Terex Demag AC40C :

Manufacturer’s Specifications
Foreword
1 Safety Instructions
1 Safety Instructions ............................................................................... 1
1.1 General ....................................................................................... 1
1.2 Intended Use .............................................................................. 3
1.3 Operating Conditions and Computed Design of the Crane......... 7
1.3.1 General ....................................................................................... 7
1.3.2 Classification of the Crane .......................................................... 7
1.3.3 Classification of the Engines ....................................................... 9
1.3.4 Workplace Ergonomics ...................................................................... 11
1.3.5 Load and Utilisation of the Crane ...................................................... 11
1.3.6 Required Ambient Conditions ............................................................ 13
1.3.7 Service Life ........................................................................................ 15
1.3.8 Standards and Calculation Regulations............................................. 17
1.3.9 Dangers to Air Traffic ......................................................................... 19
1.4 Safety Regulations ............................................................................ 21
1.4.1 Organisational Measures ................................................................... 23
1.4.2 Selection and Qualifications of Personnel ......................................... 25
1.4.3 Particular Hazards ............................................................................. 27
1.4.4 Combination of Hazards with Combined Operation“of
Two or More Cranes .......................................................................... 39
1.4.5 Driving Operation ............................................................................... 43
1.4.6 Crane Operation ................................................................................ 47
1.4.7 Power Supply Failure......................................................................... 65
1.4.8 When Assembling and Dismantling Crane Components ................... 67
1.5 Hand Signals ..................................................................................... 73
1.5.1 General Hand Signals ....................................................................... 75
1.5.2 Hand Signals for Working Movements .............................................. 77
1.5.3 Hand Signals for Driving Movements ................................................ 79
2 Overview
2.1 Overview .............................................................................................. 3
2.2 Safety Signs ........................................................................................ 5
2.3 Boom System ...................................................................................... 7
2.3.1 Boom Lengths ..................................................................................... 7
2.4 Serial Plates ........................................................................................ 9
2.4.1 Serial Plate .......................................................................................... 9
3 Cab
3.1 Operating Elements in the Driver's Cab .............................................. 3
3.2 Dashboard Installation ......................................................................... 5
e40_1-1000-387 2/6
Contents
Date: 09.CW/06
4 Engine
4 Engine .......................................................................................3
4.1 Checks before Starting ..............................................................3
4.2 Starting ......................................................................................5
4.3 Switching off ..............................................................................9
4.4 Jump Starting ............................................................................9
4.5 Automatic Engine Shutoff (Optional) .........................................9
5 Driving
5.1 Checks before Driving ...............................................................3
5.2 General ......................................................................................7
5.2.1 Driving the Crane in Transport Condition ..................................9
5.2.2 Driving with Axle Loads over 12 t to a Max. of 13t. .................13
5.3 Driving on the Construction Site ..............................................15
5.4 Driving in an Erected State ......................................................17
5.4.1 360o-Driving the Crane without Load .......................................17
5.4.2 Driving the Crane with the Main Boom Extension
(7.1 or 13 m) Fitted .................................................................. 19
5.4.3 Driving the Crane with Load (Mobile Driving) ..........................21
6 Transmission
6.1 Gear Lever ................................................................................ 3
6.1.1 Neutral Position „N“ .................................................................. 5
6.1.2 Reverse Gear „R“ ..................................................................... 5
6.1.3 Drive Position „D“ ...................................................................... 5
6.1.4 Drive Positions „1“ to „6“ ........................................................... 5
6.2 All-Terrain Transmission (Optional) .......................................... 7
6.3 Starting ..................................................................................... 9
6.4 Stopping ................................................................................... 9
6.5 Driving on Downgrades .......................................................... 11
6.6 Procedure when the Crane is Stuck ....................................... 11
