Tadano ATF 130G-5 Operational manual

Translation of the original Operating Manual
ATF 130G-5
Superstructure
Vehicle identification number WFN5RUNMXE2146097
Head Office
TADANO LTD.
ko-34
Takamatsu
Phone: [phone]
Fax: [phone]
Overseas Service Dept
TADANO LTD.
Tadano Ryogoku Bldg.
Tokio, Japan
Phone: [phone]
Fax: [phone]

Table of Contents
1Preface 9
1.1 Superstructure Model Plate 9
1.2 In case of Damage 9
1.3 Warranty 9
1.4 Structure of the Operating Manual 10
1.5 Using the Operating Manual 10
1.5.1 Symbol and warning labels 11
1.5.2 Definition of the direction specifications 12
2General safety instructions 13
2.1 Basic Safety Information 13
2.1.1 Use of the Mobile Crane 13
2.1.2 Personnel Requirements 14
2.1.3 Planning Use 17
2.1.4 Outrigger 21
2.1.5 Servicing and Maintenance 24
2.1.6 Welding and alignment work 26
2.1.7 Risk of fire and explosion 27
2.1.8 Different lengths of the hydraulic cylinders 27
2.1.9 Dismounting and disposal 28
2.2 Basic Safety Information for the Superstructure 29
2.2.1 Warning and Instruction Signs 29
2.2.2 Before Operating the Crane 38
2.2.3 Safety equipment 39
2.2.4 Crane operation with load 42
2.2.5 Errors during Crane Work 61
2.2.6 Ending Crane Work 62
3Operation 65
3.1 Crane components of superstructure 65
3.1.1 Assemblies, components – installation place 65
3.1.2 Crane cab 66
3.1.3 Operating elements 68
3.2 Before starting work 71
3.2.1 Checking the lights 71
3.2.2 Checking the oil level 72
3.2.3 Checking the coolant level 72
3.2.4 Checking the fill quantity of fuel 72
3.2.5 Cleaning windshields 73
3.2.6 Checking the hoisting rope 73
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3.2.7 Checking the bottom block 73
3.3 Crane cab 73
3.3.1 Cab door 73
3.3.2 Step adjustment 75
3.3.3 Opening/closing the window 76
3.3.4 Adjusting the seat 78
3.3.5 Heater, ventilation, air conditioning system 82
3.3.6 Interior lighting 83
3.3.7 Roller sun visor 83
3.3.8 Sun visor 84
3.3.9 Radio 84
3.3.10 Ventilator*) 84
3.4 Control & Service System CSS 85
3.4.1 Main screen 85
3.4.2 Selection menu 89
3.5 Automatic safe load indicator 96
3.5.1 Notes regarding the lifting capacity charts and supporting force tables 96
3.5.2 Control panel and displays 97
3.5.3 Entering the operating conditions 105
3.5.4 Operating the telescopic boom 112
3.5.5 Safety working range 117
3.5.6 Test function 122
3.5.7 Special functions 122
3.5.8 Lift adjuster 128
3.5.9 Warnings and error codes 130
3.6 Other safety devices 156
3.6.1 Anti-twoblock device 156
3.6.2 Overriding the automatic safe load indicator 157
3.6.3 Lower limit switch 158
3.6.4 Anemometer 160
3.6.5 Aircraft warning lamp*) 162
3.7 Commissioning 162
3.7.1 Measures and checks before commissioning 162
3.7.2 Electrical system 164
3.7.3 Starting/stopping the engine 168
3.7.4 Monitoring the display, indicator and warning lamps as well as the instruments when the
engine is running
171
3.7.5 Central lubricating system 175
3.7.6 Filling up with diesel or AdBlue® 176
3.8 Outrigger 179
3.8.1 Preparations 179
3.8.2 Outrigger 188
3.9 Functions of control levers and pedals 195
3.9.1 Instructions for actuating the crane control levers 195
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3.9.2 Superstructure lock 198
3.9.3 Swing mechanism lock*) 200
3.9.4 Overriding the slew/derrick slow-stop function 202
3.9.5 Assigning the crane control levers 204
3.10 Rigging and dismantling 225
3.10.1 Counterweights 225
3.10.2 Jib*) 253
3.10.3 Lifting work 396
3.10.4 Hook tackle/bottom block 403
3.10.5 Bottom block holder*) 403
3.10.6 Single top 405
3.10.7 Removing the second hoisting gear, mounting the balancing counterweight 407
3.10.8 Two-hook operation 409
3.11 Crane operation with load 412
3.11.1 Influence of the temperature difference in case of heating of the boom due to solar radia‐
