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UEBHERR
VOLUME
1
OPERATING
MANUAL
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VOLUME 1
OPERATING MANUAL
TYPE
CBW 45(40)/26,5(29,5)
SERIAL NUMBER
162 600
VERSION
001 -30.11.2006
IM O N U M B E I f f l l
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INDEX
INDEX-VOLUME 1
1.
INTRODUCTION 1.3
1.1.
FOREWORD 1.4
1.2. USING THE DOCUMENTATION 1.5
1.3. MACHINE'S PASSPORT 1.7
2. PRODUCT DESCRIPTION 2.3
2.1. GENERAL 2.3
2.2. GENERAL ARRANGEMENT 2.4
2.3.
TECHNICAL DATA 2.10
3. SAFETY GUIDELINE 3.3
3.1. GENERAL 3.3
3.2. UTILIZATION AS DIRECTED 3.5
3.3. AREAS OF RESPONSIBILITY 3.6
3.4. PERSONAL REQUIREMENTS OF THE CRANE OPERATOR 3.7
3.5. PERSONAL PROTECTIVE GEAR 3.8
3.6. WORK AREA 3.9
3.7. SAFETY AND MONITORING DEVICES 3.9
3.8. SAFETY SIGNS ON THE MACHINE 3.10
3.9. MACHINE SPECIFIC DANGERS 3.14
3.10.
ADDITIONAL DANGERS 3.17
3.11. NOTES ON SAFETY FOR THE MACHINE OPERATOR 3.20
3.12. NOTES ON SAFETY FOR THE BUILDING-S ITE PERSONAL 3.20
4. CONTROL AND OPERATING ELEMENTS 4.3
4.1. GENERAL 4.3
4.2. LAYOUT OF THE OPERATOR'S CONTROLSTAND 4.3
4.3. CONTROL LEVER 4.4
4.4.
CONTROL PANELS 4.5
4.5.
SWITCH CABINET 4.10
5. CRANE OPERATION 5.3
5.1. GENERAL 5.3
5.2. CHECKS BEFORE DAILY START UP 5.7
5.3. DAILY STA RT-UP 5.8
5.4. START/STOP FOR A WORK BREAK 5.11
5.5. SHUT DOWN THE CRANE 5.13
5.6. CRANE OPERATION 5.16
5.7. ADDITIONALLY OPERATIONS 5.17
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INDEX
6. EMERGENCY OPERATION 6.3
6.1. GENERAL 6.3
6.2. ARRANGEMENT OF EMERGENCY DEVICES 6.3
6.3. EMERGENCY HAND PUMP 6.4
6.4. PROCEDURE TO LOWER THE LOAD 6.5
6.5. PROCEDURE TO RELEASE THE SLEWING BRAKES 6.5
6.6. PROCEDURE TO LOWER THE BOOM 6.6
7. MAINTENANCE 7.3
7.1. QUALIFIED PERSONS 7.3
7.2. SERVICE SPARE-PARTS AND STANDARD TOOLS 7.4
7.3. MAINTENANCE INTERVALS 7.5
7.4. ELECTRIC MOTOR 7.14
7.5. GEARBOXES 7.16
7.6. MULTIPLE DISC BRAKES 7.19
7.7. CRANE ROPES 7.20
7.8. ROPE PULLEYS 7.24
7.9. HYDRAULIC LINES AND HOSES 7.27
7.10. HYDRAULIC OIL TANK 7.28
7.11.
LIEBHERR CONDITION MONITORING 7.32
7.12. PRESSURE ACCUMULATORS 7.37
7.13. MAINTENANCE OF OIL COOLERS 7.37
7.14. ELECTRICAL SYSTEM 7.38
7.15. SLIP RING UNIT 7.39
7.16.AIR CONDITION SYSTEM 7.40
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INTRODUCTION
INDEX
1. INTRODUCTION 1.3
1.1.
FOREWORD 1.4
1.2. USING THE DOCUMENTATION 1.5
1.2.1.
STORING THE DOCUMENTATION 1.5
1.2.2.
HOW IS THE OPERATING MANUAL IN VOLUME 1 COMPILED 1.6
1.2.3.
COMPUTER SYSTEM REQUIREMENTS TO USE THE CD-ROMS 1.6
1.2.4.
CURR ENT STATUS OF THE DOCUMENTATION 1.6
1.3. MACHINE'S PASSPORT 1.7
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INTRODUCTION
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IN TR OD U C TION
1.
INTRODUCTION
On our own behalf
The Liebherr name does not only represent products and performances, but has also become synonymous
with ideas and innovations. For progress that has already been proven in the market.
We are continuously expand ing and improving our already wide range of technical products and perform ances
with great vigor. For this reason, constant collaborat ion and swap ping of experiences w ith our custome rs and
business partners throughout the world is a prerequisite.
We are therefore grateful for all proposals and every improvement suggested.
Please contact:
L IEB H ER R - WER K N EN ZIN G GMB H
P.O. 10,
Dr. Hans Liebherr Strasse 1
A-6710Nenz ing
Austria / Europe
Telephone : +43 5525 606-0
Fax: +43 5525 606-44 5
Email: [email protected]
The documentat ion for this crane was compiled to customer specif icat ions.
After-sales service should therefore be informed if the machine
• is to be sold on ,
• was purchased from a previous owner.
Copyright notice
The documentat ion is protected by copyright. The documentat ion may not be duplicated, reproduced, micro
f i lmed, t ranslated or conve rted for storage an d processing in com pute rsys tem s, either wholly or part ially, wi th
out the wr i t ten consent of LIEBHERR-WERK NENZING GMBH.
© 2006 Copyright by
LIEBHERR-WERK NENZING GMBH
A-6710 Nenzing
All rights reserved
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IN TR OD U C TION
1.1.
FOREWORD
The CBW Standard cargo deck crane is the result of vast experience as well as continuous research and
development for the benefit and success of our customers and is provided with the following features:
- low height and low centre of gravity
- maintenance free hydraulic luff ing cylinders
- f irmly supported boom at all angles due to double act ing cylinders
- hydraulic load sensing control system
- continuously variable speed control from zero to maximum speed
- operat ion of all 3 motions simultaneously
- automatic power regulator for hoist ing gear
- components and completed crane tested and proven for extreme condit ions and performance
- designed with focus on low maintenance and l ifecycle costs
- preventat ive maintenance arrangements
- delivered with comprehensive instruct ion books and manuals
These features and LIEBHER R's unique design make the high performance
CBW standard cargo deck crane the perfect solut ion for the following applicat ions:
- general cargo handling, e.g., on r iver / sea vessels, t imber carriers
- fast container and pallet handling on reefer vessels
- break bulk, container and project cargo handling on mult i purpose vessels
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IN TR OD U C TION
1.2.
USING THE DOCUMENTATION
The documentat ion for the machine should enable you to,
• safely operate it,
• use it comp etently for all permitted ap plicat ions,
• maintain it regularly.
This means you have to be able to navigate your way through this mult iple chapter documentat ion:
o
the operat ing manual consists of volume 1
Volume 1 - Operat ing manual
This volume contains information for start-up, operat ion and maintenance.
o The technical documentat ion for the maintenance and service personnel are in volume 2 and volume 3.
Volume 2 - Technical Information
Information concerning the electr ical and hydraulics systems of the machine can be found
here.
Volume 3 - Spare parts catalogue
This book contains information for the provision of spare parts.
o
The com plete documentat ion f rom volume 1 to 3 is stored on CD-R OM .
O
CD-ROM - Documentat ion (optional)
This CD-ROM contains
volume 1 and 2 stored as PDF-f i les,
volume 3 as HTML-version with easy search and order funct ions.
Pr inted on each CD-ROM
• the crane type,
• the machine's serial number,
• all available languages,
• the vers ion number of the CD-R OM .
1.2.1.
STOR IN G TH E D OC U MEN TA TION
Volumen 1+2 "Operat ing manual" and "Technical information" are to be on hand in the operator's cab.
Volume 3 "Spare parts catalogue" must be available to the maintenance and service personnel.
The CD-ROM should be kept in the off ice and should be used for ordering spare parts.
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INTRODUCTION
1.2.2 . HOW IS THE OPER ATING MANUAL IN VOL UME 1 COM PILED
The operat ing manual consists of individual continuously numbered chapters. These chapters are arranged
in the yellow register of the bo und f i le.
A summary of the chapter at the beginning of the operat ing manual enables a rapid orientat ion. The subse
quent l ist of contents gives information about the compilat ion of the individual chapters.
At the beginning of the following chapters under "General" you wil l f ind a short descript ion of content.
Page numbers contains the current chapter number as a pref ix.
For example page "-2.10-" designates the tenth page of chapter two "Product descript ion".
1 .2.3 . COM PUTER SYST EM REQUIREM ENTS TO USE THE CD-ROM S
Hardware:
• At least an Intel(r) Pentium(r) or equivalent processor
• 32 MB RAM-working memory or more
• CD-ROM-dr ive
• At least 16 Bit-graphic card with 256 colors and a resolut ion of 800 x 600 (1024 x 768 reco mm ende d)
Sof tware:
• WIN9x operat ing system or newer
• Optional:
Internet Explorer 4.01 or newer version
• Acrobat Reader 4.0 or newer version
• ISOView, installed from CD-ROM
o : ^
IMPOR TA N T
For the optional funct ions of the spare parts catalogue to work, special safety sett ings m ust be mad e
in the Internet Explorer: Act ive Script ing must be act ivated.
1.2.4. C U R R EN T STA TU S OF TH E D OC U MEN TA TION
The documentat ion delivered is specially compiled for the machine indicated in the machine's passport and
is therefore not transferable to other machines from the same range.
In order that the documentat ion is always complete and up-to-date
• do not remove individual pages,
• replace unreadable pages by repr int ing them f rom the CD-R OM ,
• imme diately insert the new pages that are delivered after modif icat ion work or upgrades
• always replace modif ied documents and eliminate the invalid documents exchange,
• always replace old CD -RO Ms against the newer versions e.g. delivered along with modif icat ions
(dispose of old CD -ROM s),
• With mult i l ingual documents, always update all languages.
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INTRODUCTION
1.3. MACHINE'S PASSPORT
The name plate is arranged on the operator's cabin door
Please write into the space below
- the identification number (serial number),
- the year it was built,
- the date of its first start-up.
Serial / Order no.:
Type:
Year built:
First start-up(day/m onth /year):
This information is required for e.g. ordering spare parts.
W E R K N E N Z I N G G m b H
A-67t0 Henzinq. P.O.Box 10. Aus tria / Eurooe
Tel . 0Oi3 /5S25/606-0 . Te le foi 00 i3 /552S/M6-2O
E - n o i l : i n lo t l v n . l i e b h e r r . c o a
Baujahr
Year
of
nanufaclure
A n n é e de conslruclion
Bourtumer
Serial No.
No de cort-
slruclion
o
Erste Inbetrieb-
nalnie
Year or first coi-
nissioning
Année de 1. nise
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INTRODUCTION
As delivered this machine is fitted with the following options marked by the [x]:
[X] 45 t Main hoist system
[ ] 10 t Auxiliary hoist system
[X] Hook Block Parking System Main Hoist
[ ] Hook Block Parking System Auxiliary Hoist
[ ] Slew interlock system
[ ] Sector limitation system
[X] Flood lights slewing column
[X] Flood lights boom
[ ] Helicopter warning l ight slewing column
[X] Helicopter warning l ight boom
[ ] MIPEG load indicat ion
[ ] Mechanical boom angle indicat ion
[X] Air condition
[ ]
[ ]
Proof of origin
This Liebherr crane was designed by LIEBHERR-WERK NENZING GMBH in Austria and manufactured in
LIEBHERR-SUNDERLAND WORKS, England.
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PRODUCT DESCRIPTION
INDEX
2.
PRODUCT DESCRIPTION 2.3
2.1. GENERAL 2.3
2.1.1.
CORRECT USAGE OF CRANE 2.3
2.1.2. INCORRECT USAGE OF CRANE 2.3
2.1.3. LIMITS OF THE OPERATIONAL AREA 2.3
2.2.
GENERAL ARRANGEMENT 2.4
2.2.1.
MAIN PARTS OF THE CRANE 2.4
2.2.2. SLEWING COLUMN 2.5
2.2.3. MACHINERY ROOM 2.6
2.2.4. POWER PACK 2.7
2.2.5. CABIN 2.8
2.2.6. BOOM 2.9
2.3.
TECHNICAL DATA 2.10
2.3.1.
PROOF OF ORIGIN 2.10
2.3.2. DESIGN COND ITIONS 2.10
2.3.3. WORKING RANGE 2.10
2.3.4. PERMISSIBLE CAPACITIES / SPEEDS 2.10
2.3.5. ELECTRIC POWER SUPPLY 2.10
2.3.6. WEIGHT 2.11
2.3.7. LOAD DIAGRAM 2.11
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PRODUCT DESCRIPTION
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PRODUCT DESCRIPTION
2. PRODUCT DESCRIPTION
2.1.
GENERAL
This chapter
- gives information about the machine application possibilit ies and warns against incorrect or improper use,
- describes assembly and the main components,
- gives important technical data.
f | - ^
NOTE
The illustrations in the product description serve only to give general information and
do not necessarily correspond with the actual sett ing-up stage of the machine.
2 .1 .1 . CORRECT USAGE OF CRANE
The crane is fixed installed on a ship and serves to load and unload the ship using the lift ing equipment
supplied and approved by the manufacturer (hooks etc.)
The ship must be anchor/lashed at the quay in a harbour and equiped with fully ballast for un/loading
procedure.
The crane is to be operated only by appropriately trained personnel, in a competent physical and
psychological condit ion
2.1.2 .
INCORRECT USAGE OF CRANE
- Mechanical modifications of the crane which influence the operational safety.
- Using the crane to tear/r ip away loads that are f ixed down, by using the hook or the slewing gear.
- Lifting a load that is laying on the ground by only using the luffing winch/gear.
- Dragging a load across the ground.
- Lifting loads where the lift ing ropes are not perpendicular.
- Using the crane without complying to the relevant load chart ( in regards to load and outreach).
- Installation and use of spare parts, equipment and fluids that are not approved by the original equipment
manufacturer.
- The loading and unloading of other ships without reducing the safe working load.
- The lift ing/handling of life boots.
- Carrying of passengers through the hoist ing gear
- Cooperative operation with other cranes for lift ing loads
2 .1 .3 . L IMITS OF THE OPERATIONAL AREA
The limits of the operat ional area, is the m aximum w orking area of the crane, plus the distance cove red by
a swinging load. This area is also to be known as the area of danger.
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PRODUCT DESCRIPTION
2.2. GENERAL ARRANGEMENT
At the following pages the main components of the crane are described generally.
There may be differences to the actual crane configurations because of customized features
2.2.1.
MAIN PARTS OF THE CRANE
1
Slewing column
2 Base column
3 Operator's cabin
4 Boom
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PR OD U C T D ESC R IPT ION
2.2.2.
SLEWIN G C OLU MN
1 Hoist ing winch
2 Oil cooler cover
3 Limit switch hoist ing gear
4 Slewing bearing
5 Pivot bea ring for luffing cylinde r
6 Warning horn
7 Cabin
8 Limit switch luffing gear
9 Hatch
10 Boo m pivot bearing
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PR OD U C T D ESC R IPT ION
2.2 .3 . MACHINER Y ROO M
1 Hydraulic oil tank
2 Main motor with hydraulic power pack
3 Slewing gear boxes
4 Switch cabine t X1
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PR OD U C T D ESC R IPT ION
2.2 .4 . POW ER PACK
1 Electr ic main motor
2 Terminal box main motor
3 Coupl ing
4 Hydraul ic pump assemble
5 Suction l ine with shut off valve
6 Inspection cover
7 Oil level indicat ion
8 Return f low f i l ter
9 Oil level senso r
10 Air breather
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PRODUCT DESCRIPTION
2.2.5. CABIN
1
Lefthanded control lever
2 Operators seat
3 Righthanded control lever
4 Control panel
5 Emergency rescue device
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PRO DUCT DESCRIPT IO N
2.2.6.
B O O M
1 Boom pivot bearing
2 Luffing cylinder pivot bearing
3 Rope protection and guide
4 Floodligl i t
5 Rope fix point on boom head
6 Hook b lock
7 Hoist rope pulley
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PR OD U C T D ESC R IPT ION
2.3.
TECHN ICAL DATA
2.3.1.
PROOF OF ORIGIN
This L iebherr crane was designed by LIEBHERR-WERK NENZING GMBH in Austr ia and manufactured in
L IEBHERR- SUNDERL AND W O RKS, En g la n d .
2 .3 .2 . DESIGN CONDITIONS
Rules, R egulat ions
Certifying authority
Maximum admissib le heel / t r im
Desgin temperature
Ambient working temperature
Humidi ty
AMSA and Austra l ian Navigat ion Regulat ion
GL, See BG
5°/2°
-10°C
-25°C to +45°C
maximum 93 %
2 .3 .3 . WO RKING RANGE
- Outreach main hoist gear
Minimum radius
Maximum radius
2,8 m
27 m (at 13,9° boom inclination)
2 .3 .4 . PERM ISSIBLE CAPACITIES / SPEED S
- Main hoisting gear
Maximal hoisting capacity
Reeving
Hoist ing sp eed
Hoisting height
45 metr ic tonnes SWL
4-fall
0-20 m/min wi th fu l l load
0-33 m/min wi th empty hook
approx. 67,5 m
Luffing gear
Luffing speed 80 seconds
(from maximum to minimum radius and ful l load)
-
Slewing gears
Number of s lew gear boxes
Slewing speed
3
0 - 0,75 rpm with ful l load and at maximum radius
2 .3 .5 . ELECTRIC POW ER SUPPLY
Main motor power supply
Auxil iary power supply
440 V, 60 Hz, 3 phase
220 V, 60 Hz, 3 phase
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PRODUCT DESCRIPTION
2.3.6.
WEIGH T
Base column
Slewing column
Boom
Total weight of crane
5,3 tonnes
23,1 tonnes
18,6 tonnes
approx. 47 tonnes
2 .3 .7 .
LOAD DIAGRAIVI
DECK CRAIÆ
CBW 45{40)/24.3{27) ST
LOAD DIAGRAM
S i m . ti
4-FAU.
OPERATION
50
45
40
3 0
2 0
K)
0 6
2,8
n
15 20
126
24.3
27
30
- • RADIUS
tn)
DKk «6B3B3M n M im : 6040 400 00 00 OB On
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PRODUCT DESCRIPTION
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SAFETY G UIDELINES
INDEX
3. SAFETY GUIDELINE 3.3
3.1. GENERAL 3.3
3.1.1. DANGER SYMBOLS 3.4
3.2. UTILIZATION AS DIRECTED 3.5
3.2.1.
PURPOSE 3.5
3.3. AREAS OF RESPONSIBILITY 3.6
3.4. PERSONAL REQUIREMENTS OF THE CRANE OPERATOR 3.7
3.5. PERSONAL PROTECTIVE GEAR 3.8
3.6. WOR KAR EA 3.9
3.7. SAFETY AND MONITORING DEVICES 3.9
3.8. SAFETY SIGNS ON THE MACHINE 3.10
3.8.1.
MEANING OF THE SAFETY SIGNS 3.10
3.8.2. SAFETY LABEL INSIDE CABIN 3.13
3.9. MACHINE SPECIFIC DANGERS 3.14
3.9.1. INJURIES CAUSED BY MECHANICAL PARTS 3.14
3.9.2. INJURIES DUE TO HYDRAULIC ENERGY 3.15
3.9.3. DANGER OF BURNS 3.15
3.9.4. DANGER OF FIRE AND EXPLOSION 3.16
3.9.5. ENVIRONME NTAL PROTE CTION 3.17
3.10.
ADDITIONAL DANGERS 3.17
3.10.1.
EFFECTS FROM WIND AND STORM 3.17
3.10.2. SNOW AND ICE LOADS 3.19
3.10.3. LIGHTNING STRIKES 3.19
3.11.
NOTES ON SAFETY FOR THE MACHINE OPERATOR 3.20
3.12. NOTES ON SAFETY FOR THE BUILDING-SITE PERSONAL 3.20
3.12.1.
ASSISTANT 3.21
3.12.2. SLINGER 3.22
3.12.3. HAND SIGNALS 3.23
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SAFETY GUIDELINES
3. SAFETY GUIDELINE
3.1. GENERAL
Your safety - as mach ine ope rator or maintenan ce technician - is of utmost priority. Any numb er of occu rring
situat ions, problems or malfunct ions on the mach ine can represent se rious r isk to safety, if you are not fully
aware of the measures to take to avoid and prevent possible dangers.
This chapter
• contains information on intended uses,
• contains generally valid information on safety and safety guidelines,
• explains the mea ning of symbo ls and pictograms used in this operat ing m anua l and the signs on
the machine
• gives information about the necessary protect ive equipme nt and which req uirements apply to the
operat ing and maintenance personnel,
• gives information concerning da ngers and other r isks which can also occur during operat ion of the
machine as directed.
Special handling and situat ion related notes an safety are specif ied in the following chapters of this operat ing
manua l and in further sect ions of the docum entat ion included in delivery.
State-of-the-art techno logy
Upon delivery the machine features technology that is currently considered state-of-the-art.
Neve rtheless, dangers a round the m achine m ust be taken into considerat ion if the notes on safety in this oper
at ing manual are not observed and implemented.
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SAFETY GUIDELINES
3.1.1. DANGER SYMBOLS
In the operating manual hazards, important information and tips on utilization are characterized with special
symbols and signal words . They are always in front of the relevant work step and are marked as follows:
A
DANGER
The notes o n safety DANGER
- indicate
an imminent threat of danger
- relates to operating and maintenance procedures,
- includes WARNING and CAUTION.
Disregarding this notice w ill lead to
severe injuries (disability) or death.
A
WARNING
The notes on safety WARNING
- indicate
a dangerous situation
- relates to operating and maintenance procedures,
- includes CAUTION.
Disregarding this n otice will lead to severe injuries or death.
A
CAUTION
The notes on safety
CAUTION
— indicate a possibly dangerous situation
—
relates to operating and m aintenance procedures,
Disregarding this notice
will lead
to
severe injuries or serious damages to the
machine and/or otherwise serious property and environmental damages.
s
IMPORTANT
IMPORTANT indicates tips on readiness of operation that the user has to adhere to.
Disregarding these hints
may lead to property and other knock on
damages.
O:T
NOTE
The
NOTE
- relates to operating and maintenance procedures,
- relates to technical aspects that are helpful and that the user m ust adhere to.
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SAFETY GUIDELINES
3.2. UTILIZATION AS DIRECTED
3.2.1. PURPOSE
In principal the machine may only be used for applications as stipulated in the operating manual.
The machine is used as intended when
• national safety regulations are adhered to,
• all safety instructions in this operating manual are kept,
• when all required safety devices are in place and opera tional,
• when the operating conditions described in chapter 2. "Technical data" are adhered to and all the
recommended oils and lubricants are used (see chapter 7.).
Included in use as intended is also timely and complete service and m aintenance works by qualified and autho
rized personnel.
Special application not listed here
• are to be cleared with the manufacturer,
• may only be carried out with the written consent of the manufacturer.
The m achine is used for every kind of crane application and is designed for optimal economic operations.
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SAFETY GUIDELINES
3.3. AREAS OF RESPONSIBILITY
The
operator
or an
authorized person
• assu res that only trained and qualif ied personnel that has read the operating ma nual and has es
pecial ly understood chapter 3 "Safety guidelines" operates and services the machine,
• delegates com pete nce and assigns clear responsibi l i t ies to the individual operating and mainte
nance personnel ,
• places the required protective equipment and gear at the disposal of the operating and mainte
nance personnel ,
• regularly checks the safety -oriented work by the personn el,
• is respon sible for the safety aspec ts and condition of the m achine,
• shuts dow n the mach ine as soon as there is a safety risk involved in its operations,
• performs insp ections on the machine bas ed on national regulations in addition to the inspection s,
• stipulated by Liebherr, in the prescribed time and manner,
• assu res that the machine is service d and maintained in the prescribed intervals,
• reports every acciden t, injury or sizable property dama ge caused by the ma chine ,
• grants Liebherr-perso nnel un impe ded acces s to the ma chine in conn ection with their duty of
keeping abreast wi th moni tor ing the product 's per formance,
• carefully carr ies out work plans for the machine.
The
machine operator
has to
• wear the necessary protective gear for his personal safety,
• mak es a visual inspec tion of the mac hine every day before operating it,
• checks the brakes and emergenc y equipment dai ly before start ing the mac hine,
• is respon sible for the safe operation of the ma chine,
• operates the m achine within the l imits specified in the load chart,
• reports every irregularity that affects the safe operation of the mach ine to his superior or to the
owner of the crane,
• stops operations at once when safe operation is no longer possible,
• after operation lock
- the operator 's cab and the entrance door and
- safeguards the ignition keys and the key for the operator 's cab to prevent any unauthorized use
of the m achine,
• keeps the operator 's cab, wind shields, platforms and steps clean,
• makes sure that
- before powering up any moving parts, al l controls are set to zero or neutral,
- before powering down all moving parts are set to zero or neutral then switch off the power,
- securing the emergency controls against unintended start up.
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SAFETY GUIDELINES
3.4. PERSONAL REQUIREMENTS OF THE CRANE OPERATOR
The crane operator
• must be physically and m entally fit for the job,
• must be trained and qualif ied to operate the mac hine,
• must show the ow ner of the m achine p roof of his abil i ty to operate it,
• must have read and understood these instruct ions,
• must know h ow to adm inister f irst aid treatme nt and know how to use a fire ext inguisher,
• must have reac hed the legal age, as a rule 18 years old, to operate this crane,
• must have passed the prescribed health exam ination.
