Crawler Manual 1

Operating Manual
Transport Crawler T 1250
Freeport/Grasberg Mine
Indonesia
Order No. 84/236 430

Year built 1998
TR-Deck.eps
Krupp Fördertechnik GmbH

P.O. Box 10 22 51 – D - 45022 Essen
14.10.98
Altendorfer Straße 120 – D - 45143 Essen

Phone: (02 01) 828-04 – Telex: 857 817
Telefax: (02 01) 25 66
Table of contents
0 User’s guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical description . . . . . . . . . . . . . . . . . . . . 2
1.1 Application and designated use . . . . . . . . . . . . . . . . . . . . . 2
1.2 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– Diesel engine, hydraulic system. . . . . . . . . . . . . . . . . . . . 4
– Crawler drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– Lifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Clamping gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Crawler track tensioning device . . . . . . . . . . . . . . . . . . . 7
– Pump of the central lubrication system . . . . . . . . . . . . . . . 7
– Control of lifting and auxiliary circuit . . . . . . . . . . . . . . . . 7
– Electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Permissible transport loads, forces, inclinations . . . . . . . . . . . 9
1.3.2 Dimensions, main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.3 Drive components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.1 Safety instructions relating to operation. . . . . . . . . . . . . . . . . 13
1.4.2 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Operating instructions . . . . . . . . . . . . . . . . . . . 15
2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.1 Operator qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

– Hand-operated fire extinguishers . . . . . . . . . . . . . . . . . . . 16
– Battery master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– Emergency-stop buttons . . . . . . . . . . . . . . . . . . . . . . . . . 16
– Revolving warning lights . . . . . . . . . . . . . . . . . . . . . . . . 16
– Spring pressure multi-disk brakes. . . . . . . . . . . . . . . . . . . 16
14.10.98
2.2 Display and control panels . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Central display and control panel . . . . . . . . . . . . . . . . . . . . . 18

2.2.1.1 Multi-task display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
s
T 1250
2.2.2 Left-hand control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.3 Right-hand control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.4 Screen displays and signals . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.2.4.1 Starting mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4.2 Centre of gravity mask. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.4.3 Inclination masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.4.4 Liquid fill mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.4.5 Maintenance mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.4.6 Error message mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.4.7 Spanning displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.1 Measures to be taken prior to start-up. . . . . . . . . . . . . . . . . . 28
2.3.2 Putting the transport crawler into operation. . . . . . . . . . . . . . 29
2.3.3 Travelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.3.1 Normal travelling mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.3.2 One-hand travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.4 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3.4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.4.2 Requirements to be met by the ground travelled over . . . . . . . . 35
2.3.4.3 Clamping points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
– Clamping areas for defined loads . . . . . . . . . . . . . . . . . . 38
2.3.4.4 Positioning the lifting platform . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3.4.5 Lifting the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.4.6 Transporting/relocating the load . . . . . . . . . . . . . . . . . . . . . . 45
2.3.4.7 Ground clearance and migration of the centre of gravity . . . . . 46
2.3.4.8 Lowering the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.4.9 Pulling of loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.5 Putting the transport crawler out of operation . . . . . . . . . . . . 49
2.4 Transporting special loads . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.1 Stacker/Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
– Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
– System of co-ordinates and load co-ordinates . . . . . . . . . . 50
– Moving the transport crawler under the load and
clamping the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
– Lifting, transporting, permissible inclinations . . . . . . . . . . . 54
– Centre of gravity migration diagram . . . . . . . . . . . . . . . . 55
2.4.2 Crusher No. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
14.10.98
– Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
T 1250
2.4.3 Crusher Nos. 6/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
– Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
– Centre of gravity migration diagram . . . . . . . . . . . . . . . . 71
2.4.4 Transporting random loads . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.5 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5.1 Fault/error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

– Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
– Warning lamps of the multi-task display . . . . . . . . . . . . . . 77
– Warning lamps on central control panel . . . . . . . . . . . . . 78
2.5.2 Faults in the hydraulic system - causes and remedies . . . . . . . 79
– Loud noises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
– No or insufficient delivery. . . . . . . . . . . . . . . . . . . . . . . . 79
– No or insufficient pressure . . . . . . . . . . . . . . . . . . . . . . . 79
– Fluctuating pressure or flow . . . . . . . . . . . . . . . . . . . . . . 80
– Cylinders do not maintain position . . . . . . . . . . . . . . . . . 80
– Other hydraulic system faults . . . . . . . . . . . . . . . . . . . . . 80
2.6 Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.6.1 Servicing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

– Notes on cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
– Notes on lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.6.2 Servicing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.10.98
T 1250
Blank page
14.10.98
T 1250
0 User’s guide
This operating manual of the transport crawler (T 1250) consists of a short
technical description (section 1) and the operating instructions (section 2).
The table of contents and the headers and footers permit rapid access to the
information contained in the manual.
The operating manual contains notes and information on how to operate the
transport crawler safely, properly and most efficiently.
This manual should always be available in the driver’s cab.
The importance of particular information included in the manual is high-

lighted as follows:
Danger This draws attention to hazards which arise in connection with
a
the activities described. In case of "Danger" reference is made
to hazards or circumstances which could cause injury to per-
sons.
Caution This draws attention to hazards which arise in connection
a
with the work discribed. In case of "Caution" the main stress is
danger to the machine or other objects.
Note Additional information and tips are given here for a skilled
and economical operation of the machine.
Definitions:
right = on the right-hand side looking in transport direction
left = on the left-hand side looking in transport direction
• = operating instructions (in stated order)
– = listing in text
/ = or
14.10.98
T 1250 1
Blank page
14.10.98
T 1250
Design
1 Technical description
1.1 Application and designated use

The transport crawler is used for:
– transporting/relocating the stacker/spreader;
– transporting/relocating the crushers 5, 6 and 8;
– transporting random loads up to the nominal permissible weight and
centre of gravity height (see Section 1.3.1);
– pulling loads.
The transport crawler with all its main assembly units, assembly units, assem-
bly groups and components has been built in accordance with state-of-the-art
standards and the recognised safety rules.
Nevertheless its use may constitute a risk to life and limb of the operating/
servicing/repair personnel or of third parties, or cause damage to the
machine and to other material property.
The transport crawler must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in the
manual, and only by safety-conscious persons who are fully aware of the
risks involved in operating the machine.
The transport crawler is designed exclusively for transporting/relocating the
contractually stipulated loads (also refer to Section 1.3.1).
Using the transport crawler for purposes other than those mentioned above,
such as the transportation of other loads of superior weight and/or with
other centres of gravity without having consulted KRUPP FÖRDERTECHNIK
first, is considered contrary to its designated use. KRUPP FÖRDERTECHNIK
cannot be held liable for any damage resulting from such use. The risk of
such misuse lies entirely with the user/operator.
1.2 Design and operation
1.2.1 Design
The transport crawler consists of:
– the chassis (12) with slewing gear (13), lifting cylinders (9) and the
centre column with rotation joint (17);
– the crawler track assembly (4) with the two single-track crawlers,
hydraulic crawler motors (14) and planetary gearboxes (15), transverse
bogie (11) and crawler axles (10);
– the lifting platform (1) with hydraulic clamping device (2);
– the component bed (7) with Diesel engine (8), pump distributor gear
14.10.98
(16), driver’s cab (3), electrical equipment and central lubrication

system (6);
– the hydraulic system with hydraulic power unit (5) and tank integrated in
the chassis.
2 T 1250 Application and designated use

Design
View A
9
KRUPP
7 5 6
17 View B
1 2
B A
16 3
5
15
6
14
13
12
8
14.10.98
11 10 9 2
TR-508G.eps
Design and operation T 1250 3

Operation
1.2.2 Operation
– Diesel engine, hydraulic system
All functions of the transport crawler are powered hydraulically.

The Diesel engine powers the hydraulic system.
The hydraulic system drives the following individual systems:
– crawler drives for travelling forwards and for reversing
– lifting gear for lifting and lowering the lifting platform
– clamps securing the load on the lifting platform
– slewing gear for positioning the lifting platform
– crawler track tensioning devices
– pump of the central lubrication system
The total output of the hydraulic system under ultimate load conditions
exceeds the rating of the Diesel engine. The electronic output control via PLC
prevents overload and shuts down the Diesel engine by reducing the power
input of the hydraulic system when the transport crawler is travelling.
The power control system is activated when the speed is between 1500 and
1900 min-1. In this speed range the nominal speed is linearly reduced by
half.
At speeds ≤ 1500 min-1 driving is no longer possible.
The maximum permissible speed of the unloaded Diesel engine (2100 min-1)
must not be exceeded.
The Diesel engine is shut down by means of an actuator which interrupts the
supply of Diesel fuel whenever one of the following monitoring functions is
tripped:
– emergency off (error message 000)
– hydraulic oil level too low (001)
– feed pressure for LH and RH crawler drives too low (002 and 003)
– hydraulic suction line valve closed (004)
Whenever the Diesel engine has been stopped for one of the reasons refer-
red to above, the malfunction must be eliminated before the engine can be
re-started.
Avoid numerous starting procedures as this will discharge the batteries to
such an extent that the Diesel engine can no longer be started without using
an external ignition source.
– Crawler drives
14.10.98
The crawler drive system of the transport crawler is split up into two separate
travelling circuits for the two crawler drives. They are identical in design.
The crawler drives operate in a closed circuit, i.e. the pumps and hydraulic
motors are interconnected in a closed ring line.
4 T 1250 Design and operation

Operation
14.10.98

Operation
The travelling pumps are infinitely variable in both flow directions. This
allows the speed of the crawler motors and thus the speed in the correspond-
ing speed ranges to be adjusted with infinite variation between zero and
maximum speed. By reversing the pump flow direction, the transport crawler
can be advanced or reversed. The crawler motors are adjustable in 4 fixed
speed ranges (see section 1.3.2).
The flushing and pressure relief valve block removes from the system all
excessive amounts of oil (e.g. for cooling and filtering), limits the pressure in
both travelling circuit lines of one travelling circuit, limits the output torque
and safeguards the travelling circuit against excessive pressure.
As soon as the maximum operating pressure set at the pressure relief valve is
reached, the pressure relief valve is opened and the oil is released from the
high-pressure line into the low-pressure line. The release of the high-pressure
oil into the low-pressure line causes a substantial rise in temperature of the
oil inside the travelling circuit. The transport crawler is immobilized during
this period. Change to a lower speed range immediately.
If the crawler drive is being used (see section 2.3.3), the high pressure
inside the travelling circuit will open the release valve in the flushing and
pressure relief valve block so that the feed oil can be guided to the low-
pressure side (i.e. to the suction line of the travel-drive pump).
The other hydraulic functions of the transport crawler are used for the lifting
and auxiliary circuit.
An axial piston pump supplies oil to the lifting and auxiliary circuit. The
pump is equipped with a two-stage pressure controller. The pressure oil
flows from the pump to a corresponding valve block accommodating the
valves for the lifting gear and for the auxiliary consumers (except for the
valves of the crawler track tensioning device).
– Lifting gear
The lifting gear of the transport crawler is used for lifting the loads to be
transported/relocated. Retracting and extending the lifting cylinders is con-
trolled by directional control valves.
Each lifting cylinder has an electronic pressure sensor for indicating the
cylinder forces on the control panel, for tripping an alarm when the max.
pressure is reached and for monitoring the position of the load’s centre of
gravity. The four lifting cylinders are operated from the control panel inside
the driver’s cab (see section 2.2.2).
– Clamping gear
The clamping gear is used to secure the load to the lifting platform when the
transport crawler is moved. Oil is supplied to the clamping cylinders in the
four corners of the lifting platform through the rotation joint which is integra-
ted into the centre column of the transport crawler.
Extending/retracting the clamping cylinders is controlled by a directional
control valve. The pilot-operated check valve blocks off the piston side of the
clamping cylinders (im clamped condition) without leaks occurring.
14.10.98
The clamping cylinders are operated from the control panel inside the
driver’s cab (see section 2.2.2).
The different pressures which are required to move the clamping hooks may
cause the cylinders to be extended/retracted successively. This does not
impair the function of the clamping device.

Operation
– Slewing gear
The lowered lifting platform (lifting cylinders retracted) can be turned around
the centre column in any desired position with respect to the longitudinal
axis of the transport crawler. The slewing gear is powered by axial piston
motors.
– Crawler track tensioning device
Retracting and extending the tensioning cylinders is controlled by the directio-

nal control valves. Check valves block off the tensioning cylinders to ensure
that the pressure cannot drop.
A pressure sensor measures the pressure inside the tensioning cylinders. If

the pressure drops below the level required to ensure minimum track tension,
the directional control valve is tripped and the cylinders are extended until
the required track tension is reached. Pressure relief valves limit the maxi-
mum pressure inside the tensioning cylinders and - as such - the track tension.
If e.g. external forces act on the track when travelling in rough terrain, the
tensioning cylinders will act against the gas cushion in the accumulator. This
will only cause a small rise in pressure in the tensioning device and a minor
increase of the track forces.
– Pump of the central lubrication system
The pump of the central grease lubrication system is driven by an axial

piston motor. Two modes of operation are available for the pump. In auto-
matic mode the lubrication pump operates only when the transport crawler is
travelling (with a certain afterrunning period). In continuous mode the lubrica-
tion pump operates continuously as long as the Diesel engine is running.
– Control of lifting and auxiliary circuit
The pump of the lifting and auxiliary circuit is furnished with a hydraulic
pressure controller operating in two different pressure stages. The corres-
ponding control valves are attached to the pump.
If the directional control valve is not tripped, i.e.

