Linkbelt Crane ATC-3250 Operating Maintenance Service Manual and Diagram

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Link-belt Crane ATC-3250 Operating Maintenance Service Manual and Diagram
Size: 29.3 MB
Language: English
Format: PDF
Brand: Link-belt
Type of Machine: Crane
Type of Manual: Operating Manual, Maintenance Manual, Service Manual, Electrical and Hydraulic Diagram
Model:
Link-belt ATC-3250 Crane
Linkbelt ATC-3250 Crane
Linkbelt ATC3250 Crane
Number of Pages: 1126 Pages

Contents:
Part A Technical Details
1 General Technical Details (Chassis)
1.1 Dimensions And Weights
1.2 Driving Performance 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
3 Technical Details Of Components (Superstructure)
3.1 Engine
3.2 Hydraulic System
3.3 Hoisting Gear
3.4 Telescopic Boom
3.5 Boom Elevation
3.6 Swing Mechanism
3.7 Safety Equipment
3.8 Electrical 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)
4 Illustration Of The Vehicle
5 Notes Referring To The Load (Lifting Capacity) And Supporting Forces Charts
5.1 Explanation Regarding A Load Chart
5.2 Supporting Forces Charts
Part B0 Safety Instructions Chassis
1 Safety Instructions
1.1 Requirements And Conditions For Vehicles Used In Public Road Traffic.
1.2 Important Instructions Regarding The Load Ratings Of Tires Depending On The Maximum Travelling Speeds
And The Stress To Which The Rims Are Subject
1.3 Traveling
1.4 Towing Machine
1.5 Traveling On A Slope Or Grade
1.6 Stopping And Parking
1.7 In Cold Weather
1.8 Differences In Cylinder Stroke
2 Instructions For The Crane Operator
2.1 Applications Planning
2.2 Potential Causes Of Accidents
2.3 Fire, Smoke, Inflammation And Explosion Hazard
2.4 Instructions And Regulations Concerning The Compressed Air Tanks Installed In Air-Operated Braking Systems
Part B Operating Instructions
B1 Chassis
1 General Instructions Concerning Operation Of The Vehicle
1.3 Components, Assemblies - Installation Location And Position
1.4 Transport Condition Of The Vehicle When Used In Public Road Traffic
2 Driver’s Cab
2.1 Explanation Of The Control Elements And Of The Equipment
2.3 Front Lid
2.4 Seat Adjustment
2.5 Adjustment Of The Steering Wheel
2.6 Actuation Of The Roller Sun Visor
2.7 Seat Belts
2.8 Cab Lighting
3 Link-Belt 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; Fan; Heater Unit; Air Circulation And Air Conditioning
4.5 Start The Engine
4.6 Monitoring The Pilot, Indicator And Warning Lamps And The Instruments While The Engine Is Running
4.7 Hydraulic System Of Suspension, Inclination Adjustment, Level Control
4.8 Centralized Lubrication System
4.9 Central Warning, Cgc
5 Gearshift And Driving Operation
5.1 Gearbox
5.2 Transfer Box
5.4 Engaging The Inter-Axle And Inter-Wheel Differential Locks / Axle Drive
5.5 Lifting Axle
5.6 Brakes
5.7 Cruise Control
5.9 Steering
5.10 Towing The Vehicle
5.11 Engine Speed Regulation (Manual Throttle, Working Speed)
5.12 Locking The 4th And 5th Axles
6 Stabilizing The Vehicle By 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 4th And 5th Axles
8 Operation In Winter
8.1 Engine
8.2 Gearbox
8.3 Warming Up The Hydraulic Oil Or Changing The Oil Type
8.4 Batteries
8.5 Adjustable Air Vents
8.6 Windshield Washing System
9 Devices Facilitating Access To The Superstructure
10 Attachments, Optional Equipment And Accessories
10.2 City / Country Horn (Supertone Horn)
10.3 Abv System (Automatic Anti-Lock System)
10.4 Electronc Immobilizer (Fintronic Car Bloc Tts 24/12)
10.5 Air Conditioner
10.6 Webasto - Thermo 90 S / With 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 Underride Guard
10.15 Rear Area Surveillance
10.16 Spare Wheel
11 Instrument Panel