Physical dem ands:
• Ade qua te vision with unlimited f ield of view
• Spatial vision must be up to standard
• No color blindness
• Sufficient hearing ability
• Sufficient physical fitness
• Quick react ion t imes
• Manual dexterity
Mental and character demands:
• Sufficient intellectual abilit ies
• Spatially imaginative
• Attent ive
• Reliable under stress
• Patient
• Generally reliable
The following persons must not operate the crane
• alcoholics or drug addicts
• persons who take ref lex inhibit ing m edicat ion
Persons with the following physical symptoms may not resp. if under special medical care only operate the
machine in a l imited way:
• those who have suffered from epilept ic spells or dizziness,
• heart attack
• electronic implants e.g. pacemakers
• Physical impairme nts e.g. the loss of f ingers that l imit the abil i ty to operate the m achine .
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SAFETY GUIDELINES
3.5. PERSONAL PROTECTIVE GEAR
Alwa ys wea r t ight fit ting protect ive clothing when op erat ing, maintaining or start ing up the ma chine as well as
the correct personal protect ive gear for each respective task.
A
WA R N IN G
There is serious danger of injury from getting stuck in, caught up in or
pulled into moving machine parts.
Preventive measures:
- Do not wear loose clothin g, scarves, op en jackets or ope n shirt sleeves.
- Do not wear jewelry (r ings, bracelets, earrings or similar).
The personal protect ive gear may comprise of:
•
Protect ive helmet,
i f head injuries can be expected due to
- bumping into something,
- objects swing ing, dropping , fall ing over or flying aroun d,
- long, loose hair.
• Protect ive glasses, i f eye injuries are possible d ue to
- searing or pressurized l iquids,
- loose flying parts.
•
Ear protectors,
i f the sound level is expected to exceed 85 dB(A).
•
Dust filter mask,
for health dam aging gase s, steam , mist or dust collect ing in the vicinity of operat ion.
•
Protect ive gloves,
i f injuries to the hand are possible d ue to
- burns,
- pointed or sharp edged objects,
- searing or pressurized l iquids.
• Safety boots, i f injuries to the feet are p ossible d ue to
- banging them into something or jamming them so mew here,
- stepping on pointed or sharp objects,
- objects fall ing dow n or roil ing around .
•
We aring ref lect ive clothing of
s t r i k i ng
colors ,
i f imme diate reco gnit ion by other personnel is nec
essary.
• Special protect ive clothing, against danger from burns, freezing, chemical burns, stabbing or cut
ting injuries to the body.
^T
N O T E
The crane operator is responsible himself for
- wearing the required personal protect ive gear,
- also for regularly wash ing and caring for it ,
- for replacing damaged and useless pieces of the protect ive gear.
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SA FETY G U ID ELIN ES
3.6. W OR K AR EA
In accord ance w ith the rules of machine g uidance the following guide lines were determ ined for the operat ions
of the machine:
required operat ing personn el 1 crane operator
Prescribed working area operator's cab on the slewing column
While operat ing the machine
• no one beside the crane operator may be on the crane,
• the crane opera tor may not leave the cab -not even for a brief spe ll.
The controls may only be used from the operator's seat. Act ivat ing any controls through the door of the cab
is strictly prohibited.
The requirements for a safe working environment:
• Keep the operator's ca b clean: empty ash trays regularly, only place drinking bott les in the pro
vided holders.
• Do not place mag azines or other objects on the control panel.
• Do not keep tools in the operator's cab.
• Clothing or parts of the protect ive gear mu st not block the exit doors nor l imit access to the co ntrol
panel of the machine.
• Keep the entrance to the operator's ca b clean , free from snow a nd ice and do not block it off with
any object.
• Keep the windows of the operator's cab clea n, free of conde nsation and ice.
3.7. SAFETY AND MO NITORING DEVICES
- Helicopter warn ing l ight (opt ional)
- Emergency stop keys
- Horn and acoustic signal transmitter outside
- Acoustic signal transmitter inside cabin
- Fire ext inguisher (op t ional)
- Shut-off valve for hydraulic tank
Functions of the signaling devices:
• The wa rning l ights (opt ional) signal an obstacle in the darkne ss for air traff ic.
• The horn can be sounded by the crane operator.
The f ire ext inguishers are f i lled with powd er and are a pprove d for f ire classif icat ion
• f irm materials(incl. cable f ires)
• l iquid and l iquefied materials
• burning gases and gaseo us materials.
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SAFETY GUIDELINES
3.8. SAFET Y SIGNS ON THE MAC HINE
Important safety signs are moun ted on the m achine. I f they are not followed it could lead to serious injuries
or even to deaths.
A
WA R N IN G
There is a bridge in safety If any safety signs are missing, damaged or illegible.
Preventive measures:
- Con stantly check safety signals for their com plete nes s and legibil ity.
- Imme diately replace miss ing or i llegible safety signs with origina l one s.
- At the delivery of the m achine the safety signs are in the lang uag e of the relevant country.
I f the crane is sold to another co untry the buye r is obligated to acq uire new safety signs in the lan guage of that
country from the manufacturer and to mount them on the crane.
3 .8 .1
.
MEA N IN G OF TH E SA FETY S IGN S
The symbols on the safety signs
• have an exact mea ning,
• are divided into three groups with different shapes and co lors.
Prohibit ion signs
These symbols
• are round and have a red signal color,
• are located wherever an act ion is prohibited that would create dange rous situat ions.
Fire,
naked f lames and smoking prohibited.
Access for unauthorized personnel prohibited.
Access for persons with pacem akers prohibi ted.
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SAFETY GUIDELINES
Warning signs
These symbols
• are triangu lar and have a yellow signal color,
• should draw attention to obstacles and situations that could bring about danger to life and limb.
Warning of hovering
load.
Warning of dangerous m achine drives.
A
A
Warning of hot surfaces.
Warning of danger of slipping.
r'p-aV
Warning of danger from batteries.
nO-OA Warning of electromagne tic fields.
A
A
Warning of high tension.
Warning of dangerous spot.
Fire protection signs
These symbols
• are rectangular and have a red signal color,
• should draw attention to objects and how to use them in case of fire.
m
Fire extinguisher
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SAFETY G UIDELINES
Command signs
These symbols
• are round and blue,
• command wearing personal protective clothing to protect against dangers.
/ •
General command signs.
Wear protective helmet.
k
' • , • ,
'•' * /' / Wear ear protec tion.
\ \ Vv. / Wear protective gloves.
\ O-- . ' i Wear protective glasses.
^ < i ^ \
( ^ . '
Wear breath protection.
Wear protective boots.
Environmental sign
* e *
\ | ^ - . Keep the environment in mind.
T
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SAFETY GUIDELINES
3.8.2. SAFETY LABE L INSIDE CABIN
READ OPERATION MANUAL PRIOR
TO CRANE OPERATION I FOLLOW
INSTRUCTIONS IN OPERATION MANUAL I
1 .
U N L A S H JIB
^ r
\
Unlash jib be fore start-up of crane
2 .
MOTOR STA R T-U P
(n)
y ;V
y
1.
Control levers in zero position
2.
Press motor start
®
x r i G a x
Do not start motor
X
4 . L O A D L I F T I N G
y
Lift load only with 100% vertical ropes
X
Do not drag load in any direction
5 . S ID ELEA D
/
O F F L E A D
3 . C R A N E IS O U T OF C O N T R O L
y
n^rj,
1.
Release control levers to zero
position immediately
2.
Press EMERGENCY STOP
max.sidelead angle 5° 2°
Do not exceed side pull values stated
V J
lO.NO.
790528514 DRAW.NO. 0201-725.00.00.899-001
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SAFETY GUIDELINES
3.9. MAC HINE SPEC IFIC DANG ERS
3 .9 .1 . INJURIES CAUSE D BY MEC HANICAL PARTS
A
WA R N IN G
Numerous areas on and around and situat ions working with the
machine can cause injuries.
Therefore keep the following safety instruct ions and preventive measures in mind:
• Do not stand under a hovering
load
• No one may stand in the danger zone s of the ma chine.
• Do not reach into moving drives or parts of the m achine.
• Only remove protect ive and safety covers
- when the ma chine is at a total standsti l l and
- secured aga inst accidental restart.
• Access to the slewing column is only permitted
- to carry out assembly, maintenance or service work,
- with appropriate safety measures such as wearing slip-free protect ive boots.
• Do not walk on the roof of the opera tor's cab.
• Before start ing opera t ion, check if all
- protect ive covers and casings are mounted correct ly,
- safety devices are funct ional.
• Do not use dama ged cables or cables and ch ains that are not up to l i ft ing the specif ied
load.
• Always wear protect ive gloves when handling cables.
• Wh en driving in bolts and pins
- never align the bolt connections by hand,
- always use appropriate specialized tools (mandrel, stud wrench, etc.),
- always wea r protect ive glasses; there is always dan ger of chippe d- off part icles of the hard ened metal
surface hit ting the eyes.
• Do not let any object com e into contact with the main m otor or cooler ventilator. Objects that fall into
the venti lator or are dropped into it are shredded and hurled back and can cause sever injuries.
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SAFETY GUIDELINES
3.9.2. INJURIES DUE TO HYDRAULIC ENERGY
A
WARNING
Hydraulic oil spraying out under high pressure penetrates clothing and
the skin and causes severe injuries.
First aid for injuries:
Bandage injured area with anti-bacterial bandage and call on a medical doctor.
Preventive measures:
• Repairs to hydraulic systems may only be carried out by experienced and specialized technicians.
• Before starting the repairs depressurize all system sections to be opened and all pressure hoses.
• Do not attempt to locate hydraulic oil leakage from sm all, hard to see orifices by hand but by using a
piece of cardboard or wood.
• Check all hoses, hose connections and fittings regularly, at least however
1x annually,
for possible
leakage and damages.
• Damages hoses and hose connections are
- to be replaced by original Liebherr-spare parts,
- basically
not to be repaired.
3.9.3. DANGER OF BURNS
A
WARNING I
Certain surfaces and operating units of the machine attain an operating
temperature of over 65 °C.
First aid for burns:
First
• run cold water over the burn and cool it down, then
• cover the burn with anti-bacterial bandage and ca ll on a medical doctor.
These safety instructions and preventive measures protect against burns:
• Always wear protective gloves when working on hot components.
• Avoid touching
- coolant and hydraulic oil bearing parts,
- hot hydraulic or gear oil,
• Carry out cleaning and maintenance work on the cooled down machine.
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SA FETY GU ID ELIN ES
3.9 .4. DANG ER OF FIRE AND EXPLO SION
A
WA R N IN G
While tanking the m achine an explosive m ixture of gases may be created.
Leaking gear oil or hydraulic oil may ignite on hot surfaces
Procedure in case of f ire:
1.
Stop main motor.
2.
If possible call for help over the radio.
3. Switch off main power supply and leave the operator's cab.
4.
Evaluate the situat ion:
In a dangerous situat ion leave the machine and call the f ire brigade.
Only if there is no danger to your person should you start to f ight the f ire.
5. To f ight the f ire remove the f ire ext inguisher from its mount on the machine and prepare it for use.
A
D A N G E R
Hydraulic oil that has caught fire
— can o nly be suc cessfully put out with the fire extinguisher at the very start of the fire,
— mo stly leads after a short time to a full f led ged fire and to the total loss of the mac hine
6. Finding the se at of the f ire. Fight the f ire with several sh ort bursts from the f ire ext inguisher. Only spray the
f ire from below.
7. While f ight ing the f ire call on the cow orkers to
- alarm the f ire brigade,
- help with putt ing out the f ire by bringing in more f ire ext inguishers f i l led with appropriate substa nces .
Follow these safety instruct ions and preventive measures:
• Inform yourself on the numbe r and location of the fire ext inguish ers, familiarize yourself with their
usage.
• Befo re filling the hydrau lic tanl<
- turn off the main motor,
- turn off the cab heater.
• Wh ile f il l ing the hydraulic tank
- smokin g an d any kind of handling of f ire or open f lame is proh ibited,
- no one may remain in the operator's cab (they might start the machine by accident).
• After tanking only start the diesel engine w hen
- the tank cover is close d,
- the hose of the r ig has been removed ,
- no pe rsonne l is in the vicinity of the ma chine .
• No containers with combu stible l iquids may be carried on the ma chine
• To clean the ma chine no combustible l iquids may be use d
• In the platform area
- no cleaning towels, rags, etc. may be stored,
- f lammable residues must be removed regularly (e.g. oily spots, dry leaves, f ir needles, ashes,
was te paper, etc.).
• At the site where the mach ine is being used, only the amo unt oil may be stored as is required for
the work at hand .
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SAFETY GUIDELINES
3.9.5. ENVIRONMENTAL PROTECTION
A
WARNING
Environmental protection
Hydraulic and gear
oil,
cleaning agents or similar mustn't reach the ground ,
the waters, or the canalization
Run out oil has to be imme diately neutralized by a binder.
3.10. ADDITIONAL DANGERS
3.10.1.
EFFECTS FROM WIND AND STORM
The permissible wind speeds w ithin w hich unlimited operation of the m achine or w ith only reduced load only
is possible, depend on the selected m ain operation m ode.
This also applies for
the
maximum permissible wind speeds which when exceed ed, operation of
the
machine
should be shut down immediately.
A
WARNING
There is great danger of injury if the m aximum permissible w ind speeds are
neglected during operation of the machine
Countermeasure:
o Check the va lid load charts of the machine:
For pre-tensioning, there is a chart featuring the perm issible wind speeds for the actual set-up stage.
Wind load on the rear side of the boom
- has the effect of an additional load on the rope hook.
Effects of wind at the rear side of the load
- increase the tail radius,
- possibly lead to oscillation of the
load,
-destroy the boom.
Effects of the w ind from behind
A
WARNING
Optionally mounted catwalks on the boom reinforce the wind load on the
boom.
Wind load on the front side of the boom
- is especially dangerous w ith m aximum main boom angle without
load.
Effects of the wind on the front side of the load can lead to oscillation of the
load.
If the load comes into contact
with the boom, the boom could be damaged of destroyed.
Effects of
wind
from the front side
A
WARNING
Optionally mounted catwalks on the boom reinforce the wind load on the
boom.
Wind load on one of the boom and load
- has the effect of an additional inclined hoist,
- can buckle the boom.
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SAFETY GUIDELINES
I f i t is possible to est imate wind forc es and w ind spe eds using the following charts, if the m achine is not in op
eration.
Wind force
Beaufort
0
1
2
3
4
5
6
7
8
9
10
11
12
Descr ipt ion
Calm
Light air
Light breeze
Gentle
breeze
Moderate
breeze
Fresh breeze
Strong
breeze
Near gale
Gale
Strong gale
Storm
Violent storm
Hurr icane
Wind speed
m/s
0 - 0 , 2
0 , 3 - 1,5
1,6-3,3
3,4 - 5,4
5,5 - 7,9
8 - 10 ,7
1 0 , 8 -
13,8
1 3 , 9 -
17,1
1 7 , 2 - 2 0 , 7
20,8 - 24,4
24,5 - 28,4
28,5 - 32,6
32,7 - 36,9
km/h
1
1 - 5
6 - 1 1
1 2 -
19
2 0 - 2 8
2 9 - 3 8
3 9 - 4 9
5 0 - 6 1
6 2 - 7 4
7 5 - 8 8
8 9 - 102
103 - 117
1 1 8 - 133
m ph
under 1
1 - 3
4 - 7
8 - 1 2
1 3 -
18
1 9 - 2 4
2 5 - 3 1
3 2 - 3 8
3 9 - 4 6
4 7 - 5 4
5 5 - 6 3
6 4 - 7 3
74 and
over
Effects of the win d inland
Smo ke r ises st raight upwards .
Wind direct ion is indicated by the draw
of smoke, but not yet by the
weathervane.
Wind is not iceable in the face, leaves
rustle,
the weathervane is mo ving.
Leaves and thin twigs are moving . Wind
streches out a pennant.
wind l if ts dust and loose paper, moves
twigs and thin branches .
Smal l d ic iduous t rees begin to sway.
Wihite crests start to form on lakes.
Thick branches are moving, overhead
elect rical l ines are humm ing, umbrel las
are blown inside out.
Who le trees are mo ving.
Wind s naps branches of f trees. Walk ing
outs ide is made co nsiderably more
difficult.
Minor damage to houses (lost rooft i les,
chimney covers, etc.)
sorm uproots t rees, major damage dto
houses.
Widespread s torm damage.
Ser ious de vastat ion.
A
C A U TION
P lease note in part icular al l wi nd -re lat ed safety guidel ines an d protect ive
mea sures in the init ial pages of the valid load cha rt, as well as the fo llowin g
addit ional points:
0 Even before the applicat ion plan ning, the wind condit ions for the job site and the wea ther pred ict ions for the
period of operat ion planned must be known and taken into considerat ion.
0 The machine operator must be aware of the weather report and the actual wind speed at the machine's job
site before beginning w ork. I f imperm issibly high win d speeds are expected in the vex tfew hours, operat ion
should be aborted and protect ive measures against the storm damage should be taken.
0 During operat ion of the machine with permissible wind speeds
- respect dangerously high gusts of wind,
- if large items with expan sive su rfaces with redu ced load only (e.g. prefabricated l imits),
- move the loads carefully and slowly and avoid every oscil lat ion.
A
D A N G E R
If the maxim um permissible wind speed is excee ded, shut dow n operat ion
immediately: Lower the load a nd leave the ma chine in the park ing posi t ion.
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SAFETY G UIDELINES
The parking position
- is suitable for conditions above the m aximum permissible wind speed during crane operation, up to a wind
speed of 20 m/s; corresponding to wind force 8,
- is determined for the different main operation types under point "Park position".
A
DANGER
It is
hazardous
to
remain
in
the immediate vicinity of
the
machine
during
wind
speeds of over 20 m/s
The occurring wind loads could lead to partial or complete destruction of the boom.
Countermeasures:
With wind speeds exceeding 20 m/s or B eaufort 8, the boom must be laid down in park position.
3.10.2. SNOW AND ICE LOADS
A DANGER
Danger of accident due to chunks of ice breaking loose and falling down .
Increased danger of damage due of frozen hoist limit sw itch on the boom .
Countermeasures:
o Lay down the boom and carefully chip off the larger deposits of ice.
o Remove ice from all sensitive parts, such as hoist limit switches, guides, etc.
A
CAUTION
Deposits of snow and ice on the boom
- increase the weight of the boom ,
- enlarge the surfaces susceptible to wind.
These factors lead to a premature shutting down of the load moment limitation (LMB) - it can no longer be
operated with the m aximum permissible
load.
Considerable amounts of snow can accumulate on the optionally mounted catwalks on the boom.
3.10.3. LIGHTNING STRIKES
A
WARNING
When lightning strikes, there
Is
danger of injury
to
all persons
in
the immedi
ate
vicinity of the mac hlnefrom electric shocks or dangerous
level
of voltage.
Countermeasures:
0 Lay down the boom of the m achine punctually before the storm begins.
0 Do not remain or leave any large metal objects in the immediate vicinity of the machine during the
thunderstorm.
0 ^ =
NOTE
Within the exterior of the locked operator's cab, the machine operator is largely protected from the
direct affects of the lightning. The op erator's cab acts as a Faraday cage and channels the lightning
charge safely over the m achine.
Laying down the boom is discretionary and is the responsibility of the machine operator, especially at sites
with regular thunder storms or restricted working a rea.
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SA FETY GU ID ELIN ES
The m anufacturer expressly recommen ds that the main boom be lain down punctual ly when a thunderstorm
is brewing
- with long boom lengths,
- on exposed terrain,
- near r iverbanks.
A CAUTION
A st rike can cause major dam age to the machine , inc luding:
0 Local welds and dam age to bear ings on the rotary connect ion between s lewing column and base colum n.
Measures in accordance with a confirmed or suspected l ight ing str ike to the machine:
o Thoroughly inspect the machine. Especially for damaged cables or l ines and check for leaks
o Check funct ioning of the entire control.
0 Move the slewing gear slowly l istening for dist inct noises coming from the rotary connection, especially in
the swing.
0 Lay down the boom and inspect for damage. Repair any damage to the paintwork at the point of impact.
3.11.
NOTES ON SAFETY FOR THE MACHINE OPERATOR
Due to the num erous o ptions of the mach ine, the operat ing manu al can not describe all situat ions and dange rs
that may occur during operat ion.
It is therefore im portant for the m achine operator,
- to know the performance capabil it ies and operat ing l imitat ions of the machine off by heart
- to know all safety devices of the machine,
- to request information from the manufacturer immediately, if an undocumented, dangerous situat ion
concerning the machine occurs.
As m achine op erator, be aware o f all details that come within your area of responsibil i ty.
Be awa re of all local safety regulat ions for the mac hine's job site.
Please note the special safety regulat ions in the following chapters of this operat ing manual:
Chap ter 5 - for start-up and ope rat ion of the mac hine
Chapter 7 - for maintenance work on the machine to be carried out by yourself
3.12. NOTES ON SAFETY FOR THE BUILDING-SITE PERSONAL
No persons may remain in the danger area of the machine during operat ion.
The danger area is the area around the machine within which persons may be injured via
- work ing movemen ts of the m achine,
- a fall ing or swinging
load,
- opt ional accessories on the machine.
All boundaries bordering the danger area around the machine can neither be climbed over, reposit ioned or
removed.
Instruct ions of the machine operator are to be administered as follows an d the acoustic warn ing signals of the
machine have to be observed.
Standing in the immediate vicinity of the machine can be especially dangerous
- during a storm or thunderstorm.
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SA FETY GU ID ELIN ES
3 .12 .1 . A SSISTA N T
The n ational guidelines for ut i l izat ion of an assistant and the sign als to be used shou ld be adhe red to.
An assistant sho uld generally be available to the ope rator of the mach ine
- whenever the working or travel area is no longer completely visible from the operator's cab,
- when operat ing the machine and load in confined areas
Only one assistant m ay work with the ma chine ope rator at a t ime . Should several assistants be in the vicinity
of the machine, the assistant that is actually giving the instruct ions must be clearly not iceable (for example,
wearing a luminous vest).
The assistant m ay not stand in the dang er area of in the imm ediate vicinity of the ma chine's path of travel.
The d anger area arou nd the mach ine, or the path of travel should be m onitored by the assistant. The load may
never be directed above the heads of persons below. Perso ns should therefore be requ ested to leave the
dan
ger area imm ediately.
The assistant m ay not carry any other tasks during his instruct ion duties that may distract him.
Notes on sa fety of assist ing with radio
Before operat ion
- Check the battery capacity of the radio equipment, and if necessary, have replacement batteries ready,
- Check the radio connection to the machine operator and in the event of a fault arrange a dif ferent
transmission frequency.
Handle the radio equipm ent with care and protect against humidity.
Notes on safety for assist ing with hand signa ls.
A WA R N IN G
Misund erstood hand s ignals between assistant, s linger and m achine ope ra
tor can lead to ser ious accidents
Countermeasures:
0 Whe n assist ing , always rem ain in visual contact with the machine operator and always stand in a goo d view
ing posit ion. Arrange for suff icient l ight ing for nigh t-work.
0 Fo r signall ing, wear clearly visible (e.g.) white g loves.
o The hand signals
- should be given slowly an d clearly,
- are to be arranged with the machine o perator and slinger before hand , especially with special applicat ion s.
0 Whe n workin g together with the slinger, the assistant relays his hand signals to the m achine operator.
0 Mach ine operator, assistant and slinger always carry an overview of all hand signals used ab out their person .
r r ^ N O T E
A compilat ion of common hand signals can be found in the following pages.
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SA FETY GU ID ELIN ES
3.12 .2 . SLINGER
During operat ion of the mac hine, the slinger is responsible fo rth e safety-tec hnica l, fault less and careful sl ing
ing for releasing of the load.
The slinger, therefore, only uses suitable, undam aged lift ing and slinging equipm ent, preventing the load from
either sliding or fall ing.
The slinger alwa ys wea rs gloves whe n carrying out his tasks. He may only appro ach the load with the conse nt
of either the assistant or the m achine o perator. Standing unde r a raised load is prohibited.
The slinger
- rema ins in view or in radio contact with the assistant and follows his ins truct ions,
- reports his accessing of leaving of the danger area around the machine operator.
Standing under a raised load is prohibited.
If there is no assistant av ailable, the slinger works tog ether with the m achine operator direct ly.
When using hand signals, the same notes on safety as those forthe assistant apply.
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SAFETY GUIDELINES
3.12 .3 . HAND SIGNALS
The hand signals
- serve as communication with visual contact between machine operator and ship's crew, e.g. assistant and
slinger,
- are clearly st ipulated in their configurat ion in certain national stand ards.
I t must therefore be agreed between all persons involved which hand signals are to be used.
The following summary is l imited to common hand signals in
- Germany in accordance with BGV A8,
- the United States of America in accordance with ASME/ANSI B30.5.
- special han d signals for l i f ting gear ope rat ion.
General hand signals in accordance with BGV A8
Caution, Start , Attent ion
Hold the right arm stretched up
wards.
The palm faces forward.
Stop, Interruption, do not
continue movement
Stretch out bo th arms to the side,
horizontally.
The palms face forward.
Stop - Danger
First stretch out both arm s to the
side,
horizontally.
The palms face fon/vard.
Now bend in and stretch out the
arms alternatively.
hHand sign s, vertical mo vem ents
Lift, Up
Hold the right arm upwards.
The palm faces forward ma king a
slow circling m otion.
Lower, Down
Hold the right arm down.
The palm faces inwards making a
slow circling motion.
Slowly
Stretch out the r ight arm horizo n
tally
The palm faces down and is
moved s lowly up and down .
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SA FETY GU ID ELIN ES
General hand signals In accordance to BGV A8, continuation
Hand signals, horizontal motions
Coast down
Hold the right arm upwards.