– during stand-by operation,
– for raising the platform against the load and
– for tensioning the crawler tracks,
the first pressure stage (minimum setting approx. 60 bar) is automatically
activated.
If the directional control valve is tripped, i.e.

– for extending/retracting the lifting cylinders under load,
– for extending/retracting the clamping cylinders,
– for operating the slewing gear and
14.10.98
– for slackening the crawler tracks,

the second pressure stage is automatically activated and the pump operates
at the pressure of approx. 280 bar set on the pressure relief valve.
Tensioning the tracks is blocked when the second pressure stage is activated
for the other functions.

Operation
– Electrical equipment
The electrical equipment is split up into a power part and a control part.
The power part is required for starting and operating the Diesel engine, for
the lighting system and for all optical and acoustical warning devices on the
transport crawler.
Apart from the batteries (2 batteries of 12 V/180 Ah, each), the box on the
right-hand side of the valve cabinet contains a plug-and-socket connection
allowing the batteries to be re-charged without having to remove them and
allowing the Diesel engine to be started. Battery charging requires a 24 V
DC charger.
In the control part (control voltage 24 V DC), all signals transmitted by the
local transmitters are processed and linked.
The electrical equipment of the transport crawler consists of:

– control panels with controls and displays in the driver’s cab,
– switch cabinet with PLC system, relays, converter and other electrical
components.
The cabinet and the control panels have an engine-independent heater
(115 V, 2 x 180 W) to prevent condensation water from being produced
(external supply 115 V),
– local devices such as starter, actuator, initiators, solenoid valves, level
sensors, pressure switches, horns, headlamps, socket outlets and emer-
gency-stop buttons.
The heart of the control system is an Allen-Bradley PLC type 5/20.
This PLC (programmable logic control) is integrated in the switch cabinet and
connected to decentralized I/O’s in the control panels and in the hydraulics
cabinet via two bus systems.
The PLC has a central processor not only offering rapid word processing and
binary linking features but also allowing arithmetic functions (comparing,
adding and subtracting) to be performed.
Programming is possible by means of the Ladder Logik system.
The hardware consists of the central unit with

– central module with EEPROM,
– power supply,
– digital inputs,
– digital outputs,
– analog inputs,
– analog outputs,
– communication processor for bus systems.
14.10.98

Permissible transport loads, forces, inclinations
1.3 Technical data
1.3.1 Permissible transport loads, forces, inclinations

Weight of transported load (nominal) 1250 tons
Corresponding nominal height 11 m
of centre of gravity
Weight of stacker/spreader complete 1166 tons
Corresponding height of centre of gravity 11.6 m
Weight of stacker/spreader partly dismantled 954 tons

Weight of crusher no. 5 1086 tons

Weight of crusher no. 6/8 1375 tons

Cumulative holding force 1800 tons

of the 4 lifting cylinders
Max. weight of transported load 1500 tons
(centrical load, travelling on level ground)
Max. perm. horizontal force on centre column 3900 kN
Max. traction force 2500 kN
(at service weight without load)
Permissible slope of terrain with stacker/spreader loaded on platform

– longitudinal and transverse inclination 15% and 2%
simultaneously (ramp travel)
– Spreader resultant gradient 3%
Permissible slope of terrain with crusher loaded on platform

– longitudinal and transverse inclination 15% and 2%
simultaneously (ramp travel)
– Crusher resultant gradient 5%
Service weight of crawler (without load) approx. 440 tons
1.3.2 Dimensions, main data

Overall length 14.0 m
Width 8.6 m
14.10.98
Height with cylinders retracted 2.94 m

Stroke of platform 0.8 m
Track gauge 6.8 m
Turning circle (with crawlers not sunk in)= turning on the spot
Turning circle diameter 15.570 m
Technical data T 1250 9

Dimensions, main data
Distance between crawler centre

and front edge 7.81 m
Distance between crawler centre
and rear edge 6.19 m
Distance from centre of drive tumbler
to centre of return tumbler 10.1 m
Ground clearance 510 mm
Distance between platform side beams 6.68 m
for supporting loads
Distance between flanges 7.10 m
of clamping girders on LH and RH sides
Clamping thickness 50 mm
Clamping cylinders, type, number Differential cylinders, 8
Piston dia./stroke 140/350 mm
Number of clamping hooks 8
Max. clamping force/clamping hook 710 kN
Number of track wheels per crawler track 8

Dia. of track wheels 630 mm
Dia. of drive tumbler 1570 mm
Number of cams 10
Dia. of return tumbler 1540 mm
Chain tensioning cylinders, type, number Differential cylinders, 4

Piston dia./stroke 360/500 mm
Tensioning stroke of crawler chain 500 mm (+300/-200 mm)
Width of crawler track 1.8 m
Crawler track pitch 615 mm
Contact area of crawler tracks 36.4 m2
Average ground pressure
– loaded (nominal load) approx. 456 kPa
– empty approx. 119 kPa
Speed range 1
– Speed 0 - 2 m/min.
– Drive tumbler output torque up to 5100 kNm
Speed range 2
Speed range 3
14.10.98
Speed range 4
10 T 1250 Technical data

Drive components
1.3.3 Drive components

Diesel engine:
– Manufacturer; type Caterpillar; 3412 DI-TA
– Power (IFN based on DIN 6271) 656 kW
– Max. rated speed, unloaded 2100 min-1
– Rated speed, loaded approx. 1900 min-1
– Idling speed 650 min-1
– Diesel engine fuel Diesel oil as per DIN 51601
– Weight 2450 kg
– 3-phase generator 28 V/140 A
– Air filter, type, number CAT/1W0744, 2
– Coarse dust separator CAT with safety cartridge
Combination cooler of engine and pump distributor gear:

– Power consumption 28 kW
– Speed 1600 min-1
– Amount of cooling air 14.6 m3/h
– Air inlet temperature 45 °C
– Pressure reserve 250 Pa
– Width x height x depth 1400 x1800 x 680 mm
– Cooler volume 135 litres
– Amount of heat to be dissipated 357 kW
– Flow rate 19 litres/sec.
– Inlet temperature 72 °C
Travel gears:
– Type, number Spur planetary gear, 2
– Input speed 1464 min-1
– Output speed 1.95 min-1
– Gear ratio 750.6
– Max. output torque 5000 kNm
– Lubrication Splash lubrication
– Weight (without oil) 17017 kg
– Type of brake Spring pressure multi-disk brake
– Brake releasing pressure 20 bar
– Brake holding torque 4200 Nm
14.10.98
Hydraulic motors of crawlers:

– Type, number Axial piston motor, 6
– Size A 6 VM 500 HD2
– Max./min. displacement 500/110 cm3/rev.
– Max. input speed 2440 min-1
Technical data T 1250 11

Drive components
Pump distributor gear:

– Type, number HVP-C2, 1
– Gear ratio i = 1.15
– Nominal rating 540 kW
– Input speed (loaded) 1900 min-1
– Rated output torque 2 x 1500 Nm
– Lubrication Splash lubrication
– Gear unit temperature approx. 83 °C
– Weight (without oil) 285 kg
Slewing gear of the platform:

– Type, number Axial piston motor, 2
– Size M14-39
Lifting cylinders:
– Type, number Differential cylinders, 4
– Piston dia./stroke 540/820 mm
Hydraulic travel pumps:

– Type, number Axial piston pumps, 2
– Size A 4 VSG 500 HD
– Max. displacement 500 cm3/rev.
– Speed approx. 1750 min-1
– Max. pressure 325 bar
Lifting and auxiliary pump:

– Type, number Axial piston pump, 1
– Size A 4 VSO 125 DR
– Max. displacement 125 cm3/rev.
– Speed approx. 1750 min-1
Hydraulic oil cooler:

– Fan on combination cooler
– Width x height x depth 1200 x 1250 x 120 mm
– Cooler volume 465 litres
– Amount of heat to be dissipated 180 kW
– Flow rate 350 litres/min.
– Inlet temperature 72 °C
– Weight 141 kg
14.10.98
12 T 1250 Technical data

Safety instructions relating to operation
1.4 Safety instructions
1.4.1 Safety instructions relating to operation

• Before starting the transport crawler, ensure that no persons will be
endangered by the crawler starting up. Give additional warning signals.
• Make sure that all unauthorized persons have left the working area of the
transport crawler. Do not transport passengers other than the co-driver
with the transport crawler.
• Always use a banksman when working with the transport crawler.
Danger Even banksmen are not allowed to stand in front of or behind
a
crawler chains. This is extremely dangerous!
• Do not exceed the permissible inclinations when loads are transported.

Always keep an adequate safety distance between the transport crawler
and pit edges, slopes and other plants and machines.
• Do not touch the exhaust system of the Diesel engine when the motor is
running. Risk of burning!
• Do not touch rotating or moving parts of the transport crawler! Make
sure that all safety guards are fitted in front of such parts.
• Always wear the stipulated protective clothing when operating the trans-
port crawler.
• Always note the safety instructions and warning signs attached to the
transport crawler and keep them in legible condition.
• Avoid all kinds of ignition sources such as sparks, leak currents, over-
heating etc.
• Check the transport crawler for externally visible damage and faults
before starting. Immediately report any changes (including changes in
operating behaviour) to the department/person responsible. Stop the
transport crawler and secure it against inadvertent and unauthorized
starting.
• Do not bridge or disable safety equipment. Do not make unauthorized
changes or adjustments to the equipment.
• Do not clean, inspect and service the transport crawler unless it is shut
down.
• Do not open reservoirs, tanks or systems which are under pressure (e.g.
hydraulic systems). Beware of oil spurting out of pipes, hoses and fittings.
Risk of injury!
• Keep all steps, ladders etc. in a serviceable condition and free from
lubricants and dirt.
14.10.98
• Always observe the product safety regulations when handling oil, grease
and other chemical substances.
• Do not carry out work in the dark unless you have adequate illumination
facilities.
Safety instructions T 1250 13

Fire protection
1.4.2 Fire protection

Observe the legal regulations governing fire protection and prevention, and
supplement them with the company’s own instructions. Consult the fire-
fighting experts of the insurance company for this purpose.
Appoint supervisory personnel responsible for all matters concerning fire pre-
vention and fire fighting and provide them with the necessary authority.
The supervisors must inspect the fire fighting equipment and installations at
regular intervals to ensure that they are always ready for use.
The persons entrusted with supervisory and fire fighting tasks must have
attended first-aid courses. First-aid points must be provided.
The personnel must receive instruction in fire protection measures. Fires must
be reported immediately.
Particular attention must be paid to assemblies and components which are

heated up during operation by electrical and mechanical loads.
Fire extinguishers must be easily accessible. Personnel must be instructed

how to use the fire extinguishers so that they can fight fires using the type of
extinguishers suitable for the particular fire.
Fire fighting rules
• Trigger the warning/alarm system.
• Immediately inform the supervisor (fire brigade captain).
• Shut down the electrical system.
• Use water on burning wood, rubbish, fabric, jute, paper, belts etc.
• Always use CO2 or dry (powder) extinguishers on burning liquids,

mineral oil, petrol, oil, kerosene, paint, tar etc.
• Always use CO2 or dry (powder) extinguishers on burning cables,

motors, electrical equipment etc. 14.10.98
14 T 1250 Safety instructions

Operator qualification
2 Operating instructions
2.1 General instructions
2.1.1 Operator qualification
Caution These operating instructions for the transport crawler are no
a
substitute for proper training and instruction. The operation of
the transport crawler requires excellent skills and substantial
knowledge of the safety aspects associated with the operation
of such equipment.
The user has to prepare his own operating instructions which govern the
operation, servicing and repair of the transport crawler within his own
organization.
Caution Note the instructions associated with the designated use of the
a
transport crawler (see section 1.1).
The operating personnel must have read these operating instructions and the
operational safety instructions included in it before work is started. It is too
late to read the instructions once work has started.
The operating personnel must be familiar with the location and operation of
all safety devices.
2.1.2 Safety devices

The safety devices are designed to protect the transport crawler against over-
load and operating faults. Operation of the safety devices can only be
ensured by carrying out regular checks and by servicing them on schedule.
Danger Whenever the safety of persons or transport crawler is at risk,
a
the transport crawler has to be shut down immediately by
pressing the emergency-stop button.
Safety devices and electrical interlocks which can be bridged may only be
temporarily disabled by authorized personnel on the provision that all
necessary precautionary measures have been taken.
The transport crawler is equipped with the following safety devices:
– Hand-operated fire extinguishers
– Battery master switch
– Emergency-stop buttons
14.10.98
– Revolving warning lights

– Spring pressure multi-disk brakes
– Pressure relief valves of the hydraulic system (see section 1.2.)
– Searchlight, headlights, horns
General instructions T 1250 15