tion
412
3.11.2 Crane operation on outriggers 413
3.11.3 Crane operations on wheels 415
3.12 Ladders, access steps, railing 416
3.12.1 Double ladder 417
3.13 Add-on parts, special and ancillary equipment 421
3.13.1 Hourmeter for hoisting gear 1 421
3.13.2 Hourmeter for hoisting gear 2 422
3.13.3 Observation mirror of hoisting gear 1 422
3.13.4 Observation mirror of hoisting gear 2 423
3.13.5 Charging socket and plugbox for starting via an external power source 424
3.13.6 Load view camera*) 425
3.13.7 Amot Control (engine stop) 426
3.14 Winter operation 427
3.14.1 Engine 428
3.14.2 Hydraulic system 430
3.14.3 Windshield washing system 431
3.15 Operation in case of an emergency 431
3.15.1 Crane control 432
3.15.2 Failure of components or central unit of the safe load indicator 434
3.15.3 Resetting telescope manually 436
3.15.4 Slewing the superstructure 445
3.15.5 Counterweight 447
3.15.6 Drive unit 449
3.15.7 Emergency stop switch for the superstructure 454
3.15.8 Starting the superstructure engine using external current 454
3.15.9 Emergency exit 458
3.15.10 Superstructure emergency stop pushbutton 459
3.15.11 Emergency control/emergency release*) 459
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4Crane testing instructions 467
4.1 Periodic tests of cranes 467
4.2 Checking the load-bearing steel structures 467
4.2.1 Measures to protect electronic parts during welding 468
4.2.2 Indicators for the points to be checked 470
4.3 Checking the bottom block 475
4.4 Checking the hoisting ropes 477
4.4.1 Replacement state of hoisting ropes 478
4.4.2 Replacing a hoisting rope 481
4.4.3 Maintenance and repair of the hoisting rope 482
4.5 Service life of the hoisting gear 483
4.6 Monitoring the slewing ring 483
4.6.1 Checking the turntable fixing screws 483
5Rectifying the faults 485
5.1 Rectifying the faults 485
5.1.1 Engine 486
5.1.2 Superstructure hydraulic system - general 487
5.1.3 Swing mechanism 488
5.1.4 Telescoping system 488
5.1.5 Derrick 489
5.1.6 Hoisting gear 489
5.1.7 Counterweight 490
5.1.8 Electrical system 490
5.1.9 Wiring diagram 491
6Technical Specifications 495
6.1 Engine 495
6.2 Hydraulic system 495
6.3 Hoisting gear 496
6.4 Telescopic boom 496
6.5 Boom luffing gear 496
6.6 Swing mechanism 496
6.7 Safety equipment 497
6.8 Electrical system 497
6.9 Superstructure cab 497
6.10 Counterweight 498
6.11 Superstructure frame 499
6.12 Optional equipment 500
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7Service and Maintenance 501
8Annex/Manufacturer's documents 587
8.1 Central lubricating system 587
8.1.1 Overview of lubrication points 587
8.2 Superstructure cab 601
8.3 MTU Tier4i-Inducement-Concept 613
8.4 Dolly traveling operation 621
8.5 Fall protection system 631
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Table of Contents
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1 Preface
1.1 Superstructure Model Plate
The model plate of the superstructure is on the left of the rear of the superstructure cab.
1.2 In case of Damage
In case of damage, contact the nearest TADANO workshop or TADANO dealer.
Specify the following:
▪ Chassis number or serial number
▪Type and scope of damage.
1.3 Warranty
The type and manner of use of the mobile crane must be completely in accordance with the specifi‐
cations in the operating manual.
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NOTICE
Loss of guarantee
If parts installed in the company are removed, changed or replaced with
non-original parts, the crane authorization as well as the manufacturer's
guarantee expires.
1. Do not dismantle original parts!
2. Do not modify original parts!
3. Use only TADANO original spare parts.
The mobile crane may be modified only after a written approval of the manufacturer.