6.7 Gear Oil Information ............................................................... 13
6.8 Fault Codes ............................................................................ 15
6.9 Troubleshooting with the Fault Table ...................................... 17
7 Brakes
7 Braking System ........................................................................ 3
7.1 Service Brake ........................................................................... 3
7.2 Parking Brake ........................................................................... 3
7.3 Engine Brake (Sustained Action Brake) ................................... 5
7.4 Anti-lock Brake System (ABS) .................................................. 5
8 Steering
8.1 Steering during Road Travel ......................................................3
8.2 Electric-hydraulic Rear-Axle Steering ........................................5
8.2.1 Switching on the Electric-Hydraulic Rear-axle Steering.............5
8.2.2 Steering Figures ....................................................................... 7
8.2.3 Switching off the Electric-Hydraulic Rear-axle
Steering / Placing Axles 2 and 3 in Road Travel Position ......... 9
e40_1-1000-387 3/6
Contents
Date: 09.CW/06
9 Differential Locks
9 Differential Locks ........................................................................ 3
10 Hydraulic Suspension
10.1 Suspension Circuits .................................................................... 3
10.2 Level Adjustment ........................................................................ 5
10.3 Monitoring the Level ................................................................... 7
10.4 Locking the Suspension (Travel Operation) ............................... 9
10.4.1 Engaging Procedure ................................................................... 9
10.4.2 Disengaging Procedure ............................................................ 11
10.5 Height Adjustment .................................................................... 11
10.6 Raising the Axles ...................................................................... 13
11 Outriggers
11.1 Instructions for Supporting the Crane on the Outriggers ............ 3
11.1.1 Support Pressure Display (optional) ........................................... 3
11.2 Arrangement of the Control Elements for the Outriggers ............ 5
11.3 Before Extending the Outriggers ................................................ 7
11.4 Procedure for Extending the Outriggers ..................................... 9
11.4.1 Extending the Outriggers (Support Area 4.40 m x 6.30 m and
6.20 m x 6.30 m) ......................................................................... 9
11.4.2 Retracting the Outriggers (for Driving the Crane in Transport
Conditio) ................................................................................... 15
11.4.3 Retracting the Outriggers (for Driving the Crane in Configured
Condition) ................................................................................. 17
11.5 Supporting the Crane on Outriggers from the Cab (optional) ..... 19
11.6 Permissible Ground Pressures ................................................. 21
11.6.1 Safety Distances from Slopes and Ditches ............................... 23
12 Parking
12.1 Leaving the Vehicle in Transport Condition ................................ 1
12.2 Leaving the Crane in Configured Condition an with Outrigger
Extended .................................................................................... 1
13 Towing the Crane and Towing the Crane to Start
13.1 Towing the Crane to Start ........................................................... 1
13.2 General Towing Regulations ...................................................... 1
13.2.1 Towing the Crane in case of Engine demage or Defective
Automatic Transmission ............................................................. 1
13.2.2 Towing the Crane with Defective Distributor Gear ...................... 7
13.3 Towing the Crane Free on Soft Ground ...................................... 9
e40_1-1000-387 4/6
Contents
Date: 09.CW/06
14 Heating and Ventilation
14.1 Operating the Heating and Ventilation ...................................... 3
15 Safety Equipment
15 Load Limit Device (LLD) ........................................................... 3
15.1 Load Limit Device Console (LLD) ............................................. 5
15.1.1 Operating Elements .................................................................. 5
15.1.2 Display Contents During Crane Operation ............................... 7
15.2 Operating the Load Limit Device ............................................ 11
15.2.1 Working with a lifting platform (optional) ................................. 13
15.2.2 Setting the Screen Contrast .................................................... 13
15.2.3 Displaying the Fault Codes (4) ............................................... 15
15.2.4 Data Logger (Optional) ........................................................... 15
15.3 Operating range limits (Limit) .................................................. 15
15.3.1 Slewing angle limit .................................................................. 17
15.3.2 Head height limit ..................................................................... 17
15.3.3 Radius limit ............................................................................. 19
15.3.4 Luffing angle limit .................................................................... 19
15.3.5 Virtual wall .............................................................................. 21
15.3.6 LIM settings – saving the limit values ..................................... 23
15.4 Hoist Limit Switch ................................................................... 23
15.4.1 Assembling the Hoist Limit Switch .......................................... 23