Safety devices
– Hand-operated fire extinguishers
The hand-operated fire extinguishers are provided on two points on the trans-
port crawler. Their location is specially marked and easily accessible.
Each fire extinguisher contains 6 kg of powder and meets fire class ABC
requirements. The fill and operation of fire extinguishers must be checked at
regular intervals.
– Battery master switch
The battery master switch is provided on the component bed. It is mounted

on the right-hand outer wall of the valve cabinet. All electrical devices are
de-energized when the master switch is turned off. The Diesel engine cannot
be started.
The battery master switch has a turning knob which can be removed when
the system is shut down to prevent the transport crawler from being started
up inadvertently.
Caution Do not turn off the battery master switch when the engine is
a
running as this will destroy the electric generator.
– Emergency-stop buttons
Emergency-stop buttons may only be pressed in emergencies to prevent

accidents or damage to the transport crawler.
Pressing the emergency-stop buttons will interrupt the supply of fuel to the
Diesel engine so that all drives are immediately shut down. Emergency-stop
buttons are provided on easily accessible locations and can easily be identi-
fied by their red button. There are 3 emergency-stop buttons provided on the
transport crawler:
– inside the driver’s cab on the right-hand control panel,
– on the right-hand side of the valve cabinet,
– on the right-hand gear unit in the rear part of the transport crawler.
After an emergency-stop button is pressed, notify the responsible depart-

ment/person. Before the transport crawler is re-started, clarify what caused
the button to be pressed and eliminate such cause.
– Revolving warning lights
Revolving warning lights are located on the left-hand and right-hand sides of
the driver’s cab and at the rear end of the transport crawler. They are inter-
locked with the crawler drive and are automatically turned on as soon as the
crawler drive is activated.
– Spring pressure multi-disk brakes
The spring pressure multi-disk brakes on the crawler gear units are used as
holding brakes. They are automatically applied when the transport crawler
14.10.98
comes to a standstill.
16 T 1250 General instructions

Safety devices
2.2 Display and control panels
0 1 0 1
0 0
1 2 KN KN 1 2
0 0
1 2 KN KN 1 2
1
2 3
6
5 4
0 0 1 2 23
1 2 1 2 0 3 1 4
0 0 0
1 1 1 0 1 1 2 0 1
2 2 2
0
0 1 0 1 ()
1 2
TR-533.eps
bedien.eps
1 Central control panel (including multi-task display)
2 Left-hand control panel
3 Right-hand control panel
4 Foot-operated switch for the horn
5 Foot-operated switch for the windscreen washing system
6 Screen (touch screen)

14.10.98
Display and control panels T 1250 17

Central display and control panel
2.2.1 Central display and control panel
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
1 2 KN SCREEN KN 1 2
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
7 TR-535.eps bedien-m.eps
1 Multi-task display
2 Warning and status signal lamps
3 Lamp test button

4 Signal and reset button
8 Twist switch for extending/retracting front LH lifting cylinder

9 Twist switch for extending/retracting rear LH lifting cylinder
10 Twist switch for extending/retracting front RH lifting cylinder
11 Twist switch for extending/retracting rear RH lifting cylinder
12 Warning lamp max. pressure on front LH side

13 Warning lamp max. pressure on rear LH side
14 Warning lamp max. pressure on front RH side
15 Warning lamp max. pressure on rear RH side
16 Lifting force display, front LH side

17 Lifting force display, rear LH side
18 Lifting force display, front RH side
19 Lifting force display, rear LH side
20 Turn switch for cab lighting

14.10.98
21 Twist switch - heating/0/ventilating
22 Illuminated button "High lifting force"

23 Illuminated button "One-hand travel"
24 Screen (touch screen)
18 T 1250 Display and control panels

Central display and control panel
2.2.1.1 Multi-task display
The pushbuttons are used to have the digital display (12) show the para-
meters which are important for the Diesel engine:
– battery voltage (1),
– operating hours (2),
– oil pressure (3),
– coolant temperature (4),
– speed (5).
Green status signal lamps

Ready for operation (7) Monitoring functions are O.K.
Diesel engine ready for starting.
PLC in operation (6) PLC is active. All control functions are
available.
Red warning lamps

Battery charging lamp (9): When Diesel engine is running: fault in
electric generator.
Oil pressure lamp (10): When Diesel engine is running: check oil level
top up oil. Possible oil losses. Immediately
stop engine.
14.10.98
Cooling water Motor overheated. Shut down all drives (slewing

temperature (8): gear, crawlers).
Coolant level (11) Shut down engine. Top up coolant. Possible
leaks.

Left-hand control panel
2.2.2 Left-hand control panel
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
0
0 1
1 2
TR-534.eps bedien-l.eps
1 Control lever for LH crawler/One-hand travel
2 Clamping device
3 Chain tensioning device
4 Inclining platform, LH side/RH side

5 Inclining platform, front end/rear end
6 Turning platform
7 Raising platform against load

8 Extending/retracting all lifting cylinders
14.10.98

Right-hand control panel
2.2.3 Right-hand control panel
1 2
3 4 6
1 2 2 3
0 3 1 4
5 7
1
0 1 1 2 0 2
9
IDLE
OPERAT.
()
8
TR-536.eps bedien-r.eps
1 Control lever for RH crawler/One-hand steering
2 Emergency-stop button
3 Headlights
4 Speed ranges
5 Searchlight
6 Lubrication, permanent/automatic
7 Windscreen wiper
8 Ignition lock
9 Speed selector switch for Diesel engine

14.10.98

Screen displays and signals
2.2.4 Screen displays and signals

The screen is designed as touch screen protected by a nonreflective foil
which can be replaced.
• Keep the screen surface clean to avoid malfunctions. Regularly wipe the
screen clean with a moist cloth to remove dust and fingerprints.
2.2.4.1 Starting mask Once the PLC has started and initialization is completed, the screen displays
the starting mask.
The right-hand side of the screen shows the different screen masks which can
be called up by touching them.
• Touch the symbol of the screen mask you want to call up.
Caution Do not touch the "Configure" symbol (bottom left-hand side).
a
This function is strictly reserved to service personnel for a
number of possible settings. If this symbol were touched by
unskilled personnel, communication may be interrupted and
the software deleted.
In the left-hand upper corner all screen masks display the actual speed range
(see section 2.2.4.7). Any malfunctions and faults are displayed in the
middle of the upper mask line ("emergency off" shown as an example here -
see section 2.2.4.6).
14.10.98

2.2.4.2 Centre of gravity Touch the GRAVITY symbol on the screen (24) to display the centre of
mask gravity mask.
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
The mask outlines the transport crawler, the lifting platform and the lifting
cylinders. The area in which the centre of gravity of the load is allowed to
move (shown by means of a cursor) is boxed in.
The movement of the centre of gravity away from the centre point is also indi-
cated in centimetres (on top in longitudinal direction and on the right-hand
side in transverse direction).
If the centre of gravity moves beyond the permissible area, the screen dis-
plays error 014 "Tilting edge reached".
The centre of gravity mask is active only with a load placed on the lifting plat-
form, i.e. the cursor appears only after the clamping device is operated and
after the cumulative pressure of 25 bar in the lifting cylinders is exceeded.
14.10.98

2.2.4.3 Inclination masks Touch the INCLINATION symbol on the touch screen. The screen again dis-
plays the centre of gravity mask for transporting the stacker/spreader or the
centre of gravity mask for transporting the crusher. Touch the GO TO symbol
to change from stacker/spreader to crusher or vice versa.
14.10.98
The transport crawler outline includes a boxed-in area showing the permis-
sible inclination of the transport crawler while transporting the stacker/
spreader or crusher. The cursor shows the quality of the actual inclination(s).
The cursor begins to flash once it has left the permissible area.
The figures show the respective longitudinal inclination, transverse inclination
and resultant inclination in degrees.

2.2.4.4 Liquid fill mask Touch the LIQUIDS symbol on the screen to display the liquid fill mask.
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
The mask contains diagrams of the reservoirs for hydraulic oil and Diesel
fuel showing the respective minimum and maximum filling levels.
The approximate filling levels are graphically displayed in form of columns
and are indicated in litres underneath each column. The minimum display is
90 litres for the Diesel fuel tank and 800 litres for the hydraulic oil reservoir.
Alarm 018 is triggered in the hydraulic oil reservoir just before the min.
filling level is reached. If the oil level drops below minimum, the Diesel
engine is shut down and error 001 is displayed.
The temperature of the hydraulic oil is also displayed. Hydraulic drives are
only fully operative when a temperature of 68 °F is exceeded. Error 005 is
displayed at a temperature of 158 °F and the crawler drives are shut down
to prevent the oil from being heated up any further.
14.10.98

2.2.4.5 Maintenance mask Touch the MAINTENANCE symbol on the screen to display the maintenance
mask (static display).
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
14.10.98

2.2.4.6 Error message After a malfunction or fault has occurred, touch the ALARMS symbol on the
mask screen to display the list of pending error messages ("emergency-off" shown
as an example here). A complete list of error messages is included in section
2.5.1.
New error messages appear in the top line of the screen and must be sepa-
rately acknowledged by pressing the reset button (4 - see opposite page).
After all pending new error messages have been acknowledged, the war-
ning buzzer (7) is turned off. The pending error messages are chronologi-
cally listed in the error message mask. An error message disappears after
the respective malfunction or fault has been rectified.
2.2.4.7 Spanning displays New error messages (see previous section) and the actual speed range are
displayed in the top line of all masks.
A display of the actual speed range is important since the PLC only accepts
a change in speed range when the transport crawler is stopped. Changing
the speed range when the transport crawler is travelling therefore has no
effect and the position of the speed range selector switch is no decisive
criterion. Only the speed range shown in the display with an illuminated
background is decisive.
Regardless of the selector switch position, the speed range is set to "P"
during positioning (see section 2.3.4.3).
If none of the speed ranges has an illuminated background, the speed of the
Diesel engine is too low for travelling. This requires the selector switch of the
Diesel engine speed to be set to "Operation".
The actual travelling speed of the crawlers is displayed in form of columns
14.10.98
on both sides of the centre of gravity mask and inclination masks. The
columns are fully filled when the crawlers are run at maximum speed within
the selected speed range (from the middle upwards when travelling forward,
from the middle downwards when reversing).
Despite a full deflection of the control lever the column is not fully filled when
the speed is reduced by the power control system (see section 1.2).

Measures to be taken prior to start-up
2.3 Operations
2.3.1 Measures to be taken prior to start-up

Inbetween transport missions, the transport crawler is usually put out of
service. In order to ensure a permanent stand-by duty, it is recommended to
put the transport crawler into operation at least once every week.
Measures to be taken prior to start-up:
• Check that all instructions and safety regulations associated with the
operation of the transport crawler have been observed.
• Read the logbook to see if there have been unusual occurrences during
the previous transport crawler mission. The operating instructions have to
be available in the driver’s cab.
• Carry out a visual inspection. Check the transport crawler for leaks (oil,
fuel).
• Check that the fills of operating fluids and lubricants are in accordance
with the liquid fill mask and/or maintenance mask and check the lubri-
cating condition:
– Oil level of the 2 travel gears using the dipsticks.
– Oil level of the pump distributor gear using the dipstick.
– Oil level of the Diesel engine using the dipstick.
– Lubricating condition (existing grease collar) of:
2 drive tumblers
2 return tumblers
16 track wheels
8 track wheel bogies
2 crawler axles
1 central axle
2 side axle pivot bearings
2 supporting rails
– Grease level in grease reservoir of central lubrication system
• Check the crawler track tension. The tracks of both crawlers must be
properly tensioned (see section Hydraulic system).
• Subject the central lubrication system to a test run. Grease must be
supplied to the most remote lubrication points (fresh collar of grease).
Check the operation of the grease distributors and check the lubricating
pressure.
Measures to be taken for starting up the transport crawler once a week

• Start up the transport crawler (see following section) and set central lubri-
14.10.98
cation system to continuous lubricating mode.