The palm faces forwards.
Move the arm back and forth
tothe side.
Approach
Bend both arms.
The palms face inwards.
Wave in with the forearms.
Leave
Bend both arms.
The palms face outwards.
Wave out with the forearms.
Hand signals, horizontal motions
Travel r ight (from the assistant 's
angle)
Gently wave in the r ight arm
while move back and forward to
to the side
Travel left (from the assistant 's
angle)
Gen tly wave in the left arm w hile
holding up horizontally and move
back and forward to the side
Indicate redu ction of distance
Hold both palms parallel and
bring together to the correspond
ing distance.
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SA FETY GU ID ELIN ES
Hand signals for l ift ing operat ion in accordance w ith ASM E/AN SI B30.5
Lift load
Bend out the r ight arm and hold it
upwards.
The stretched out index f inger
points upwards.
The hand makes small, circular
movements.
Lower load
Hold the right arm downwards.
The stretched out index f inger
points do wnw ards.
The hand makes small, circular
movements.
Use main winch
Rap on the protect ive helmet with
the fist.
Then give further hand signals.
Hand s ignals ASME/AN SI B30 .5
Use auxil iary w inch
Bend out the r ight arm and hold
upwards.
Rap on the elbow from under
neath with the left hand.
Then give further hand signals.
Raise main boom
Stretch out the r ight arm horizo n
tally.
The thumb points upwards, all
other f ingers remain closed.
Lower main boom
Stretch out the r ight arm horizo n
tally.
The thumb points down wards, al l
other f ingers remain closed.
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SA FETY GU ID ELIN ES
Hand signals in accordance with ASME/ANSI B30.5, continuation
Move slowly
Give the hand signal for the de
s ired movement with one hand.
Hold the other ha nd abo ve it or
below it.
Example: Raise load slowly.
Lift main boom and lower load
Stretch out the r ight arm ho rizon
tally. The thumb points upwards.
Stretch and bend in the remaining
fingers alternatively for as long
the load has to be lowered.
Lower main boom and lif t load
Stretch out the r ight arm horizon
tally. The thumb points down
wards.
Stretch and b end in the remaining
fingers alternatively for as long as
the load has to be lifted.
Hand signals in accordance with ASME/ANSI B30.5
Swinging
Stretch out the right or left arm
horizontally.
The palm faces downw ards.
The pointed f ingers point in the
swing direct ion.
Stop
Stretch out one arm horizontally.
The palm faces downwa rds.
Swing the arm back and forwards
horizontally.
Emergency stop
Stretch both arms horizontally.
The palms face dow nwards.
Swing both arms back and for
wards horizontally.
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SA FETY G U ID ELIN ES
Hand signals for lift ing operation in accordance with ASIVIE/ANSI B30.5, continuation
Travel
Stretch out one arm forward s.
The palm faces forward and is
gently raised.
Make a movement in the travel
direct ion with the open hand.
Shut down and lock machine
Hook in your hands in front of
your body.
Travel with both crawler tracks
Hold both fists in front of the
body.
Indicate travel direct ion w ith cir
cular movements (forwards or
backwards).
Hand signals in accordance with ASIVIE/ANSI B30.5
Travel with one crawler track
Bend o ut the arm w ith the f ist
raised on the side of the crawler
track that has stopped.
Bend ou t the other arm in front of
the body.
Indicate the travel direct ion via
circular movements with the f ist
(forwards and backwards).
Extend boom
(Telescopic arm)
Hold both fists in front of the
body.
The thumbs point outwards.
Retract boom
(Telescopic arm)
Hold both fists in front of the
body.
The thumbs point toward each
other.
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SA FETY GU ID ELIN ES
Hand signals for l if t ing operat ion in accordance with ASME/ANSI B30.5, continuation
//AI
T K ^ J
Extend boom (Telescopic arm)
One-handed s igna l:
Hold one fist in front of your
chest.
The thumbs point to your chest.
Retract boom (Telescopic arm)
One-handed s ignal:
Hold one fist in front of your
chest.
The thumbs point outwards.
Special han d signals for l if ting o perat ion
No special standards have been allocated to these hand signals and they complete the quoted hand signals.
Lift load slowly
Bend out the r ight arm and hold it
upwards. The pointed index
f in
ger points upwards.
The right hand makes small, cir
cular movements. Stretch out the
left hand and hold it over the right
hand.
Lower load slowly
Hold the right arm downwards.
The pointed index f inger points
downwards.
The hand makes small, circular
movements.
Hold the left hand do wn .
The palm faces upw ards.
Lift main boom slowly
Bend o ut the r ight arm.
The thumb points upwards.
Hold the left hand abo ve it .
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SAFETY GUIDELINES
Special signals for l i fting operation, continuation
Lower main boom slowly
Bend out the r ight arm .
The thumb points dow nwards.
Hold the left hand down. The
bacl< of the hand faces upwards.
Lift main boom and hold load
Bend out the r ight arm.
The thumb points upwards.
The left hand makes a f ist under
the right hand.
Lower main boom and hold
load
Bend ou t the r ight arm.
The thumb points do wnwa rds.
The left hand makes a f ist under
the right hand.
Special signals
Lift main boom and lower load
Bend out the r ight arm.
The thumb points upwards.
Bend out the left arm.
The index f inger points down
wards.
Hold the left hand unde r the r ight
hand and rotate.
Lower main boom and lift load
Bend out the r ight arm.
The thumb points downwa rds.
Bend ou t the left arm.
The index f inger points upwards.
Hold the left hand under the r ight
hand and rotate.
Swing slewing platform to the
right
Bend out left arm and hold up.
The thumb points outwards with
the direct ion of swing .
Stretch out the r ight arm dow n
wards.
The index f inger points down
wards. The hand makes sm al l ,
circular movements.
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SAFETY GUIDELINES
Special hand signals for lifting operation, continuation
Swing slewing platform to the
left
Bend
out
the left arm and hold
up.
The thumb points outwards with
the direct ion of
turn.
Stretch out
the left arm downwards.
The index f inger points down
wards .
The
hand makes smal l ,
circular movements.
Open grapple
Stretch
out
the r ight arm horizon
tally.
Hold the hand down wards with
f ingers sem i-open.
Close grapple
Stretch
out
the r ight arm horizon
tally.
Close the hand into a fist.
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CONTROL AND OPERATING ELEMENTS
INDEX
4. CONTROL AND OPERATING ELEMENTS 4.3
4.1. GENERAL 4.3
4.2.
LAYOUT OF THE OPERATOR'S CONTROLSTAND 4.3
4.3.
CONTROL LEVER 4.4
4.4. CONTROL PANELS 4.5
4.4.1. CONTROL PANEL X20 4.5
4.5. SWITCH CABINET 4.10
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CONTROL AND OPERATING ELEMENTS
4. CONTROL AND OPERATING ELEMENTS
4.1. GENERAL
In this chapter the con trol and operating elements are described. According the function of
the
elements, they
are mounted in the cabin or around the crane.
All other authoritative devices for safe crane operation, are listed in chapter
3
"SAFETY G UIDELINES" section
safety and supervisory apparatus.
4.2.
LAYOUT OF THE OPERATOR'S CONTROLSTAND
1 Lefthanded control lever
2 Righthanded control lever
3 Switch unit X20
4 Foot switch for sector bypass operation (optional)
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CONTROL AND OPERATING ELEMENTS
4.3. CONTROL LEVER
Combined control levers for stepless control of the hoisting, luffing and slewing system.
Luffing and slewing motion can be carried out at the same time.
Hoist motion can be carried out at the same time with luff or slew motion.
The control levers are spring centered and will automatically return to neutral when it is released.
Right-handed control lever
^
Hook N \ \^ \
lowering ^ - ^ / \ ) y
Hook
lifting
Left-handed control lever
Push button "Horn"
Crane
slewing left
Boom
lifting
^— Boom
<X^ lowering
Crane
slewing right
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C ON TR OL A N D OPER A TIN G ELEMEN TS
4.4. CONTROL PANELS
4 .4 .1 . CONTRO L PANEL X20
The control panel X20 is located inside the operator's cabin at the r ight-handed sidewall
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C ON TR OL A N D OPER A TIN G ELEMEN TS
CONTROL ELEMENTS FOR LIGHTING
Switch "cabin lighiting"
For operat ing the l ight inside the operator's cabin.
Pusli button "crane light ing"
For operat ing the l ights inside the slewing column.
An addit ional switch is located at the ascent ladder.
Push button "f loodlight"
For operat ing the f lood l ights at the crane
CONTROL ELEMENTS FOR TROUBLE INDICATION
Pilot light "main motor fault"
The pilot l ight i l luminates, if one of the l isted faults o ccurs:
- overtemperature protect ion (PTC) main motor tr ipped
- overcurrent relay main motor
Pilot light "niveau / temperature fault"
The pilot light i l luminates, if one of the l isted faults occu rs:
- low level sw itch In hydraulic tank tr ipped
- temperature switch "hydraulic oil temperature" tr ipped
- temperature switch "gear oil temperature hoist ing winch" tr ipped
Pilot light "circuit breaker tripped"
i l luminates, if the circuit breaker of the hydraulic oil cooler motor has tr ipped
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C ON TR OL A N D OPER A TIN G ELEMEN TS
CONTROL ELEMENTS FOR CRANE START UP
0 I
®
Key switch "crane on/off"
for switching on/off the main breaker of the electr ic power supply
Pilot light "crane on"
i l luminates, if the electr ic power sup ply is available to start the ma in m otor
Push button and pilot l ight "motor on"
Press push button to start the main motor
The inserted pilot l ight i l luminates, if main motor is running
Push button "motor off"
Press push button to stop the electr ic main motor
A
A TTEN TION
Before leaving the operator's cabin the main motor
must always be shut down
CONTROL ELEMENTS FOR CRANE PARKING
Key switch "park posit ion"
Turn key switch to bypass the l imit switches of boom motion.
Keep turned during parking procedure of the boom.
A
ATTENTION I
The movement of boom is not stopped automatically via l imit
switches I
Pilot l ight "boom below working range"
i l luminates, if the boom is below working range of the crane for
parking procedure
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C ON TR OL A N D OPER A TIN G ELEMEN TS
CONTROL ELEMENTS FOR SCREEN WIPER OPERATION
Switch "screen wiper"
for operat ing the screen wiper of the front window
Pos. "0": off
Pos.
I :
screen wipe r interval operat ion
Pos.
"11":
screen wiper continues operat ion
Switch "screen wiper pump"
for operat ing the pump for screen wiper operat ion of the front window
CONTROL ELEM ENT FOR EM ERGENCY STOP
Red push button "emergency stop"
The but ton should be used in emergency case only
If one of the emergency stop buttons is pressed the main motor stops and
all gear brakes closing immediately
CONTROL ELEM ENT FOR CRANE POWER M ANAGEM ENT SYSTEM
Push button "start request crane"
The cranes are equipped with a passive power management system to
avoid overloading of the ships generators during start ing up of the crane
main motors. lf crane shall be started up the push button "start request
crane"
must be pressed.
Pilot light "start ok"
i l luminates, as soon as eno ug h electr ic power from ships ide is available a nd
the crane can be started
0=
N OTE
The power management is a passive system.
If not enoug h po wer is available start ing up is not locked automatically.
The crane o perator is allowed to start only if the pilot light "start ok" is i lluminated .
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C ON TR OL A N D OPER A TIN G ELEMEN TS
CONTROL ELEMENT FOR HOOK PARKING
bypass h.g.
0 ^ ^ I
-p rese lec t ion -
hook parkpos.
0y<=^A
hook parking
3 - fa ) l . 2 - fa
- ' ^ o ^
r®
^ hook park ing
Key switch "hook parking"
Operate key switch to preselect hook parking
A
A TTEN TION
DO NOT OPERATE KEY SWITCH "HOOK PARKING" AS LONG
AS LOAD IS ATTACHED ON THE HOOK
Remove key after process is f inished
CONTROL ELEMENT FOR SECTOR OPERATION
Key switch "preselection sector bypass "
Turn key switch to preselect bypass the sector l imits.
Press addit ionally foot switch "bypass sector" to enable bypass sector l imits.
A
A A TTEN TION
The key switch "preselect ion sector bypass" may be operated
by trained personnel only and the key must be removed after
process is f inished
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C ON TR OL A N D OPER A TIN G ELEMEN TS
4.5.
SWITCH CABINET
Red push button "Emergency stop"
The main motor stops and all brakes apply immediately, if this button is pressed.
r r ^ N O T E
U SE ON LY IN EMER GEN C IES
To reset, turn button to the r ight and relea se
r r ^ IMPOR TA N T
I f using this button during o perat ion w ith full load, the mu lt iple disc
brakes of the hoist winch(es) must be inspected and checked for
proper funct ion
Operat ion hours counter
The operat ion hours are used to determinate the maintenance Intervalls
l ooooo lo Ih
^
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C ON TR OL A N D OPER A TIN G ELEMEN TS
Switch "Aircraft warning light"
Switches on/off the helicopter warn ing l ight on the boom hea d.
Main switch "Auxiliary power supply"
Operates the auxil iary power supply for the entire l ight ing and heating system on
the crane.
^r
IMPOR TA N T
Must be switched on all the t ime in order to prevent conde nsation inside the crane and its main
comp onen ts ( electr ic main motor, fan moto rs, hydraulic oil tank, etc. ).
Switch off only for maintenance in the electr ical system
Main switch "Main power supply"
Operates the main power supply for the crane main drive system. Switch
cabinet door can't be opened, when the switch is in the "ON" posit ion.
r r 3 = IMPOR TA N T I
I f main sw itch tr ipped, f irst reset the switch and s witch it on ag ain
A WA R N IN G
BEFORE OPENING ANY ELECTRICAL EQUIPMENT, IT IS ESSENTIAL TO SWITCH
OFF TH E POWER SU PPLY
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CONTROL AND OPERATING ELEMENTS
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CRANE OPERATION
INDEX
5. CRANE OPERATION 5.3
5.1.
GENERAL 5.3
5.1.1.
SAFE OPERATIONS WITH THE CRANE 5.3
5.1.2. CRANE ACCESS 5.4
5.1.3. EMERGENCY RESCUE DEVICE 5.5
5.1.4. CRANE MOVEMENT POSITIONS 5.6
5.2. CHECKS BEFORE DAILY START UP 5.7
5.2.1.
INSPECTION TOUR 5.7
5.2.2. CHECKS 5.7
5.3. DAILY STA RT-UP 5.8
5.3.1.
STARTING MAIN MOTOR 5.8
5.3.2. MOVE HOOK OUT OF THE HOOK GARAGE 5.10
5.4. START/STOP FOR A WORK BREAK 5.11
5.4.1.
SHUT DOWN THE CRANE FOR A WORK BREAK 5.11
5.4.2. STARTING UP THE CRANE AFTER A WORK BREAK 5.11
5.5. SHUT DOWN THE CRANE 5.13
5.5.1. MOVE CRANE TO PARKING POSITION 5.13
5.5.2. SHUT DOWN MAIN MOTOR 5.14
5.5.3. LONGER STANDSTILL PERIOD OF THE CRANE 5.15
5.6. CRANE OPERATION 5.16
5.6.1.
HOOK OPERATION 5.16
5.7. ADDITIONALLY OPERATIONS 5.17
5.7.1. AIRCONDITION 5.17
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C R A N E O PER A TION
5. CRANE OPERATION
5.1. GENERAL
This chapter familiarizes you with op erat ion of the crane.
It guides you through the work f low and describes the operat ional steps
- for daily use,
- to operate the main components such as the boom or hook,
- for crane operat ion with detailed information,
- to safely shut dow n the crane.
5.1.1. SA FE OPERA TIONS WITH THE CRA NE
The crane operator is responsible for the safe operat ion of the crane.
Pay special attent ion to the following:
- the safety instruct ions in chapter 3.
- familiarize yourself with the layout of the controls before start ing up the cra ne (see chapter 4 ).
- to the information in this chapter and rem emb er the instruct ions provided by the crane manufacturer.
A
^ D A N GER
OPER A TIN G ER R OR S C A N EN D A N GER H U MA N L IVES A N D
SEVER ELY D A MA GE OR D ESTR OY TH E C R A N E
The crane is equippe d with various safety devices to prevent dange rous ope rat ional condit ions. These safety
devices cannot however prevent damage occurred due to negligence or erroneous operat ional input.
PR EC A U TION S:
- Simultaneous l if ting and swingin g of load with maximum spe ed is prohibited
- Do not carry out any jerky mo veme nts with the crane; avoid every sudden accelerat ion or braking.
- Start each move men t from a stand sti l l posit ion slowly and gently.
- Do not permit any dynamic effects, such as oscil lat ion or jerkily l if t ing and lowering of load.
- Alwa ys work with foresight: allow plenty of t ime and space for braking a moveme nt.
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CRANE OPERATION
5 1 2 CRANE ACCESS
A ATTENTION
Never ascent a crane during crane operation I
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CRANE OPERATI ON
5.1.4 . CRAN E MOVEM ENT POSITIONS
Hook block
parking posit ion
Upper limit
Working range
Lower limit
parking
position 0°
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C R A N E OPER A TION
5.2. CHECKS BEFORE DAILY START UP
Ac
CAUTION
N EVER U SE A D A MA GED C R A N E OR EQU IPMEN T
All defects and errors found are to be reported at once to the person responsible.
They are also to be professionally corrected before start up.
Wh en there is a change in crane ope rator, defects foun d are to be passed on to the next operator.
5 .2 .1 . IN SPEC TION TOU R
The following visual inspection tour has to be performe d daily before start up of the crane :
Check slewing column and boom if there are
- leaks (hydraulic oil),
- (wil l ful) damages,
- all safety dev ice are in place an d correct ly funct ion,
- all bolts are In firmly,
- ropes do not show any sign of wear.
Check, if safety labels are attached and readable
5 .2 .2 . CHECKS
r r ^ N O T E
Pay attent ion to the following du ring the check s:
Refil l ing fuels and lubricants is described in chapter 7. "M aintenan ce"
Required safety precautions are described in chapter 3. "Safety guidelines"
- Assure a clear view from the operator's cab:
- clean wind shield and side window glasses
- ref il l wipe r-wash er f luid
- Perform daily lubricat ion according to mainten ance plan.
See chapter 7.
- Check hydraulic oil levels.
See chapter 7.
- Availabil i ty of the auxil l iary power supply
- Unlock all EM ER GE NC Y-O FF switches by rotating them counter clock-wise.
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CRANE O PERATION
5.3. DAILY START-UP
5.3.1.
STARTING MAIN MOTOR
- Switch on the main switch manually at switch cabinet X I .
o:?
IMPORTANT
If main switch in tripped position, reset the
switch first and switch it on again
Check if hand valve (below the hydraulic tank) for hydraulic oil supply, is in open position
A,
AUTION
The hydraulic system can be destroyed, if the main motor is started with closed shut-off valve
Turn key sw itch "crane control on/off' to position
I
Pilot light "crane on" illuminates
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CRANE OPERATION
Press push button "start request crane"
As soon as
enough electric power from sh ipside
is available,
the inserted pilot light illuminates
and the
crane
can be started.
Press the "motor on" button at switch unit X20 (all control levers must be in neutral position).
Wait until the pilot light "motor on" lights up
A A
TTENTION I
While starting the hydraulic asse mbly it is not al lowe d to operate the control levers u nti l
the pilot l ight "motor on" i l luminates
Check if no trouble is indicated at the control switch unit X20
r r ^ IM PO RT AN T
If one or more of the pilot lights are illuminated, check reson and eliminate troubles
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CRA NE OPERATION
5.3.2. MOVE HOOK OUT OF THE HOOK G A RA GE
- Turn key switch "parking" to position
I
bypass h.g.
0 ^ — ^ I
hook parkpos.
-p rese lec t ion -
3-fall 2-fatl
- Keep turned key switch "bypass park position" in position
I
A ATTENTION
The luffing motion is not stopped by a limit switch
Lift boom until pilot light "hook parking position" is flashing
Move boom very slowly when approaching a boom angle of 80 degrees from horizontal I
A
AATTENTION
The hoisting winch is automatically spooling on while lifting the boom with the hook in
the garage. How ever, the hoisting rope needs to be m onitored
by an
assistant
to the
crane
operator in orde rto ensure that the rope is actually spooling on , if not the parking m otions
are to be stopped immediately and reason to be investigated
- Lower
hook
carefully
out from
its hook
garage and
lower hook
by using
the hoisting control lever
until
approxi
mately 10 meters below the top of the boom .
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CRANE O PERATION
•
Lower the boom slowly into the working radius using the luffing control lever
(i.e.
between minimum and maximum working radius")
•
Turn back key switch "parking" to position "0"
A A
TTENTION I
The key switch "parking" may be operated by trained personnel only and the key
must be removed after process is finished
THE CRANE IS READY FOR OPERATION
A
ATTENTION I
In case of any doubt about the correct handling of the hook garage system or if the system
is not operating correctly for any reason, then please lash the hook to the vessel's deck in
order to avoid damage to the crane. The lashing tension has to be less than
1
ton
5.4. START/STOP FOR A WORK BREAK
5.4.1. SHUT DOWN THE CRANE FOR A WORK BREAK
- Lower load to ground
- Move the boom and the hook to a position, which will not endanger anyone on board.
- Press the "motor off' push button
5.4.2. STARTING UP THE CRANE AFTER A WORK BREAK
Press push button "start request crane"
As soon as
enou gh electric power from shipside
is
available, the inserted p ilot light illuminates
and the
crane
can be started.
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CRANE OPERATION
Press push button "motor on"
®
1 /
M
I
0 I
(D
Wait until pilot light "motor
on"
lights up
THE CRANE IS NOW READY TO CONTINUE WORK
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CRANE OPERATION
5.5. SHUT DOWN THE CRANE
5.5.1. MOVE CRANE TO PARKING POSITION
A
AATTENTION
It
is
absolutely essential
during
the hook parking operation,
that all
crane motions
are
executed
at very slow speed and without any jerks so that any swinging of the hook block is totally
avoided I
Turn the crane to a position without side-lead and off-lead angle of the hosting ropes and consequen tly
the hook block.
To
avoid swinging of
the
hook, leave a distance of at least 10 meters between hook block and boom head
Lift the boom slowly to m inimum working radius
• Turn key switch "parking" to position
I
i
bypass h.g.
C
å
^ O ^
(
prc^
1 hookjyt^king
(%
election —
3 - f a n .
C
Keep turned key switch "bypass park position" in position
I
Lift boom until pilot light "hook parking position" is flashing
Move boom very slowly when approaching a boom angle of 80 degrees from horizontal I
A/
ATTENTION
The luffing function is not stopped by a limit switch
Keep turned key switch "bypass park position" and lift the hook very slowly using the hoisting control lever
into the parking garage.
A
AATTENTION
The m otions of the hook have to be closely m onitored by the crane operator or an assistant.
The operation has to be stopped immediately if the hook block m isses the garage bracket
(e.g. due to inclination, swinging hook, etc.), as the hoisting of the hook has been stopped by
the limit switch
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C R A N E O PER A TION
Keep turned key switch "bypass park pos it ion" and low erth e boo m very slowly using the luff ing control lever
to horizontal po sit ion
A
ATTENTION I
The h oist ing winch brake Is automatically opene d for un-spooling which enables the low ering
of the boom with the hook in the garage. However, the hoist ing rope needs to be monitored
by an assistant to the crane operator in order to ensure that the rope is actually spooling off,
if not the parking m otions are to be stopped immediately an d reason to be investigated I
5 .5 .2 . SHUT DOW N MAIN MOTOR
- Press the "motor off ' push button
- Turn key switch "crane control on/off ' to posit ion "0"
- Switch off the main switch manu ally on the switch cabine t
Close f irmly all windows and doors
AAI
A A T T E N T I O N I
The auxil iary supply m ust remain switched on for crane standstil l heat ing
THE CRANE IS NOW READY FOR SEAGOING
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C R A N E OPER A TION
5.5 .3 . LONGER STAND STILL PERIOD OF THE CRANE
A
A TTEN TION
Shou ld the crane be shut down for a period m ore than four (4) weeks - the crane has to be
operated once a month for at least approx. one (1) hour. In addition to that all the greasing,
oil inspections and oil level checks have to be done as
well .
The standstil l heat ing mu st be switched on all the t ime in order to prevent m oisture in the
electric and h ydraulic systems . Switch off only for service work I
The crane has to be pres erved, if not in operat ion for m ore than three (3) months. Detailed
preservat ion instruct ions are obtainable at your local LIEBHERR service department .
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CRANE OPERATION
5.6. CRANE OPERATION
Safety instructions
A
DANGER
- Before starting any operation, the crane must be in operational condition, meaning no trouble
is indicated on switch unit X20
- It is strictly forbidden to lift heavier loads with the luffing gear than it is possible with the
hoisting gear
- Crane operation must be stopped at a windspeed more than 20 m/sec.
5.6.1. HOOK OPERATION
^ . ^ °
A -
Hook lifting
B - Hook lowering
C - Boom luffing in
D - Boom lufling out
E - C rane slewing left
F - Crane slewing right
Operation:
- Start up crane as described under item "Start up of crane"
ALL CRANE MOTIONS ARE AVAILABLE
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CRANE OPERATION
5.7. ADDITIONALLY OPERATIONS
5.7.1. AIRCONDITION
Switch "Air"
Switch "Temp"
a n
Main sw itch
on control box
OPERATION:
- Turn main switch at control box to position
1
- With switch "Air" strength of air-flow can be set
- With switch
"Temp"
desired temperature can be set
- To switch off operation of the air condition
turn main switch to position "0"
o : ^
IMPORTANT
During operation of the air condition all doors and windows of the cabin have to be closed
1
The outlets of the blowers on the outer side may not be blocked
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CRANE OPERATION
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EMERGENCY OPERATION
INDEX
6. EMERGENCY OPERATION 6.3
6.1.
