SPIERINGS AT3 Manuel utilisateur

MANUAL SPIERINGS TRUCK AT3

T AT3-EN-051115 truck.doc

Preface

Dear user,

This operating manual provides the user of the Spierings folding crane with information concerning the crane's

construction and operation. You will find detailed technical specifications and maintenance instructions in the

maintenance part of this manual.

No part of this publication may be reproduced or published, in any form or in any way, by print, photo print, microfilm or any other means without prior permission from the

manufacturer.

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Liability clause

SECTION 1. OPERATION

1.1 The Spierings truck may only be used for the purpose it was manufactured and designed for and only as

described in the user manual or in the additions to it.

1.2 Any use of the Spierings truck that differs from its design purpose or as described in the use manual or

the additions to it, will cause the product warranty and the manufacturer’s liability, for any direct or

indirect damage, to expire.

1.3 Only qualified, skilled personnel are allowed to operate the truck. The driver should have a special

driving license for driving heavy vehicles. The driver/operator must be in good physical and mental

health, so that he/she is able to carry out the work without restrictions and react with responsibility in all

given situations.

1.4 The driver/operator/user of the Spierings truck should be informed immediately of any additions/changes

to the user manual.

SECTION 2. SAFETY

2.1 For safety reasons the driver/operator/user should carry out all operations as stated in the user manual

or in the additions to it.

2.2 If more stringent safety demands are locally placed on the truck/crane than specified in the Spierings

truck user manual or additions to it, these more stringent requirements must be strictly complied with. If

not, all warranty will expire and the manufacturer will not be liable for any damage or costs.

2.3 The Spierings truck manufacturer points out explicitly, that the driver/operator/user and local personnel

should not enter the cranes/trucks danger zone. If, for any reason or cause, an unexpected situation

occurs during operation one should contact the technical department or Spierings Service department

first before proceeding.

SECTION 3. WARRANTY

3.1 It is prohibited to carry out modifications or welding to the Spierings truck without prior written permission

of the manufacturer of the Spierings truck.

3.2 Frequent maintenance and periodic checks should be carried out in accordance with the user manual, or

in the additions to it. If maintenance or checks are carried out otherwise, or less frequent, without prior

written permission of the manufacturer of the Spierings truck, all warranty will expire and any liability, for

direct or indirect damage, is explicitly excluded.

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III

Explanation of the symbols used

CAUTION!

Wear safety goggles!

Wear safety gloves!

Wear safety boots!

Wear head protection!

Use safety belt!

Check!

Manual action!

Automatic action!

Wrong!

Right!

Information!

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Index

PREFACE ................................................................................................................................................................ I

LIABILITY CLAUSE................................................................................................................................................ II

EXPLANATION OF THE SYMBOLS USED.......................................................................................................... III

INDEX ....................................................................................................................................................................IV

1. GENERAL DATA AT3.............................................................................................................................. 1-1

2. OPERATION............................................................................................................................................. 2-1

2.1. Get to know the truck .................................................................................................................. 2-1

2.2. Truck cab .................................................................................................................................... 2-4

2.2.1. Getting in....................................................................................................................... 2-4

2.2.2. Doors............................................................................................................................. 2-4

2.2.3. Wing mirrors.................................................................................................................. 2-4

2.2.4. Seats............................................................................................................................. 2-4

2.2.5. Fuse box........................................................................................................................ 2-4

2.2.6. Windscreen washer reservoir........................................................................................ 2-5

2.2.7. Battery charger remote control batteries ....................................................................... 2-5

2.2.8. Fire Extinguisher............................................................................................................ 2-5

2.3. Control panel............................................................................................................................... 2-6

2.4. Driving the Spierings crane carrier............................................................................................ 2-13

2.4.1. Starting........................................................................................................................ 2-13

2.4.2. Turning off the engine.................................................................................................. 2-14

2.5. Driving on the road.................................................................................................................... 2-14

2.6. Driving off the road.................................................................................................................... 2-15

2.6.1. Off the road gear shift road/terrain transfer case......................................................... 2-15

2.6.2. Front wheel drive......................................................................................................... 2-15