• Run the engine and hydraulic system up to operating temperature and
check all functions (see following sections).
• For servicing work please refer to section 2.6.2 (tabular form). More
detailed information is included in the operating and maintenance
instructions.
28 T 1250 Operations
Putting the transport crawler into operation
2.3.2 Putting the transport crawler into operation

• Turn the ignition key in the ignition lock (8) to zero.
1 2
3 4 6
1 2 2 3
0 3 1 4
5 7
1
0 1 1 2 0 2
9
IDLE
OPERAT.
()
8
• Turn on the battery master switch. The battery master switch is located on
the right-hand side of the valve cabinet.
Turn on the switch by locking the switching knob into the bore and
turning it clockwise by 90 degrees. This activates the electrical system.
• Turn the ignition key to position 1 and wait until the signal lamp (7) in the
14.10.98
multi-task display lights up. If the signal lamp does not light up, either:
– one of the emergency-stop buttons is pressed (000) or,
– the hydraulic oil level is lower than minimum (001) or
– the shut-off valve of the suction line is closed (004).
Operations T 1250 29
These error messages (with shutdown criteria) are only displayed on the
screen when the PLC is operating and the signal lamp (6) in the multi-task
display is on.
Note: The PLC is not needed to start up the Diesel engine. If the
respective signal lamp goes out because the on-board voltage
suddenly drops when the Diesel engine is started, this has no
effect on the starting procedure. The Diesel engine monitoring
functions of the PLC are only activated after the engine is
started.
• Acknowledge any pending optical and acoustical error messages by

pressing button (4). Error messages without actual cause can be dis-
played when the control voltage is turned on.
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
14.10.98
• Evaluate any remaining error messages and eliminate the malfunctions/

faults (or have them eliminated).
• Use switch (9) to adjust the Diesel engine speed to idling.
1 2
3 4 6
1 2 2 3
0 3 1 4
5 7
1
0 1 1 2 0 2
9
IDLE
OPERAT.
()
8
• Shortly turn the ignition key into position 2 and start the Diesel engine.
The starter is operated by the built-in solenoid switch.
• Repeat the procedure should the Diesel engine not start up.
Avoid numerous starting procedures as this will discharge the batteries to
such an extent that the Diesel engine can no longer be started without
using an external ignition source.
• Use switch (6) to set the lubricating system to continuous lubricating

mode for the time being.
• For safety reasons, check if there is an error message 019 "Lubrication

fault" by touching the ALARMS symbol on the screen. Do not operate the
transport crawler with a disabled lubrication system.
14.10.98
Travelling
2.3.3 Travelling
2.3.3.1 Normal travelling Before the transport crawler can be moved, the hydraulic oil must have
mode reached a temperature of 68 °F. Run the Diesel engine until this temperature
is reached.
• Use selector switch (9) to adjust the engine to nominal speed (position
"Operation").
1 2
3 4 6
1 2 2 3
0 3 1 4
5 7
1
0 1 1 2 0 2
9
IDLE
OPERAT.
()
8
• Select the desired speed range using the turn switch (4). The speed
range can only be changed when the transport crawler is stopped.
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
0
0 1
1 2
14.10.98
• Turn the twist switch (3) of the track tensioning device to "Automatic".
Travelling
• For travelling forward/reversing, first press the "dead man’s switches"

on the control levers (1 - LH side + RH side) and keep them depressed.
1
1 2
5 2 3 3 4 6
0 0 1 2 2 3
1 2 1 2 0 3 1 4
4 6 5 7
0 0 0 1
0 1 1 2 0 2
1 2 1 2 1 2
7 8 9
0 1
0
IDLE
OPERAT.
()
8
1 2
TR-534.eps bedien-l.eps TR-536.eps bedien-r.eps
• Fully deflect both control levers into the desired travelling direction
(forwards = travelling forward/backwards = reversing).
The control levers have the following functions:
– fully deflected = accelerating
– deflected halfway = maintaining speed
– released = slowing down
The driver can feel how the levers engage in the different positions.
• Cornering requires the left-hand/right-hand control lever (1) to be
returned to neutral position:
– left-hand control lever = left-hand bend,
– right-hand control lever = right-hand bend.
• Turning on the spot requires one control lever to be fully deflected
forwards and the other to be fully deflected backwards. Pushing the left-
hand control lever forwards and pulling the right-hand lever backwards
will cause the transport crawler to turn to the right. Operating the two
levers in the other direction will cause the crawler to turn to the left.
Caution Turning on the spot without load is only allowed in speed
a
ranges 1 to 3. With a load on the platform, the crawler may
only be turned in speed ranges 1 and 2. Do not turn on the
spot when the crawlers are sunk in. Instead, change the travel-
ling direction by maneuvering the transport crawler forwards
and backwards choosing a radius which should be as large as
possible.
14.10.98
Temperature monitoring system

When the temperature of the hydraulic oil exceeds maximum (158 °F), the
error message 005 "Hydraulic oil temperature > max." is displayed and the
crawler can no longer be moved.
Travelling
2.3.3.2 One-hand travel If long distances have to be covered without a load on the platform, the trans-
port crawler can be operated in the special "one-hand travel" mode. This
operating mode is only available when travelling forwards in speed range 4.
• Select speed range 4 to initiate one-hand travel.
• Press the illuminated button (23) "One-hand travel".
The illuminated button is on when the crawler is travelling. One-hand
operation is automatically stopped when the crawler drive is shut down.
• Push the left-hand control lever forwards.
• In bends with a large radius the travelling direction can be influenced
with the right-hand control lever:
– pushing the lever forward = left-hand bend
– pulling the lever backwards = right-hand bend
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
1
1 2
5 2 3 3 4 6
0 0 1 2 2 3
1 2 1 2 0 3 1 4
4 6 5 7
1
0 0 0 0 1 1 2 0 2
1 2 1 2 1 2
7 8 9
0 1
0
IDLE
OPERAT.
()
8
1 2

14.10.98
Note: In the course of transport crawler operation, worn components

(e.g. crawler tracks) may affect straightforward driving. Such
effects can be corrected by adjusting the control program of
the PLC.
Transporting loads
2.3.4 Transporting loads
2.3.4.1 Requirements
Caution Only operate the transport crawler in accordance with its
a
designated use (see Section 1.1). Always use a banksman/
several banksmen when working with the transport crawler.
The following general requirements must be met before the transport crawler
is used for transporting loads:
– Dimensions, weights, position of the centre of gravity and inclinations
must be known.
– The design of the load must allow it to be secured by means of the
clamping system (outer edge of clamping flange 7.10 m).
– The load must be able to take up the propulsive forces produced by the
transport crawler.
– In critical transport situations it must be possible to put down the load
which must therefore be equipped with suitable pontoons/feet.
– The load must be placed as close to the platform centre as possible.
– The transport crawler must stand on level ground and the requirements
associated with the bearing capacity of the ground on the transport route
must be met (see following Section).
Before the transport crawler is moved under the load, check that:
– the load has the appropriate clamping marks. If not, use the centre of
gravity mask to determine the clamping points (see Sections 2.3.4.3 and
2.3.4.4),
– the lifting cylinders are fully retracted,
– the platform is resting on the rollers of the slewing gear,
– the speed selector switch of the Diesel engine is set to "Operation",
– all clamping levers are folded down and are parallel to the load,
– the crawler drive is set to speed range 2 (or smaller).
2.3.4.2 Requirements to be Before loads are transported it is recommended to make a test trip on the
met by the ground planned transport route without a load on the platform. Measure how deep
travelled over the transport crawler sinks in and how it is inclined along the way. Inclinati-
ons can be measured using the instrumentation on board of the transport
crawler. Simple geodetic surveying methods can be adopted to measure
how deep the crawler sinks in.
The results obtained during the test trip in unloaded condition allow conclusi-
ons to be drawn with respect to the travelling behaviour in loaded condition.
For an unloaded transport crawler, the following maximum ground settle-
ment rates apply with respect to the different loads to be transported:
14.10.98
Transporting loads
Permissible settlement sobs [cm] caused by an unloaded transport crawler

(GE = 440 tons):
Load to be transported Transport weight Perm. settlement caused

by unloaded crawler
Nominal load 1250 tons 6.51 cm
Spreader 1166 tons 6.83 cm
Spreader reduced* 954 tons 7.89 cm
Crusher 5 1086 tons 7.24 cm
Crushers 6/8 1375 tons 6.06 cm

* partly dismantled
The following Fig. shows a possible track and the resultant settlement sobs.
Depending on the load that has to be transported, the following maximum

values apply for inclinations caused by a different compressibility of the
ground:
Permissible inclination iobs [%] for an unloaded transport crawler:
Load to be transported Transport weight Perm. inclination for

unloaded crawler
Nominal load 1250 tons 0.65 %
Spreader 1166 tons 0.68 %
Spreader reduced* 954 tons 0.79 %
Crusher 5 1086 tons 0.72 %
Crushers 6/8 1375 tons 0.61 %
* partly dismantled
The following Fig. shows a possible track and the resultant inclination iobs.
Special care must be taken when travelling near slopes (landslides !). Ensure
that the ground travelled over is stable enough in these particular areas.
14.10.98
Should the results obtained during the test trip exceed the specified maxi-
mum values, measures must be taken to improve the ground travelled over.
Transporting loads
Measures taken to improve the ground
A simple solution would be to use the transport crawler (partially loaded if

necessary) to travel over the ground three to four times. The weight to be
transported should then exceed one third of the load which has to be trans-
ported later to achieve a significant improvement of the ground.
This also evens out the settlement potential in the filled subsoil so that an
excessive load-induced inclination can be excluded. It is important that the
transport route is essentially identical to the future travelling track.
Note: Before measures are taken to improve the ground to be travel-

led over, consult the mining and/or civil engineer.
If it shows that conditions cannot be adequately improved (e.g. because the

soil cannnot be properly compacted under the compacting energy being
applied), it is necessary to excavate the ground of isnufficient bearing
capacity down to max. 2 m below ground level and replace it by a suitable,
non-cohesive and consistent coarse material which must be compacted in
layers (layer thickness < 0.5 m).
The grain size of the coarse material should be between 0 mm and
100 mm, the portion < 20 mm not exceeding a weight portion of 20 %.
Compacting requirements should be defined through the layer thickness
(reference: Proctor density) or through the rigidity (reference: plate load
bearing tests). Similar to the requirements applying to road construction
(unbound surfacing), the ground to be travelled over should have a com-
pacting level Dpr of 100 % (a deformation modulus EV2 of 100 MN/m2).
2.3.4.3 Clamping points The most favourable load clamping point is the point underneath the centre
of gravity of the load where the centre of the transport crawler’s lifting plat-
form should be during clamping. The clamping points are marked by appro-
priate clamping marks (plates) attached to the two clamping girders of the
load in a visible location.
When travelling on slopes, the position of the centre of gravity will shift
(migrate) which has a negative effect on the equilibrium, load situation and
stability of the transport crawler. The clamping point must therefore be
adjusted accordingly (see the diagram showing the migration of the centre
of gravity in Section 2.3.4.7).
The clamping area is restricted by clamping points "1" and "3".
Anklemmpunkte/Anklemmarkierungen für Schwerpunkt bei horizontalem Planum

Clamping points/clamping marks for centre of gravity at horizontal level ground
1 2 3
Anklemmbereich
Clamping area TR-623.eps
14.10.98
Adjusting the clamping marks
General rule: the accuracy with which the centre of gravity of the load is
positioned above the centre of the transport crawler is a function of the size
of the load to be transported and/or the height of its centre of gravity.
Transporting loads
Owing to possible changes in the as-built condition of the load to be trans-

ported, the actual position of the centre of gravity may differ from the calcu-
lated position of the centre of gravity so that the clamping point has to be
changed, too.
Before the load is transported for the first time, it is therefore necessary to
determine the actual position of the centre of gravity by weighing the load
with the transport crawler in horizontal position (on level ground), i.e. by
lifting the load by way of trial and checking the centre of gravity mask
together with the cylinder force displays. Then the clamping marks are
attached to the clamping points and/or existing clamping marks are adjus-
ted/relocated. The following descriptions show the sequence of adjustment
steps on the stacker/spreader by way of example.
1. The calculated centre of gravity of the stacker/spreader is located at a
distance of 15.440 m from the rear edge of the rear pontoon in direction
X (see Section 2.4.1,page 53). This is where the calculated clamping
mark "2" is attached.
2. Position the centre of the transport crawler under this mark "2".
Weigh the load to determine the actual position of the centre of gravity
using the centre of gravity and cylinder force displays. If necessary,
relocate the transport crawler (see pages 43 and 44). Should the centre
of gravity determined in this way be located at a distance of e.g.
15.420 m from the rear edge of the rear pontoon, the deviation would
be: 15.440 m – 15.420 m = 0.02 m = 20 mm.
3. Shift mark "2" by the difference between the calculated and practically
determined positions of the centre of gravity (i.e. 20 mm in our example).
Note the direction in which the mark is shifted. In our particular example
the mark has to be shifted 20 mm in the direction of the rear edge of the
rear pontoon.
Caution If the difference between calculated and practically deter-
a
mined values exceeds 100 mm, KRUPP FÖRDERTECHNIK
must be consulted.
– Clamping areas for defined loads
Clamping area for stacker/spreader complete and partly dismantled (Fig.

see Section 2.4.1, pages 53 and 54), measured from the rear edge of the
rear pontoons of 13.110 m up to 17.100 m (in direction X) for longitudinal
and transverse transport.
Clamping point for crusher No. 5 (no clamping area, merely one clamping
point. Fig. see Section 2.4.2, page 63 and opposite page) measured from
the rear edge of the main pontoon at 9.470 (in direction X) only for longi-
tudinal transport.
Clamping area for crushers Nos. 6/8 (Fig. see Section 2.4.3, page 69)
measured from the rear edge of the main pontoon at 7.240 m to 10.310 m
(in direction X) only for longitudinal transport.
Clamping marks (plates see Fig. on page 37).
On the stacker/spreader and on crushers Nos. 6/8 the clamping mark "2"
14.10.98
corresponds to the appropriate positions of the centre of gravity on level

(horizontal) ground. Clamping marks "1" and "3" restrict the possible clamp-
ing area applying when travelling on slopes or in case of unfavourable
ground conditions.
The clamping area of the stacker/spreader is also the turning area. It is im-
possible to turn the transport crawler underneath the crushing stations.
Transporting loads
Clamping point for crusher No. 5
Clamping mark "1" on crusher No. 5 is the only clamping point for the trans-
port crawler. In this point the centre of gravity is shifted by 439 mm towards
the centre of the transport crawler. This special clamping situation restricts
the cylinder forces (see table) for lifting the load on level ground. Do not
exceed the forces without consulting KRUPP FÖRDERTECHNIK. Appropriate
counterweights can then be determined.
Cylinder/ Max. permissible lifting forces

cylinder combinations for lifting crusher No. 5
Front LH cyl. = front RH cyl. = 2800 KN
Rear LH cyl. = rear RH cyl. = 4100 kN
Front LH cyl. + front RH cyl. = 5000 kN
Rear LH cyl. + rear RH cyl. = 7400 kN
2061 Clamping marks see dwg. no. 2678069

S
Brechermittelachse
1 Nur ein Anklemmpunkt

Only one clamping point
Crusher C/L
Centre of transport crawler

Mitte Transportraupe
10898
200
700
2500
3000
Z remove
X
9470
4500
ZHL ZVL ZHL = Rear LH cyl.
ZVL = Front LH cyl.
+Y ZHR = Rear RH cyl.
4000
ZVR = Front RH cyl.