GENERAL 6.3
6.2. ARRANGEMENT OF EMERGENCY DEVICES 6.3
6.3. EMERGENCY HAND PUMP 6.4
6.4. PROCEDURE TO LOWER THE LOAD 6.5
6.5. PROCEDURE TO RELEASE THE SLEWING BRAKES 6.5
6.6. PROCEDURE TO LOWER THE BOOM 6.6
6.6.1.
LOWER THE BOOM WITH EMPTY HOOK BLOCK 6.6
6.6.2. LOWER THE BOOM WITH HOOK BLOCK IN HOOK GARAGE 6.6
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EMERGENCY OPERATION
EMERGENCY OPERATION
6.1. GENERAL
With the hand pump it is possible to carry out the following em ergency m ovements or operations at a total
standstill of the crane.
- lower the hook
- lower the boom
- open the slewing brakes
WARNING
In case an emergency operation is carried out, the crane movements are not
stopped by limit switches or other safety devices.
Therefore the movements have to be supervised by additional perso nne l
6.2.
ARRANGEMENT OF EMERGENCY DEVICES
INSIDE MASCHINERY HOUSE
- Connection for emergency
handpump
- Hand valve H62B
- Hand valve D62- Hand valve D63
- Hand valve E69
- Regulation valve E60
AT HOISTING WINCH
- Connection for emergency
handpump
- Hand valve H62
- Hand valve H62A
- Hand valve H63
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EMERGENCY OPERATION
6.3. EMERGENCY HAND PUMP
The hand pump shall be used in case of a total standstill of the crane since the hydraulically controlled multi
disc brakes are closed without pressure.
With this hand pump it is possible to make an em ergency lowering operation on the hoist system by releasing
the spring loaded multiple disc brake.
A
WARNING I
The operation of
the
emergency hand pump must be done at a place from where the
emergency movement can be seen
In case of emergency operation there is no stopping of crane movements by limit
switches or other safety devices.
Therefore the movements have to be supervised by additional personnel I
LAYOUT OF EMERGENCY HAND PUMP
1
Pump lever
2 Pressure gauge (minimum 15 bar to release the brakes)
3 Connection to hydraulic system (pressure line of pump)
4 Breather filter
5 Oil filling and dipstick
6 Tank
NOTE
I At longer usage of hand pump during emergency operation (for examp le at large lifting heights)
check oil level of hand pump with dipstick and if necessary refill tank with hydraulic oil.
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EMERGENCY OPERATION
6.4. PROCEDURE TO LOWER THE LOAD
Location of used valves:
H63 - located at the bulkhead plate near the hoisting winch
H62
/
H62A
- located near the hoisting motor
H62B
- located at the top of the hydraulic tank
- Close hand valve H63 to disconnect the hoisting gear from LUDV block
- Change over position of hand valve H62A to emergency p osition.
- Change over position of three way hand valve H62 to emergency po sition.
- Connect one hose from hand pump to the tank and the second hose from the hand pump to the hand valve
H62A
- Increase the pressure to the disc brake by use of the hand pump.
- Now the mu ltiple disc brake
H61U
opens and the load will lower as long as the hand pump is operated.
A
ATTENTION
After emergency operation is finished:
- Change back three way
valve
H62 and hand valves H62A,
H63
to normal position.
6.5. PROCEDURE TO RELEASE THE SLEWING BRAKES
Location of used valves:
D62 / D63 - located at the slewing gears
- Connect one hose from hand pump to the tank and the second hose from the hand pump to the hand valve
D62
- Open bypass valve
D63
(pressure balance in the main lines)
- Increase the pressure to the disc brakes by use of the hand pump
- Turn the crane slowly by additional gear (e. g. second crane, chain block)
A
ATTENTION
After emergency operation is finished:
- Change back hand valve D62 and bypass valve D63 back to normal position 1
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EMERGENCY OPERATION
6.6. PROCEDURE TO LOWER THE BOOM
E69 - located at the bottom of the hydraulic tank by the suction line
E60 - located at the top of the hydraulic tank
H62
/
H62A
- located near the hoisting motor
H62B / E60 - located at the top of the hydraulic tank
A,
A T T E N T I O N I
Check hook block position, inside/outside hook garage before start emergency operation.
6.6.1. LOWER THE BOOM WITH EMPTY HOOK BLOCK
- Open hand valve
E69
- Open slowly adjustable throttle valve
E60
and the boom starts to lower
- With adjustable throttle valve E60 it is possible to adjust the lowering speed of the boom.
A
ATTENTION I
After the em ergency operation is
finished,
throttle valve E60 must be closed
completely and hand valve E69 brought back to normal position.
6.6.2. LOWER THE BOOM WITH HOOK BLOCK IN HOOK GARAGE
- Open hand valve E69
- Open hand valve
H62B
- Close hand valve H63
- Change over position of hand valve H62A
- Change over position of "three way hand valve"
H62
- Open slowly adjustable throttle valve E60 and the boom starts to lower
- With adjustable throttle valve E60 it is possible to adjust the lowering speed of the boom.
A
ATTENTION
After emergency operation is finished, throttle valve E60 must be closed completely.
Hand valves
E69,
H62A, H62B, H63 and three way valve H62 must be brought back to nor
mal position .
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EMERGENCY OPERATION
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MAINTENANCE
INDEX
7. MAINTENANCE 7.3
7.1. QUALIFIED PERSONS 7.3
7.1.1.
GENERAL 7.3
7.2. SERVICE SPARE-PARTS AND STANDARD TOOLS 7.4
7.3. MAINTENANCE INTERVALS 7.5
7.3.1. GREASING SCHEMATIC 7.9
7.3.2. OIL FILLING SCHEMATIC 7.10
7.3.3. LUBRICANT REQUIREMENTS 7.11
7.3.4. TABLE OF LUBRICANTS 7.12
7.4. ELECTRIC MOTOR 7.14
7.4.1. GENERAL SAFETY CONSIDERA TIONS 7.14
7.4.2. MAINTENANCE AND LUBRICATION 7.14
7.5. GEARBOXES 7.16
7.5.1. SLEWING GEARBOXES 7.16
7.5.2. HOISTING WINCH GEARBOX 7.17
7.6. MULTIPLE DISC BRAKES 7.19
7.7. CRANE ROPES 7.20
7.7.1.
SELECTION OF WIRE ROPES 7.20
7.7.2. ROPE INSTALLATION 7.20
7.7.3. MAINTENANC E 7.21
7.7.4. INSPECTION 7.21
7.7.5. INSTRUCTIONS FOR UNTW ISTING OF HOIST ROPES 7.22
7.7.6. DISCARD CRITERIA 7.23
7.8. ROPE PULLEYS 7.24
7.8.1.
GENERAL LAYOUT 7.24
7.8.2. STORAGE 7.24
7.8.3. TRANSP ORT 7.24
7.8.4. DURING OPERATION 7.25
7.8.5. INSPECTION AND MAINTENAN CE 7.25
7.8.6. RESISTANCE TO CHEMICAL PRODUCTS OF LAMIGAMIDR ROPE PULLEYS 7.26
7.9. HYDRAULIC LINES AND HOSES 7.27
7.9.1.
GENERAL 7.27
7.10. HYDRAULIC OIL TANK 7.28
7.10.1.
RETURN FLOW FILTER HYDRAU LIC OIL TANK 7.29
7.10.2. VALVE AND FILTER PLATE AGGREGATE ROOM 7.30
7.11.
LIEBHERR CONDITION MONITORING 7.32
7.11.1.
GENERAL 7.32
7.11.2. TECHNIQUES EMPLOYED IN CONDITION MONITORING 7.32
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MAINTENANCE
7.11.3. OIL SAMPLE / OIL EXCHANGE 7.34
7.11.4. TAKING AN OIL SAMPLE 7.35
7.11.5. CON DITION MONITORING REPORT 7.36
7.12. PRESSURE ACCUMULATORS 7.37
7.12.1.
GENERAL 7.37
7.12.2. SAFETY INSTRUCTIONS 7.37
7.13. MAINTENANCE OF OIL COOLERS 7.37
7.14. ELECTRICAL SYSTEM 7.38
7.14.1.
MAINTENANCE TO THE ELECTRICAL SYSTEM 7.38
7.14.2. WE T CLEANING 7.38
7.15.SLIP RING UNIT 7.39
7.16.
AIR CONDITIONING SYSTEM 7.40
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MAINTENANCE
7. MAINTENANCE
In tables, this chapter lists all maintenance w orks that have to be carried out on the crane.
However, only the works the crane operator may perform by himself (after 10 and after 50 operating
hours) are explained. They are indicated with "Chapter 7" in the "Remarks" column.
Maintenance work after 500 operating hours may only be carried out by qualified personnel or by LIEB-
HERR-CUSTOMER SERVICE respectively by authorized LIEBHERR partners contracted do to so. These
maintenance works are m arked "By LWN-Service only" in the "Remarks" column.
7.1. QUALIFIED PERSONS
PERSONS RESPONSIBLE FOR THE SAFETY OF THE CRANE MUST ENSURE THAT:
- qualified persons are only delegated to work on the m achinery or apparatus,
- these persons m ust keep the Operating manual provided, and other documents, available when carrying
out the operations to w hich they refer and to follow that documentation w ithout fail,
- unauthorized persons are prohibited from w orking on , or approaching, the machinery or apparatus.
Qualified persons are persons who, as a result of their training, experience and the instruction they have re
ceived, and of their knowledge of the relevant Standards, directives , acciden t prevention regulations and oper
ating conditions, have been authorized by those responsible for the safety of the machine to carry out the par
ticular task required and who are able to recognize and avoid the potential hazards. A knowledge of first-aid
and local rescue equipment is essential. A ccording to regu lations, unqualified personnel are forbidden to work
for example on power installations and apparatus.
7.1.1. GENERA L
^T
NOTE
The specified maintenance and inspection intervals must not be exceeded.
When required, shorten the intervals.
The safety guidelines in chapter 3 must be observed and strictly adhered to.
Maintenance must be carried out conscientiously within the specified intervals. These maintenance
intervals are indicated in operating hours and calendar days. Apply the maintenance interval that
comes first.
The intervals supplement
each
other. This means that when maintenance of higher intervals is car
ried out, maintenance of lower intervals are to be carried out also.
Whenever the crane will not be in use for at least 3 m onths, all exposed parts must be covered and
protected against the environment. The protective covers have to be removed before restarting the
crane.
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MA IN TEN A N C E
7.2. SERVICE SPARE-PARTS AND STANDARD TOOLS
A comprehensive
spare part list is
provided
for
reference when ordering spare parts
or
replacements.
The
drawing s reprod uced in the spare part manual are for the purpose to ass ist in identifying sp are parts, they need
not necessarily ag ree exactly with the actual construct ional details
of
the parts involved.
In
order to avoid mis
takes, it is
advisable
to use
only
the
terms
and
expressions used
in the
these instruct ions.
It
is
part icularly imp ortant that spare part orders should include
the
following information:
- CRANE TYPE
and
CRANE SERIAL NUM BER
- L IEBHERR IDENT-NUMBER of each single spare part
- QUANTITY of parts required
- BRIEF DESCRIPTION
of
parts required
Careful attent ion to correct ordering is a lways important as omission of essential information w il l inevitably
cause delay and may even lead to incorrect parts being supplied.
In order to avoid any delay we kindly ask to provide addit ionally following details:
- YOUR PURCHASE ORDER-
OR
REFERENCE NUMBER
- DELIVERY ADDRESS
- DELIVERY M ODE
- YOUR CONTACTS (Address, Telephone No. , Fax No.)
r r ^ NOTE
A LL SPARE PA RTS SEE SPARE PA RT CA TA LOGUE
A complete l ist
up of
standard sup plied tools, addit ional safety de vices, etc.
is
provided
in
the spare
part catalogue.
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MAINTENANCE
7.3.
MAINTENANCE INTERVALS
INFORMATION FOR MAINTENANCE SCHEDULE
The maintenance intervals m entioned in this section are guiding times and should be observed.
If due to extreme environmental conditions (i.e. dust, tropical conditions) or extreme operational co nditions
(i.e.
multiple shift operation) a deviation to the given maintenance interval(s) should become necessary, ask
your local LIEBHERR CUSTOMER SERVICE for advice and confirmation to do so.
OIF
NOTE
IT SHOULD BE NOTED THAT IN PARTICULAR THE MAINTENANCE TIME INTERVALS
INDICATED ARE APPROXIMATE. IN REALITY THESE INTERVALS SHOULD DEPEND
ON CRANE USAGE AND THEREFORE - MAY NEED TO BE UPDATED ACCORDINGLY.
^
IMPORTANT
The maintenance intervals indicated in the maintenance list are based on the
ACTUAL OPERATING HOURS OF THE CRANE. Should the crane be standing for a period
of more then four ( 4 ) weeks - the crane has to be operated ONCE A MONTH FOR AT LEAST
TWO ( 2 ) HOURS. In addition to that all the greasing, oil inspections and oil level checks
have to be done as well.
GEN ER A L MA IN TEN A N C E
"(5
• o
O
X
X
X
0)
0)
CM
O
O
O
in
(A
SI
* J
c
o
E
CO
£
O
O
in
X
X
X
X
£
c
o
E
(O
£
O
O
O
0
0
re
0)
>«
£ •
>
£
O
O
O
CM
0
X
X
0 = First t ime maintenance
X = Repeated maintenance
LS = LIEBHER R S ervice personel l
Check funct ion and correct indicat ion of all control devices
Check correct funct ion of emergency stops
Check cables and plug connection of main sensors
Check correct funct ion of l ight ing
Check screw connections, brushes of sl ipring unit
Check-up of steel structure, welds, brackets, ladders, platforms
Drive all funct ions, check safety devices and l imit switches
Check all terminals and venti lat ion of switch cabinet
Check junct ion boxes
Check correct f i t of cables and sensors
Replace air fi l ter of switch cabinet
LS
LS
LS
-7.5-
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MAINTENANCE
GR EA SIN G SYSTEM
"(5
•a
£
o
0)
0)
£
O
m
X
X
X
M
CM
£
O
O
O
m
CM
X
(A
sz
4-»
c
o
E
CO
£
O
O
i n
0
X
(A
£
C
O
E
CO
£
O
O
O
re
0)
0)
>
0)
£
O
O
O
CM
0 - First t ime maintenance
X = Repeated maintenance
LS = LIEBHERR Service personel l
Check all greasing l ines.
Check greasing points.
Regrease all greasing points
Visual Check of all greasing points, check t ightness of graesing
lines
Regrease all greasing points
Regrease all greasing points, greasing l ines and blocks
H YD R A U LIC SYSTEM
'a
73
£
O
X
£
(fl
0)
$
(N
£
O
O
0
£
O
IA
CM
M
£
C
O
E
ro
£
O
O
m
X
0
X
£
C
O
E
(O
£
O
O
O
n
0)
>.
0)
>
0)
£
O
O
O
CM
X
X
X
X
X
0 = First t ime maintenance
X = Repeated maintenance
LS = LIEBHER R Service personell
Checking leakightness and condit ion (hoses, pipes, f it t ings),
check oil level.
Replace f i l ter element of feed pressure f i l ter, oil cooler f i l ter and
return flow filter
Drive system to working temperature. Take a oil sample, if re
quired change oil; drain oil, clean complete inside tank.
Drive system to working temperature. Check oil level.Take oil
sample.
Drive system to working temperature. Take oil sample, if required
change oil; check leakt ightness.
Check wear of tooth prof i le of hydraulic motors
Check pressures, adjustments if required
Replace air breather filter of hydraulic oil tank
Replace (check) pressure accum ulators
LS
LS
LS
LS
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MAINTENANCE
SLEWIN G GEA R B OXES A N D SLEWIN G B EA R IN G
n
•a
o
X
o
O
»O
X
tf)
0)
0)
£
O
O
X
O
CM
(A
£
^ - »
C
O
E
CO
o
o
• n
X
X
0
IA
£
C
O
E
(O
£
O
O
O
0
0
re
0)
>
£
O
O
O
CM
X
X
0 = First t ime maintenance
X = Repeated maintenance
LS = LIEBHERR Service personel l
Check condition of gear r im and slewing bearing, regrease
Check gear oi l level of slewing gearboxes
Grease slewing gear r im
Check correct oi l level of slewing gear boxes
Check air breather of slewing gear boxes
Take oil sample on slewing gearboxes, check oil level
Drive to temperature, take oil samples, i f required renew oil to
correct level.
Che ck correct torque of bolts of slewing r ing LS
R OPES A N D R OPE PU LLEYS
> >
"re
• a
£
O
X
£
S
(A
0)
0)
CM
£
O
O
£
O
i n
CM
tf)
£
- »
C
O
E
£
O
O
i n
X
X
IA
£
C
O
E
(O
£
O
O
O
re
0)
0)
>
0)
£
O
O
O
CM
0 = First t ime maintenance
X - Repeated maintenance
LS = LIEBHERR Service personel l
Check condition, lubricants, function of ropes
Check condition and rope fix points
Check for dam ages / wear of rope pul leys
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MAINTENANCE
HOISTING WINCH
• a
o
X
X
f
(A
CM
O
O
0
O
m
CN
£
^ - »
C
O
E
CO
O
O
i n
X
(A
£
C
O
E
(O
£
O
O
O
(0
0)
>.
£>
O)
>
JC
o
o
o
CM
X
o = First t ime maintenance
X = Repeated maintenance
LS = LIEBHERR Service personel l
Check correct function of l imit switches
Check gear oi l level, grease counter bearing
Take oil samples, i f required renew oil to correct level. Before fi t
t ing new oil f lush the gear boxes with l i tt le preheated oil in order
to wash off any contamination.Check level after a short while
again.
Check for correct oi l level, check air breathers
Drive to temperature, take oil samples, i f required renew oil to
correct level. Before fi tt ing new oil f lush the gear boxes with l i tt le
preheated oil in order to wash off any contamination.Check level
after a short while again
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MA IN TEN A N C E
7 .3 .1 .
GR EA SIN G SC H EMA TIC
LUBRICANTS AND SERVICE FLUIDS should be selected f rom the SPECIFICATIONS OF SER
VICE PRODUCTS of L IEBHERR
1 Slewing bearing - slewing gear r im
2 Inside slewing column: slewing gears
3 Hoist ing winch counter bearing
4 Ropes
5 Central greasing point for rope pulleys
Regarded grease qualit ies
System
Rope pulleys
Ropes
Slewing bearing
Slewing ring gear r im
Slewing gear
Winches
Grease
AVIALITH 2EP
Calc ium-grease EP
AVIALITH 2EP
AVIA ALUPLEX 2
AVIALITH 2EP
AVIALITH 2EP
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MAINTENANCE
7.3.2. OIL FILLING SCHEMATIC
1 Hoisting winch gearbox
2 Hydrau lic oil tank
3 Slewing gear boxes
Regarded oil qualities and quantities
System
Hoist ing winch
Hydraulic oil tank
Slewing gearboxes
Type of oil
API GL-5 (SAB 90 / SAE 80 W90)
ATF or similar
API GL-5 (SAE 90 / SAE 80 W90)
Filling quantities
61
1050 1
3 x 1 1 , 2 1
rr^ NOTE I
The oil filling quantities in the following chart are approximate values.
Determine the effective filling quantities always with the oil dipstick or oil sight glass.
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MAINTENANCE
7.3.3. LUBRICANT REQUIREMENTS
Number
1.
2.
3.
4.
5.
6.
7.
8,
9.
10.
11.
12.
13.
Lubrication Points
Engine'')
500 Bh
Engine'')
250 Bh
Oilbath air cleaner
IVIechan. g earboxes and
winches
Axles
Hydrosta tictransmiss ion
Powersteering
Ball resp. Roller slewing
nngs,
cardan shafts,
other greasing points
Open gears and geared rims
Ropes'»)
Ambient-
temperature
all the year
up to - 20 °C
all the year
up to - 20 °C
up to -1 5 °C
up to - 20 C
up to - 25 "C
up to - 25
°C
all the year
upto-15°C2)
all the year
up to - 20 °C 2)
up to - 25 "C 2)
upto-15°C2)
up to - 20
C
2)
up to - s e e
all sections
Type ISOVG/SAE
SAE10W-40
SAE10W-40
SAE15W-40
See
lubricant requirement motor
SAE90
SAE85W-140
SAE 80W-90
SAE80W-140
ATF
ISO VG 46
ISO VG
46
ISO VG 46
SAE15W-40
SAE10W-40
Multipurposegrease
Lithium based
First fill "Liebherr Sp ezialfett
9610 Plus"
Lubricant and preservative
Specification
ACEA E4
APICF
ACEA E2/E3
API CE / CF-4 / CG-4
MIL-L-2104C/D
(SHPD)
API
GL-5
MIL-L-2105B/C/D
1.DEXR0NIID/E
2. DEXRON III
DIN 51 524 / 2
TypHLP/HLPD
DIN 51 524 / 3
Typ HVLP / HVLPD
VDMA24 568/Typ HEES 3)
ACEA E2 / E3
API
CE
/
CF-4
/ CG-4
MIL-L-2104C/D
ACEA E2 / E3 / E4
API
CE
/
CF-4
/ CG-4
MIL-L-2104C/D
DIN51825,NLGI2
KP 2 K-30
KPE 2 K-30
DIN 51 502
O G P F 0 / 1 / 2
1) The instructions of the manufacturer are obligatory ( pay attention to the man ual)
2) With heating of crane in operation outside temperatures could be
appr.
15 °C
lower.
3) quickly biodegradable
4) See also the operating manual
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MAINTENANCE
7.3.4. TAB LE OF LUBRICANTS
Nu m
ber
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
gågnp
A g l p S I G M A U l t r a T F E
1 0 W - 4 0
A g i p S i g m a S u p e r
T F E 1 0 W - 4 0
A g i p S I G M A T F E
1 0 W - 4 0
A g i p B l i t u m T 1 5 W - 4 0
Agip Universa i Mul t i -
f leet 15W-40
A g i p R O T R A M P D B
8 5 W - 9 0
A g i p R O T R A M P
8 5 W - 1 4 0
A g i p R O T R A M P
9 0 W - 9 0
A g i p R O T F t A T R U C K
G E A R 8 0 W - 9 0
A g i p R O T R A T R U C K
S ( L S X ) G E A R
7 5 W - 9 0
Agip ATF D 309
Agip ATF I I D
A g i p D E X R O N I I I
A g i p O S O 4 6
A g i p O S O - D 4 6
A g i p A R N I C A D 4 6
A g i p A R N I C A 4 6
A g i p P R E C I S S y s t e m
Mui t i F lu id
4^^^
M e g a T u r b o r a l S A E
1 0 W - 4 0
Ext ra Turbora l SAE
1 0 W - 4 0
Plus Turbora i SAE
1 5 W - 4 0
Mui t i Turbora l SAE
1 5 W - 4 0
Get r iebeöl Hyp
8 5 W - 1 4 0
Get r iebeöl Hyp
8 5 W - 1 4 0
Get r iebeöl EP P lus
8 0 W - 9 0
1. A T F E - S
2. ATF 55
V i t a m G F 4 6 /
V l t a m D E 4 6
V i t a m H F 4 6 /
V i t a m V F 4 6
A V / A
^ ^ ^
A V I L U B M o t o r e n ö l W D B
1 0 W - 4 0
A V I A T U R B O S Y N T H
C F E
L U S 1 0 W - 4 0
A V I A M U L T I H D C P L U S
1 5 W - 4 0
A V I A M U L T I H D C E X
T R A 1 5 W - 4 0
A V I A H Y P O I D 9 0 E P
A V I A H Y P O I D 8 5 W - 1 4 0
EP
A V I A S Y N T O G E A R P E
22 0 (PAO)
A V I A S Y N T O G E A R F E
8 0 W - 9 0
A V I A H Y P O I D F E
8 0 W - 1 4 0
A V I A S Y N T O G E A R F E
75W-90 EP (PAO)
1.AVIA F L U I D A T F 8 6
AVIA FLUID ATF 92 S
2. AVIA FLUID ATF 98
A V I A F L U I D R S L 4 6
A V I A F L U I D H L P D 4 6
AVIA FLUID HVI 46
sm
Vanel lus E7 P lus
Vanel ius C6 G lobal
P lus
Vanel lus E6
E n e r g e a r H y p o
8 5 W - 9 0
E n e r g e a r H y p o
8 5 W - 1 4 0
E n e r g e a r F E 8 0 W - 9 0
E n e r g e a r F E 8 0 W - 1 4 0
E n e r g e a r H y p o
8 0 W - 1 4 0
1. A u t r a n L T F ( D e x r o n
H E )
A u t r a n M B X ( D e x r o n
II D)
2. Aut ran DX I I I
E n e r g o l H L P - H M 4 6
E n e r g o l H L P - D 4 6
Bar t ran HV 46
^ C h e v r o n
C h e v r o n D e l o ® X L D
S A E 1 0 W / 4 0
1 0 W - 4 0 A V I A M U L T I
C F E P C h e v r o n
D e l o ® X L D
S A E 1 0 W / 4 0
C h e v r o n D e l o ® 4 0 0
S A E 1 5 W / 4 0
C h e v r o n R P M
Universa l
S A E 8 5 W / 1 4 0
C h e v r o n R P M U n i v e r
s a l 8 0 W / 9 0
C h e v r o n A T F
C h e v r o n A T F - 2
Hydrau l ic O i l AW
ISO
4 6
Chevron C lar i ty® Iso
4 6
e i F c E i
P e r f o r m a n c e E x p e r t y
1 0 W - 4 0
P e r f o r m a n c e T r o p h y
D X 1 0 W - 4 0
P e r f o r m a n c e T r o p h y
D X 1 5 W - 4 0
Transe l f Typ B 90
Transe l f Typ B
8 5 W - 1 4 0
Transe l f Typ B
8 0 W - 9 0
Transet f Un iversa l
F E 8 0 W - 9 0
Transe l f Un iversa l
F E 8 0 W - 1 4 0
El fmat ic G 2 SYN
El fmat ic G 3 SYN
A z o l l a Z S 4 6
A z o l l a D 4 6
Equiv is ZS 46
Equiv is D 46
Only on request by Liebherr
A g i p B l i t u m T 1 5 W - 4 0
Agip Universa l Mul t i -
f leet 15W-40
A g i p S I G M A U l t r a T F E
1 0 W - 4 0
A g l p S i g m a S u p e r
T F E 1 0 W - 4 0
A g i p S I G M A T F E
1 0 W - 4 0
Agip GR MU EP 2
A g i p L o n g t i m e G r e a s e
2
A g i p / A u t o l T O P 2 0 0 0
A g i p / A u t o l T O P 2 0 0 0
BIO 3)
A g i p S A G U S 6 0
A g i p G R E A S E S M 2
Mui t i Turbora l 15W-4Q
Ext ra Turbora l 10W-40
M e g a T u r b o r a i
1 0 W - 4 0
A r a l u b H L P 2
Langzei t fe t t H /
A r a l u b B A B E P 2
Ara lub MKA Z 0
A r a l u b M K A Z 1
A r a l u b M K A P L
As I tem 3
As I tem 1 & 2
A V I A L I T H 2 E P
A V I A S Y N T O G R E A S E
2 3)
A V I A A L U P L E X O
R H S
A V I A A L U P L E X 2
R H Y
A V I A A L U P L E X R H S
F L U I D
Vanel lus E6
Vanel lus E7 P lus
E n e r g r e a s e L S - E P 2
B iogre ase EP 2 3)
E n e r g r e a s e O G
As I tem 3
As I tem 1 & 2
U l t l -P lex Grease EP
#2
O p e n G e a r G i e a s e
P e r f o r m a n c e T r o p h y
D X 1 5 W - 4 0
P e r f o r m a n c e T r o p h y
D X 1 0 W - 4 0
Mul t is EP 2
C e r a n A D
C e r a n M M
1) The instructions of the manufacturer are obligatory (pay attention to the ma nu al)
2) With heating of crane in operation outside temperatures could be appr. 15 °C lower.