15.4.2 Caution, Function Test of the Hoist Limit Switch .................... 25
15.5 Troubleshooting ...................................................................... 27
15.5.1 Fault Codes ............................................................................ 28
15.6 Service and Maintenance ....................................................... 29
15.7 Bridging the Limit Switch ........................................................ 31
15.8 Bridging the Load Limit Device ............................................... 33
15.8.1 Bridging the Shut-down of the Movement
“Raising Luffing gear” ............................................................. 33
15.8.2 Bridging the Shut-down of All Movements .............................. 35
16 Notes on Operation
16.1 General Notes on Operation ..................................................... 1
16.2 Raising a Load Using Several Cranes ...................................... 7
16.3 Checking the Safety Measures ................................................. 9
16.4 Operating Information on Pilot Control.................................... 11
16.5 Emergeny Control ................................................................... 13
16.6 Limiting the engine speed (optional) ....................................... 15
17 Slewing
17.1 Preparations for Slewing........................................................... 3
17.2 Slewing the Superstructure....................................................... 5
17.3 Slew Speeds............................................................................. 5
17.4 Braking the Superstructure ....................................................... 7
e40_1-1000-387 5/6
Contents
Date: 09.CW/06
18 Telescoping
18.1 Telescoping the Main Boom .......................................................3
18.1.1 Extension Lengths of the Telescopic Sections ...........................5
18.1.2 Control Levers for Telescoping ...................................................7
18.1.3 Telescopic Control ......................................................................7
18.2 Telescoping Procedure .............................................................11
18.2.1 Telescoping without Load .........................................................11
18.2.2 Telescoping Loads ...................................................................11
18.2.3 Telescoping Speeds .................................................................11
19 Luffing
19.1 Raising and Lowering the Main Boom ........................................3
19.2 Luffing Speeds............................................................................3
20 "Hoist" Hook Operation
20.1 Raising and Lowering the Load ..................................................3
20.2 Hoist Speeds ..............................................................................5
21 Main Boom Extension
21.1 Fitting the Main Boom Extension ................................................3
21.2 Folding the Main Boom Extension ..............................................3
21.2.1 Folding the 7.1 m Basic Boom out of the Transport Position
into Operating Position ...............................................................5
21.2.2 Folding the 13 m Main Boom Extension from the Transport
Position into Operating Position ................................................13
21.2.3 Folding the 13 m Main Boom Extension (7.1 m or 13 m)
from 0o into the 30o Operating Position .....................................19
21.3 Fitting Procedure ......................................................................23
21.4 Boom Point (Hall Point, Option) ................................................25
21.4.1 Lift loads with a main boom angle of 24-44o
(medium length boom point) .....................................................25
21.4.2 Lift loads with a main boom angle of less than 24o
(short boom point).....................................................................27
21.4.3 Lift loads with a main boom angle of greater than 44o
(long boom point) ......................................................................27
21.4.4 Lifting loads ..............................................................................29
21.4.5 Boom Point in the Transport Condition .....................................29
21.5 Hook (15 t) for boom point (Option 1) .......................................31
21.5.1 Double Load Hook (15t) for boom point (Option 2) ...................35
21.6 Searcher Hook (Option) ............................................................39
21.6.1 Operating with the Searcher Hook ............................................39
e40_1-1000-387 6/6
Contents
Date: 09.CW/06
22 Reeving
22.1 Rope Equipment and Reeving .................................................. 3
22.1.1 Uneven-numbered reeving ....................................................... 5
22.1.2 Even-numbered reeving ........................................................... 5
22.2 Load Lifting Equipment ............................................................. 7
22.2.1 Hoist ropes ............................................................................... 9
22.2.1.1 General ..................................................................................... 9
22.2.1.2 Rope End Connections ............................................................. 9
22.2.2 Hook Blocks ........................................................................... 13
22.2.2.1 Definition ................................................................................. 13
22.2.2.2 Markings ................................................................................. 13
22.2.2.3 Handling ................................................................................. 15
22.3 Reeving the Hoist Rope on the Main Boom Head .................. 19
23 Counterweight
23 Counterweight 5.45 t..................................................................3