11.1 Pilot, Indicator And Warning Lamps
11.2 Other Components
11.3 Instruments
11.4 Switches, Rocker Switches (Ws) And Rocker Tip Switches (Wt)
Part B0 Safety Instructions Superstructure
1 Safety Instructions
1.1 Basic Safety Rules
2 Instructions For Crane Operation
2.1 Crane Application In Accordance With The Intended Use
2.2 Crane Application Not In Accordance With The Intended Use
2.3 Lifting Capacities Of Crane
2.4 Safety Devices
2.5 Before Crane Operation
2.6 Placement Of Crane
2.7 Counterweight
2.8 Rigging And Signaling
2.9 Lifting Operation
2.10 Operation Near Power Lines
2.11 Grounding The Crane
2.12 In Wind And Lightning
2.13 How To Behave In Case Of Sparkover (If The Crane Has Touched The Power Line)
2.14 Work In The Vicinity Of Supply Lines
2.15 In Cold Weather
2.16 Potential Causes Of Accidents
2.17 Fire, Smoke, Inflammation And Explosion Hazard
B 2 Superstructure
1 General Information About Operation
1.3 Components, Assemblies - Installation Location And Position
2 Crane Cabin
2.1 Explanation - Control Elements
2.2 Adjustment Of The Seat
2.3 Roller Sun Visor - Skylight
2.4 Opening The Windscreen
2.5 Opening The Rear Window
2.6 Cab Lighting
2.7 Emergency Exit
2.8 Assignment Of Functions To The Crane Control Levers
2.9 Superstructure Locking System
2.10 Acoustic Warning Aml / Swing Mechanism
3 Link-Belt 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 The Pilot, Indicator And Warning Lamps And The Instruments While The Engine Is Running
4.7 Centralized Lubrication System
4.8 Central Warning, Cgc
5 Outrigger Operation From The Superstructure
5.1 Changing-Over To Outrigger Operation From The Superstructure
5.2 Starting The Engine In The Chassis From The Superstructure
5.6 Outrigger Operation From The Superstructure
6 Crane Movements In No-Load Condition
6.1 Instructions Regarding Actuation Of The Crane Control Levers
6.2 Actuation Of The Hoisting Gear (Main Hoisting Gear)
6.3 Boom Elevation
6.4 Telescoping
6.5 Slewing The Superstructure
6.6 Counterweights
6.7 Work Involving Metallic Ropes
6.8 Inspection Of The Safety Equipment
6.9 Rope Limit Switch Hoist Winch 1/ Hoist Winch 2**)
6.10 Anemometer
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 Functions And Elements
9 Operation In Winter
9.1 Engine
9.2 Warming Up The Hydraulic Oil Or Changing The Oil Type
9.3 Batteries
9.4 Adjustable Air Vents
9.5 Windshield Washing System
11 Attachments, Optional Equipment And Accessories
11.1 Optional Equipment Mentioned In Other Sections
11.2 Positioning The Double Ladder For Mounting The Jibs, And For Access To The Crane Superstructure
11.3 Mounting The Jib (Boom Extension)
11.4 Jib
11.5 Heavy-Lift Sheave
11.6 Single Top
11.7 Heating Of Working Mirror
11.8 Aircraft Warning 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 Hourmeter, Hoist Winch
11.18 Hourmeter, Auxiliary Hoist Winch
11.19 Emergency Control Of Superstructure / Emergency Drainage Device
12 Instrument Panel
12.1 Monitoring Superstructure, Chassis, And Outrigger Operation From The Superstructure, Asli Control Unit
12.2 Operation Of The Superstructure
Part C S E R V I C E A N D M A I N T E N A N C E
C 1 Chassis
1 General Information
1.1 Before Starting Service And Maintenance Work
1.2 Welding And Straightening Work
1.3 Inspection Of Screw Couplings
1.4 Checking The Hydraulic System And Its Screw Couplings For Leakage
1.5 Cleaning
1.6 After Having Finished Service And Maintenance Work
1.7 Configuration Of Electronic Components
1.8 Lubrication
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 Oil Change/Oil Filter Change
4.4 Clutch, And Clutch Control Mechanism
5 Transfer Box
5.1 Oil Level Inspection