3) quickly biodegradable
4) See also the operating manua l
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MAINTENANCE
Num
ber
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
(isso)
ESSOLUBE XTS 5
ESS0LUBEXT5
ESSOLUBE XT 5
ESSO Gear Oil GX-D
85W-90
ESSO Getrieteool GX
85W-140
ESSO Gear Oil TDL
75W-9D
ESSO Gear Oil TDL
80W-140
ESSO ATP Dexron II
ESSO ATP D 3
Nuto H 46 (HLP)
Esso HLPD 46
Univis N 46 (HVLP)
^RNAI
Kappa Ultra
10W-40
Kappa Ultra
10W-40
Kappa Extra Plus
15W-40
Pontonic MP
80W-90
Pontonic MP
85W-140
Pontonic MP
80W-90
Pontonic A
80W-140
Finamatic S 6726
Finamatic HP
Azolla ZS 46
Azolla D 46
Equivis ZS 46
Equivis D 46
ip^s
TITAN CARGO MC
S AE 10W40
TITAN UNIC MC
SAE 10W40
TITAN UNIVERSAL
HD SAE 15W40
TITAN GEAR HYP
SAE 90
TITAN SUPERGEAR
SAE 85W-140
TITAN SUPERGEAR
SAE 80W90
TITAN SUPERGEAR
SAE 85W-140
TITAN ATF 3000
TITAN ATF 4000
TITAN ATF 5000
REN0LINB15
REN0LINMR15
RENOLIN B46HVI
RENOLINMR46MC
S h e l l
Rimula Ultra 10W-
40
Rimula Super FE
10W- 40
Rimula Super
15W- 40
Spirax A 90
Spirax A
85W- 140
Spirax A 80W-9Q
Spirax ST eOW-140
3. Donax TA
4. Donax TX
Teilus 46/ Tellus S
46
Tellus DO 46
Tellus T 46
Tellus TX 46
Tellus TD 46
M©bil
Mobil Delvac XHP
Extra
Mobil Delvac 1
Mobil Delvac 1
SHC
Mobil Delvac MX
Mobilgard HSD
Mobil Delvac MX
Mobilgard HSD
Mobilube HD
85W-90 A
Mobil SHC 630
Mobilube HD
85W-140
Mobil SHC 632
Mobilube 1 SHC
75W-90
Mobil SHC 630
Mobilube HD-N
80W-140
Mobil SHC 632
Mobil ATF 220 (IID)
Mobil ATF
Mobil DTE 25
(HLP)
Mobil DTE 15M
(HVLP)
Mobil SHC 525
TOTAL
åmmS—J
Rubia TIR 8600
10W-40
Rubia TIR 8600
10W-40
Rubia TIR 6400
15W-40
Total EP B
80W-90
Transmission TM
85W-140
Total EP B
80W-90
Transmission TM
80W-90
Transmission TM
FE 85W-140
Fluide SYN FE
Fluide matic SYN
Azolla ZS 46
Azolla D 46
Equivis ZS 46
Equivis D 46
UNIL
UNIMOTTRUCK
LD 10W-40
UNIMOTTRUCK
LD 10W-40
MARMAX TD
15W-40
HYPOID GEAR
O1LTS80W-140
AS 4 +
MPGO85W-140
ATF II
HYDRAULIC OIL
46
PREMIUM HY
DRAULIC OIL HVI
46
Only on request by Liebherr
ESSOLUBE XT 5
ESSOLUBE XT 5
Beacon EP 2
Kappa Ultra
10W-40
Kappa Extra Plus
15W-40
Multis EP 2
Ceran AD
Ceran MM
TITAN UNIVERSAL
HD SAE 15W40
TITAN UNIC MC
SAE 10W40
RENOLIT MP
RENOLIT LZR 2 H
PLANTOGEL 2 S2 3)
RENOLIT CX-HAT 0
RENOLIT CX-HAT 2
Rimula Super
15W-40
Rimula Super FE
low- 40
Alvania EP(LF)2
Alvania EPB2
Malleus OGH
Malleus GL 95
Mobil Delvac MX
Mobilgard HSD
Mobil Delvac MX
Mobilgard HSD
Mobilgrease XHP
222
Mobilith SHC 460
Mobiltac 375 NC
OGPF 1-2 K-20
Mobilith SHC 460
Mobilgrease XHO
222
KP 2 G-30
Rubia TIR 6400
15W-40
Rubia TIR 8600
10W-40
Multis EP 2
Ceran AD
Ceran MM
MARMAX TD
15W^0
UNIMOT TRUCK
LD 10W-40
SPECIALUBE MB
2
Unigrease 1732
1) The instructions of the manufacturer are obligatory (pay attention to the m an ual)
2) With heating of crane in operation outside temperatures could be appr. 15 °C lower.
3) quickly biodegradable
4) See also the operating manu al
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MAINTENANCE
7.4. ELECTRIC MOTOR
7.4.1.
GENERAL SAFETY CO NSIDERATIONS
The electric motor is intended to be installed and used by qualified personnel who are familiar with relevant
safety requirements. Safety equipment necessary for
the
prevention of accidents
at the
m ounting and o perating site shall be provided in accordance with the regulations prevailing in the local country.
POINTS TO OBSERVE
• The machine shall not be used to step on.
•
The
temperature of the outer
casing
of the machinery may
be
too
hot to touch
during normal opera
tion.
• Some special machine applications require special instructions (eg using frequency converter
supplies).
• Lifting lugs shall be used for lifting the motor alone.
INFORMATIONS ON NAME PLATE
Rating plate
ce
ABB Oy, Electr ical Macti ines
j-"-?^
LV Motors, Vaasa, Finland ^
3 - ^ M o to r M 3 B P 3 1 5 S M B 4 B 3
IEC 315 S/M 80
S1
V
690 Y
4O0D
660 Y
380 D
415 D
440 D
Prod.cod
6319
l o _
Hz
50
50
50
50
50
60
e 3GBF
C3
1 ''^-^
kW
160
160
160
160
160
185
r/min
1487
1487
1485
1485
1488
1785
No. 3291111 7711 SM
Ins.cl. F
A
166
287
171
296
279
295
coscp
0.85
0.85
0.86
0.86
0.84
0-86
iP 55
Duty
31223D-ADG
iNmax 2300 r/min
Ö ) 6316/C3 1 1000 kg
e w ' l lEC 60034-1 O ^
Lubrication plate
(^
i t I B I B
o]
R e g r e c s i n g i n t e r v a l s i n d u t y h o u r s
B e a r i n g s 6 3 i 9 ^ . 6 3 1 6
A m o u n t o f g r e a s e 9 0 g J ^ 7 0 g
Mounting
Hor
Hor
Ver t
Ver t
Ambient
temp.
2 5 ' C
4 0 ' C
25 'C
40 'C
1 8 0 0
r/min
6 5 0 0
3 2 5 0
3 2 5 0
1 6 3 0
1 5 0 0
r/min
8 5 0 0
4 2 5 0
4 2 5 0
2 1 3 0
1 0 0 0
r/min
1250Q
6 2 5 0
6 2 5 0
3 1 3 0
5 0 0 - 9 0 0
r/rnin
1 6 0 0 0
8 0 0 0
6 0 0 0
4 0 0 0
D o n o t e x c e e d t h e m e t e r m o x . s p e e d
The following cr similar high pertarinance creese ccn be 'jsed:
Esse
Shell
SKF
Unirex N2, N3 or S2 |Uobil
.«Ibido Ek(S2
LCHO 3
Klüber
FAG
Mobiith SHC 100
Kliiterplex BEU il-132
Arconol TIMPIIO
1
O See the "Lew Voltags Motors Manual" O
7.4.2. MAINTENANCE AND LUBRICATION
GENERAL INSPECTION
• Inspect the machine at regular intervals.
• Keep the machine clean and ensure free ventilation air-flow.
• Check the condition of connections and mounting and assembly bolts.
• Check the bearing condition by listening for unusual noise, vibration measurement, bearing tem
perature, inspection of spent grease
rr-^
N OTE
When changes of condition occur, dismantle the machine, check the parts and replace if necessary.
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MA IN TEN A N C E
LUBRICATION
Machines f it ted with grease nipples (see picture above)
Lubricate the machine while running.
If grease outlet plug f it ted, remove tem porarily wh en lubricat ing.
r p ^
I M P O R T A N T
The m achine is f it ted with a lubrication informa tion plate. Follow the given valu es.
The greas e am oun t is used if small quantit ies of fresh grea se are replaced at regular intervals as above. As
an alternative, when the machine is f it ted with grease escape valves, fresh grease may be pressed into the
bearings un ti l the old g rease is totally rep laced.
LUBRICANTS
When regreasing, use only special ball bearing grease with the following propert ies:
• good quality l ithium base or l i thium complex grease
• bas e oil visco sity 100 -140 cST at 40 °C
• consistency NLG grade 2 or 3
• temp erature range -30 °G - +120 °C, continou sly
Greases with the correct propert ies are available from all the major lubricant manufacturers. I f the make of
grease is chang ed an d compa tibili ty is uncertain, lubricate several t imes at short intervals in order to displace
the old grease.
Highly loaded an d / or slowly rotat ing bearings require EP -grease . I f lubricat ion intervals are short due to b ear
ing temperatures above 80 °C or above, use high temperature greases which normally permit approximately
15° G higher bearing temp eratures .
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MA IN TEN A N C E
7.5. GEARBOXES
7 .5 .1 . SLEWIN G GEA R B OXES
1
x\\\/
3 ~ - . , ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ : : ; r ^ ^
4 ^
7 _
.2
^^_^ 5
^y] /®
?
8
1 Hydrau lic motor
2 Gea r oil f i l ling and air release of gear
3 Mult i disc brake
4 Oil sight glass
5 Slewin g gear box
6 Drainag e plug
7 Protect ion cover
8 Slew ing pinion (engag ed to gear r im
of slewing bearing)
OIL LEVEL INSPECTION
can be carried out by the provided oil sight glass (Pos. 4):
If required, refill gearoil
r r ^
IMPOR TA N T
Shut down the crane before making an oil change or oil level inspection
OIL CHANGE
Remove the drainage plug (Pos. 6) when exchanging the oil, but don't forget to put it on again after the oil
exchange.
Let the oil f low out at the oil drain (Pos. 6). Refill the gearbox at the oil f iller inlet (Pos. 2).
Oil change should be carried out at the working temperature of the gearbox. I t is recommended to f lush
the gear with a l i t t le preheated new oil. In this way any abrasives and contamination can be washed off .
' ^
N OTE
I
Further informa tion about f i l l ing qualit ies and f i l ling quantit ies are describe d in the chapters "FILLING
QUANTITIES and TABLE OF LUBRICANTS".
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MA IN TEN A N C E
7.5 .2 . HOISTING WINCH GEARB OX
1 Breather
2 Oil filler inlet with dipstick
3 Oil drain
r r ^ IMPOR TA N T I
Shut down the crane before making an oil change or oil level inspection
OIL LEVEL INSPECTION
can be carried out by the provided oil dipst ick (Pos . 2):
If required, refill gearoil
OIL CHANGE
Remove the drainage plug (Pos. 3) and breather plug (Pos. 1) when exchanging the oil, but don't forget to
put it on again after the oil exchange.
Let the oil f low out at the oil drain (Pos. 3). Refill the gearbox at the oil f iller inlet (Pos. 2).
Oil change should be carried out at the working temperature of the gearbox. I t is recommended to f lush
the gear with a l i t t le preheated new oil. In this way any abrasives and contamination can be washed off .
o : ^
N O T E
Further information about f i ll ing qualities and f i l ling quantit ies are described in the cha pters "FILLING
QUANT ITIES and TABLE OF LUBRICANTS".
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MAINTENANCE
ROPE KICKER (DEFLECTOR):
r p ^ NOTE
Following maintenance works must be performed every 500 operations hours or every three
months.
- Check wear and if neccessary remove chaffing from rope kicker
- Check if screws are in counter sunk position (Detail 1)
Detail 1
\^~'
I
Ei--
^-\
I h i
Rope
kicker
Detail 2
Rope
drum
I—ih
h-- |h
In case of excessive wear exchange rope kicker to avoid damages of the hoisting rope
r p ^
N O T E
When mounting new rope kicker check, if in correct alignment (Detail 2)
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MAINTENANCE
7.6. MULTIPLE DISC BRAKES
HYDRAULIC MOTOR
5 6
GEAR-BOX
1
Outer spring for brake force (AF)
2 Inner spring for brake force (IF)
3 Hydraulic pressure connection
4 Friction faces
(RFL)
5 Brake disc with inner gear rim (IL)
6 Brake disc with outer gear rim
(AL)
7
8
9
10
11
12
Discs bracket
Leak oil connection
Housing
Piston
Inner seal
Outer seal
GENERAL:
The spring loaded m ultiple disc brakes on our machines are used as HOLDING BRAKES ONLY, as
the slow down of any movement is done by the hydraulic system. Therefor they are subject to very
little wear. The brakes are only on high wear, in the case of an EMERGENCY STOP SITUATION
with full load. In this case the multiple disc brake of the wlnch(es) must be inspected and
checked for proper function.
The maximum holding moment of
a
respective machine or drive is determined by the various arrange
ments of the disks and springs in these brakes.
A
WARNING
For this reason, the arrangement
and
layout of
the
multi-disc-brake m ust al
ways be exact and special caution must always be exercised, when repairs
are carried out
or when
brakes are replaced. Only
an
exact arrangement pro
tects the drives
from
overloading
as well
as guaranteeing the maximum
hold
ing moment
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MA IN TEN A N C E
7.7. CRANE ROPES
7 . 7 . 1 .
SELEC TION OF WIR E R OPES
Rope construct ions l isted in this crane manual have been chosen after extensive test ing. They provide the
best possible match betw een crane and rope characterist ics. Based on ma ny years of experienc e these ropes
guarantee an optimal crane performance. Characterist ics of
ropes,
although of equal standa rd, may vary
con
siderably if rope construct ion, nu mbe r of strands or tensile strength is mod if ied - even if offering equ al rotat ion
resistant propert ies.
A WA R N IN G
If ropes are exchanged only use ropes of the same construct ion and
tensile strength as the original rope. Should it be necessary to use a
dif ferent rope crane manufacturer must be contacted for consen t .
Max. actual rope diameter must be 4 %, in the case of hoist ropes for truck mounted cranes exceeding 25
mm dia. it should be max. 3 %, above the no minal diameter. A r ight-hand rope is to be moun ted on a left-hand
drum and v ice versa.
7.7.2 .
ROPE INSTALLATION
Wire ropes are easily affected by external dam age , i.e. they must be ha ndled with utmost care during transport
and unloading. All wire ropes should be stored clean, dry and cool, soil contact must be excluded.
Only an installat ion of an untwisted rope free of any outer damage wil l guarantee a trouble-free operat ion.
Ropes always must be uncoiled from the reel or the r ing in the direct ion of winding (picture 1). Lateral uncoil ing
causes the rope to be twisted unti l i ts total destruct ion by kink formation .
I t is recom me nded to use a frame -mou nted reel for coiling the rope on the drum (picture
2 ).
Coil ing in the direc
t ion of bend prevents add it ional tension build-up in the rope and results in an excellent f it of the rope on the
drum. Never drag ropes through soil or dirt .
For the installat ion the ne w rope is f ixed to the old rope st il l mou nted or it is to be f ixed to a auxil iary rope .
Con nection b etween the two ropes can be achieved either by a basket or two welded ey es. Any transm ission
of torsion from either the old or the auxil iary rope to the new rope must be definit ively exclud ed. R otat ion-resis
tant ropes must be protected from torsion by inserted swivels.
Mult i- layer reeving requires that even the lower layers must be t ight ly coiled with a pretension of 1 - 2 % of
minimum breaking load of the rope. This pretension is achieved by braking the
reel.
For mult i strand ree ving hoist ing rope and drum shou ld have the sam e direct ion. I f i t is required to spread out
a l imited rope length on the f loor for mou nting the rope into the crane block it is important to avoid an y twist
or torsion in the rop e.
Non-rotat ion free ropes may be used with f ixed points at both ends only.
A test-run of several l i f ts under part ial load and later with alternately loaded a nd unloa ded crane bloc k is re
quired. Thus a f lexible adaptat ion of the rope to bending direct ion and b ending radii of pulleys and drum wil l
be achieved.
PICTURE 1
i
PICTURE 2
/ ' — N -
( X )
w
RIGHT
)Å \
RIGHT
— — — .
9.
T^^
^
i
^ ~ ~ N
f REEL
y^
WRONG
WRONG
y^ ' '^ -v j ' 'S^
' ^m
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MA IN TEN A N C E
7.7 .3 . MAINTENANCE
Mainten ance at regular intervals guarantee s safe crane operat ion and conside rably increases rope l ife. Wire
ropes must be regrea sed at regular intervals acco rding to crane ope rat ion, this especially applies to the bend
ing zones at the drums and pu lleys. Wh en exp osed to the sam e test condit ion a well-greased rop e has sho wn
four times as many working c ycles than an ungrea sed rop e. Relubricants must be compa tible with the original
lubricant used.
The following lubricants are recommended:
All standard lubricants recommended by the crane manufacturer for open gears
Special lubricants l ike e.g.Texaco Novatex Grease EP2, Rocol RD 105, Aral Aralub LFZ1
For ropes being reeved in mult iple layers and therefore being exposed to extreme w ear use of graph
ite containing lubricants is recommended like e.g. :
Reiner Ceplattyn KG 10, Texaco Novatex FK 10
Heavily soiled wire ropes have to be clean ed regu larly with a brush. I f the lower layers on the drum are seld om
used or not used at all, ropes have to be unreeled from t ime to t ime and then have to be reinstalled under
prestress. A rope operates most economical when used in its whole length. Therefore it is recommended to
always use the appropriate rope length according to crane operat ion; this is mainly true if crane is operated
continuously for a long period of t ime.
If a rope is unequa lly loaded it may be reversed . The formerly free end is f ixed in the drum by posit ioning un
worn zones at zones mostly exposed to wear thus rope l ife can be extended considerably.
I f wea r ma inly occurs if rope is mult i- layer reev ed on the Lebus d rum , rope l ife may be increas ed by cutt ing-off
one length according to 1/3 of drum circumfere nce. This pro cedure can be repeated up to three t imes per rope .
7 .7 .4 . INSPECTION
Wire ropes have been dimensioned to provide suff icient safety margins after the occurrence of f irst signs of
a wire breakag e before a replacem ent of the rope is required . The rope s have to be inspected in regular inter
vals; espe cially in the t ime period following direct ly after its installat ion. In addit ion spe cial attent ion is req uired
if a rope has been ex posed to excess ive wear, if non-visible da mag e is suspected or if there are other indica
t ions for rope damage.
The following criteria for a safe operat ion of the ropes can be applied:
- type and number of wire breakages (see table)
- posit ion and t ime sequence of the wire breakages
- decrease of rope diameter
- corrosion, abrasion, deformation
- heat-effects
- length of period of running
First signs of a change in rope behavior must be carefully monitored.
A
A TTEN TION
A twist ing and waving of strands above the crane block can be an indicat ion for a severely
damaged rope. This twist ing/waving is caused always by an addit ional torsion in the rota
t ion-resistant ho ist ing rope originat ing from a num ber of adverse effects but may also be due
to an overstretching of the hoist rope during heavy duty operat ion or due to shock loads resp.
tearing on st icky container in hold. The torsion has to be untwisted at the rope f ixpoint and
requires extreme care and respective know-how. Therefore inspection is necessary at regu
lar intervals especially shortly after the new rope has been installed.
Untwist ing of crane pu lley block with rotat ion-stable rope f ixed p oint:
- Set down of pulley block
- Determine direct ion of twist.
- Detach rope from f ixpoint and turn rope at the end approx. 180 - 360° into the direct ion which compen
sates the twist ing resp. waving of the rope.
- Connec t rope at f ixpoint and carefully l if t pulley block, operate crane u nloade d with pulley block and also
with cran e trolley if present
- Repeat if necessary
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MA IN TEN A N C E
r ^
IMPOR TA N T
Make sure that twist is distr ibuted to a long free rope en d. By operat ing the crane in unloaded co ndi
t ion twist is to be distr ibuted to the entire rope leng th. By operat ing the crane in unloaded condit ion
twist is to be distr ibuted to the entire rope len gth. By no m eans forcefully twist a short length of rope;
this may permanently damage rope structure.
I f the hoist ing rope wa s operated with ope n swivel an untwist ing can be achieved by operat ing the trolley sev
eral t imes under no load condit ions and with unloaded hook. I f not successful, follow same procedure given
for ropes with f ixed point, e.g. if crane does not provide of a swivel, i f rope is predama ged or if cause s of twist
can not be reme died otherw ise. At the same t ime a regular check of all rope end termination s and suspe nsions
for proper funct ion is required. Individual components of rope drive unit , drums and pulleys must turn freely
in their bearings. Grooves should not show any rope marks. Minimum groove radius on drums and pulleys
should be 0,53 x nominal rope diameter.
7 .7 .5 . INSTRUC TIONS FOR UNTW ISTING OF HOIST ROPES
1) Twist ing of a mult i-reeved crane block may be due to a number of cause s. An y faults in the rope drive m ust
be eliminated, the load/stretch torsion wil l "seat in" after some t ime of rope operat ion.
2) If a hoist rope is operated with ope n swivel an untwist ing by several runs with unloa ded h ook will be sufficient
in most cases. I f this procedure proves to be ineffect ive refer to the instruct ions given for compensation of
twist for ropes with rotat ion- stable f ixed point, e.g. - i f no swivel is provided
- if the rope is predamaged or
- if the ca uses o f the twist can't be eliminate d.
3) Determination of direct ion of twist
At f irst the direct ion of the twist of the crane pulley block must be determ ined. Pictures 1 and 2 show a possible
twist of a r ight han d lay rop e, on picture 3 + 4 of a left hand lay rope. In the r ight hand corner of each picture
a sketch sh ows the o ccurrence of mult iple twist. The resp ective direct ion of twist is indicated by a continuo usly
drawn arrow printed in boldface. If it is difficult to identify the direction of twist for large hoisting heights turn
rope in direct ion of arrow with dashed l ine once thus eliminating "braid". For compensation turn rope end
show n separately in the direct ion of the con tinues arrow. I t is important that the correct reference point is se
lected i.e. the crane operator must hold the rope in front of himself .
The direct ion of untwist can be determined also by simulat ing this situat ion by simply using a str ing.
4) Untwist ing of crane pulley block with rotat ion-stable rope f ixed point:
- Set down of pulley block
- Determine direct ion of twist
- Detach rope at f ixed point
- Carefully turn rope at free end of at least 15 m length up to max. 180 - 360 degrees to compensate
pulley block twist
- Reattach rope at the f ixed point
- Carefully l i f t pulley block and operate unloaded crane with pulley block and j ib
- Repeat if necessary
o : ^
IMPOR TA N T
Mak e sure that twist is distr ibuted to a long free rope
end.
By operat ing the crane in unloade d condi
t ion twist is to be distr ibuted to the entire rope length. By no means forcefully twist a short length
of rope; this may permanently damage rope structure.
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MA IN TEN A N C E
7.7.6.