2.6.3. Transverse differential lock.......................................................................................... 2-15

2.7. Braking system.......................................................................................................................... 2-16

2.7.1. Operating brake........................................................................................................... 2-16

2.7.2. Parking brake .............................................................................................................. 2-16

2.7.3. Vacuum brake/engine stop.......................................................................................... 2-16

2.8. Parking...................................................................................................................................... 2-16

2.9. Towing the crane....................................................................................................................... 2-17

2.9.1. Towing free.................................................................................................................. 2-17

2.9.2. Towing on the road...................................................................................................... 2-17

2.9.3. Switching the transfer case to neutral.......................................................................... 2-18

2.10. Driving with erected tower......................................................................................................... 2-18

2.11. Axle height adjustment.............................................................................................................. 2-19

2.11.1. Levelling.................................................................................................................... 2-19

2.11.2. Block suspension....................................................................................................... 2-19

2.11.3. Off the road mode...................................................................................................... 2-19

3. MAINTENANCE........................................................................................................................................ 3-1

3.1. General ....................................................................................................................................... 3-1

3.1.1. Clothing......................................................................................................................... 3-1

3.1.2. Surroundings................................................................................................................. 3-1

3.1.3. Diesel engine................................................................................................................. 3-1

3.1.4. Moving parts.................................................................................................................. 3-1

3.1.5. Oils and coolant............................................................................................................. 3-1

3.1.6. Environment .................................................................................................................. 3-2

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3.1.7. Welding ......................................................................................................................... 3-2

3.1.8. Refreshing oil/cooling system........................................................................................ 3-2

3.1.9. Fire extinguisher............................................................................................................ 3-2

3.1.10. Fire-risk ....................................................................................................................... 3-2

3.1.11. Cleaning of components.............................................................................................. 3-2

3.2. Maintenance plan AT3 truck........................................................................................................ 3-3

4. GREASING............................................................................................................................................... 4-1

4.1. Central grease system (Option) .................................................................................................. 4-1

4.1.1. Timer central lubrication system (optional).................................................................... 4-1

4.1.2. Grease reservoir central lubrication system .................................................................. 4-1

4.1.3. Greasing points central lubrication system.................................................................... 4-2

4.2. Manual lubrication....................................................................................................................... 4-3

4.2.1. Outrigger cylinders ........................................................................................................ 4-3

4.2.2. Gear change mechanism .............................................................................................. 4-4

4.2.3. Driven axles................................................................................................................... 4-4

4.2.4. Tower support................................................................................................................ 4-5

4.2.5. Cardan shafts................................................................................................................ 4-5

4.2.6. Steering system............................................................................................................. 4-6

4.2.7. Miscellaneous grease points ......................................................................................... 4-6

5. DRIVE LINE.............................................................................................................................................. 5-1

5.1. The diesel engine........................................................................................................................ 5-2

5.1.1. Specification diesel engine............................................................................................ 5-2

5.2. Maintenance plan diesel engine.................................................................................................. 5-3

5.2.1. Maintenance A-service interval...................................................................................... 5-3

5.2.2. Maintenance B-service interval...................................................................................... 5-3

5.2.3. Check components and hose connections for leaks...................................................... 5-3

5.3. Engine oil .................................................................................................................................... 5-4

5.3.1. Check engine oil level.................................................................................................... 5-4

5.3.2. Fill up engine oil............................................................................................................. 5-4

5.3.3. Engine oil change.......................................................................................................... 5-5

5.4. Oil filter........................................................................................................................................ 5-6

5.4.1. Oil filter replacement...................................................................................................... 5-6

5.5. Cooling system............................................................................................................................ 5-7

5.5.1. Check coolant level ....................................................................................................... 5-7

5.5.2. Changing coolant........................................................................................................... 5-8

5.5.3. Check antifreeze concentration..................................................................................... 5-8

5.5.4. Radiator and intercooler element inspection/cleaning................................................... 5-8

5.5.5. Cooling system hoses ................................................................................................... 5-9