In case of non-adherence, the warranty of the mobile crane becomes invalid. We do not assume
liability for damage resulting from non-adherence to the operating manual and its notes or due to
improper use of the mobile crane. The operating manual does not specify our sales and delivery
conditions.
1.4 Structure of the Operating Manual
The cover page contains an image of the mobile crane. It specifies:
▪the vehicle type,
▪the chassis number or the serial number,
▪the manufacturer,
▪ the After-sales Service.
"PREFACE" contains general information about the mobile crane and the operating manual.
"SAFETY NOTES" contain all the information required for the safe operation of the mobile crane.
"OPERATION" contains all Information required for the correct operation of the mobile crane.
"MAINTENANCE AND REPAIR" contains a list and description of all the inspection and mainte‐
nance activities. The TADANO After-sales Service Department provides additional information.
"CRANE TESTING INSTRUCTIONS" contains information about the checks to be carried out on
the mobile crane.
"TROUBLESHOOTING" helps in locating and eliminating errors quickly.
"TECHNICAL SPECIFICATIONS" contains all the important technical data.
"Annex" contains documents of supplier companies as regards vehicle components as well as spe‐
cial equipment.
1.5 Using the Operating Manual
This operating manual should make it possible for the user to operate the mobile crane safely and
use its functions. It provides important information that is a prerequisite for safe operation. Carrier
(chassis) and superstructure have been separately explained.
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The operating manual is primarily intended for the operator and the maintenance expert. The oper‐
ator and the maintenance personnel must be able to access it at all times. The operating manual
should thus be kept near the workplace of the operator, i.e. in the driver's or crane cab. The operat‐
ing manual is a part of the mobile crane.
If you receive additional information from our after-sales service, make a note of it and keep it with
the operating manual.
Read the operating manual carefully before the commissioning of the mobile crane. Be well ac‐
quainted with the content as well as the instruction signs and their meanings. You must also be
acquainted with the structure, function and the actuation direction of all operating elements before
operating the mobile crane.
DANGER
Risk of accident due to incorrect use.
Incorrect use or maintenance of the mobile crane can lead to accidents.
This could cause fatal injuries to persons.
1. Operation and maintenance of the mobile crane may be carried out
only by qualified and trained experts.
Always adhere to the notes in the operating manual during all activities!
The operating manual describes the delivered design as well as the special equipment, if any. The
Table of Contents helps you find the desired information. In addition, the header on every page al‐
so contains the title of the relevant chapter.
The control and switching equipment installed in the driver's cab (at the driver's seat) or the crane
cab has been specified on several pages of the operating manual. The chapter "Crane compo‐
nents" at the beginning of the operating manual provides an overview of the carrier and the super‐
structure.
The images in the operating manual may deviate from the actual design. The functional information
is not affected by this.
Please follow the specifications in the additional pamphlets of the vehicle documentation.
This operating manual has been translated to the best of the knowledge and capacity of the trans‐
lator. Only the German version is definitive for the functional correctness.
The TADANO After-sales Service is at your disposal for answering any questions that you may
have. Please contact the Customer Service Department if you have any questions even after read‐
ing through the operating manual. Put get all questions clarified before operating the mobile crane.
The operating manual is not a work instruction for carrying out greater commissioning work. The
TADANO After-sales Service will explain this to you.
If the mobile crane is sold, the operating manual must be handed over the new owner.
1.5.1 Symbol and warning labels
The following warning labels have been used in this operating manual.
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DANGER
Type and source of danger
If the warning is ignored, it could result in immediate death, serious
body injuries (e.g. permanent handicap, inability to work for at least one
week).
WARNING
Type and source of danger
If the warning is ignored, it could result in possible death, serious body
injuries (e.g. permanent handicap, inability to work for at least one
week).
CAUTION
Type and source of danger
If the warning is ignored, it could possibly or probably result in slight
body injuries (e.g. temporary handicap, inability to work for max. one
week) or material damage.
NOTICE
Type and source of danger
If this note is ignored, it could possibly or probably lead to considerable
material damage to the mobile crane.
Provides information if adherence to specific instructions is important for
economical use of the mobile crane or in case of additional information
and tips about the use of the mobile crane.