D ISCARD CRITERIA
Warning for safety reasons crane ropes have
to be discarded if showing one of the follow
ing criteria:
- Break of one strand
- Accumulat ion of wire breaks
- Number of wire breaks as defined in table
- Corkscrew-type deformations of more than
1/3 rope diameter (pic. 1)
- Baske tl ike distort ions (pic. 2)
- Hair-pin type extrusion of wire or groups of
wire (pic. 3)
- Decrease of rope diameter by 15 % against
nominal diameter of rope or
- by 10 % if there are signs of corrosion and / or
abrasion (pic. 4)
- Loosening of rope structure (pic. 4)
- Local decrease of rope diameter (pic. 5)
- Bends and local crushing (pic. 6 + 7)
- Kinks or result ing permanent deformations
(pic. 8)
I f special rope dam age is fou nd, the cause has to
be determined and eliminated before a new rope
will be installed. Damage or stress markings at
crane components provide valuable information
for possible causes of rope damage.
If
in
doubt disca rd rope or consult expert for further
assistance.
Picture 1
Picture 2
Picture 3
Picture 4
Picture 5
Picture 6
Picture 8
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MAINTENANCE
7.8. ROPE PULLEYS
7 . 8 . 1 .
GENERAL LAYOUT
Rope pulleys are constructed and m anufactured as a result of many years of experience and knowledge of
expectations and requirements of heavy machinery.
Smooth and reliable running of the equipment can however, only to be obtained if regular maintenance and
care is given. Adhering to regular service intervals and use of correct lubricants as per the lubricants chart
are also part of this. Special tools are not required for servicing.
All rope pulleys are designed with large diameters and with anti-friction bearings.
steel rope pulley / sheave LAIVIIGAMID® rope pu lley / sheave
lubrication
groove
lubrication
groove
1
2
1 Rope pulley / sheave
2 Anti-friction bearing
3 Circlip
7.8.2. STORAGE
Rope pulleys in storage should be kept away from steam or hot water pipes, heated air ducts or any other
source of he at, which can thin out lubricant and cause it to drain out of the rope pulley.
When storing rope pulleys -th e following rule should be applied: FIRST IN - FIRST OUT. That means the rope
pulleys should be used in the order of delivery. In this way it can be avoided that certain rope pulleys are only
put into service after being stored for many years.
7.8.3. TRANSPORT
Rope pulleys are easily affected by external damage, i.e. they m ust be handled with utmost care during trans
port and unloading.
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MA IN TEN A N C E
7.8 .4. DURING OPE RATION
Rope pulleys are easily affected by external damage, i.e. they never should rub against the provided rope
guard device , never to lay down to ground without proper protect ion device. Thus could cause excessive w ear
to the components or even damaging the pulleys.
Damaged pulleys must be replaced immediately.
inexpert rest ing of hook block inexpert resting of boom tip I
1
broken
worn out cable groove
7.8.5 .
IN SPEC TION A N D MA IN TEN A N C E
The rope pulleys ha ve to be inspected in regular intervals; especially in the t ime pe riod following direct ly after
its installat ion. In addit ion special a ttent ion is required, if a rope has b een e xpose d to excessive w ear, if non -
visible damage is suspected or if there are other indicat ions for damage.
rr-^ N O T E
HEAVILY DIRTY OR SOILED WIRE ROPES HAVE TO BE CLEANED REGULARLY I
The frequency of rope pulley inspection is inf luenced by:
- Statutory requirements
- Type of appliance
- Operat ional environmental condit ions
- Method and frequency of operat ion
- Manufacturer 's recommendat ions
- Results of previous inspections
- Experience with previous rope pulleys on the appliance or system
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MA IN TEN A N C E
Serv ice in terva ls :
Smooth and reliable running of the equipment can however, only to be obtained if regular maintenance and
care is given. Adhering to regular service intervals and use of correct lubricants as per the lubricants chart
are also part of this. Special tools a re not required for servicing.
ANTI -FRICTION BEARINGS OF the rope pulleys must be regreased at regular intervals according to crane
operat ion.
Individual components of rope pulleys must turn freely in their bearings.
GROOVES should not show any rope marks.
At the same t ime a REGU LAR C HEC K OF TH E ROP ES for proper
funct ion,
cleanless and suff icient lubrica
t ion is required.
Q : ^
^T
\ ^
N O T E
AFTER FIRST 100 H RS ALL PULLEYS HAVE TO BE CHECKED FOR SMO OTH AND RELIABLE
RUNNING, CORRECT FIT OF ROPE PROTECTION AND OTHER SECURING DEVICES.
THE MINIMUM RE QUIREMENT FOR MAINTENANC E / CHECK UP IS EVERY 500 H R S, IF THE
CRANE IS NOT OPERATED A T LEA ST TWIC E PER YEA R FOR ANY MECHANICAL DAM
A G E S , LUBRICATION CONNECTIONS AND CONDITION.
N OTE I
ENSURE THAT THE GREASE DOES ESCAPE FROM / BETWEEN THE ROPE PULLEYS AT
LEAST EVERY 500 WOR K IN G H OU R S.
N O T E
CHECK THE WEAR OF THE ROPE GROOVE, FIRST SIGNS OF A CHANGE IN THE ROPE'S
BEHAVIOR OR THE PULLEY ITSELF MUST BE CAREFULLY MONITORED
THE RO PE PULLEY MUST BE EXCHANGED IF THE ROPE GRO OVE IS SHRINK UP TO THE
HALF ROPE DIAMETER.
CHECK THE PULLEYS GROOVE PROFILE AT LEAST EVERY
500 WOR K IN G H OU R S.
At this point we also do recommend to study carefully the " INSTRU CTION S FOR U SE OF CFIANE RO PES".
7 .8 .6. RESISTAN CE TO CHEM ICAL PRO DUCTS OF LAMIGAM ID® ROPE PULLEYS
For cleaning of
LAMIGAMID® rope pul leys
var ious benzine may be used. However, the PULLEYS
SH OU LD N OT B E C LEA N ED OR GET IN TOU C H W ITH TH E FOLLOWIN G C H EMIC A LS OR C H EMIC A L
C O M P O U N D S :
RESISTANT FOR
Petroleum, benzine, Kerosine, diesel fuel
LIMITED RESISTANT
alcohol
except
ethyl-, me thyl- and propyl alcohol
anorganic chlorides, such as calcium, l i thium-, magnesium- and zincchloride
NOT RESISTANT AGAINST
concentrated mineral acids ( i.e. sulphuric acid, hydrochlorid acid, nitric acid)
concentrated organic acids ( i.e. formic acid)
concentrated alkalines ( i.e. sodium, potash lye or caustic potash)
phenolic resin, phenolic plast ic
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MAINTENANCE
7.9. HYDRAULIC LINES AND HOSES
7.9.1.
GENERAL
[ r ^
IMPORTANT
HYDRAULIC LINES, HOSES AND FITTINGS MAY NEVER BE REPAIRED
Any dam aged sections must be replaced immediately.
A,
ATTENTION I
Pressurized oil can cause body injuries or fires
7.9.1.1. STORAGE
Even when hoses and lines are installed, stored and used according to sp ecification - they undergo a natural
aging process. For that reason, their service life is limited.
Improper storage, m echanical damage and improper use are the most frequent causes of hose fractures.
r ^
NOTE
I
USE ONLY
ORIGINAL SPARE PARTS according to manufacturers specification.
For replacement to the units we recommend that you acquire the necessary knowledge first or you
ask for assistance / advise from your local
LIEBHERR CUSTOMER SERVICE.
7.9.1.2. SERVICE LIFE
o : ^
NO T E
THE SERVICE LIFE OF A HYDRAULIC HOSE
MAY NOT EXCEED 6 YEARS,
FROM THE DATE
OF THE LIEBHERR LABEL DATE ON THE HOSE CONNEC TION. ADDITIONALLY C HECK THE
MANUFACTURES DATE ON THE HO SE. THE DATE BETWEEN THE MANUFACTURES DATE
AND THE DATE OF THE LIEBHERR LABEL SHOULD NOT EXCEED 2 YEARS.
7.9.1.3. INDICATION OF HOSES
Using hoses and lines close to the permitted working limit can shorten the service life (for example
at high temperatures, frequent working cycles, extreme high impulse frequencies, multi shift opera
tion or round the clock operations).
7.9.1.4. REPLACEMENT AND INSPECTION OF HOSES
Hoses and lines must be replaced if any of the following points are found during an inspection:
- Damage on the external layer into the inner layer (such as chaffing, cuts and rips)
- Brittleness of the outer layer (crack formation of the hose material)
- Changes
in
shape, which differ
from
the natural shape of
the
hose or
line,
when under pressure or when
not pressurized, or in bends and curves - such as separation of layers, blister or bubble formation.
- Leakages
- Non observance of installation requirements
- Damage or deformation of hose fittings, which m ight reduce the strengths of the fitting or the
connection between hose and fitting
- Any m ovement of the hose away from the fitting
- Corrosion on fittings, which might reduce the function or the strength of the fitting
- Storage or service life has been exceeded
o : ^
NO T E
To avoid excessive leaks a
VACUUM-PUMP
could be connected to the hydraulic oil tank.
Route or install the hoses and lines properly. DO NOT MIX UP CONNECTIONS I
DISPOSAL
I
USED MATERIALS MUST BE PROPERLY DISPOSED OF IN
ACCORDANCE WITH THE RELEVANT STATE REGULATIONS
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7.10. HYDRAULIC OIL TANK
SHUT-OFF VALVE IN CLOSE POSITION
SHUT-OFF VALVE IN OPEN POSITION
1 Oil level sight glass
2 Suction l ine with suct ion shut-off valve
3 Inspection cover
4 Retu rn flow filter
5 Brea ther filter
r r ^ IMPOR TA N T
Shut down the crane before making an oil change or oil level inspection I
OIL LEVEL INSPECTION
can be carried ou t by the pro vided oil level sight glass (Pos. 1)
The oi l level should always be between the MINIMUM and MAXIMUM mark.
OIL C H A N GE
is made by letting the oil flow out at the oil drain.
Refi l l the tank through the return f low f i l ter (Pos. 4). Remove the breather f i l ter (Pos. 5 when exchanging
the oil, but don't forget to put it on aga in after the oil exchan ge.
TA N K C LEA N IN G
Let the oil flow out as de scribed ab ove and close the shut-off valve (Pos. 2) before cleaning the tank.
The empty oil tank should be cleaned carefully and must be dry and clean.Take care that no impurity is in
the tank. Impur i ty can damage the hydraul ic system
A A TTEN TION
Keep SUC TION SHUT OFF VA LVE open all the t ime Close ONLY for Inspection or
service purpo se. Before start-up of main mo tor check open posit ion of shut off valve
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7 .10 .1 .
RETURN FLOW FILTER HYDRAULIC OIL TANK
ARRANGEMENT
1
Filter indicat ion device :
green
= satisfactory,
re d
= f i l ter element blocked
2 Filter cover
3 Filter housing of Return flow filter
A7
4 Hyd raulic oil tank
r
^ ^ \
4
1
1 1 '
I I I
1 1
2
j f \ \
11
^
>
o
7.10.1.1.
MAINTENANCE OF RETURN FLOW FILTERS
- Check leakt ightness, t ight f it at appropriate intervals.
- Should the indication device reads re d "= filter element
clogged"
Filter element ( insert) has to be checked and to be
replaced immediately ( latest at next working brake).
7.10.1.2. REPLACEMENT OF FILTER ELEMENTS
- Lower the load / auxiliary equipm ent safe to ground and
shut off the m ain m otor. Wait a few m inutes t i l l the
pressure is reduced to 0 bar.
A
WA R N IN G
Prior replacing the filter element (insert), wait until the
pressure reads 0 bar, all parts and the hydraulic oil are down
to low temperature.
Remo ve the cover (2) gently
by using a spanner for the screws (1) of adequate size.
1 screw, washer
2 cover
3 sealing ring
4 magnet stick
5 tension spr ing
6 pressure piece
7 0-r ing
8 fi l ter element
9 f i l ter housing
- Pull out gently magnet piece (4) and tension spring (5), pressure piece (6), 0-r ing (7) and used f i l ter elemen t
(8) of the f i l ter housing,Check the magnetic rod (there must be only metal dust - normal abbrasion)
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CSy DISPOSAL
% &
USED MATERIALS MUST BE PROPERLY DISPOSED OF IN ACC ORD ANC E WITH THE RELE-
VANT STATE REGULATIONS I
Clean all parts carefully (1 - 7, 9), check S ealing r ing (3) and 0- ring (7)
for good condit ion and replace damaged parts if required
Insert new f i lter elemen t (8) into center of the f il ter housing, parts 7 - 4 , check co rrect seat of sealing r ing
and 0-ring, screw the cover (2) onto the housing.
Tighten all screws (1) on the cover plate with a spanner.
Start the ma in motor - watch indicat ion on the indicat ion device - check for t ightness
of cover after 5 minutes again.
7 .10 .2 . VALV E AND FILTER PLATE AGG REG ATE ROOM
1 Filter dirty indica tion
2 Filter dirty indica tion
3 Filter ( A2 2 ) for oil coo ling circuit
4 Filter (A 2 ) for feed pressure circuit
5 Oil tray
7.10.2.1.
CHECK TO FILTERS
During operat ion of the crane the f i l ters are
monitored
by th e f i l ter sensors installed on top of the filters.
Check
leakt ightness, t ight f it
o f senso r ( 1 , 2 ) and
clean the oil t ray ( 5 ) if required at appro priate intervals.
Should one of the f i l ter sensors indicate (red colour)
"pressure filter clogged", the Filter element (insert)
has to be checked and to be replaced immediately.
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7.10.2.2. REPLACEMENT OF FILTER ELEMENTS
Lower the load / auxil iary equipment safe to ground and shut off
the main m oto r Wait a few minu tes t il l the pressure is reduced to 0 bar.
A
WA R N IN G
Prior replacing the f i lter elem ent ( insert), wait unt i l the pressure
reads 0 bar and all parts and the hyd raulic oil are down to low
temperature.
- Unscrew the lower housing (1 ) gently by using a spanner
- Pull out gently used f i l ter eleme nt ( 2 ) of the lower housing
- Drain the remaining hydr. oil of the lower housing
D ISPOSA L
C O . USED MATERIALS MUST BE PROPERLY DISPOSED OF IN ACCO RDAN CE WITH THE RELE-
%^ VANT STATE REGULATIONS
- Clean all parts carefully, check O-ring ( 4 ) for good condit ion (replace if required)
- Insert new f i l ter element, check correct seat of O-ring ( 3, 4 ) - and screw low er housing c lockwise (by hand
only) to the upp er part again.
- Tighten lower housing ( 1 ) gently with combina tion spanner c lockwise (max. turn 30 - 45°), check t ight f it of
filter sensor ( 5 ).
- Start main motor - wa tch the fi l ter senso rs - check for tightness of housing after appr. 5 minutes a gain.
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7.11. LIEBHERR COND ITION MONITORING
7 .11 .1 .
GEN ER A L
The LIEBHERR CONDITION MONITORING system for major components in a crane (e.g. diesel engine,
distr ibut ion gear, winch gear etc.) relies on oil analys is.
Object ives: - Prevent major failure
- Reduce downt ime
- Minimise repair cost.
The idea of condit ion monitoring by spectrom etric analysis of used oils is not new, it wa s first used in prev enta
t ive maintenance programmes to solve the problem of short engine l ife.
Economically it is therefore essential for crane owners/operators to be aware of abnormal condit ions before
they become crit ical problems.
Cond it ion monitoring through oil analysis Is an excellent wa y to achieve this in units such as en gines , transmis
sions and other oil f i l led systems.
7 .11 .2 . TECHN IQUES EMP LOYE D IN COND ITION MONITO RING
Condit ion monitoring Involves monitoring wear metals and physical parameters. Comprehensive and reliable
programmes are made up of three parts:
a) spectroscopic metal analysis
b) physical and chemical oil tests
c) Interpretat ion a nd diagno sis of data
Specif ic oil tests and spectrom etric metal analysis are necessa ry to evaluate the true ma chine a nd oil cond i
t ion.
The ideal combination of tests are given below, with the information to be g ained from e ach . I t wil l be evident
that the purposes of the tests tend to overlap other tests. This is deliberate act ion, to ensure results of one
test is confirmed by data from another. The w ork is repeated if this is not the cas e.
Used tests:
- Wear and addit ive metal analysis
- Viscosity
- Fuel dilution
- Oil condit ion index OCI
- Dispersancy
- Water/Glycol/Antifreeze
- Environmetal dirt
- Total base number
- Particle count
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7.11.2.1.
SPEC TROSC OPIC METAL ANALYSIS AND SIGNIFICANCE
Metals determined Signif icance
Barium Addit ive metals
Calcium Oil type
Mag nesium contam ination by other oil
Zinc Addit ive metals
Sodium Addit ive metals
Sil icon Coolant contam ination
Aluminium Upper cy l inder and bear ing, wear accessory dr ives, thrust washers
Chrom ium Ring and seal wear, hydraulic rod we ar
Molybd enum Addit ive metal, r ing and seal wea r
Coppe r bearing and bushing wear, thrust was hers and clutch discs, cooler and turbo
wear
Lead Bearing and cooler wear, corrosion , petrol contam ination
Tin Bearing and l iner we ar
Mangane se Wear to steel compon ents
Titanium Environme ntal contam ination in special cases
Nickel comp ressor tube wear, special steel com pone nt wear, fuel contam ination
Silver Bearing and l iner wea r in special cases
Vanad ium Valve stem wear, special steel com pone nt wear, fuel contam ination
The level of we ar metals used to assess a bnorm al cond it ions differ for each eng ine or unit type, indeed they
differ slightly for particular units of one type.
The informa tion required mu st, therefore , be built-up for each unit by regular monitoring. Neve rtheless, regular
condit ion mo nitoring on a particular mach ine ult imately relies, not on the actual m etall ic values , but on sudd en
increases from the average.
7.11.2.2. VISCOSITY
The viscosity of the oil is important for its perform ance . I t depe nds very m uch on the working co ndit ions (e.g.
temperature) and the t ime the oil has been in use. A viscosity change of 10 % is considered abnormal.
7.11.2.3. FUEL DILUTION
This is me asured by either dist i l lat ion or f lash p oint. This test is essential to detect over r ich mixtures, fau lty
injector systems and leaking p ipework etc. An excess of fuel can lead to poor lubricat ion and exce ssive w ear
or failure. 5 % is considered abnormal.
7.11.2.4. OIL CON DITION INDEX OCI
The OC I is a measure of the con ductivity of the oil. It indicates the concentrat ion of soot and o ther co nducting
materials present in the sample, e.g. water and metal part icles. An arbitrary seal of 0-40 is used. A value of
10-12 is typical of new oils and values u p to 28 are typical of used oils in good cond it ion. Higher values indicate
a problem may e xist. Aga in to establish the cause of an increase in the OCI value , other tests must be ca rried
out.
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7.11.2.5. DISPERSANCY
This is relevant to engine oils only, and is simply assessed by the blotter spot method.
Engine oils contain deterge nts and dispersan ts to disperse soot and other insoluble carbon residues through
out the oil. If insufficient is present the solids wil l coagu late to form slud ges. The se wil l tend to block passage
ways etc. and prevent lubricat ion of vital components.
Gene rally, an even distr ibut ion of soot is a good sign and a n on-eve n distr ibut ion is a poor s ign. This informa
t ion is used with the other data to assess the condit ion of the oil.
7.11.2.6. GLYCOL - ANTIFREEZE - WATER
Wh ere water is detected it is measured by disti l lat ion or other mean s to establish its concentrat ion . More than
0.2% is considered signif icat. Having established water is present, it is necessary to identify its origin. The
options include:
1. Coolant contamination
2.
Condensat ion
3. supply tank contamination
7.11.2.7. ENVIRONMENTAL DIRT
The third ma jor cause o f engine or mach ine failure is dirt contamina tion. I t acts as an abrasive on pistons rings,
l iners and bearings, etc. to cause severe problems.
7.11.2.8. TOTAL BASE NUMBER
To protect the crankcase from acid attack by corrosive acids produced in the combu stion cham ber, the lubri
cant contains a degree of reserve alkalinity. This reserve alkalinity is expressed as mg of KoH/gm of oil and
is described a s the Total Base N umber (TBN ). It is mea sured by one of two m ethods a dopted by the Inst itute
of Petroleum under the numbers IP177 and IP276 . The TBN is a measure of the neturalizing propert ies of
the oil.
7 .11 .3 . OIL SAM PLE / OIL EXCHA NGE
7.11.3.1.
GENERAL
The FIRST OIL EX CHA NGE has to be performed as stated in the MAINT ENA NCE LIST of the crane. This
oil exch ange can not be delaye d as at the "start up" period of any eng ine or transmission higher contamina tion
of the oil can occur. NO OIL SAMPLE IS TAKEN I
7.11.3.2. SAMPLING PERIODS
AFT ER the FIRST O IL EXCHA NGE the sampl ing per iods are the same as the in the MAINT ENAN CE LIST
required oil exchange periods for that specif ic engine or transmission.
7.11.3.3. OIL EXCHANGE
NO SAMP LE HAS BEEN TAKE N: The oi l has to be exchang ed as stated in the crane's MAINTE
NANCE LIST
SAMPLE HAS BEEN TAKEN: The CONDITION MONITOR ING REPORT wi ll
tel l ,
if:
- the oil is st i l l in good condit ion and no exchange is needed
- another sample is required
- the oil has to be exchanged
- further act ions are required
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7.11.4 . TAKING AN OIL SAMP LE
7.11.4.1. G ENERAL
For taking an o i l sample a specia l PLASTIC SYRINGE-CUM-BOTTLE-KIT is avia lable:
The kit consists of:
- Plastic syr inge / bottle to take and contain the sample
-1,5 m of plastic tubing for easier access of the oil
- Postal carton
- Sam ple inform ation form to state al l important data about the oil and the unit is wa s
used in.
syringe
plunger tall
nozzled cap
to fit syringe
PLASTIC
SYRINGE /
BOTTLE
PLASTIC TUBE
>-
DC
B: O
^ b
l i j <
I oc
m O
LU m
i f l ^ S M B K I K a K U )« Br T: tM ai i> lB a. Q> im ML UB I5 A. UJ L
C O N D m O N A A O N r r O R I N Q T M . p i «n . : |> < « S M ii i i
T M c i i t z i M i T i w i n a B M S c i
S A M P L E I N F 0 H M A T 1 Q I 1 F O R M H B t m i i . : i H n ) n u i <
OUUrt 1 SCTIM. 1 CR«H£
mK L 1 NO. 1 »CURS
OJSTWER: 1 WB> fHlG /sni :
K W Mn H B t T » Mn . E D 1 p u u n M
e c o E
ip
asv^^ m
M C m U E D H I I { K D
I M R U J C I M : n ( H ü )
w m o s M . m
I U . K 1 E T H . ( M
i i » n » o « o t flti|
a-BOBM/ni IK11
a A M i E M i i t ax i )
a f i O d B n n ( s a i l )
i M B i u i t o n
svMB a^
o n e s l u i x s n i F
n n u n
K B L U I
K C M K I 1 f U B R U n
g t E H s a r m 1 n m u u s ?
n u a i r n u H r u i a | urtrn | | t r f c iu |
U
H A MIOF S A K P L E U
1"- 1""
U D I l £ S S | n t i c M ( U w * < i B
POSTAL CARTON
SAMPLE
INFORMATION FORM
7.11 .4 .2 . HOW TO TAKE A REPRESENTATIVE OIL SAMPLE
- Ensure the main m otor or other units has been work ing for at least 15 minutes just pr ior to taking the samp le.
- To obtain from the DRAIN PLUG allow about a quarter l i tre oi l to empty away before holding the sampling
vessel under the free flowing oil stream.
- Drain approx. 200 ml of oi l into the sam pling ves sel
- Close the drainage hole again and check the oil level of that syste m - refi l l i f necessa ry
- Conn ect the nozzled cap with the tube to the syringe
- Shorten the plastic tube to the minimum needed lenght
- Hold the free end of the plastic tube into the sam pling vess el and fi ll the syringe with the sampling o il by
pull ing its plunger, while holding the syringe vertically with the nozzle pointing upwards.
- If the oil stops flowing before the syringe is full, loosen the cap and gently push the oil level to the top. Re-
tighten the cap and continue drawing the oil .
- When the syringe is
ful l ,
discard the nozzled c ap, tubing and plunger tal l ( twist-off), f i t the blank cap tightly.
- F i ll in the provided SAMP LE INFOR MATIO N FO RM (complete ly )
- Put the SAMPLE INFORMATION FORM toghether wi th the SYRINGE / BOTTLE into the POSTAL CAR
TON
- Send it to the the in section AD RE SS stated adress
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7.11.4.3. SAMPLING POINTS (EXAMPLES)
HYDRAULIC OIL TANK
H OIST IN G WIN C H
SYRINGE
SYRINGE
SLEWING GEAR
SAMPLING VESSEL
SYRINGE
SAMPLING VESSEL
7.11.4.4. POST ADDRESS
LABORATORY: LLANDUDNO
G W Y N E D D L L 3 0 I S A
UNITED KINGDOM
7 .11 .5 . CONDITION MONITO RING REPOR T
The resul ts of the oil sample exam inat ion are al l s tated in the CO NDITION MO NITOR ING REPOR T wh ich
is sent to the in the SA MP LE INFO RMA TION FOR M stated addre ss. In this report a diagnos is of the oil sample
is given as well as a a dvice for further act ion.
Four dif ferent symbols are indicated to signalize the main act ion:
V
I
l b
\
INDICATES Normal
INDICAT ES High result reading obtained, submit second samp le for recheck
INDICATE S Cha nge oil as indicated
INDICATES Action required as indicated
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7.12. PRESSURE ACCUMULATORS
7 .12 .1 .
GEN ER A L
For hydraulic accumulators, the relevant regulations at the place of instal lation must be adhered to pr ior to
commissioning and dur ing operat ion.
7 .12 .2 . SAFETY INSTRUCTIONS
- On no accoun t should weldin g, soldering or any mechanica l work be carr ied out on the accum ulator shell.