5.2 Oil Change
5.3 Cleaning The Radiator
6 Axles
6.1 Checking The Oil Level In The Axle Drive Assemblies Of The Steering Driven Axles And The Planetary Gears
6.2 Oil Change In The Axle Drive Assemblies And Planetary Gears
6.4 Greasing The Axles
6.5 Check For Leakage / Visual Inspection / Inspection Of The Control Function
6.6 Checking The Axial Play Of The Steering Axle Bearings And The Planetary Bearings; Check The Wheel
Bearing Backlash.
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 Minor Inspection
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 Hydraulic Oil Level.
10.2 Replacement Of Filter Cartridges
10.3 Oil Change In The Hydraulic System
10.4 Changing The Oil Type
10.5 Hydraulic System Of Steering Assembly
10.6 Hydraulic System Of Suspension
10.7 Hydraulic System Of Outriggers
10.8 Axle Load Adjustment For 3rd Axle
11 Brakes
11.1 Drainage Valves In The Compressed Air Tanks
11.2 Air Drier
11.3 Pressure Governor With Tire Inflation Socket (Integrated In Air Drier)
11.4 Brake Cylinder
11.5 Wheel Brakes
11.7 Check Pressure Limiting Valve
11.8 Automatic Anti-Lock System (Abv) - Maintenance
11.9 Engine Brake
11.10 Test Connectors For Inspection Of The Compressed 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 Torque Of Wheel Nuts (With Thrust Plate)
13.4 Tire Pressure
13.5 Replacement Of A Disc Wheel
13.6 Interchanging Wheels In View Of Tire Wear
14 Outriggers
14.2 Inspection And, If Necessary, Adjustment Of The Slide Pieces And Slideway Liners
14.3 Inspection And, If Necessary, Readjustment Of Chains For Extension And Retracting
14.4 Checking The Outrigger Floats
15 Driver’s Cab
15.1 Warm Water Heating
15.2 Wiper-Blade Elements / Washing System
15.3 Air Conditioner
15.4 Supplementary Heater Unit
15.5 Engine Pre-Heating Unit**)
15.6 Control And Service System
16 Miscellaneous; Other Points Of Lubrication, Servicing 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
16.9 Rear Area Surveillance
24 Summary Of Oil Types And Filling Capacities
25 Summary Of Lubricating Grease Types (Recommended Grease Types)
26 Chart Of Approved Consumables And Lubricants
27 Inspection Scheme (Before Start-Up, Daily)
28 Inspection And Cleaning Scheme
29 Oil/Coolant Level Inspection And Change Scheme
30 Lubricating Scheme
C2 Superstructure
1 Maintenance Intervals
1.2 Maintenance Schedule
2 Engine
2.1 Oil Level Inspection
2.2 Oil Change / Oil Filter Replacement
2.3 Inspection Of Hose Clamps Of The Charge Air Hoses
2.4 Fuel Tank
2.5 Coolant
2.6 Cleaning The Radiator
2.7 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 Hydraulic Cylinders
4 Swing Mechanism
4.1 Check For Correct Oil Level And Leakage
4.2 Oil Change
4.4 Check Tooth Face Backlash On Swing Motor Gearbox Drive Shaft
4.5 Swing Mechanism - Greasing Ring Gear And Pinion
4.6 Greasing The Ball Bearing Slewing Ring
4.7 Greasing The Swing Lock Pin
4.8 Check Mechanical Superstructure Lock And Proximity Switch For Proper Working Order.
4.9 Lubrication Of The Swing Mechanism Multi-Disc Compartment
4.10 Checking The Ring Gear Connecting Bolts, The Securing Bolts Of The Hydraulic 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 Greasing Of Hoisting Gear Drum Bearing Bush
5.7 Preservation Of The Hoisting Gear Drive
5.8 Inspection Of Hoisting Gear Brake
5.9 Check Hoist Limit Switch For Proper Function.
5.10 Checking The Hoist Limit Switch On The Hoisting Gear
6 Winch Rope
6.1 Inspection
6.2 Cleaning And Lubrication Of The Winch Rope
6.3 Removal (Replacement) Of The Winch Rope
6.4 Inspection Of Winch Rope Drum
6.5 Placing A New Winch Rope
6.6 Care To The Winch Rope
7 Electrical Equipment
7.1 Batteries
7.2 Three-Phase Generator
7.3 Starter