23.1 Dismantling the 2.35 t Counterweight Section (Optional) ..........3
23.2 Dismantling the Counterweight Blocks (Optional)......................5
34 Radio System
34.1 Radio-remote Control of the Crane (Optional) ...........................1
34.2 Safety Regulations ....................................................................3
34.3 Important Information before Operating the Radio System .......3
34.4 Radio Receiver ..........................................................................5
34.5 Indicator Light Field of the Radio Receiver ................................5
34.6 Control Elements of the Radio Transmitter ................................7
34.7 Display Screens During Crane Operation..................................9
34.8 Safety Instructions for Operation .............................................11
34.9 Safety Instructions for the Battery and Charge Unit .................15
34.10 Servicing
Contents (Part 2)
Foreword (Part 2)
Notes for the Operator
1 Notes on Safety
1 Notes on Safety ....................................................................... 1
1.1 General Recommendations for the Lubrication and
Maintenance Tasks ................................................................. 1
1.2 Notes on Safety ....................................................................... 5
1.3 Recurrent Inspections of the Crane ......................................... 9
1.4 Measures to Ensure Safe Operating Periods ........................ 10
1.4.1 General .................................................................................. 10
1.4.2 Theoretical Service Life ......................................................... 10
1.4.3 Actual Operating Conditions .................................................. 11
1.4.3.1 Determining the Operating Conditions (Load Spectrum) ....... 11
1.4.3.2 Operating Hours of the Hoists per Inspection Interval ........... 11
1.4.4 Determining the Spent Share of the Theoretical Service Life
of the Winches ....................................................................... 13
1.4.5 Documentation....................................................................... 15
2 Fuels and Lubricants
3 Capacities
4 Lubrication and Maintenance Schedule
4 Lubrication and Maintenance Schedule................................... 2
4.1 Initial Lubrication and Maintenance ......................................... 2
4.2 Regular Routine Lubrication and Maintenance ........................ 3
4.3 Maintenance List...................................................................... 4
5 Drive
5 Drive ........................................................................................ 1
5.1 Engine OM 906 LA .................................................................. 1
6 Transmission
6 Transmission ........................................................................... 1
6.1 Drive Gear - Checking and Topping Up the Oil Level .............. 1
6.2 Changing the Oil in the Drive Gearbox and Replacing the Filter .... 4
6.3 Distributor Gear - Checking and Topping Up the Oil Level ...... 7
6.4 Distributor Gear - Changing the Oil .......................................... 7
7 Joint Shafts
7 Joint Shafts .............................................................................. 1
7.1 Flange Connections ................................................................. 1
7.2 Lubricating the Joint Shafts ..................................................... 1
8 Axles
8 Axles ........................................................................................ 1
8.1 Checking and Tightening the Axle Fixings ............................... 1
8.2 Lubricating the Axles ............................................................... 2
8.3 Steering and Track Arm ........................................................... 2
8.4 Axle Drive - Checking and Topping Up the Oil Level ............... 3
8.5 Wheel Hub Drive - Checking and Topping Up the Oil Level .... 4
8.6 Axle Drive - Changing the Oil .................................................. 5
8.7 Wheel Hub Drive - Changing the Oil ........................................ 7
8.8 Suspension Cylinders .............................................................. 7
9 Steering
9 Steering ................................................................................... 1
9.1 Steering Components .............................................................. 1
9.2 Lubricating the Steering Components ..................................... 1
9.3 Replacing the Hoses................................................................ 2
9.4 Angular Gear ........................................................................... 2
9.5 Lubricating Independent Rear Axle Steering ........................... 3
9.6 Electric-hydraulic Steering ....................................................... 3
10 Braking System
10 Braking System........................................................................ 1
10.1 Check brake linings for wear ................................................... 2
10.2 Renew brake linings ................................................................ 2
10.3 Replace brake drums............................................................... 3
10.4 Perform brake function check .................................................. 3
10.5 Check expanding cylinder........................................................ 3
10.6 Replace other brake parts ....................................................... 3
10.7 Air Drier with Integrated Pressure Regulator ........................... 4
10.8 Draining Water from the Air Tanks........................................... 4
11 Wheels and Tyres
11 Wheels and Tyres .................................................................... 1
11.1 Tightening the Wheel Nuts ...................................................... 1
11.2 Tyres - Checking Pressure and Tread Depth and