X
14.10.98
–Y
ZHR ZVR
TR-624.eps
(2678679)
Transporting loads
2.3.4.4 Positioning the • Move the transport crawler under the load taking into account the
lifting platform calculated/practically determined clamping marks.
• Position the platform so that both its sides run parallel to the load. This
requires the platform to be turned and/or inclined.
Caution Do not operate the slewing gear unless the lifting platform is
a
lowered and free of load.
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
0
0 1
1 2
• Turn the twist switch (6) into position 1 and hold it there to turn the plat-
form to the left. The platform is turned as long as the switch is held in this
position. Turn the twist switch into position 2 and hold it there to turn the
platform to the right. The platform is turned as long as the switch is held
in this position.
• Turn the twist switch (4) into position 1 and hold it there to incline the plat-
form to the left. The two left-hand lifting cylinders are retracted and the
two right-hand cylinders are extended. Turn the twist switch (4) into
position 2 and hold it there to incline the platform to the right. The two
left-hand lifting cylinders are extended and the two right-hand cylinders
are retracted.
• Turn the twist switch (5) into position 1 and hold it there to incline the plat-
form forwards. The two front lifting cylinders are retracted and the two
rear cylinders are extended. Turn the twist switch (5) into position 2 and
hold it there to incline the platform backwards. The two front lifting cylin-
ders are extended and the two rear cylinders are retracted.
14.10.98
Transporting loads
• Turn the corresponding switch (8)/(9)/(10)/(11) into position 1 for

extending a single lifting cylinder.
• Note the corresponding lifting force displays (16)/(17)/(18)/(19) and

warning lamps (12)/(13)/(14)/(15).
• Turn the corresponding switch (8)/(9)/(10)/(11) into position 2 for

retracting a single lifting cylinder.
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
• For raising the lifting platform against the load (at low pressure) without
lifting it, hold the twist switch (7) "Position platform" in position 1. The
platform is raised. Stop the lifting process when the platform is in contact
with the clamping girders of the load.
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
14.10.98
0
0 1
1 2
Transporting loads
• Turn the twist switch (2) "Clamping device" into position 2 to clamp the
load to the platform. The clamps are hydraulically operated and the load
is secured to the platform.
Clamping is continued as long as the switch is held in position 2.
Should the clamping pressure of the lever drop after the load is clamped
to the platform, this particular switch position will automatically trigger a
second clamping operation through the pressure switch.
If it is necessary to release the clamps, turn twist switch (2) into position 1
and hold it there until the clamps have released the load.
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
0
0 1
1 2
Note Limitation of propulsive/tractive power:

When the switch is in position 2 "Apply clamps" and the
pressure in the lifting cylinders is < 20 bar, the engine is auto-
matically changed to speed range P (see section 2.2.4.7).
The maximum tractive power on each crawler track is limited
to approx. 2250 kN. This allows the transport crawler with a
relatively small load on top to be turned without the load
which is still standing on the ground being turned along.
In switch position 1 "Release clamps" or at a pressure
> 20 bar in the lifting cylinders (load lifted), this limitation is
ineffective so that the maximum tractive power of the transport
crawler is available.
• Check that all clamps are properly applied to the load.
Danger Never transport loads which are not properly clamped to the
a
transport crawler. Never move loads with a defective clamp-
ing system. This is extremely dangerous!
14.10.98
• If only the positions of the clamping marks for the calculated centre of
gravity are known, determine the actual position of the centre of gravity
by weighing the load before changing/relocating the corresponding
clamping marks. Proceed as follows:
Transporting loads
• Lift the load by way of trial (if necessary, pull the load free first - see next
Section).
Check the position of the centre of gravity on the centre of gravity mask
(see Section 2.2.4.2) and check the load distribution of the four lifting
cylinders. The forces are detected by means of pressure sensors, proces-
sed in the PLC and shown on the lifting force displays (16), (17), (18)
and (19). Lifting is interrupted by the PLC in case of overload, upon
which the cylinders are slowly receding.
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
Note: High lifting force:

For transporting the different loads the transport crawler has
two lifting force levels (see table). The "high lifting force" level
is activated by means of the illuminated button (22).
From a cylinder pressure > 25 bar onwards it is possible to
increase the lifting force for certain transport jobs. This is also
always possible in critical transport situations.
The illuminated button is on as long as this lifting force level
is activated. When the load is put down to the ground, the
higher lifting force level is automatically deactivated.
Max. permissible retaining force for transporting
per single cylinder/cylinder combination Spreader Crusher*

(item of lifting force display) [kN] [kN]
Single cylinder 4500 5500

Front LH cylinder (ZVL - 16) + front RH cylinder (ZVR - 18) 9000 11000
Rear LH cylinder (ZHL - 17) + rear RH cylinder (ZHR - 19) 9000 11000
Front LH cylinder (ZVL - 16) + rear LH cylinder (ZHL - 17) 9000 11000
Front RH cylinder (ZVR - 18) + rear RH cylinder (ZHR - 19) 9000 11000
Cumulative force (16 + 17 + 18 + 19) 18000 18000

* Travelling on slopes with a crusher on top requires the high lifting force.
14.10.98
Relocating the transport crawler

• If the centre of gravity is not located near the centre of the mask and
the lifting forces of the cylinders are not nearly identical, the transport
crawler must be relocated as follows.
Transporting loads
• Safely put down the load and disengage the clamps.

• Relocate the transport crawler by the displayed deviation of the centre of
gravity position.
• Apply the clamps again, lift and weigh the load.
• Repeat the procedure as often as necessary.
• Adjust/relocate the clamping marks in accordance with the practically
determined actual position of the centre of gravity.
Since clamping and turning areas are identical for the stacker/spreader and
since the transport crawler cannot be turned underneath the crusher stations,
the following applies when other permissible loads are transported.
• Retract the lifting cylinders and check that the crawler is positioned within
the permissible turning area of the transport crawler underneath the load.
Turn the transport crawler on the spot until the crawlers point into the
desired travelling direction.
2.3.4.5 Lifting the load • If lifting cylinders were lowered in the meantime, use the twist switch (7)
to raise the lifting cylinders against the platform.
• In order to be able to lift the platform uniformly, turn twist switch (8) into
position 1 and hold it there. Lift the load until it has sufficient clearance
from the ground to allow it to be relocated.
If it is necessary to put the load down again, turn the switch into position
2 and hold it there.
5 2 3
0 0
1 2 1 2
4 6
0 0 0
1 2 1 2 1 2
7 8
0
0 1
1 2
Caution Pontoons/feet may be stuck in the mud so that they first have
a
to be pulled free before the load can be lifted. The transport
crawler therefore has to lift each pontoon/foot separately.
14.10.98
• For pulling the load free, position the transport crawler at a right angle
under the load as far as possible. Crushers require the transport crawler
to be positioned in longitudinal direction as close as possible to the
pontoon to be pulled free. The load must be introduced into the transport
crawler through the webs of the platform.
Transporting loads
• Clamp the load at the points adjacent to the pontoon feet.

• Lift each single pontoon/foot a little bit without exceeding the cumulative
lifting cylinder forces.
2.3.4.6 Transporting/ • Select speed range 1 first and start to move the transport crawler by
relocating the load uniformly operating the control levers (1 - LH and RH) (also refer to
Section 2.3.3).
1
1 2
5 2 3 3 4 6
0 0 1 2 2 3
1 2 1 2 0 3 1 4
4 6 5 7
0 0 0 1
0 1 1 2 0 2
1 2 1 2 1 2
7 8 9
0 1
0
IDLE
OPERAT.
()
8
1 2
• For correcting the position of the centre of gravity should slopes or unfa-
vourable ground conditions cause a so-called migration of the centre of
gravity, stop the transport crawler and proceed as follows:
1. relocate the transport crawler (see pages 43 und 44), or
14.10.98
2. tilt the platform by lifting/lowering the lifting cylinders in pairs, or

3. lift/lower individual lifting cylinders, or
4. activate the high lifting force level (see previous Section).
• Always check that there is a sufficient ground clearance during travelling.
Transporting loads
2.3.4.7 Ground clearance The ground clearance of the lifted load is limited by the pontoons/feet.
and migration of It must not be too large as this would raise the position of the centre of
the centre of gravity gravity. But it must also not be so small that the transport crawler is pre-
vented from travelling on slopes.
Danger If the pontoons/feet make contact with the ground, the centre
a
of gravity can suddenly shift and cause the load and transport
crawler to overturn. This is extremely dangerous. Such contact
can also seriously damage the load and transport crawler.
When transporting loads in longitudinal direction (a must when covering

long distances) it is therefore strictly forbidden to travel directly from the
horizontal into the maximum permissible longitudinal slope or vice versa.
Always use ramps especially made for this purpose.
The ascending angle of a maximum permissible uphill grade must e.g. be

compensated by two intermediate ramps. The slope angle of the first ramp
must be 1/3 and the slope angle of the second ramp must be 2/3 of the
maximum permissible slope angle.
The ramps must have a certain total length.
Centre of gravity
TR-611.eps
(2678637)
1 α°
2
1/3 α°
3
2/3 α°
14.10.98
15 m
15 m TR-616.eps
(2678670)
Transporting loads
Migrations of the centre of gravity (beyond the permissible area of the centre
of gravity display) may be caused by unfavourable ground conditions,
slopes or uphill grades and must be compensated by relocating the transport
crawler (see pages 43 and 44) and/or by inclining the lifting platform.
The following exemplary diagram (example: stacker/spreader complete)

shows the migration of the centre of gravity ξ [m] at force introduction level
(cylinder caps) as a function of the slope α [%;°] of the ground being travel-
led over.
In order to prevent the load from overturning, the cylinders from being over-
loaded and to achieve a uniform loading of the crawler track assembly, the
transport crawler has to be relocated by ξ when travelling on slopes α.
Stacker/Spreader complete
ξ [m]
[%]
α
[ ˚]
TR-600.eps
(2678625)
14.10.98
Transporting loads
2.3.4.8 Lowering the load • When the load has reached its destination, it is lowered by retracting the
lifting cylinders. This requires the switch (8) to be turned into position 2
and held there.
1
1 2
5 2 3 3 4 6
0 0 1 2 2 3
1 2 1 2 0 3 1 4
4 6 5 7
0 0 0 1
0 1 1 2 0 2
1 2 1 2 1 2
7 8 9
0 1
0
IDLE
OPERAT.
()
8
1 2
• Provided there is enough room for turning (which is not the case under
crushing stations), turn the transport crawler on the spot underneath the
load by operating the crawler drives in opposite direction until a position
is reached in which it can be safely driven from under the load.
• Use switch (7) to raise the lifting cylinders against the platform.
• Release the clamps by operating the twist switch (2). The clamping
device releases the load.
• Lower the platform and move the transport crawler from under the load.
2.3.4.9 Pulling of loads The transport crawler has two traction lugs with which loads can be pulled.
Loads may only be pulled horizontally.
Danger Do not use wire ropes as these may break and cause serious
a
accidents. Only use towbars or chains.
14.10.98
Putting the transport crawler out of operation
2.3.5 Putting the transport crawler out of operation

The transport crawler can be shut down at any time.
1 2
3 4 6
1 2 2 3
0 3 1 4
5 7
1
0 1 1 2 0 2
9
IDLE
OPERAT.
()
8
• Reduce the speed of the Diesel engine to idling speed by actuating

switch (9).
• Turn the ignition key to zero.

The actuator interrupts the fuel supply so that the Diesel engine is shut
down.
• Switch off the battery master switch and remove the switching knob.
Caution The battery master switch may only be switched off when the
a
Diesel engine is stopped.
The actuator also interrupts the supply of fuel when one of the monitoring
functions of the Diesel engine or hydraulic system has been tripped.
• Immediately press the emergency-stop button in hazardous situations.