1.5.2 Definition of the direction specifications
Forward drive means: Moving in the direction of the driver's cab.
Reverse drive means: Moving in the direction of the tail-lights of the carrier.
Forward, backward, right, left as regards the mobile crane means that the driver's cab and the
boom head point in the same direction. Front is then always the direction of the driver's cab.
Forward, backward, right, left in the driver's cab refers to the carrier. The driver's cab is then always
forward.
Forward, backward, right, left in the crane cab refers to the superstructure. Forward is then always
the direction of the boom head.
Option
Options, special equipment and country-specific versions are marked with *).
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2 General safety instructions
2.1 Basic Safety Information
2.1.1 Use of the Mobile Crane
This mobile crane has been built in accordance with the latest technology and approved safety reg‐
ulations. Nevertheless, danger to life and limb and damage to property may occur during its use. It
is therefore necessary to pay attention to the operating instructions to reduce these risks.
It is only permitted to operate the mobile crane when it is technically in sound condition and in ac‐
cordance with its regulations. Problems or faults which affect the safety of the mobile crane must
be rectified immediately. Please contact TADANO After-sales Service if you have any questions.
DANGER
Improper use of the mobile crane!
Improper use causes danger to life and limb.
1. Read and understand the operating instructions.
2. Only trained, qualified personnel may operate the mobile crane.
All specifications and descriptions in the operating instructions assume that the mobile crane is be‐
ing operated and used as described in the chapter "Proper use".
Proper Use
Proper use of the mobile crane consists exclusively of the lifting and lowering of unfixed loads. To
do this, the weight and center of gravity of the load must be known. The weight of the load may not
exceed the lifting capacity of the mobile crane.
A bottom block or hook tackle, in either case approved by TADANO, must be reeved to the hoisting
rope. The bottom block must be centered over the center of gravity of the load before lifting. It may
only be operated in the permissible setup conditions.
The mobile crane may only be moved if this is permitted according to the available moving and lift‐
ing capacity charts. The setup conditions and specifications given in the operating instructions must
be adhered to.
The mobile crane may only be operated in the temperature range from -25 °C to +40 °C (-13 °F to
104 °F) ambient temperature.
Any other use is classified as improper.
The manufacturer bears no liability for damage resulting from improper use of the mobile crane.
The responsibility for this is exclusively that of the director of operations and the crane operator.
Improper Use
Incorrect use includes:
▪ using equipment parts not approved for the mobile crane,
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▪ using lifting capacity charts which do not correspond to the actual setup condition,
▪ working in slewing ranges and jib lengths which are not permitted according to the lifting ca‐
pacity charts,
▪ working with setup conditions which are not permitted according to the lifting capacity charts,
▪by-passing safety devices e.g. anti-twoblock device,
▪ increasing the jib length of the lifted load after an automatic safe load indicator shut-off,
▪ sliding, pushing or lifting loads with the outrigger beams, the outrigger cylinders or the suspen‐
sion,
▪ sliding, pushing or lifting loads with the luffing or the slewing gear,
▪ using the mobile crane to break off fixed objects,
▪ using the mobile crane for handling operations,
▪ loading or unloading the mobile crane suddenly (use with chutes, containers or claws),
▪ using the mobile crane for work in which the swinging load alters in weight, e.g. filling a con‐
crete container, containers or chutes,
▪ using the mobile crane to transport flammable or other hazardous materials,
▪ using the mobile crane to catch falling objects or parts,
▪ using the mobile crane for bungee jumping,
▪ driving the mobile crane in an unsuitable condition,
▪ driving on public roads when the equipment is not in a permitted state (dimensions, axle loads),
▪ using the mobile crane for pile-driving or vibrating operations.
The mobile crane may not be used for:
▪ rigging loads whose centers of gravity and weights are unknown and which are then released,
e.g. by disconnecting, separating,
▪ working without the necessary additional equipment, e.g. two hook block operation,
▪ transporting loads on the carrier,
▪ carrying persons outside the driver's cab on the chassis,
▪ carrying persons in the crane cab while driving,
▪ carrying persons on the load or the load lifting device,
▪ carrying persons in workman's baskets without written authorization from the responsible au‐
thorities. National regulations of the area of use must also be observed.
2.1.2 Personnel Requirements
DANGER
Risk of accident due to incorrect use!