- Work on systems with accumulators (repairs, connection of pressure gauges etc.) should only be carr ied
out once the pressure fluid has been drained out. Once the hydraulics have been connected, al l air should
be complete ly v ented.
- New or repaired accumulato rs m ust be charge d with nitrogen prior to comm issioning .
- Never use oxygen or air Danger of explosion
- If the accumulato r is supplied already pre -charged with the requested gas charging pre ssure , the
pressure is marked.
- Note the l imits of gas charging pres sure and operating tem perature
OIF
IMPOR TA N T
TO ENSURE THE SAFETY O F THE L IFT ING APPL IANCE THE PRESSURE ACCUMU L ATO RS
HAVE TO BE CHECKED OR REPLACED EVERY TWO YEARS I
7.13. MAINTENANCE OF OIL COOLERS
The coo ling lamella of the hydraulic oi l cooler unit and winch ge ar
oil
cooler unit have to be free of dir t to ac hieve
the maximum cooling capacity.
Therefore the lamella have to be inspected visually at least every week and cleaned if necessary.
CLEANING OF OIL COOLER UNIT
Depending on the kind of the dir t on the oil cooler unit the fol lowing methods may be used:
DRY DU ST = > Clean with air pressure (max. pressure 10 bar)
WET DU ST = > Clean wi th steam cleaner (max. pressure 150 bar)
OILY DUS T = > Clean with steam cleaner (max. pressure 150 bar) and add solvent cleaner
r r ^
N O T E
If in doubt of the correct cleaning metho d for a certain type of dir t, contact any LIEB HE RR repres en
tative for advice
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MAINTENANCE
7.14. ELECTRICAL SYSTEM
7.14.1. MAINTENANCE TO THE ELECTRICAL SYSTEM
Maintenance of the electrical system is largely restricted to changing fuses and bulbs, if blown and clean
ing the filters on the switch cabinet.
The filter on the switch cabinet fan should be renewed or cleaned every 3000 working hours.
All screws and bolts used for or with electrical equipment should be retightened in regular intervals, (see
MAINTENANCE LIST)
A
ATTENTION
ALL ELECTRIC SAFETY EQUIPMENT (E.G. LIMIT SWITCHES, EMERGENCY STOP
BUTTONS ETC.) SHOULD BE CHECKED IN REGULAR INTERVALS AS WELL TO EN
SURE A SAFE OPERATION OF THE CRAN E. (SEE MAINTENANCE LIST)
A
WARNING
BEFORE OPENING ANY ELECTRIC EQUIPMENT, It is essential to
SWITCH OFF THE POWER SUPPLY.
7.14.2. WET CLEANING
Wet cleaning of the switch box or switch gear is not allowed
When washing or steam cleaning the crane or components - close all terminal- and switch boxes in order
to prevent water from entering
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MAINTENANCE
7.15. SLIP RING UNIT
The slip ring is installed inside the crane.
Access to slipring unit, ascent ladder inside base column.
A
DANGER
SWITCH OFF POWER SUPPLY, BEFORE OPENING ANY ELECTRIC EQUIPIVIENT
ONLY QUALIFIED AND AUTHORIZED SERVICE PERSONS ARE ALLOWED TO
PERFORIVI MAINTENANCE OR SERVICE TO THE SYSTEM
TERMINAL BOX
Every 500 hours a tightness test of a random sample of the terminal clamp screws should be carried out.
POWER SECTION
Due to
the low turning speed
and
the hardness of
carbon
brushes, the brushes have
a
relatively long
life.
They
must be checked
every 1500 hours or latest every 6 months,
and must be changed in good time so that
it never happens that a metal part of the brush holder touches the slip
ring.
During this check it is also necessary
to clean
any carbon dust
from
the insulating barriers between the slipring
ways so as to avoid creeping current. Every 500 hours a random sample of the screw connections of the
copper bus bars should be checked for tightness.
SIGNAL SECTION
The
16
Amp. circuits
are fitted
with nickel plated and gold plated copper-beryllium wire brushes
and with
nickel
plated and gold plated sliprings. About every 1000 hours or latest every 6 months the insulating barriers
between the slip-ring w ays should be cleaned of metal particles.
To reduce wear the slip-ring w ays should be lightly sprayed with a contact oil such as "Cram olin B".
A random sam ple of the terminal screws for
the
terminals
of the
cables
from
the copper-beryllium wire brushes
should be checked for tightness.
The carbon brush blocks must be checked according to point 2 mentioned above.
CABLE INSULATION
The cables have to be checked for any damages in insulation when ca rrying out an inspection.
When cables connected to the slipring or have to be replaced always asure that the insulation to be kept
as short as possible.
rr^ NOTE
SHOULD YOU HAVE ANY QU ESTIONS RELATING TO OPER ATION, SERVICE, REPAIRS
OR PARTS FOR THE SLIP RING INSTALLED ON THE C RANE, PLEASE CONTACT
THE LIEBHERR CUSTOMER SERVICE.
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VOLUME 2
TECHNICAL INFORMATION
TYPE
CBW 45(40)/26,5(29,5)
SERIAL NUMBER
162 600
VERSION
001 -30.11.2006
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INDEX
INDEX-VOLUME 2
1. GENERAL DRAWINGS
2.
HYDRAULIC DRAWINGS
3. ELECTRIC DRAWINGS
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GENERAL DRAWINGS
1.
GENERAL DRAWINGS
Drawing title
General arrangement
Reeving plan
Drawing number Pages
5052.001.02.00.000-000 1 page
2784.721.01.00.000-002 1 page
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MftX . RADIUS 27000
AT 13.9' BOOM IfJCUNATION
MIN. RADIUS 2800
" Y " .
4-FALL ftfl t-FALL
MAX. SWL t5 t IflJ MAX. SWL tO t
D [ T A L
"V
15
V O R S P A N N K R A F T 66 5 KN
PRE TENSION LOAD
VORSPANNEN NACH ARBEITSANWEISUNC QSA 09.6 01. 00-X X
PRETENSI0NIN5 ACC. TO WORKING-INSTRUCTIO N QSA 09. 601 .00 -XX
SCHRAUBENSPANN2YLINDER; ID.NR.: 10020 200
PRETENSION JACKING TOOL: lO.NQ.: 10 0202 00
GEWINDE GEFETTET. KEINE MOLYKOTE
ODER GRAPHITFETTE VERWENDEN
THREAD GREASED. DONT USE MOLYKOTES
OR 3RAP HIZE0 GREASES
REFERENZPUNKT / REFERENCE POINT 'A"
E
RAN KOMPLETT / CRANE COMPIEIE
AUSLEGER KOMPLETT / JB COMPLETE
OREHSAEULE KOMPLETT / SLEWING COLUMN COMPLETE
INIERFLASCHE / LOWER E OCK
GRUNGSAEUE KOMPLETT / BASE CCLUHN COMPLETE
S S H
SCHWERPUNKT / C.O.ri .
IgMCh Dfl n BIwdlK
IV«^r Zmkarinluiiii •miKMn
AENDERUNGSINOEX
INDEX CF AllEHATION
SCHWERPUNKT
CENTRE DF GRAVITY
G.A.
CBW
4BH0)/24.3(27) ST
G.A,
CBW
45(401/24.3(27)
ST
5052
001 02 00 000 000
983636614
»aitHl.trJt tt^ t- 'O ' '
• 1/11 1 I
CA D
P TC
AI
t ? 9 9 S kg
•5<innin«wn;»'n*> » D"«
Stmnin«»
DMrtMcnormn Dm lU -JC
bwr« la rnn ISO tt»
ttn
1:50
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D E T A I L S E I L F I X P U N K T W INDE
DETAIL ROPE ANCHORAGE POINT WINCH
D E T A I L
ANZUQSDREHMGMENT
FESTIGKEITSKLASSE
ANZAHL
GEWINDE GEFETTET, KEINE MÜLYKGTE
ODER GRAPHITFETTE VERWENDEN
210 Nm
M16 8 .8
10 STK
TIGHTENING TORQUE 210 Nm
BOLT GRADE M16 6. 8
QUANTITY
10 PCS
THREAD GREASED, USE NO MOLYKOTE
OR GRAPHITIZED GREASES
0800
0650
-SEILFIXPUNKT
ANCHORAGE POINT
2x 0500
HAUPTHUBSEIL
/
MAIN HOIST ROPE
RECHTSGAENGIG / RIGHTHANDED
0 2 5
X 315M
1068 KG
ID -NO . :
790223014
-ACHTUNG
S E i L F I X P U N K T A U S S E N AN
DER
T R O M M E L
A T T E N T I O N
R O P E A N C H O R A G E O U T S I D E
THE
D R U M
V
S T E I G U N G / P I T C H
R E C H T S G A E N G I G
/
R I G H T H A N D E D
" * * ' % ' . , ' »
Diese Zeichnung dart otnne unsere Genehmigung weder kopiert noch vervieLfseltigt, noch Qritten 2ugaengLtch gemacht werden. Zuwiderhandlungen verpflichten
zu Schadenersatz und sind bei Vorsatz strafbar.
These drawings and al l information contained herein are the property of Liebherr. To copy or disclose them to any other party respectively use them except
for projecls they were provided for is forbidden. Anyone doing i t wi l l be held l iable therefore. t lEBHERR WERK NENZING GMBH . A-6710 Nenzing/Vlbg
Bezeichnung/description
BESEILUNG
ROPES
^ ~ r 2 7 8 4 7 21 01 00 000 002
Idenr. Nr.
ident. no.
9187252U
^ 6]<
Gezeichn./drawn
IO-Jan-00
P roj ekt l . / proj . enn.
Ngepr . / i nsp. s tand.
Ersatz fuer/rol . (or
Ersetzt durcti /rpt- by
lO-Jan-OO
BRR
BURGER
Bl J l t / von
St>eel/o(
1/1
CAD
PTC
41326
Aenderung
A3
2 7 -S e p -0 5
11989 D8-AUÜ-00
Dalum
lee
lee
Fertiggewicl i tAfeiQti l
2354.0 kg
Allgemeintoleranzen ISO 2168 mK-E
Fretmasatoleranzen
-Schweisskl instruKtionen BF 0INa570
Oberflaectienzeichen DIN ISO 1302
General tolerances ISO 3766 mX-E
General tolerances for welding
- constructions BF DIN 6570
Indicating surface texture
- according DIN ISO 1302
Massstab
scale
1:50
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N
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HYDRAULIC
2. HYDRAULIC DRAWINGS
Drawing title
Schematic hydraulic
Drawing number Pages
5052.970.00.00.002-000 4 pages
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D R U C K S P E I C H E R
p r e s s u r e a c c u m u l a t o r
NR.
1
2
IDENT. NR.
5 1 1 7 027 U
5117 028 U
Bezeichnung
description
[max. Druckl
(max. pressure]
5 B 0
210
SB O
210
Volumen
volume
[ d m ^ j
0,32
0,32
Vorspanndruck
pre-charge
pressure
[ ba r ]
18
8
Typ
type
B
B
Stück
piece
1
1
UM DIE SICHERHEIT DES GERÄTES ZU GEWÄHRLEISTEN, MÜSSEN DIE
DRUCKSPEICHER ALLE
2
JAHRE ÜBERPRÜFT ODER AUSGETAUSCHT WERDEI
To ensure the s a fe t y of the l i f t ing appl iance, the pressure
accumulators have to be checked or rep laced every two years .
CAD-hp @
A4
Copyright
(c)
LIEBHERR-WERK NENZING GMBH
A-6710 Nenzing
/
Vibg
Benennung/description
S c h e m a H y d r
s c h e m a
tic
hydr
erstellt / issued 25.02 .04 Vrisk geprüft/approved 25.02.0 4 Kräutler
Ind.
Änderung Datum
Name
Zeiclinungsnummer:
/
drawing
no,:
5 0 5 2 - 9 7 0 . 0 0 . 0 0 . 0 0 2 - 0 0 0
Blatt/Sheet
2
Identnummer:
ident
no.:
9 8 3 6 3 6 2 U
von/of
4
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~ W ü
2
^ucktdbe I le
pressure J/st
Au s g e f C Ä I
C o m p l e t e d
5,
„^„
E i n s t e i i a n w e i s u n g v e r b i e i t ^ F i m K r a n a l< t . K
Cineck i is t to be f i ied in Crane F i ie . Copy
Einstellung lediglich überprüfen / only to be clieciced ttie adjustment
opie
to
an TBi
TBH
Bezeichnung
Indentification
4 E - S e
4 E - 5 1 7
4 E - S 2 0
4 H - S 1 5
4 H - S 2 1
4 H - S 2 2
4 H - S 2 3
4 H - 5 2 4
4 H - 5 2 5
4 H - S 2 8
H2G
H4
n s ø
R5 1
D22
D22
D23
D23
D4 1
D4 1
Koordinaten
Coordinates
SheetNo.Xyy
1 . ? / D
1 . 7 / D
1 . 2 / B
1 . 1 0 / B
1 . 7 / H
1 . 8 / H
1 . 7 / C
1 . 1 0 / D
1 . 1 0 / E
i . 8 / R
1 . 4 / F
1 . 7 / F
1 . 4 / D
1 . 2 / D
1 . 8 / E
1 . 3 / E
1 . 3 / C
1
. 3 / C
1 . 4 / n
1
. 4 / H
o
11" Druck
calculated
pressure
bar
* 5 , 5
* 5 , 5
270
15
30
305
215
G
6
345
120
25
345
400
^ 1 0
* 1 0
275
275
360
3G0
Ausführender Monteur / Commision ing Engineer
Auf t ragsnummer :
0 r d9 r-numbG r•
Ist-Einstellung Durchs chal ten
actual-adjust. funct ionaltest
bar Sign, by Personal No.
Name:
Data:
Signature:
Ist-Einstellung Prüfstand
actuaJ-adJust. teststand
bar Sign, by Personal No.
Name:
Data:
Signature:
Ist-Einstellung Übergabe
actual-adjust. delivery
bdr Sign, by Personal No.
Name:
Data:
Signature:
CAD-hp
a D CE I E DO [E æ æ
CopyrigM Icl
LIEBHERR-WERK NENZING GMBH
A-6710 Nenzing / Vlbg
A 4
Benennung/description
S c h e m a H y d r
s c h e m a t i c h y d r
erstellt / issued 18,03.0' i
Vr isk
geprüft/approved 1 8,03.04 Kräutler
I n d , Änderung Dotum
Nome
Zeichnungsnummer: / drawing no,:
5 0 5 2 - 9 7 0 , 0 0 . 0 0 . 0 0 2 - 0 0 0
Identnummer:
ident no,:
9 8 3 6 3 6 2 U
Blatt/Sheet
3
von/of
4
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~ W üucktabe J
le
pressure I ist
' Ä U s ' g e T ü H l E i n s t e i i a n w e i s u n g . ui b l u i L J ^ i i n K r a n a l < t . K o p i e on T ' B R ^ ^
C o m p l e t e d C h e c [ < i i s t
to be
f i i e d
in
C r a n e F i i e . C o p y
to TBH
' ^ " Einstellung lediglich überprüfe n
/
only
to be
checked
the
adjustment
Bezeichnung
Indent iiicat ion
E23
E23
E2G
EG2
ER
En
ER
H22
H23
H23
HR
HR
HR
X23
X23
Koordinaten
Coordinates
SheetNo.X/Y
1 .2 /C
1 .3 /C
1 .B/D
1 . 1/B
1 .2 /G
1
.2 /G
1 .2/G
1 .9/C
1 .4 /C
1 .4 /C
1 .2 /E
1 . 2 /F
1 . 2 / r
1 .5/C
1 .5/C
"So 1 " Druck
calculated
pressure
bar
305
170
- 1 5
4 0 0
^ 2 0
180
3B0
X8
150
3 G 0 / G 0
^ 2 0
180
3G0
150
3 G 0 / G 0
Ausführender Monteur / Commisioning Engineer
A u f t r a g s n u m m e r :
0r dø
r
numbs
r•
Ist-Emstel lung Durchschalten
actual-adjust, functionaltest
bar Sign, by Personal No.
Name:
Data:
Signature:
Ist-Einstel lung Prüfstand
actual-adjust, teststand
bar Sign, by Personal No.
Name:
Data:
Signature:
Ist-Einstel lung Übergabe
actual-adjust, delivery
bar Sign, by Personal No.
Name:
Data:
Signature:
C A D -h p
@
CL D CE [B DO H
æ
[B
A4
Copyright Ic)
LIEBHERR-WERK NENZIN6 GMBH
A -6 7 1 0 Ne n z in g / V ibg
B e n e n n u n g / d e sc r i p t i o n
Schema Hydr
schematic hydr
e rs t e l l t / i s s u sd 1 8 , 0 3 . 0 4 V r i s k g e p rü f t / a p p ro ve d 1 8 , 0 3 . 0 4 K rä u t l e r
Ind, Änderung Datum Name
Zeichnungsnummer: / drawing no;
5 0 5 2 - 9 7 0 , 0 0 . 0 0 . 0 0 2 - 0 0 0
Identnummer:
ident
no,:
9836362U
Blat t /Sheet
4
von/o f
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C
I
N
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ELECTRIC
3. ELECTRIC DRAWINGS
Drawing title
Outline power supply
Electric wiring diagram
Hook garage
Power management system
Drawing number Pages
5052.600.00.00.031-004 5 pages
5048.600.00.00.061-009 51 pages
2784.690.00.05.000.001 19 pages
27994.690.00.00.000.003 8 pages
1234
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1_
INDE
X
1 OUTLINE POWER SUPPLY
5 MODIFICRTION INDEX
INHRLTSVERZEICHNIS
:
UEBERSICHT STROMVERSORGUNG
RENDERUNGSINDEX
P oL ue r c a l c u l a t i o n m e t h o d s :
P n om i s c a l c u l a t e d a s t h e r e l e v a n t i n t e r m i t t e n t p ou i e r r e q u i r e m e n t
f o r 4 0 / : i n t e r m i t t e n t d u t y . T h e c r a n e m ai n d r i v e i s
d e s i g n e d a c c o r d i n g t o t h i s v a l u e ( 5 G - 4 0 / i r a t i n g ) .
CBN STANDARD 220 KNRRNE TYPE
K r a n t y p :
ORDER NO.:
fluftragsnr.:
CUSTOMER :
K u n d e
:
P o w e r s u p p l y t o l e r a n c e s :
R l l p o w e r s u p p l i e s t o t h e c r a n e h a v e t o
b e w i t h i n t h e f o l lo L u i n g t o l e r a n c e s :
- R C s t e a d y s t a t e
- R C t r a n s i e n t
- D C
F a u l t l e v e l :
+ / -
Ißy.
v o l t s
+ / - 5Z f r e q u e n c y
+ / - 2 0 X v o l t s
+ / -
10'/.
f r e q u e n c y
+
/ -
]y,
v o l t s
F u s e d p o w e r s u p p l i e s s h a l l b e p r o v i d e d t o t h e c r a n e .
T h e s h o r t c i r c u i t c a p a c i t y o f t h e c r a n e e l e c t r i c a l
s w i t c h g e a r i s b a s e d o n t h e f o l l o w i n g m a x . s h o r t c i r c u i t
f a u l t l e v e l a t t h e c r a n e t e r m i n a t i o n p o i n t :
m a i n s u p p l y : m a x . 4 2 k R r m s
a u x . s u p p l y : m a x . 1 0 k R r m s
L I E B H E R R - N E R K N E N Z I N G G E 5 .M B H
R - G 7 1 0
N E N Z I N G
Copyright (c)
issued
E rs t e l l t
approved
geprüf t
1 8 . 0 2 . 0 4
22 .12 .05
Da t u n / Ja t e
i u n u i d l Ø
l u j n k l t Ø
Nane/naMe
naue/Benennung
O U T L I N E
P O N E R S U P P L Y
U E B E R S I C H T
S T R O M V E R S O R G U N G
22.12 .05
I.B5.B5
23.07.01
22.0G.(
date
liunnitØ
yjnualØ
lu jnqacl
n jng
01
« 4 3 6
41625
3G93B
3G135
mii.na:
ra»,ng no.: 5 3 5 2 GØØ
/e ichnunqs.Nr.
031
ident .no.:
IdentnumiJEr:
9 8 3 B 2 4 G H
B la t t / sh e e t 1
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D e s c r i p t i o n o f P o w e r r e q u e s t / p o w e r a v a i i o b i e s i g n a l s :
T h e p o w e r r e q u e s t / p o w e r a v a i l a b l e s i g n a l s a r e f o r in d i c a t i o n o n l y a n d
do no t i n t e r l o c k c r a ne s t a r t i n g . T h i s m ea ns , t he s y s t e m is a pas s i v s y s t em .
T h e p o w e r r e q u e s t / p o w e r a v a i l a b l e s i g n a l s a re a s d e s c r i b e d b e l o w :
A pus h bu t t on f o r pow er r eq ues t i s p r o v ide d in t he c ab in c on t r o l pane l .
T h i s p u s h b u t t o n a c t i v a t e s a r e l a i s w i th a v o l t a g e f r e e o u t p u t c o n t a c t
( N / 0 , c l o s e d w h e n p u s h b u t t o n is p r e s s e d b y c r a n e o p e r a t o r t o a n n o u n c e
powG r r eques t ) . T he c on t ac t i s k ep t c l os ed w i t h o s e l f ho ld i ng un t i l t he
c r ane i s s w i t c hed o f f . T he s i gna l v o l t age on t o t h i s c on t ac t i s t o be
p r o v i d e d f r o m t h e v e s s e l , t h e m a x . v o l t a g e i s 2 2 0 V A C .
A v o l t a g e f r e e c o n t a c t ( N / 0 , c l o s e d w h e n p o w e r i s a v a i l a b l e ) f o r p o w e r
av a i l ab le s i gna l i s t o be p r ov ided on t he v es s e l . W hen t h i s c on t ac t i s
c l o s ed , an i nd i c a t i o n l am p s i gna l l i n g " power a v a i l a b le " is ac t i v a t ed i n
t he c ab in c on t r o l s t and . Howev e r , no i n t e r l oc k o f c r ane s t a r t i ng i s
p r o v i d e d . T he s i gna l v o l t age on t o t h i s c on t ac t i s 110V A C and i s
p r o v i d e d f r o m t h e c r a n e c o n t r o l s y s t e m .
L I E B H E R R - H E R K N E N Z I N G G E S .M B H
R - G ? 1 0
N E N Z I N G
Copyr ight
(c)
issued
E rs t e l l t
approved
geprüf t
1 8 . 0 2 . 0 4
Dat i i i i i / Jate
lunualØ
Name/nane
näiie/Benennung
O U T L I N E P O W E R S U P P L Y
U E B E R S I C H T
S T R O M V E R S O R G U N G
date
nane
ind.
QJm
drawing no. : 53 52 SØØ
/e icnnunqs-Nr.
0 3 1 ØXX
ident .no.:
Identnummer:
9 8 3 G P 4 B H
3 l a t t / s h e e t
4
von/o f
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r e v i s i o n I
date
22.06.04
m o d . n o :
36135
mod. /pages
±
m o d i f i c a t i o n i n d e x
r e v i s i o n 2
date
29.07.04
m o d . n o :
36338
mod. /pages
r e v i s i o n 3
da te
11.05.05
m o d . n o :
41825
mod. /pages
r e v i s i o n
'\
date
22,12.05
m o d . n o :
46436
mod. /pages
r e v i s i o n 5
date
m o d . n o :
mod. /pages
r e v i s i o n 6
date
m o d . n o :
mod. /pages
r e v i s i o n 7
date
m o d . n o :
mod. /pages
r e v i s i o n 8
date
m o d . n o :
mod. /pages
r e v i s i o n
9
date
m o d . n o :
mod. /pages
r e v i s i o n 10
da te
m o d . n o :
mod. /pages
T I A
LIEBHERR-WERK NENZING GES.^
fl-G?tØ NENZING
Copyright Ic)
issued
Erstellt
approved
geprüft
18.02.04
Datum/date
l iunwalØ
Name/narne
name/Benennung
NODIFICflTION INDEX
RENDERUNG5INDEX
22.12.05
1.05.05
29.07.04
22.06.04
date
iunnitt
lujnuialØ
lujnuialØ
luinqaci
name
46436
41825
36336
36135
mod.no:
drawing n o. : j g ^ j G 0 0 0 0 0 0 0 3 1
Zeicnnungs.Nr.
ØXX
ident .no.:
Identnunimer:
983B24614
] la t t / sheet 5
von/of
5
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CRANE
TYPE:
CBW STANDARD 120
-
220 KW
KRANTYP:
ORDER NO:
AUFTRAGSNR.:
PROJECT:
PROJEKT:
basic wiring diagram
Grund - Schaltplan
Nots RFK
-
additional wiring diagrams may as
on
option amend this basic wiring diagram.
NRS - Zusatzsciialtpiäne l^önnen auftragsspezifisch
als Option diesen Grundplan ergänzen.