The error message "Emergency-stop" (000) is displayed on the screen.
• Eliminate the reason for pressing the emergency-stop button and turn the
transport crawler back on (see section 2.3.2).
The switch cabinet and control panels are equipped with standstill heaters
for 115 V. If the transport crawler is shut down for a considerable amount of
time, the heaters must remain plugged to the 115 V mains. The plug-and-
14.10.98
socket connection is provided on the right-hand side of the valve cabinet.
Stacker/Spreader
2.4 Transporting special loads
2.4.1 Stacker/Spreader
– Preparations
• Note the requirements to be met for transporting the loads (see Section
2.3.4.1) and the requirements to be met with respect to the ground con-
dition (see Section 2.3.4.2).
• Before the stacker/spreader is moved, make the necessary preparations

also by consulting the operating manual of the stacker/spreader.
• Depending on the ground conditions and on the resultant vibrations, the

stacker/spreader can be transported either
– in completely assembled condition or
– partly dismantled.
Disassemble the discharge boom and remove the counterweight in
accordance with KRUPP FÖRDERTECHNIK instructions.
• Run the stacker/spreader empty. If not, the centre of gravity may shift
and cause the crawler and stacker/spreader to overturn.
• Disconnect the supply lines.
– System of co-ordinates and load co-ordinates
x - axis measured from the centre of the rear supporting feet
y - axis measured from the centre of the stacker/spreader
z - axis measured from the ground
Stacker/spreader complete
Distance of the centre of gravity (m)

Transport weight
x y z
(tons)
approx. 1166 13.692 0.078 11.612
Stacker/spreader partly dismantled

Transport weight
x y z
(tons)
approx. 954 13.561 0.096 11.089

14.10.98
50 T 1250 Transporting special loads

Stacker/Spreader
12˚
Übersicht/overview 5˚
Absetzer komplett
rt position
anspo position
ortstellung
ng
rtstellu
ort
po
normale Transp
transp
tra ns
T r
standard
max.
ma x.
X
13692
X
Z
+Y
–Y
14.10.98
11612
TR-612.eps
(2678645/1)
Transporting special loads T 1250 51

Stacker/Spreader
Übersicht/overview
Absetzer teildemontiert
Stacker/Spreader partly dismantled
12˚
5˚
port position
sportstellung
sports sition
tellung
standard trans
normale Tran
or t p o
transp
T r a n
max.
max.
X
S
13561
Z
+Y
–Y
11089
TR-613.eps
(2678645/2)
14.10.98

Stacker/Spreader
– Moving the transport crawler under the load and clamping the load
• Move the transport crawler under the centre of gravity of the stacker/
spreader using a banksman.
Danger The banksman may not stand in front of or behind the crawler
a
tracks. This is extremly dangerous!
• Position the lifting platform and clamp it to the stacker/spreader.
Clamping points 1 to 3 indicate the max. possible clamping area/the max.

possible clamping distance of the spreader. The transport crawler can be
moved/relocated and turned under the spreader between clamping points 1
to 3 to compensate for any migration of the centre of gravity when travelling
on slopes. Clamping point 2 corresponds to the calculated position of the
centre of gravity on level ground.
The clamping points have been determined by calculation. Determine exact
dimensions after finding out the exact position of the centre of gravity using
the centre of gravity display (see section 2.3.4.3).
Note: Clamping marks apply to longitudinal and transverse trans-

ports.
Clamping marks stacker/spreader (complete)
S
Clamping marks see dwg. no. 2678069 Stacker/Spreader complete

1 2 3
1750 8200
500
3055
X min. 13110 Klemmstrecke

*15440 Clamping distance
max. 17100
3500 15000 8500
14.10.98
* Genaues Maß nach Bestimmung der exakten

Schwerpunktslage mittels Schwerpunktanzeige
+Y
der Transportraupe festlegen.
X * Determine exact distance after establishing exact
position of the centre of gravity by means of the centre
of gravity display of the transport crawler.
–Y TR-620.eps
(2678678)

Stacker/Spreader
Clamping marks stacker/spreader (partly dismantled)

Clamping marks see dwg. no. 2678069 Stacker/Spreader partly dismantled
1 2 3
1750 8200
500
3055
X min. 13110 Klemmstrecke

*15311 Clamping distance
max. 17100
3500 15000 8500

Schwerpunktslage mittels Schwerpunktanzeige
+Y
der Transportraupe festlegen.
X * Determine exact distance after establishing exact
–Y TR-620A.eps
(2678678)
– Lifting, transporting, permissible inclinations
• Lift the stacker/spreader. The high lifting force level (see page 43) may
not be applied as this would affect the buckling strength of the stacker/
spreader’s load-bearing structure.
• The spreader can be transported in longitudinal direction (crawler

longitudinal axis runs parall to the longitudinal axis of the spreader) and
in transverse direction (crawler longitudinal axis is at a right angle to the
longitudinal axis of the spreader).
The permissible wind pressure during transport is 75 N/m2.
• Transport the spreader in speed range 1 or 2.
• During transport, monitor the stability using the centre of gravity display
14.10.98
and the cylinder force display on the central control panel.
• Have the banksman constantly check the distance between the load (e.g.
pontoons) and ground.

Stacker/Spreader
Centre of gravity
TR-611.eps
(2678637)
Caution If the load makes contact with the ground, the centre of gravity
a
can suddenly shift and cause the load and transport crawler to
overturn. This is extremely dangerous. Such contact can also
seriously damage the load and transport crawler.
• Migrations of the centre of gravity caused by unfavourable ground con-

ditions, major slopes or uphill grades must be compensated by relocating
the transport crawler (see pages 43 and 44) and, if necessary, by tilting
the platform.
– Centre of gravity migration diagram
The diagrams show the migrations of the centre of gravity ξ at force intro-
duction level (cylinder caps) as a function of the slope α of the ground being
travelled over. When travelling on slopes the transport crawler has to be
relocated by ξ to prevent the load from overturning, the cylinders from being
overloaded and to achieve a uniform loading of the crawler track assembly.
Migration of the centre of gravity of the stacker/spreader complete
ξ [m]
14.10.98
[%]
α
[ ˚]
TR-600A.eps
(2678625)

Stacker/Spreader
Migration of the centre of gravity of the stacker/spreader partly dismantled
Stacker/Spreader partly dismantled

ξ [m]
[%]
α
TR-601A.eps [ ˚]
(2678625)
Permissible inclinations during longitudinal and transverse transport
The maximum inclinations or slopes shown in the illustrations on the

following pages may not be exceeded during longitudinal and transverse
transport.
The resultant inclination is the mean value of the inclination towards the
longitudinal axis of the load and the inclination towards the transverse axis
of the load. Both axes can take any random position with respect to each
other.
14.10.98

Stacker/Spreader
Zulässige Neigungen Längstransport

Permissible inclinations for longitudinal transport
1. Neigung in Längsachse der Last 15% = 8,53˚; gleichzeitig Neigung in Querachse der Last 2% = 1,15˚
1. Inclination in longitudinal axis of load 15% = 8.53˚; simultaneous inclination in transverse axis of load 2% = 1.15˚
.53˚
15% = 8 2% =
1.15˚
2. Neigung in Längsachse der Last 0% = 0˚; gleichzeitig Neigung in Querachse der Last 3% = 1,72˚
2. Inclination in longitudinal axis of load 0% = 0˚; simultaneous inclination in transverse axis of load 3% = 1.72˚
3% =
TR-608A.eps 0% = 0˚
(2678628/1) 1.72˚
Zulässige Neigungen Quertransport

Permissible inclinations for transverse transport
1. Neigung in Längsachse der Last 0% = 0˚; gleichzeitig Neigung in Querachse der Last 3% = 1,72˚
1. Inclination in longitudinal axis of load 0% = 0˚; simultaneous inclination in transverse axis of load 3% = 1.72˚
3% =
0% = 0˚
1.72˚
2. Neigung in Längsachse der Last 3% = 1,72˚; gleichzeitig Neigung in Querachse der Last 0% = 0˚
2. Inclination in longitudinal axis of load 3% = 1.72˚; simultaneous inclination in transverse axis of load 0% = 0˚
14.10.98
3% = 1.72˚
TR-609A.eps
0% = 0˚
(2678628/2)

Stacker/Spreader
Zulässige Neigungen für Transport in resultierenden Neigungen/Permissible inclinations for transport in resultant gradients
ResultierendeNeigung 3% = 1,72˚/Resultant gradient 3% = 1.72˚

1. Neigung in Längsachse der Last 1,7% = 1˚; gleichzeitig Neigung in Querachse der Last 2,4% = 1,4˚
1. Inclination in longitudinal axis of load 1.7% = 1˚; simultaneous inclination in transverse axis of load 2.4% = 1.4˚
1.7% = 1˚ 2.4% =
1.4˚
Resultierende Neigung 3% = 1,72˚/Resultant gradient 3% = 1.72˚

2. Neigung in Längsachse der Last 2,4% = 1,4˚; gleichzeitig Neigung in Querachse der Last 1,7% = 1˚
2. Inclination in longitudinal axis of load 2.4% = 1.4˚; simultaneous inclination in transverse axis of load 1.7% = 1˚
.4˚
2.4% = 1 1.7% = 1˚
TR-610A.eps
(2678628/3)
Travelling on slopes
When transporting the stacker/spreader in longitudinal direction it is for-

bidden to travel directly from the horizontal into the maximum permissible
longitudinal slope or vice versa. Always use ramps especially made for this
purpose.
The ascent of max. 15% (8.53°) must be compensated by 2 intermediate

ramps with a length of 15 m each and with ascending gradients of 5% and
10%/with slope angles of 2.84° and 5.69°.
For travelling on the ramps and for interim relocations of the transport
crawler by size ξ see illustrations on the following pages.
14.10.98

Stacker/Spreader
Befahren von Neigungen - Absetzer

Travelling on slopes - spreader/stacker
Fahren in der Ebene
Fig. 1 Raupe bereits um ξ1 umgesetzt
für Fahrt in Rampe 1
Travelling on level ground

Crawler already relocated by ξ1
for travelling on ramp 1
Beginn Rampe 1 Beginn Rampe 2 Beginn 15%

ξ1 Start of ramp 1 Start of ramp 2 Start of 15% slope
Fig. 2 Fahrt in Rampe 1

Travelling on ramp 1

Start of ramp 1 Start of ramp 2 Start of 15% slope
Fahrt in Rampe 1
Raupe bereits um ξ 2 umgesetzt
Fig. 3
Crawler already relocated by ξ 2

14.10.98
Start of ramp 1 ξ2 Start of ramp 2 Start of 15% slope
TR-604.eps
(2678662/1)

Stacker/Spreader
Befahren von Neigungen - Absetzer

Travelling on slopes - spreader/stacker
Fig. 4
Fahrt in Rampe 2

Fahren in Rampe 2
Raupe bereits um ξ 3umgesetzt
Fig. 5
für Fahrt in Steigung 15%
Crawler already relocated by ξ 3
for travelling on slope 15%
Beginn Rampe 1 Beginn Rampe 2 Beginn 15% Start of 15% slope

Start of ramp 1 Start of ramp 2 ξ3
Fig. 6
Fahrt in Steigung 15%

Travelling on slope 15%
14.10.98
Beginn Rampe 2 Beginn 15%

Beginn Rampe 1
Start of ramp 2 Start of 15% slope
Start of ramp 1
TR-605.eps
(2678662/2)

Crusher No. 5
2.4.2 Crusher No. 5

– Preparations
• Do not transport crusher No. 5 unless the conversion required for moving
the transport crawler under the crusher is completed.
• Before crusher No. 5 is moved by the transport crawler, make the

necessary preparations also by consulting the crusher’s operating manual.
• Run the crusher station empty. A crusher station which is not run emtpy
has a different centre of gravity which may cause the transport crawler
with crusher to overturn.
• Remove the service trolley/erection car from the crushing station.
• Disconnect the supply lines.
• Dismount the removable braces of the crusher substructure.
• Weld the required welding plates to the clamping girders of the crushing
station.
x - axis measured from the centre of the crushing station
y - axis measured from the centre of the crushing station
z - axis measured from grond level

Transport weight
x y z
(tons)
approx. 1086 2.061 0.265 10.898
Fig. see next page

14.10.98

Crusher No. 5
Übersicht/overview
Brecher Nr.5/crusher no. 5
2061
S
5000 5000 3500 6000

10898
439
B 2500 B
700
700 3000
remove
Einfahrsituation
Entrance situation
A-A
handholes
2900 100
Z
removable
3100 3100
"Z"
3700
265
S
Detail "Z"
500
Weld. plate
200
700
14.10.98
6200
50
7100
Y
TR-625A.eps 100 4300 4300 100
(2553061)

Crusher No. 5
• Reverse the transport crawler under the centre of gravity of the crusher
using a banksman. Clearance = 3.0 m. Entry width = 8.8 m.
Danger The banksman must not stand in front of or behind the crawler
a
tracks. This is extremely dangerous!
• Position the platform and clamp it to the crusher.
Clamping point 1 is the only possible clamping point on the crusher sub-
structure. The transport crawler cannot be relocated. The clamping point was
determined in the factory. Check the actual deviation from the exact position
of the centre of gravity using the centre of gravity mask. Note the permissible
lifting forces of the cylinders (see page 39).
Caution Clamping marks only apply to transport missions in longi-
a
tudinal crusher axis direction (longitudinal transport).
Clamping marks crusher no. 5
2061 Clamping marks see dwg. no. 2678069

S
1 Nur ein Anklemmpunkt
Brechermittelachse
Only one clamping point

Crusher C/L
10898
200
700
2500
3000
Z
remove
+Y
9470
X
14.10.98
–Y TR-621.eps
(2678679)

Crusher No. 5
• Lift the crusher station.
• Only transport the crusher station in longitudinal direction, i.e. the longi-
tudinal axis of the crawler track runs parallel to the longitudinal axis of
the crusher station.
The permissible wind pressure during longitudinal transport is 250 N/m2.
• Transport the crusher station in speed range 1 or 2.
a
• On crusher No. 5, migrations of the centre of gravity caused by unfa-

vourable ground conditions, major slopes or uphill grades can only be
compensated by tilting the platform.
Neigen der Plattform/

Tilting the platform
Tr-606A.eps
Permissible inclinations during longitudinal transport
Do not exceed the maximum permissible slopes or uphill grades shown in

14.10.98
the illustrations on the opposite page during longitudinal transport.