5.6. Air inlet system.......................................................................................................................... 5-10

5.6.1. Air cleaner cleaning/replacement ................................................................................ 5-10

5.6.2. Check the air inlet system ........................................................................................... 5-10

5.7. Fuel system............................................................................................................................... 5-11

5.7.1. Fuel filter replacement................................................................................................. 5-11

5.7.2. Cleaning filter bolt fuel system..................................................................................... 5-11

5.7.3. Bleeding the fuel system ............................................................................................. 5-12

5.7.4. Check for fuel leaks..................................................................................................... 5-12

5.8. Water separator ........................................................................................................................ 5-13

5.8.1. Draining water separator............................................................................................. 5-13

5.8.2. Clean filter water separator.......................................................................................... 5-13

5.8.3. Replace filter water separator...................................................................................... 5-14

5.9. V-belts....................................................................................................................................... 5-14

5.9.1. V-belts inspection........................................................................................................ 5-14

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5.9.2. V-belts tensioning........................................................................................................ 5-16

5.9.3. V-belt replacement: ..................................................................................................... 5-16

5.10. Exhaust system......................................................................................................................... 5-16

5.11. Valve clearance......................................................................................................................... 5-16

5.11.1. Valve clearance check and adjustment..................................................................... 5-16

5.12. Injectors..................................................................................................................................... 5-18

5.12.1. Injectors opening pressure inspection and adjustment.............................................. 5-18

5.13. Clutch and gear box.................................................................................................................. 5-20

5.13.1. Specifications gear box ............................................................................................. 5-20

5.13.2. Check oil level gearbox ............................................................................................. 5-20

5.13.3. Bleeding gearbox....................................................................................................... 5-20

5.13.4. Gear box oil change .................................................................................................. 5-21

5.13.5. Clutch fluid level ........................................................................................................ 5-21

5.13.6. Clutch bleeding.......................................................................................................... 5-22

5.13.7. Check clutch.............................................................................................................. 5-22

5.13.8. Maintenance gear box............................................................................................... 5-22

5.14. Transfer case............................................................................................................................ 5-23

5.14.1. Specifications transfer case....................................................................................... 5-23

5.14.2. Maintenance transfer case........................................................................................ 5-23

5.14.3. Check oil level transfer case...................................................................................... 5-23

5.14.4. Transfer case oil change........................................................................................... 5-24

5.15. Axles ......................................................................................................................................... 5-25

5.15.1. Maintenance axles..................................................................................................... 5-25

5.15.2. Check oil level differentials........................................................................................ 5-25

5.15.3. Differential oil change................................................................................................ 5-26

5.15.4. Check oil level hubs................................................................................................... 5-26

5.15.5. Hubs oil change......................................................................................................... 5-27

5.16. Tires.......................................................................................................................................... 5-27

5.16.1. Maintenance tires...................................................................................................... 5-27

5.16.2. Tire pressure ............................................................................................................. 5-27

5.17. Check the brake lining thickness............................................................................................... 5-28

5.17.1. Brakes....................................................................................................................... 5-28

6. THE HYDRAULIC SYSTEM ..................................................................................................................... 6-1

6.1. Structure hydraulic system.......................................................................................................... 6-1

6.1.1. Hydraulic pump system................................................................................................. 6-1

6.1.2. Hydraulic steering system ............................................................................................. 6-2

6.1.3. Hydraulic suspension .................................................................................................... 6-2

6.1.4. Hydraulic outrigger system............................................................................................ 6-2

6.2. Maintenance hydraulic system.................................................................................................... 6-3

6.2.1. Check oil level ............................................................................................................... 6-3

Change hydraulic oil.................................................................................................................... 6-3

6.2.2. Replace oil filter............................................................................................................. 6-4

6.2.3. Check the accumulators of the suspension................................................................... 6-4

6.2.4. Check the hydraulic system........................................................................................... 6-4

7. STEERING SYSTEM................................................................................................................................ 7-1

7.1. Structure mechanical steering system ........................................................................................ 7-1

