance.

8.3 MTU Tier4 i-Inducement-Concept

Details the MTU Tier4i-Inducement-Concept, likely related to engine emissions.

8.4 Dolly traveling operation

Covers procedures and requirements for operating the crane with a dolly for transportation.

8.5 Fall protection system

Explains the proper use and installation of the fall protection system for safety.

Tadano ATF 130G-5 Specifications

General IconGeneral
BrandTadano
ModelATF 130G-5
CategoryConstruction Equipment
LanguageEnglish

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