The resultant inclination is the mean value of the inclination towards the longi-
tudinal axis of the load and the inclination towards the transverse axis of the
load. Both axes can take any random position with respect to each other.

Crusher No. 5
Längstransport Brecher Nr. 5/Longitudinal transport crusher no. 5

Zulässige Neigungen/Permissible inclinations
1. Neigung in Längsachse der Last 15% = 8,53˚;

gleichzeitig Neigung in Querachse der Last 2% = 1,15˚
1. Inclination in longitudinal axis of load 15% = 8.53˚;
simultaneous inclination in transverse axis of load 2% = 1.15˚
.53˚
15% = 8
2% = 1.15˚
2. Neigung in Längsachse der Last 0% = 0˚;

2. Inclination in longitudinal axis of load 0% = 0˚;
5% = 2,86˚
0% = 0˚
3. Resultierende Neigung 5%:

Neigung in Längsachse der Last 4% = 2,3˚;
3. Resultant gradient 5%:
Inclination in longitudinal axis of load 4% = 2.3˚;
14.10.98
˚
4% = 2.3˚ 3% = 1.72
Bei Zylinderüberlastanzeige Korrektur der Schwerpunktlage durch Neigen der Plattform.

If display indicates overload of cylinders, correct position of centre of gravity by tilting the platform
TR-606B.eps
(2678626)

Crusher No. 5
When transporting the crushing station in longitudinal direction it is for-

purpose. The ascent of max. 15% (8.53°) must be compensated by 2 inter-
mediate ramps with a length of 15 m each and with the indicated ascending
angles/slope angles.
When travelling on slopes, tilt the platform of the transport crawler so that
the migration of the centre of gravity is compensated.
When travelling on uphill or downhil grades the centre of gravity must

always be positioned on the side facing the hill.
TR-629A.eps
(2678626)
Neigen der Plattform/
Tilting the platform
8.53˚
5.69˚
2.84˚
15 m
15 m
Bergabtransport/ Bergauftransport/
Downhill transport Uphill transport
14.10.98
tung/
tung/
Fahrtrich irection Fahrtrich irection
gd
Travell in gd Travellin

Crusher Nos. 6/8
2.4.3 Crusher Nos. 6/8

– Preparations
• Run the crushing station empty and clean.
• Restrictions with respect to the transport weight require parts of the

crusher (cap, spider/crossbeam, crusher axle) to be dismounted.
• For preparations to be made prior to transport refer to the operating

manual of crusher 6 or 8 (Book 1, section 3.2).
x - axis measured from the outer edge of the rear pontoon
y - axis measured from the centre of the crusher station
z - axis measured from ground level

Transport weight
x y z
(tons)
approx. 1375 2.216 0.213 11.276
Fig. see next page

14.10.98

Crusher Nos. 6/8
Übersicht/overview
Brecher Nr.6/8; crusher no. 6/8
Z
1700
2216
S
5500 5500 3500 6000
7526
11276
4150
B B
350 800
4150
X
700
3400 3400
"Z" A-A
800
Z
350
3700
3400 bis Mitte Brechstation

to centre line crusher
3340 bis Mitte Transportraupe
to centre line transport crawler
Detail "Z" 213
S
350
50
to ground level concrete
6800
to ground level sand
3340 3340
3350 bis Planum Beton
3275 bis Planum Sand
Entrance height
3000 Einfahrhöhe
7080 Außenkante Klemmflansch

Outer edge of clamping flange
14.10.98
2400
Y
8600
12000
TR-627A.eps
(2677617)

Crusher Nos. 6/8
• Reverse the transport crawler under the centre of gravity of the crusher
using a banksman.
Danger The banksman must not stand in front of or behind the crawler
a
tracks. This is extremely dangerous!
• Position the platform and clamp it to the crusher.

Clamping points 1 to 3 indicate the max. possible clamping area of the
crusher. The transport crawler can be relocated between these clamping
points to compensate for any migration of the centre of gravity when travel-
ling on slopes. Clamping point 2 corresponds to the calculated position of
the centre of gravity on level ground. The clamping points have been deter-
mined by calculation. Determine dimensions after finding out the exact
position of the centre of gravity using the centre of gravity display (see
section 2.3.4.3).
Caution Clamping marks only apply to transport missions in longi-
a
tudinal crusher axis direction (longitudinal transport).
Clamping marks crusher nos. 6/8

Brechermittelachse
2216
S
Crusher C/L
1 2 3
Clamping marks see dwg. no. 2678069
11276
4150
350
50
Klemmstrecke
Clamping
distance
min. 7240

*9016 Schwerpunktslage mittels Schwerpunktanzeige
max. 10310 der Transportraupe festlegen.

* Determine exact distance after establishing exact
14.10.98

TR-622.eps
(2678680)

Crusher Nos. 6/8
• Lift the crusher. Activate the high lifting force level (see page 43) if
necessary.
• Only transport the crusher station in longitudinal direction (i.e. the longi-
tudinal axis of the crawler track runs parallel to the longitudinal axis of
the crusher station).
The permissible wind pressure during longitudinal transport is 250 N/m2.
• Transport the crusher in speed range 1 or 2.
a
• Migrations of the centre of gravity caused by unfavourable ground con-

ditions, major slopes or uphill grades must be compensated by relocating
the transport crawler (see pages 43 and 44) and, if necessary, by tilting
the platform.
Neigen der Plattform/Tilting the platform
TR-607A.eps
(2678627)
14.10.98

Crusher Nos. 6/8
– Centre of gravity migration diagram
The diagram shows the migration of the centre of gravity ξ [m] at force intro-
duction level (cylinder caps) as a function of the slope α [%;°] of the ground
being travelled over.
For travelling on slopes the transport crawler has to be relocated by ξ to
prevent the load from overturning, the cylinders from being overloaded and
to achieve a uniform loading of the crawler track assembly.
Crusher No. 6/8

ξ [m]
[%]
α
[ ˚]
TR-602.eps
(2678625)
Permissible inclinations during longitudinal transport
Do not exceed the maximum permissible slopes or uphill grades shown in

the illustration on the following page during longitudinal transport.
The resultant inclination is the mean value of the inclination towards the longi-
tudinal axis of the load and the inclination towards the transverse axis of the
load. Both axes can take any random position with respect to each other.
When transporting the crushing station in longitudinal direction it is for-

purpose.
The ascent of max. 15% (8.53°) must be compensated by 2 intermediate
ramps with a length of 15 m each and with ascending gradients of 5% and
10%/with slope angles of 2.84° and 5.69°.
14.10.98
Travelling on slopes and interim reloactions of the transport crawler see illu-
strations on pages 73 and 74.
Before travelling on major inclinations make sure that the larger clamping
area (distance to clamping point 1 or 3) as seen from clamping mark 2
faces the downhill side.

Crusher Nos. 6/8
Längstransport Brecher Nr. 6/8/Longitudinal transport crusher no. 6/8 TR-607B.eps

(2678627)
Zulässige Neigungen/Permissible inclinations
1. Neigung in Längsachse der Last 15% = 8,53˚;

1. Inclination in longitudinal axis of load 15% = 8.53˚;
.53˚
15% = 8 2% = 1.15˚
2. Neigung in Längsachse der Last 0% = 0˚;

2. Inclination in longitudinal axis of load 0% = 0˚;
5% = 2.86˚
0% = 0˚
3. Resultierende Neigung 5%:

Neigung in Längsachse der Last 4% = 2,3˚;
3. Resultant gradient 5%:
Incclination in longitudinal axis of load 4% = 2.3˚;
14.10.98
˚
3% = 1.72
4% = 2.3˚
Bei Zylinderüberlastanzeige Korrektur der Schwerpunktlage

durch Umsetzen und Neigen der Plattform
If display indicates overload of cylinders, correct position of centre of gravity
by relocating and tilting the platform

Crusher Nos. 6/8
Befahren von Neigungen - Brecher Nr. 6/8

Travelling on slopes - crusher no. 6/8
Fahren in der Ebene
Fig. 1 Raupe bereits um ξ1 umgesetzt
Travelling on level ground

ξ1
Fig. 2
Fahrt in Rampe 1

Fig. 3
Fahren in Rampe 1
Raupe bereits um ξ2 umgesetzt
14.10.98

TR-614.eps
ξ2
(2678651/1)

Crusher Nos. 6/8
Befahren von Neigungen - Brecher Nr. 6/8

Travelling on slopes - crusher no. 6/8
Fig. 4
Fahren in Rampe 2

Fig. 5
Fahren in Rampe 2
Raupe bereits um ξ3 umgesetzt
für Fahrt in Steigung 15%
for travelling on slope 15%

Beginn Rampe 1
Start of ramp 2 Start of 15% slope
Start of ramp 1 ξ3
Fig. 6
Fahrt in Steigung 15%

Travelling on slope 15%
14.10.98

Start of ramp 2 Start of 15% slope TR-615.eps
(2678651/2)

Transporting random loads
2.4.4 Transporting random loads

The general requirements for transporting a load (see Sections 2.3.4.1 and
2.3.4.2) must be met and/or observed.
Loads living up to the following standards can be transported with the trans-
port crawler:
– Max. weight of 1250 tons with a max. height of the centre of gravity of
11 m.
– Max. horizontal force acting on the centre column is 3900 kN.
Do not transport loads exceeding the above standards without consulting

KRUPP FÖRDERTECHNIK first (see Section 1.1).
14.10.98

Fault/error messages
2.5 Malfunctions
2.5.1 Fault/error messages

– Error messages
The following fault/error messages are displayed on the screen masks (see
Section 2.2.4).
Error No. Text
000 Emergency off
001 Hydraulic oil level < min (trip)
002 Left crawler feeding pressure < min

003 Right crawler feeding pressure <min
004 Hydraulic suction line valve closed
005 Hydraulic oil temperature > max

006 Diesel engine overspeed
007 Diesel engine too slow for travel

008 Diesel engine speed transmitter fault
009 Mini circuit breaker tripped
010 Crawler tension < min
011 Crawler tension pressure transmitter fault
012 Hoist cylinder pressure transmitter fault

013 Hoist circuit filter clogged
014 Tilting edge reached
015 Return filter clogged
016 Feeding circuit filter clogged
017 Fuel level < min

018 Hydraulic oil level < min
019 Lubrication fault
020 Devicenet 1 control desk trouble
021 Devicenet 2 hydraulic panel trouble
022 Fuel level gauge fault
023 Hydraulic oil temperature gauge fault
024 Hydraulic oil level gauge fault

14.10.98
An error is displayed in the message display field and a buzzer (7) is

activated.
The transport crawler is automatically shut down/has to be shut down
depending on the fault/error.
Press the reset button (4) to acknowledge the error and to silence the buzzer.
76 T 1250 Malfunctions
Check the error display mask for any pending messages.

Have the fault/malfunction eliminated.
The message is deleted from the error display mask.
– Warning lamps of the multi-task display
Malfunctions of the Diesel engine are displayed on the warning and status
display field (2) of the multi-task display (1) (also refer to Section 2.2.1.1).
2 1
20 21 22 23
3
0 1 0 1
24
4
0 TOUCH
0
12 8 16 18 10 14
0 0
1 2 KN KN 1 2
13 9 17 19 11 15
Warning lamp Causes and measures taken
Battery charging lamp Malfunction of generator.

(9) Eliminate malfunction.
Oil pressure too low Possible oil leaks. Shut down engine, check oil
14.10.98
(10) level, top up oil.