7.4 Lamps And Lights
7.5 Load Moment Limiter (Asli - Automatic Safe Load Indicator) (Aml)
7.6 Inspection Of The Asli At Regular Intervals According To The Legal Regulations
7.7 Fuse / Relay Arrangement
8 Crane Cab
8.1 Air Conditioning System
8.2 Wiper-Blade Elements / Washing System
8.3 Supplementary Heater Unit
8.5 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
9.8 Swing Lock
15 Summary Of Oil Types And Filling Capacities
16 Summary Of Lubricating Grease Types (Recommended Grease Types)
17 Chart Of Approved Consumables And Lubricants
18 Inspection Scheme (Before Start-Up, Daily)
19 Inspection And Cleaning Scheme
20 Oil/Coolant Level Inspection And Change Scheme
21 Lubricating Scheme
Part D Diagrams
D1 Diagrams Of Chassis
0 Diagrams
1 Electric Circuit Diagrams
1.1 Chassis (99707025300)
1.2 Connection Diagram - Slipring (99707782068)
1.3 Emergency Off - Engine Stop (Stalling Device) 99707782491
1.4 Heater Unit Webasto Thermo 90s (99707792167)
1.5 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 (99707793789
3.3 Transfer Box (99707783346)
3.4 Front Outriggers (99707791175)
3.5 Rear Outriggers (99707791176)
3.6 Oil Tank (99707793659)
3.7 Engine (99707783371)
3.8 Emergency Control (99707018314)
D 2 Diagrams Of Superstructure
1 Electric Circuit Diagrams
1.1 Chassis Control System (99707025374)
1.2 Superstructure (99707025374)
1.3 Aml (99707025374)
1.4 Crane Control (99707025374)
1.5 Counterweight (99707025374)
1.6 Crane Control (99707025374)
1.7 Telescope Control (99707025374)
1.8 Aml (99707025374)
1.9 Jib (99707025374)
1.10 Heavy-Lift Fly Jib / Single Top (99707025374)
1.11 Superstructure (99707025374)
1.12 Webasto Heating, Type Thermo 90 (99707025374)
1.13 Air Conditioning System (99707025374)
1.14 Boom Rest (99707025374)
1.15 Removal The Boom (99707025374)
3 Hydraulic Piping Diagrams
3.1 Hydraulic System (99707709062
3.2 Emergency Control (99707018314)
Part E Crane Testing Instructions
1 Inspection Of Supporting Steel Structures
1.1 Guidelines For Areas To Be Checked
2 Inspection Of The Hook Blocks
2.1 Inspection For Widening Of The Hook Mouth
2.2 Inspection For Wear
2.3 Inspection For Corrosion
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 Consumed Portion Of The Theoretical Service Life
5 Monitoring The Slewing Device
5.1 Inspection Of The Ring-Gear Securing Pins
Part F Troubleshooting
F 1 Chassis
Troubleshooting
1 Engine
2 Gearbox
3 Transfer Box
4 Axle Differential Locks And Drive Assemblies
5 Hydraulic System In General
5.1 Steering System - 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
F2 Superstructure
Troubleshooting
1 Engine
2 Hydraulic System Of The Superstructure In General
3 Slewing Gear
4 Telescoping Mechanism
5 Boom Elevation
6 Hoisting Gear
7 Counterweight
8 Electrical Equipment
F4 Conection Diagram Chassis
4 Connection Diagram - Chassis
Part G Annex
G1 Chassis
Operating Instructions For Zf Gearbox
Operating Instructions For Zf Intarder
Chart Of Lubricants For Zf Gearbox
Centralized Lubrication System
Documents Regarding Heating, Ventilation And The Air Conditioning System **) - Chassis
Cabin
G2 Superstructure
Load Moment Limiter (Aml)
Centralized Lubrication System
Documents Regarding Heating, Ventilation And The Air Conditioning System**) -
Superstructure Cabin
Documents On Various Optional Equipments Of The Vehicle
G3 Document Sonvarious Optional Equipments Of The Vehicle
Conversion Table
Dolly Traveling Operation
Diagrams Swing Table Lock

 

[Komatsu]

Thanks for your sharing.

 

[cranes]

Thanks for your sharing.

 

[Alex169]

Thanks for your sharing.

 

[Master]

Link-belt ATC-3250 Crane
Linkbelt ATC-3250 Crane
Linkbelt ATC3250 Crane