Incorrect use or maintenance of the mobile crane can lead to accidents.
This could cause fatal injuries to persons.
1. Operation and maintenance of the mobile crane may be carried out
only by qualified and trained experts.
2. Observe the warning and instruction signs.
3. Observe the operating instructions.
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DANGER
Risk of accident due to inappropriate clothing!
Loose clothing can get caught in rotating parts. This can lead to body
parts being squeezed or crushed. Loose clothing can get caught on to
protruding parts.
1. Wear appropriate clothes; tie long hair and protect them with a hair
net.
DANGER
Danger due to influence of alcohol, drugs and medicines!
The personnel should not be under the influence of alcohol, drugs or
medicines or suffer from exhaustion. This is because in such situations,
dangers cannot be correctly estimated.
WARNING
Risk of slipping and accidents!
When climbing and stepping on ladders, take utmost care especially in
case of humid weather.
1. Keep ladders clean at all times!
2. Remove dirt and other greasy substances immediately and thor‐
oughly.
3. Always hold the ladder beams or handles while climbing up or
down.
4. Wear non-slip shoes and keep them clean.
5. Ensure that the ladders are safe.
General and type-specific driver and after-sales service training courses are carried out at TADA‐
NO Ltd..
Persons who are still undergoing training may only work on the mobile crane under the supervision
of qualified members of staff.
Crane Operators
The crane operator requires technical knowledge of mobile cranes and their applications.
The crane operator must be able to recognize risks to themselves and others and to implement
suitable measures to avoid these risks.
Only trained and authorized personnel may work with the mobile crane.
The crane operator must fulfill the following prerequisites, among others:
▪permission to drive and operate the mobile crane in the country of use,
▪ basic knowledge of working with mobile cranes and the qualifications required in the country of
use,
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▪ the intellectual and physical requirements to be able to operate a mobile crane,
▪ knowledge and understanding of the operating instructions for the mobile crane,
▪ knowledge and understanding of the relevant accident prevention regulations.
▪knowledge and understanding of the mobile crane emergency.
Only those persons who have been briefed and are aware of the valid accident prevention regula‐
tions may engage in the rigging of loads and signaling to the crane operator.
Cleaning and Maintenance Personnel
The cleaning staff must possess relevant knowledge, e.g. onto which vehicle parts no high-pres‐
sure water cleaning jet may be directed.
Only trained personnel with specialist knowledge of and experience in the fields of electrics, elec‐
tronics, hydraulics and pneumatics may carry out maintenance work on the mobile crane.
Skilled Repair Technicians
Only qualified and trained, expert personnel may carry out repairs on the mobile crane. These are,
for example, trained specialists from the fields of mechatronics or the automotive trade.
Only personnel from a specialist brakes workshop or with equivalent qualifications may carry out
work on the brakes and compressed air system.
National regulations which differ from the above regulations should be observed.
Personal Protective Equipment
DANGER
Falling of non-secured personnel!
Installation personnel working on unsecured installation and mainte‐
nance work can fall and be seriously or fatally injured.
1. Use suitable aids to sure that personnel cannot fall from the mobile
crane during installation and maintenance work (e.g. auxiliary crane,
lifting platform, scaffolding or ladders).
2. Use the provided railing and ladders.
3. Wear personal protective gear.
Personal protective equipment must be worn for all work with and on the mobile crane. National
regulations regarding this should also be observed.
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If it is not possible to carry out installation or maintenance work from the ground or with the help of
appropriate aids, the personnel must be secured against falling with personal protective equipment
(e.g. safety belts).
Observe the accident prevention regulations of the country of use.
2.1.3 Planning Use
The national legislation and regulations applicable at the place of use must be observed.
WARNING
Missing information on use!
A lack of information may make the planned work at the site of use un‐
feasible and may force the crane operator to improvise.
1. Work with the crane may only be carried out when all documents/
specifications are complete and correct.
Smooth operation requires careful planning of use.
The operator must have all the required specifications and documents before going to the installa‐
tion location.