7.2. Maintenance mechanical steering system................................................................................... 7-2

7.2.1. Check steering arms, ball joints and steering rods for play and deformation................. 7-2

7.2.2. Check steering system joints and splains for sufficient lubrication ................................ 7-2

7.2.3. Truck aligning................................................................................................................ 7-2

8. THE PNEUMATIC SYSTEM..................................................................................................................... 8-1

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8.1. Structure pneumatic system........................................................................................................ 8-1

8.1.1. Braking system.............................................................................................................. 8-1

8.1.2. Accessories................................................................................................................... 8-1

8.2. Maintenance pneumatic system.................................................................................................. 8-2

8.2.1. Change filter element air-dryer...................................................................................... 8-2

8.2.2. Check air vessels .......................................................................................................... 8-2

8.2.3. Check air hoses and connections.................................................................................. 8-3

8.2.4. Check brake pressure ................................................................................................... 8-3

9. ELECTRICAL SYSTEM............................................................................................................................ 9-1

9.1. Structure electrical system.......................................................................................................... 9-1

9.1.1. Power for powering the crane........................................................................................ 9-1

9.1.2. Fuses............................................................................................................................. 9-1

9.1.3. Lighting.......................................................................................................................... 9-2

9.1.4. Check the batteries........................................................................................................ 9-3

9.1.5. Recharging the batteries ............................................................................................... 9-3

9.1.6. Replacing batteries........................................................................................................ 9-3

10. TECHNICAL DATA................................................................................................................................. 10-1

11. ENCLOSURES ....................................................................................................................................... 11-1

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1-1

1. General data AT3

The AT3 carriage is especially designed for the Spierings SK365 folding crane. Extra attention is paid to a smooth

and comfortable transport to the work site. The crane is suited for driving on public roads, fully equipped with

counterweight and tools. The chassis is an especially rigid structure to create a good crane support.

In Picture 1-1 you will find the measurements of the SK365 with the AT3 carriage. The dimensions given are the

overall dimensions, axle bases and turning circle.

Picture 1-1

Drive unit:

•8.65 litres DAF diesel engine with turbo compressor and intercooler (type RS 222L).

•ZF gearbox with 8 gears forward, a slow speed gear and one gear reverse.

•STEYR high/low gear shift, transfer case, with high speed (road) and low speed (off the road) transmission.

•Three Ginaf axles, where axles one and three are driven.

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1-2

Steering:

•Axles one and two are steered.

•Mechanically coupled steering, where axle three is steered in the opposite direction of axle one, realizing a

small turning circle.

•Hydraulically powered 1-circuit steering system.

•Hydraulically powered 2-circuit steering system (serial no. 36550 and higher)

•Fitted with an emergency steering pump, so when the main steering pump malfunctions, the truck remains

steerable until it is at a standstill.

•Provisions for driving off the road:

- Axle height adjustable

- high/low gear shift transfer case can be put in low gear for driving off the road

- longitudinal and transverse differentials can be locked

Suspension:

•Hydro-pneumatic suspension

•The suspension can be blocked (e.g. when driving with erected tower).

Braking system:

•Pneumatic brakes.

4-point outrigger system:

•Wide support base : 6.90 m x 5.80 m

•Narrow support base : 6.90 m x 4.20 m

Power supply:

The superstructure can be supplied with power in two different ways:

•External power-supply 40 kVA during erecting and folding, 40 kVA during operation.

The truck built-in Leroy Somer 75 kVA generator is used for power supply to the superstructure when (sufficient)

external power is lacking.

Further data:

•Maximum speed limited to 84 km/h.

•Minimum speed at 1400 rpm: 2.3 km/h (is 38 m/min) .

•Truck weight including superstructure and counterweight 36,000 kg.

•The axle load is 12,000 kg per axle.

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1-3

Identification:

•Engine number: on top of the engine block.

•Carriage frame number: On the identification plate in the co-driver's leg-room

(See Picture 1-2) and stamped in the right frame girder in front of the

first axle (See Picture 1-3)

Picture 1-2

Picture 1-3

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