Coolant temperture too Engine overheated. Shut down all drives (lifting
high (8) gear, crawler track assembly).
Coolant level too low Possible leaks. Shut down engine, top up
(11) coolant.
Malfunctions T 1250 77
– Warning lamps on central control panel
The following warning lamps on the central control panel will flash when the
max. pressure in the lifting cylinders is reached:
– max. pressure front LH cylinder (12)
– max. pressure rear LH cylinder (13)
– max. pressure front RH cylinder (14)
– max. pressure rear RH cylinder (15)
When maximum pressures are reached, reduce the pressures (i.e. lower
the load).
The warning lamps can be checked by pressing the lamp test button (3).
14.10.98
Faults in the hydraulic system - causes and remedies
2.5.2 Faults in the hydraulic system - causes and remedies

– Loud noises
Fault Cause Remedy
Directional control valves - defective Spool is stuck (soiled) Check by manual operation, clean
control causing restrictions
Defective solenoid Replace solenoid
Pressure relief valves vibrate Faulty pressure setting or air Check pressure setting, bleed air
inclusions from system
Faulty pump drive or damaged seals Wear, air is sucked in Replace pump or seals
– No or insufficient delivery
Fault Cause Remedy
Directional control valve - inaccurate Spool is stuck (soiled) Check by manual operation, clean
spool position
Defective solenoid Replace solenoid
Restrictor closed or clogged Flow cross section of restrictor is too Check by increasing flow cross
small section, clean
Pressure relief valve does not hold Faulty setting Correct setting
specified pressure
Valve seat damaged or stuck (soiled) Replace valve
Internal cylinder leaks Worn seals (wear caused by dirt) replace seals
Insufficient pump delivery Major internal pump leaks (wear Replace pump
caused by dirt)
– No or insufficient pressure
Fault Cause Remedy
Faulty spool position of directional Mechanically stuck Check by manual operation

control valves
Broken reset spring Replace valve
Pressure relief valve does not hold Faulty setting Correct setting
specified pressure
Valve seat damaged or stuck Replace valve
(soiled), broken spring
Pump does not produce specified Excessive internal leaks (wear Damaged pump drive
pressure caused by dirt)
14.10.98
Cylinder pressure is not built up Internal or external leaks (wear Replace seals
caused by dirt)
Malfunctions T 1250 79
Faults in the hydraulic system - causes and remedies
– Fluctuating pressure or flow
Fault Cause Remedy
Jerky cylinder movements Air not or improperly bled from Bleed air from cylinder
cylinder
Defective seals, stick-slip effect Replace seals
Pressure relief valves vibrate Faulty pressure setting Check pressure setting
Damaged valve seat Replace valve
Air inclusions Bleed air from system
Foam or air inclusions in fluid Pressure fluid level in reservoir is too Check oil level
low
– Cylinders do not maintain position
Fault Cause Remedy
Leaky seals and valves Shut-off valves or secondary pressure Check valves and replace if
relief valves are worn or soiled necessary
Worn cylinder seals Replace seals
– Other hydraulic system faults
Fault Cause Remedy
Return line filter clogging indicator A return line filter of the hydraulic Change over to stand-by unit.
power unit is clogged Replace clogged filter element
Indicator for hydraulic oil level too The level in the hydraulic oil Top up hydraulic oil (check system
low reservoir has dropped below for leaks)
minimum
Rectifying/eliminating faults/malfunctions in the hydraulic system requires

the hydraulic circuit diagram to be consulted. Hydraulic systems offen react
differently to faults/malfunctions. It is important to find out at what time,
under which circumstances and how often a fault/malfunction occurs:
– already after a short operating time,
– at regular intervals,
– after a long trouble-free operation.

14.10.98
Note Whenever a fault/malfunction occurs, first check if pressure is

built up.
Servicing instructions
2.6 Servicing
2.6.1 Servicing instructions

Detailed instructions relating to servicing and repair work to be carried out
on the transport crawler are included in the operating and maintenance
instructions.
Operational safety, trouble-free operation and service life of the transport

crawler depend on proper handling, cleaning, inspection and servicing.
• Check the operation, lubrication and wear of the transport crawler at the
stipulated intervals. Replace/repair all damaged/worn components (or
have them replaced/repaired).
• Have all control and monitoring equipment checked for proper operation
by qualified electricians at regular intervals.
• Note the applicable safety instructions whenever servicing work is
carried out.
• Do not clean, inspect and service the equipment unless the transport
crawler is shut down and secured against inadvertent starting (e.g. by
removing the battery master switch).
• Do not loosen or tighten up fittings of the hydraulic system as long as the
system is under pressure.
• Start the transport crawler once a week, run the Diesel engine and
hydraulic system up to operating temperarure and check all functions.
• Put all guards and safety devices back in place once servicing work
is completed and check their electrical, hydraulical and mechanical
functions.
– Notes on cleaning
Danger Do not clean the transport crawler unless it is shut down.
a
Clean the transport crawler after each transport mission.
• Close/tape up all openings into which water, steam and detergents

should not be allowed to penetrate for safety and operational reasons.
• Always wear a safety mask when carrying out cleaning work with high-
pressure or steam jet cleaning equipment.
• Do not use agressive detergents/caustic solutions.
• Never direct the spray jet at electrical devices, relays and switch
cabinets, intake and breather filters or greased surfaces.
• Thoroughly clean the cooler once a week. Soiled coolers prevent the heat
of the Diesel engine, pump distributor gear and hydraulic system from
14.10.98
being properly dissipated. This will cause frequent shutdowns due to

excessive oil temperature levels. The hydraulic oil ages prematurely.
The hydraulic components wear down much faster.
• Remove material caking to the crawler track support rails.
Servicing T 1250 81
Servicing instructions
– Notes on lubrication
• Keep the central lubrication system absolutely clean and use only clean
lubricants for topping up (lubricant quality see maintenance mask).
• Check the operation of the central lubricating system including grease

distributors. Lubrication points must have a fresh collar of grease.
• When changing oil, only use the oil grades/brands indicated in the
maintenance mask.
• Avoid contact between electrical equipment and grease.
14.10.98
82 T 1250 Servicing
Servicing table
2.6.2 Servicing table

This section shows all inspections and servicing work required to be
carried out on the transport crawler in tabular form. Servicing work has to
be carried out at definite servicing intervals. Servicing intervals are defined
periods of time or a defined number of operating hours. The transport
crawler has to be serviced at defined periods. The periods in which the
transport crawler is not in operation should also be used for servicing.
The following table includes the principal servicing intervals and the abbre-
viations used for these in the servicing table (D = daily, W = weekly and
M = monthly).
Servicing interval Servicing interval Number of operating

abbreviation hours (oh)
D daily or before starting up

the crawler
W weekly
M1 monthly
M3 every 3 months (quarterly)

M6 every 6 months (halfyearly)
M12 every 12 months (annually)
The servicing intervals represent sugggestions and recommendations of

KRUPP FÖRDERTECHNIK. However, the frequency with which servicing
work should be carried out depends on the particular operating conditions
prevailing at the site, such as duration of operations, operating state and
wear.
For this reason the operating conditions under which the transport crawler
is being used are to be observed and taken into account. It may prove
necessary to change or adapt the servicing intervals over the course of time.
The following servicing table contains:
– the inspections/servicing work to be carried out on the transport crawler

in brief form,
– the quantities of lubricant (grease/oil);
– the designation of lubricants, the levels of which must be checked, which

must be topped up, with which lubrication should be carried out or which
should be changed;
– black dots indicating the applicable servicing intervals (D to M12), upon

expiry of which the servicing work in question should be carried out. The
longer servicing intervals always include the shorter ones. In other words
an item of servicing that should be carried out every day will also always
14.10.98
be part of the weekly, monthly, 3-monthly, 6-monthly and 12-monthly

servicing routines in as far as these servicing intervals are marked with a
dot in the table.
Servicing T 1250 83
Servicing table
Assembly group: Oil/lubricant: Servicing interval:
related inspection/servicing work Qty. Desig- D W M1 M3 M6 M12

nation
Crawler track assembly:
• Check oil level of travel gear units and check them 500 l ISO VG 220 • • • • • •
for leaks
• Check tensioning strokes of track tensioning system • • • • • •
• Check that there is a grease collar on the labyrinth • • • • • •

ring on the output end of the travel gear unit
• Check air bleeder valve of travel gear unit for • • • • • •

soiling
• Check that there is a grease collar on the • • • • •

lubricating points of the crawler track assembly
(see page 28)
• Check supporting rails for soiling • • • • •
• Check that the external bolted connections of the • • • •

travel gear unit are complete and have a tight fit
• Check supporting rails for wear • • • •
• Take an oil sample of the travel gear unit and ISO VG 220 • •
have it analysed by the oil producing company
• Drain leakage oil from the holding brakes • •
• Check bolted connections and wear of disks of the • •

holding brakes
• Check that bolted connections of the structure are • •

complete and have a tight fit
• Change the oil of the travel gear unit 500 litres ISO VG 220 •
14.10.98
Component bed:
• Visually check the Diesel engine for leaks and • • • • • •

loose fittings
84 T 1250 Servicing
Servicing table

nation
• Check the oil level of the Diesel engine 46 litres SAE 15W-40 • • • • • •
• Check the water level in the cooler compensating 146 litres • • • • • •

reservoir of the Diesel engine
• Check the intake filter of the Diesel engine. If the • • • • • •

signal lamp lights up: change the filter cartridge
• Check the oil level of the pump distributor gear 11 litres ISO VG 100 • • • • • •
and check for leaks
• Check the air bleeder valve of the pump distributor • • • • • •

gear for soiling
• Check operation of the central lubrication system • • • • • •

and check for leaks
• Check the grease level in the reservoir of the 150 litres Mobilux EP2 • • • • • •
central lubrication system
• Check the operation of the grease distributor • • • • • •
• Check the lubricating pressure • • • • • •
• Clean the combination cooler • • • • •
• Check the coupling of the lubrication pump for • • • • •

wear
• Check the external bolted connections on the • • • •

pump distributor gear
• Carry out additional servicing work on the Diesel • • •

engine in accordance with the Caterpillar
servicing schedule
• Take an oil sample from the pump distributor ISO VG 100 • •

gear and have it analysed by the oil producing
14.10.98
company
• Clean the filter of the central lubrication system • •
Servicing T 1250 85
Servicing table

nation
• Change the oil of the pump distributor gear 11 litres ISO VG 100 •
• Change the oil in the gear unit of the central •

lubrication pump
Lifting platform:
• Check the rubber lining on the lifting platform for • •

wear and check that it fits tightly
Hydraulic system:
• Check the oil level in the hydraulic reservoir 2600 litres Mobil • • • • • •
DTE 24/
DTE 15M
• Check the hydraulic system for leaks and loose • • • • • •

fittings
• Check the condition of the hydraulic hoses • • • • • •
• Drain condensation water from the hydraulic oil • • • • •

reservoir
• Check that the valve plug fits tightly, carry out a • • • •

lamp test
• Check the gas filling pressure in the hydraulic • • •

accumulator of the track tensioning device
• Take an oil sample from the hydraulic system and Mobil • •

have it analysed by the oil producing company DTE 24/
DTE 15M
• Check valve settings • •
• Check the hydraulic accumulator and check that it • •

is firmly attached
14.10.98
• Check the rotation joint and cylinder seals for leaks •
86 T 1250 Servicing
Servicing table

nation
• Change the hydraulic oil 2600 litres Mobil •

DTE 24/
DTE 15M
Electrical equipment and safety devices:
• Check the state of charge of the batteries, • • • • • •

recharge if necessary
• Test the lights/lamps • • • • • •
• Check the operation of the safety devices • • • •
• Use dry compressed air to blow out operating • • •

panels and switch cabinet
• Check contact points, tighten up terminal screws • •
• Check that plug-and-socket connections have a • •

tight fit
• Check electrical equipment for mechanical damage • •
• Check that fire extinguishers are complete and • •

ready to be used
Steel structure:
• Check steel structure and paintwork for damage •* •
• Check that bolted HSFG connections of the steel •

structure have a tight fit
* In the course of the first 6 months following initial start-up the structural steel
parts have to be inspected once a month. Later, the supporting structure
14.10.98
must be checked once a year.
Servicing T 1250 87
Servicing table
Blank page
14.10.98
88 T 1250 Servicing

Crawler Manual 1

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Crawler Manual 1

Uploaded by

Copyright:

Available Formats

Operating Manual

Transport Crawler T 1250

Order No. 84/236 430

Krupp Fördertechnik GmbH

Altendorfer Straße 120 – D - 45143 Essen

1.1 Application and designated use . . . . . . . . . . . . . . . . . . . . . 2

1.2 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3.1 Permissible transport loads, forces, inclinations . . . . . . . . . . . 9

1.3.2 Dimensions, main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3.3 Drive components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4.1 Safety instructions relating to operation. . . . . . . . . . . . . . . . . 13

1.4.2 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.1 Operator qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.2 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Display and control panels . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2.1 Central display and control panel . . . . . . . . . . . . . . . . . . . . . 18

2.2.3 Right-hand control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.2.4 Screen displays and signals . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3.1 Measures to be taken prior to start-up. . . . . . . . . . . . . . . . . . 28

2.3.2 Putting the transport crawler into operation. . . . . . . . . . . . . . 29

2.3.4 Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3.5 Putting the transport crawler out of operation . . . . . . . . . . . . 49

2.4 Transporting special loads . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.4.4 Transporting random loads . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.5.1 Fault/error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.6.1 Servicing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

This manual should always be available in the driver’s cab.

The importance of particular information included in the manual is high-

Danger This draws attention to hazards which arise in connection with

Caution This draws attention to hazards which arise in connection

right = on the right-hand side looking in transport direction

left = on the left-hand side looking in transport direction

• = operating instructions (in stated order)

1.1 Application and designated use

1.2 Design and operation

(16), driver’s cab (3), electrical equipment and central lubrication

2 T 1250 Application and designated use

Design and operation T 1250 3

All functions of the transport crawler are powered hydraulically.

The hydraulic system drives the following individual systems:

– crawler drives for travelling forwards and for reversing

– lifting gear for lifting and lowering the lifting platform

– clamps securing the load on the lifting platform

– slewing gear for positioning the lifting platform

– crawler track tensioning devices

– pump of the central lubrication system

– emergency off (error message 000)

– hydraulic oil level too low (001)

– hydraulic suction line valve closed (004)

4 T 1250 Design and operation

Design and operation T 1250 5

6 T 1250 Design and operation

– Crawler track tensioning device

Retracting and extending the tensioning cylinders is controlled by the directio-

A pressure sensor measures the pressure inside the tensioning cylinders. If

– Pump of the central lubrication system

The pump of the central grease lubrication system is driven by an axial

– Control of lifting and auxiliary circuit

If the directional control valve is not tripped, i.e.

If the directional control valve is tripped, i.e.

– for slackening the crawler tracks,