When going to the installation location:
▪ an exact route plan,
▪ a plan to the place of use for the vehicle with regard to its length, width and height as well as its
total weight, taking into accounting bridge loads, access heights and the width of streets,
▪if necessary request police escort and obtain approval from the authorities,
▪ the necessary driving and special approvals,
▪ observe the paragraphs of the Road Traffic Licensing Regulations and the Highway Code (ob‐
serve the regulations valid in the area of use),
▪ permissible axle loads and total weight for the journey.
When carrying out the planned work:
▪ a precise schedule,
▪ the type of planned crane use,
▪ weight and size of the load to be lifted,
▪ required jib length and lifting height,
▪ load bearing capacity of the ground at the site of the mobile crane (channels, water and gas
pipes, underground channels or cavities);
▪ space and possible limitations at the site of the mobile crane,
▪ overhead electric lines and their voltage,
▪ more personnel for instructing or for loading/equipping work,
▪ communication procedure, contact addresses, emergency addresses,
▪ any authorization from the authorities.
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Because of the existing specifications, the necessary crane equipment must be assembled to carry
out the planned use:
▪ hook tackle or bottom blocks,
▪ jibs,
▪counterweights,
▪ rigging ropes, chain suspension, cross beams and similar aids,
▪ support base plates,
▪ additional transport vehicle.
Choice of Site
A basic prerequisite for working safely with a mobile crane is that it is used on ground which can
bear sufficient load.
WARNING
Weak ground!
Wear ground implies risk of tipping and thus risk of accidents.
1. Only position and operate the mobile crane on ground which can
bear sufficient load.
2. Thus, place outrigger plates underneath.
When selecting the site, it should be ensured that
▪the available ground conditions can withstand the resulting strain,
▪the outriggers can be extended in accordance with the value specified in the lifting capacity
chart,
▪the work can be carried out with as small a jib length as possible,
▪ there are no obstacles in the slewing range of the superstructure.
Permissible Ground Pressure
When the mobile crane is supported, the support cylinders transmit the forces to the ground. The
maximum force can reach almost the weight of the mobile crane including the load. These forces
are sent directly into the ground via the surfaces of the outrigger pads. If these surfaces are insuffi‐
cient, the ground must be appropriately supported.
The maximum supporting forces which can occur with 360° slewing of the load are specified in the
supporting force tables.
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WARNING
Tipping of the mobile crane due to unstable support!
In case of an unstable ground, there is a risk of tipping and thus a risk of
accidents.
1. Only use stable materials to support the crane, such as adequate
wooden planks.
2. The support must be situated centrally underneath the support
plates so that the distribution of pressure is equal.
The minimum support surface required may be calculated from the supporting force of the mobile
crane (see supporting force table) divided by the permissible load bearing capability of the ground.
necessary support surface =
supporting force
permissible load bearing capability of ground
On no account may the supporting surface be smaller than the required surface calculated.
If the load bearing capability of the ground is unknown, its strength must be determined with appro‐
priate tests, for example with a penetrometer.
Permissible ground pressure (extract from DIN 1054)
Type of ground daN/cm2
Backfilled ground, not artificially compressed: 0-1
Natural, obviously untouched ground:
Mud, peat, moor earth
Fine to medium sand
Coarse sand to gravel
0
1.5
2.0
Cohesive soils:
mushy
soft
firm
semi-solid
hard
0
0.4
1.0
2.0
4.0
Rock with minimal jointing in good, unweathered condition and favourable stratifica‐
tion:
in closed sequence of strata
in bulky and columnar formation
15
30
Artificially compressed ground:
Asphalt
Concrete B I
Concrete B II
5 - 15
50 - 250
350 - 550
Slopes and depressions
When choosing the site to position the mobile crane, it must be ensured that the mobile crane does
not stand too close to ditches, slopes or trenches.
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WARNING
Vehicle tips over!
The edge of the slope or trench could cave in under the resulting stress
and cause the mobile crane to turn over.
1. A safe distance must be maintained between the mobile crane and
the edge of the trench.
2. Support slope or trench.
A safe distance between the outriggers and the edge of the trench must be maintained, according
to the type of ground.
The safe distance is measured from the edge of the trench.
Subsurface Safe distance
Firm, natural, non-grainy soil (∝≥ 45°) 1 times depth of depression (A = 1 x T)
Grainy, soft or backfilled soil (∝ ≤ 30°) 2 times depth of depression (A = 2 x T)
T - depth of depression A - safe distance α - gradient
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