Checking for Damage .............................................................. 1
12 Hydraulic System
12 Hydraulic System ..................................................................... 1
12.1 Hydraulic Tank - Checking and Topping Up the Oil Level ....... 2
12.2 Hydraulic Tank - Filter .............................................................. 3
12.3 Hydraulic Tank - Replacing the Aeration Filter ...................... 12
12.4 Changing the Hydraulic Oil .................................................... 13
12.5 Hydraulic System - Pressure Accumulator,
Checking the Preliminary Gas Tension ................................. 15
13 Outriggers
13 Outriggers ................................................................................ 1
13.1 Lubricating the Sliding Surfaces on the Outrigger Struts ......... 1
14 Electrical System
14 Electrical System .................................................................... 1
14.1 Checking the Lighting System ................................................. 1
14.2 Replacing the Headlamp Bulbs ............................................... 1
14.3 Battery maintenance ................................................................ 1
14.4 Fuses ....................................................................................... 2
15 Fuel System
15 Fuel System ............................................................................. 1
16 Air Intake and Cooling System
16 Air Intake and Cooling System ................................................ 1
17 Piston Rods
17 Piston Rods ............................................................................. 1
18 Optional Equipment
18 Optional Equipment ................................................................. 1
18.1 Refilling the Central Lubrication System .................................. 1
19 Visual Inspections
19 Visual Inspections .................................................................... 1
20 Slew Ring
20 Slew Ring................................................................................. 1
20.1 Lubricating the Bearing ............................................................ 1
20.2 Lubricating the Gear Ring ........................................................ 1
20.3 Check slew ring bolt connections ............................................ 2
21 Slew Gear
21 Slew Gear ................................................................................ 1
21.1 Slew Gear Mechanism - Checking and Topping Up
the Oil Level ............................................................................. 1
21.2 Slew Gear Mechanism - Changing the Oil ............................... 1
21.3 Checking and Tightening the Screw Connections ................... 2
22 Hoists
22 Hoists ....................................................................................... 1
22.1 Hoist Gear - Checking and Topping Up the Oil Level .............. 1
22.2 Hoist Gear - Changing the Oil .................................................. 3
22.3 Checking the Gear Oil ............................................................. 4
22.4 Lubricating the Rope Drum Bearing ........................................ 5
22.5 Checking and Tightening the Screw Connections ................... 5
22.6 Lubricating the Hook Block ...................................................... 6
22.7 Determining the spent share of the theoretical service life ...... 6
23 Luffing Gear
23 Luffing Gear ............................................................................. 1
23.1 Luffing Cylinders - Lubricating the Foot and Piston Bearings .. 1
24 Equipment
24 Equipment ............................................................................... 1
24.1 Main Boom - Lubricating the Linings ....................................... 1
24.2 Main Boom - Lubricating the Sliding Surfaces ......................... 1
24.3 Lubricating the Basic Bolts on the Main Boom ........................ 2
24.4 Ropes ...................................................................................... 2
24.4.1 General Notes on Handling and Assembly .............................. 3
24.4.1.1 Transport ................................................................................. 3
24.4.1.2 Storage .................................................................................... 3
24.4.1.3 Assembly ................................................................................. 4
24.4.2 Lubricating the Ropes ............................................................ 12
24.4.3 Cleaning the Ropes ............................................................... 13
24.4.4 Checking the Cables and Replacing as Necessary ............... 13
24.5 Checking the Main Boom for Weld Cracks ............................ 20
24.6 Main Boom - Adjusting the Rope Drive .................................. 21
24.7 Main Boom - Visual Inspection of the Extending and
Retracking Ropes .................................................................. 22
24.8 Inspect Rope Track Rollers ................................................... 24
24.9 Checking the Sheaves ........................................................... 24
24.10 Sheaves - Checking the Roller Bearing ................................. 25
24.11 Checking the Pins for Cracks ................................................ 26
24.12 Checking the Draw Bars ........................................................ 26
24.13 Lubricate Main Boom Extension Bolts ................................... 28
25 Heating
25 Heating .................................................................................... 1
25.1 Checking and Filling Up the Fuel Tank .................................... 1
25.2 Checking the Fuel Feed and Cleaning the Fuel Filter if Necessary .. 1
25.3 Checking and Replacing the Glow Plug .................................. 2
25.4 Fine dust filter .......................................................................... 3