40665
modJio.:
A n d . N r . :
07.03.05
Datum
Iwigacl
name
Name
Erstelt
geprüft
04.02.04
04.02.03
Iwngad
IwnkItO
L I E B H E R R - W E R K N E N Z I N G G M B H
A - 6 7 1 0 N E N Z I N G
Copyright ( c l
Urtieberrecht (c)
w i l i n g d ia g r a m
S t r o m l a u fp i a n
drawing no.:
ZeKtinunasnr.:
5048
600 00 00 061 009
ident.no.:
Identnr.:
983605214
assemlily
group
ktcalon
O r t
7
7/21/2019 H4-1 crane
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\mEX\
INHALTSVERZEICHNIS:
t wiring diagram
Stromlaufplan
2 index
Inhaltsverzeichnis
3 components identification
Gerätebezeichnung
4 hydraulic control
Hydraulil«steuenjng
5 general control
Allgemeine Steuerung
6 lighting and heating
Beleuchtung und Heizung
7 lighting
Beleuchtung
8 RFK - auxiliary hoist
NRS - Hilfshub
9 RFK - slewing gear interlock
NRS - Drehwerksverriegelung
10 RFK - outline electric of crane
NRS - Übersicht Elektrik Kran
11 power supply
Stromversorgung
12 emergency stop
Not-Aus
13 motor start
Motor Start
15 motor control
MotoriJberwachung
16 indicating devices
Anzeigegeräte
17 hydraulic control
Hydrauliksteuerung
18 limit switches hoisting gear
Endschalter Hubwerk
19 limit switch luffing gear
Endschalter Einziehwert«
20 hoisting gear, luffing gear, slewing gear stop
Hubwerk, Wippweri<, Drehweri« Stop
21 screen wiper / horn
Scheibenwischer / Hupe
22 auxiliary supply
Hilfseinspeisung
23 heating
Heizung
24 lighting
Beleuchtung
25 floodlight boom
Scheinwerfer Ausleger
26 RFK - floodlights slewing column
NRS - Scheinwerfer Drehsäule
27
28
29
30
33
34
RFK - helicopter waming light boom
NRS - Helikopten«amleuchte Ausleger
control lighting + heating
Steuerung Beleuchtung + Heizung
slip ring element
Schleifringkörper
RFK - luffing slewing sector
NRS - Wippweri< Drehwerk Sektor
RFK - load & radius limit
1-,
2-fold
NRS - Lasteck
1 -,
2-fach
RFK - load & radius limit 2-fold
NRS - Lasteck 2-fach
35 RFK - load & radius limit
1-,
2-fold
NRS - Lasteck
1-,
2-fach
37 RFK - auxiliary hoist
NRS - Hilfshub
40 RFK - slewing stop parkposition
NRS - Drehweri< Stop Part<position
41 RFK - slewing gear interiock
NRS - Drehwerksvemegelung
45 PE - connection
PE - Anschluss
46 setpoint table
Einslellwerttabelle
47
48
name plate fuse list
Schild Sicheaingsaufstellung
checklist electric safety devices
Checkliste El. Sicherheitseinrichtungen
modification index
Andeoingsindex
location
Ort
X1
X10
X20
X57
X58
4
switch cabinet
Schaltschrank
slip ring element
Schleifringkörper
indication unit
Meldeeinrichtung
terminal box
Klemmkasten
terminal box
Klemmkasten
device outside
Gerät außen
i n d :
W:
imd.no.:
A n d .
Nr.:
Data
name
Name
Erste»
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright
{cl
Urtieberrecht (c)
i n d e x
I n h a l t s v e i z e i c h n i s
drawing no,:
Zeichnüngsur.:
5048 600 00 00 061 009
idenl.no.:
identir.:
983605214
assembly group
kKaSon
Ort
sheet
of
von
3
I
4
7
7/21/2019 H4-1 crane
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*
ECTRICAL COMPONENTS IDENTIFIC
Bezeichnung elektrischer Geräte
^WlON
CABLES
Kabel
1W 20
.1
running number
laufende Nummer
to location
zu m Einbauor t
from location
vo m Einbauor t
COMPONENTS & INSTRUMENTS
Geräte & Instnjmente
=DS
+
4H-S01
l(ind
o f i tem,
r unning number
Art des Betriebsmittels, l aufende Nummer
location, function group
Einbauort,
Funkt ionsgruppe
assembly group
Anlage
LOCATION
Ort
X... panel..., j unc t ion box...
Scha l tschrank. . . , K l emmkas ten. .
4 . . . f eld dev ice
externe Geräte
..1 mnning number
laufende Nummer
ASSEMBLY GROUP
Anlage
FUNCTION GROUP
Funkt ionsgruppe
KIND OF ITEM
Art des Betr iebsmit tels
COLOUR - CODE FOR CABLE CORES
Farb - Code für Kabeladern
A l. boom
Ausleger
A W dr ive wagon
Antr iebswagen
DB slewing platfonn
Drehbühne
DS slewing column
Drehsäule
ET external
Extern
FB travell ing beam
Fahrtalken
FS dr ivers cabin
Fahrerhaus
GE generator
Generator
GS base cloumn
Grundsäule
HW hoisting gear
Hubweri(
KB cabin
Kabine
KZ trol ley
Katze
MA mast
Mast
MH
engine room
Maschinen haus
OW superstructure
Oberwagen
QT girder
Querträger
RK slewing head
Rollenkopf
ST stmt
Stütze
TM tower
Turm
TK tank
Tank
UW under oaniage
Untenivagen
ZA
aggregate
Zentralaggregat
general control
Al igemeine Steuenjng
lighting
a nd
heating
Beleuchtung u nd Heizung
c lamping cy l inder / casing Oszil lator
Anpresszy l inder
/
Ve r rohrungsmaschine
slewing gear
Drehweri<
luffing gear
Wippwerk
travell ing gear
Fahnwerk
grab control
Greifersteuerung
hoisting gear (main)
Hubwerk (Haupt-)
trol ley gear
Katzfahrwerk
steering
Lenkung
mill
Fräse
cable drum
Kabeltrommel
strut cyl inder
/
outr igger
AbStützung
/
Schwenkholme
spreader
Spreader
additional devices
Zusatzeinrichtungen
dri l l ing devices
Bohrgerät
whip noist gear
Hilfshubwerk
tugger winch
BertJhigungswinde
closing winch
Schliesswinde
A
B
C
D
E
F
Ü
H
K
L
M
P
U
K
S
T
V
W
X
Y
amplifier
Verstäri<er
converter
Umformer
capacitor
Kondensator
binary elements
Binäre Elemente
anything else
Verschiedenes
protective devices
Schutzeinr i chtungen
genera tors , power supplies
Genera toren, Stromversorgungen
indicating devices
Anzeigegeräte
contactors,
relais
Schütze , Relais
inductance
Induktivität
motors
Motoren
test devices
Pri i feinr ichtungen
power switch gears
Starkstromgeräte
resistors
Widers tände
switches
Schalter
transformers
Transformatoren
semiconductors
Halbleiter
cab les , transmission paths
Kabel, Obertragungswege
term inal strips, plugs, sockets
Klemmle i s ten ,
Stecker, Steckdosen
valves
Venti le
BK
sw
BN
br
RD
rt
OG
or
YE
ge
GN
gn
BU
bl
VT
VI
GY
9<
WH
ws
PK
rs
TQ
tk
GNYE
gnge
SR
black
Schwarz
brown
Braun
red
Rot
orange
Orange
yellow
Geib
green
Grijn
blue
Biau
violet
Violett
grey
Grau
withe
Weiss
pink
Rosa
turquoise
Türkis
green/yel low
Grün/Gelb
sl iver
Sliber
ind ;
M:
mod
no . :
And *.:
Daum
name
N a m e
i s s u e d
E i s l e i l l
g e p r i i f l
0 4 . 0 2 . 0 4
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
C o p y r i g h t ( 0 )
U r t i e b e r r e c l i t (c)
components identification
Gerätebezeiclinung
d r a w i n g
n o . :
Z e i c i i n u n f l s n r . :
5048 600 00 00 061 009
i d e m n o , :
i d e n l n r . :
983605214
a s s e m b l y g r o u p
l o c a t i o n
at
s i i e e l
7
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X -
gear temperature hoisting winch cvi^
Getriebetemperatur Hubwinde '•? •"
-S22
117 02
50 nole 2
+4H
-S01-04
e
-1W4.15
< ^ m
limit switch hoisting gear
Endschalter Hubwerk
cMTj-mtotoiocotor-h».
47
note 3
— TmcoScQcuca . . . . •, ,., tr
limit switch lumng gear
3;3;i;E2ÖSa3;CsS
Endschalter Einziehwerk
+X1
-X1
-1W20.01
-1W20.02
-1W20.03
-1W20.05
-1W4.01A
-1W4.01B
•1W4.01C
-1W4.01D
-1W4.01E
-1W4.01F
-1W4.01G
-1W4.08
-1W4.21
-mrn-
=ZA
-M01
/13.E3
main motor
Hauptmotor
31
note 7
h ^
-S03
/12.B3
84,255 note 1
emergency stop
Not-Aus
=GS
+X10
-X10
=KB
+X20
-X 2 0
15
note
4
20W4.01
screen wiper pump
Scheibenwischerpumpe
-20W4.02
screen wiper .^^Q-]
Scheibenwischer ^21
E4
=KB
+4T
-S09.X
- ^ -
2
21
note
4
-20W4.04
-10W1.01A
-10W1,01B
-10W1.01C
-10W1.01D
-10W1.01E
-10W1.01F
-10W1.01G
H
-10W4.02
,
16 note
5
VA
7
/ ^
/ /
reference to relevant parts list position
Referen z zur relevanten Stücklistenposition
notel
riote2
note 3
note 4
notes
slewing column remaining EL
Drehsäule Rest EL
hoisting winch EL
Hubwinde EL
limit switch luffing gear EL
Endschalter Wippwerk EL
cabin EL
Kabine EL
ring carrier pre-assembly EL
Schleifringkörper Vonnontiert EL
note 6 switch cabinet
Schaltschrank
note 7 central power unit EL
Zentralaggregat EL
it. supplied by customer
L
Vom Kunden geliefert
33721
m o d m :
And.».:
19.02.04
Datum
tangacl
name
Name
issued
Erstelt
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710NENZING
Copyright (c)
3
g e n e r a l c o n t r o l
A l l g e m e i n e S t e u e r u n g
I < ~
ZeSsnr:
50 48 600 00 00 061 0 09
ident.no.:
Idenlnr.:
983605214
7
assembly group
kxaSon
O r t
=DS
+4A
Sheet
7/21/2019 H4-1 crane
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reference to relevant parts list position
Referenz zur relevanten Stücklistenposition
slewing column remaining EL
Drehsäule Rest EL
cabin EL
Kabine EL
note 3 tanl< hydr. EL
Tank Hydr. EL
* .
suppl ied
by
c u s t o m e r
I V o m K unden ge l ie fer t
modjio.:
And
Nr:
dale
name
Name
issued
Erstell
geptijfl
04.02.04
Iwngad
LIEBHERR-WERK NENZING GIVIBH
A-6710 NENZING
Copyright (c)
Uftiebeirechl (c)
T
3
lighting and heating
Beleuchtung und Heizung
drawing no.:
Zeidmunqsnr:
5048 600 00 00 061 009
ident no :
Identnr:
983605214
assembly grap
Anlage
kxation
at
=DS
+4B
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reference to relevant parts list position
Referenz zur relevanten Stücl<listenposition
note1
RFK - auxiliary hoist
NRS - Hilfshub
M:
hd:
modm:
Änd.Nr.:
name
Name
issued
Erste«
gepiüfl
04.02.04
Iwngad
LIEBHERR-WERK NENZING GIHBH
A-6710 NENZING
Copyright (c)
üftieberrecht (c)
RFK - auxiliary hoist
NRS-Hilfstiub
drawing no:
Zettmunflsnr.:
5048 600 00 00 061 009
idem no,:
Idenlnr:
983605214
sssemUy group
kxaüon
Ott
=DS
+4X
slieel
Blatt
3
7
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5152 note 1
optional
50
note
1
crawling speed slewing gear
Kriechgang Drehwerk
-S31
/41.B5
optional 50 note 1
parking - slewing gear position
Parkposition - DrehwerksposiUon
SP%5
-S32
/41.B6
optional
50
note
m^^
lock cylinder locked
Vemegelungszylinder verriegelt
SHfr
S33
/41.B7
optional
50 note 1
lock cylinder unlocked
Verriegelungszylinder entriegelt
5152
note
1
51,52
noe 1
reference to relevant parts list position
Referenz zur relevanten Stücklistenposition
note
1
RFK - slewing gear interlock
NRS - Dretiwerl^sverriegelung
modm:
And.».:
name
Name
issued
Erstelt
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright
(c)
Urheberrecht (c)
I 3
RFK - slewing gear interlock
NRS - Drehwerlæverriegelung
I
4
drawing no.:
Zeichnunjsnr.:
5048 600 00 00 061 009
ident, no,:
Idenlnr.:
983605214
7
assemUy group
Anlage
locaton
at
=DS
+4D
Blalt
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25 note 2 \
-S12
M0.B2
O
-1W4.31 j
optional 1
+X1
-X1
1
reference to relevant parts list position
Referenz zur relevanten Stücklistenposition
RFK - luffing slewing sector
NRS - Wippwerk Drehwerk Sektor
RFK - slewing stop parkposition
NRS - Dretiwerk Stop Parkposition
RFK - emergency stop in pedestal
NRS - Not Aus in der Grundsäule
modJio,:
A n d .
Nr: Datum
name
Kame
Erste«
gepiüfl
04.02.04
Iwngad
LIEBHERR-WERK NENZING GIMBH
A-6710 NENZING
Copyiighl (c)
Uitieben-edit (c)
RFK-outline electric of crane
NRS-Übersicht Elektrik Kran
drawing no:
ZeJclmungsnr:
5048 600 00 00 061 009
i()ent.no.:
Menmr:
983605214
asseml)iy group
k)caton
O r t
=DS
+4D
slieet
Blatt
10
3 4
7
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7/21/2019 H4-1 crane
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A
b
-
C
D
E
F
_ l
1 2 1 3 _ 1 4 1 5
/11.F
( . ( J T T 1 1 0 V A C r
-X 1 f
switch cabinet s-i
Schaltschrank
-S01
0 - '=--^-
- X 1 ,
=KB
+X 2 0
-X 2 0 (
=KB
cabin + X 2 0
i-p
Kabine -S01 ( | - = - ^ -
=KB
+X 2 0
- X2 0 ,
f
i
(opt.) refer
to
order partsl ist
21
r
22
21
T
22
r
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turning ladder
'•'^A i-p
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,
3
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C C
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i ( Op t . ) s ie h e Au f t r a g sstü ck i i s te
i only
if RFK
e me r g e n cy s to p
:
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p e d e sta l
is
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r
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N o t - A u s
in der
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^ /1 1 .B1
A2
04
-K03 main switch
/12.D3 Hauptschalter
/12A7
^ ^ - j J "
3 3 < ~ 3 4
4 3 - r T 4
5 3 - f ^
7 1 J 4 _ J 2
83
1 84
->^
e me r g e n cy s to p
N o t - Au s
o;
ind:
hd:
39412
mod™.:
And. Nr.:
03.12.04
date
Daum
Iwigaci
name
Name
issued
Erste«
apvoved
gepiijfl
0 4 .0 2 .0 4
Iw n g a ci
U E B H E R R - W E R K N E N Z I N G G M B H
A - 6 7 1 0 N E N Z I N G
Copyrght (c)
Ufheberrecht (c)
e m e r g e n c y s t o p
Not-Aus
1 2 1 3
1 * 1 5
1 . - - «
•
1 ;
1
;
1
1
:
1 :
1 ;
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/ H j s c J U l i M A a
note 4
note 4
50m m ' CTOSS
section area
internal wiring only for
motor rating 120 / 140kW
50m m '
Querschnitt interne
Verdrahtung nur bei
Motorleistung 120/140kW
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(opt.) refer to order parfslisi
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Nur wenn NRS Amperemeter
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±
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2 4 6
notes
actual motor rating refer to drg.
outline power supply
XXXX 600 00 00 031 OXX
Atuelle Motorleistung siehe Zng.
Obersicht Stromversorgung
XXXX 600 00 00 031 OXX
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22
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PTC-protecUon
Kaltleiterschutz
33801
ind:
mdm. ;
And. Nr.;
24.02.04
Dabin
Iwigaci
name
Name
issued
Erste»
apfroved
gepri f l
04.02.04
Iwngaci
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright
(c)
T
3
motor start
Motor Start
drawing no.:
Zeichnungsnr.:
5048 600 00 00 061 009
idenl.
no.:
983605214
assembly group
locaton
01
=DS
steel
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/ 1 7 . A 8 I > -
24VDC
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NRS - Drehwerl< Stop Parkposition
M108
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no lifting stop
kein Heben Stop
no lowering stop
kein Senken Stop
no luffing in stop
, kein Einwippen Stop
no luffing out stop
kein Auswippen Stop
^ ^ = 1 ^
no slewing rigfit stop
^
V- kein reclitsdretien Slop
^ j = ^
no slewing left stop
' kein iinksdrehen Stop
optional scxipe of supply
Optionaler Liefeaimfang
If not applicable, plug Is to be sealed
witii cover plate or tape
Falls nicht vorhanden, Stecker mit
Blindkappe oder Klebeband abdichten
40040
26,01.05
M.
hd:
rrtodJio.:
And. Nr.:
hvngacl
name
Name
Erstelt
04.02.04
Iwngaci
UEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright
(c)
Uftiebeiredit (c)
hoisting gear, luffing gear, slewing gear stop
Hubwerk, Wippwerk, Drehwerk Stop
z e S . : 5048 600 00 00 061 009
ident. no.:
Idenlnr:
983605214
assembly group
locaton
at
=DS
+X1
sleet
20
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3 7
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If
aux,
supply
is
2Ph.,
a
suitable Jumper
is
to
be fitted between terminal L14 and
L16
Bel 2Ph. Hilfseinspelsung ist eine Drahtbrücke
zwischen Klemme L14 und L16 zu legen
40665
modJo.:
And
Nr.:
07.03.05
Daum
tangad
name
Name
issued
Erste«
approved
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
UrtiebHTedit fe
auxiliary supply
Hilfseinspeisung
drawing no.:
Zechnun sn :
5048
600 00 00 061 009
idenl no.:
Identnr.:
983605214
7
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ar^r.:
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i d e n l . n o . :
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/20.A5O-
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sec t or
is
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N u r w e n n N R S W i p p w e r k
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ist
40040
ind:
hd:
mod
no.
And.
Nr.:
26.01.05
Datum
Iwngacl
issued
Erste»
gepÆl
04. 02. 04 I wngac l
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyrigl i t
(c)
i t(c)
RFK-luffing slewing sector
NRS - Wippwerk Dreliwerk Sektor
drawing no.:
ZeKhnundsnr.:
5048 600 00 00
061
009
ident. no.:
Identnr:
983605214
assemby group
Anlage
kcauon
Or
=DS
sheet
32
+X1
of
von
3
;
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/31.A80
M1 110VAC
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Msim.:
Daum
issued
EtseH
04.02.04
Iwngacl
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
Urtiebefrectit
(c)
RFK-load & radius limit
1 -,
2-1
NRS-Lasteck 1-,2-fach
drawng no:
Zekhnun(sn :
5048
600 00 00
061
009
ident.no.;
Identr.:
983605214
assemby group
Anage
kcatkn
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=DS
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33
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3
7
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/33.A80
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ind
M:
riKxlw.:
And Nr.: Daum
name
Name
issued
Erste«
geprüft
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
Urtiebefrächl (c)
RFK-load & radius limit 2-1
NRS-Lasteck 2-fach
T
4
drawng no.:
Zecfnunisnr.:
ident.no.:
Idennr.:
5 48
600 00 00 061 009
9836 5214
7
assemby group
Anage
kxaton
Or
=DS
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34
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(Opt.) siehe Auftragsstücl<liste
only if RFK auxiliary hoist
is applicable
NurwennNRS Hilfshub
vorhanden ist
^0 - / 3 9 . E 1
pressure limit switch auxiliary hoisting gear
Druckschalter Hilfs-Hubwerk
40040
W: modno.:
A n d . Nr.:
2 6 . 0 1 . 0 5
D a l u m
hvngad
name
Name
issued
Erstelt
ap(n>ved
geprOf
04.02.04
Iwngad
L I E B H E R R - W E R K N E N Z I N G G M B H
A - 6 7 1 0 N E N Z I N G
Copyright
(cl
Urheberrecti t
(c)
I 3
R F K - a u x i l ia r y h o i s t
N R S - H i l f s h u b
I
< "
drawing no.:
Zek^tnunfsnr.:
ident. no.:
Identir:
5048 600 00 00 061 009
983605214
7
assembly gro(p
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M
=DS
sheet
37
+X1
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/37.A8t>
Ml 110VAC
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/18.B41
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M140
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i -
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143
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auxiliary hoist /8 B I
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lower ing s t op work ing range
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auxiliary hoist
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|54
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on ly if RFK aux i l ia r y ho is t
I s app l icab le
N u r w e n n N R S H i l f s h u b
v o r h a n d e n ist
40040
M:
n w d m:
And. *.;
26.01.05
Daum
Ivmgac
name
Name
issued
Ersteit
gepfül
04 . 02 . 04
I wngac i
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
Urtieberrecht (c)
I
3
RFK • auxiliary hoist
NRS-Hilfshub
I « ~
drawing no,;
Zeidinungsnr.:
5048 600 00 00 061 009
idem no,:
identir.:
983605214
assemby group
locaton
at
=DS
sleel
38
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modm:
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name
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UEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (cl
Urtiebeirechl (c)
RFK
•
slewing stop parkposition
NRS - Drehwerk Stop Parkposition
drawing no.:
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UEBHERR-WERK NENZING GMBH
A-6710 NENZING
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unlock park position
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(opt.) refer to order partslist
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A n d . Nr.:
03.12.04
Iwngac
issued
gepiüf
04.02.04 Iwngaci
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
recht (c'
I
RFK - slewing gear interiock
NRS -
Drehwerksverriegelung
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drawng no.:
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ident-no.:
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983605214
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NAME:
Name:
main motor
Hauptmotor
X1-Q01
main motor
Hauptmotor
X1-Q01
main motor
Hauptmotor
X1-Q01
SETPOINT TABLE
Einstellwerttabelle
RANGE:
Bereich:
ADJUST.:
Einstell.:
120kW 400V / 50Hz, 140kW 440V / 60Hz
In = 630A
lo = 0 ,5 -0 ,8x ln
lr
=
0 ,8 -1 x lo
lsd = 6 -13x l r
t r = 1 0 A / 1 0 / 2 0
lo = 0,5
X
In
lr =
0,8xlo
lsd = 13xlr
t r=10
140kW 400V / 50Hz, 180kW 440V / 60Hz
In = 630A
lo = 0,5 - 0,8 X In
lr = 0 ,8 -1 x lo
isd = 6 -1 3x l r
t r = 1 0 A / 1 0 / 2 0
lo = 0,5xln
lr =
0,9xlo
lsd = 13xlr
t r=10
195kW 400V / 50Hz, 220kW 440V / 60Hz
In = 630A
lo = 0,5 - 0,8
X
In
lr
=
0 ,8 -1 x lo
lsd = 6 -13x l r
t r = 1 0 A / 1 0 / 2 0
lo = 0,63
X
In
lr =
0,9xlo
lsd = 13xlr
t r = 1 0
DEVICES:
Geräte:
main switch crane
Hauptschalter Kran
main switch crane
Hauptschalter Kran
main switch crane
Hauptschalter Kran
class
installation note: the setpoint table has to be placed inside
the relevant switch cabinet on a good visible location
Installationshinweis: Die Einstellwerttabelle muss innen
im jeweiligen Schaltschrank gut sichtbar platziert werden
3 5 2 4 2
r a o d j w . :
A n d . N r . :
0 3 . 0 5 . 0 4
D a t u m
h v n g a c l
n a m e
N a m e
E r s l eH I
a p p r a v e d
g e p r ü f t
04.02.04
Iwngad
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
C o p y r i g h t ( c )
U i t i e b e i r e c l i t ( c )
I 3
setpoint table
Einstellwerttabelle
d r a w i n g
n o . :
Z e k J i n u n g s n r . :
5048 600 00 00 061 009
i d e n t . n o . :
I d e n l n r :
983605214
a s s e m b l y g r o u p
A n l a g e
l o c a t i o n
«
s l i e e l
46
Ol
v t n
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FUSE LIST
Sicherungsliste
NAME:
Name:
+X1-F03
+X1-F04
+X1-F06
+X1-F08
+X1-F09
+X1-F23
+X1-F24
+X1-F26
+X1-F28
+X1-F29
+X1-F30
+X1-F31
+X1-F32
+X1-F33
+X1-F35
+X1-F36
+X1-F40
+X1-Q01
+X1-Q02
RANGE:
Bereich:
3A
10A
3A
13A
13A
3A
13A
10A
10A
16A
16A
6A
16A
16A
6A
16A
3A
lr=0,8-1xln
9-14A
ADJUST.:
Einstell.:
ln=630A
10A
DEVICES:
Geräte:
control voltage 11OVAC
Steuerspannung
11
OVAC
control voltage 11 OVAC
Steuerspannung 110VAC
indication unit
Meldeeinrichtung
control voltage 24VDC
Steuerspannung 24VDC
AC/DC converter
AC/DC Umrichter
control voltage heating + lighting
Steuerspannubg Beleuchtung + Heizung
lighting + power socket XI
Beleuchtung + Steckdose XI
standstill heating
Stillstandsheizung
heating hydraulic tank
Hydrauliktank Heizung
blower cabin heating
Lüfter Kabinenheizung
air condition
Klimaanlage
lighting
Beleuchtung
floodlight
Scheinwerfer
floodlight
Scheinwerfer
helicopter warning light
Helikopterwarnleuchte
floodlight
Scheinwerfer
screen wiper / horn
Scheibenwischer / Hupe
main switch
Hauptschalter
trafo control voltage prim.
Prim.
Steuerspannung Trafo
installation note the fuse list has to be placed inside the relevant switch cabinet on a good visible location
Installationshinweis: Die Sicherungsliste muss innen
im
jeweiligen Schaltshranl< gut sichtbar platziert werden.
ind:
M:
mtw:.
And. Nr.; Datum
name
Nan»
Erete«
approved
gepiM
LIEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright (c)
Urtiebeiréchl
fc)
I 3
name plate fuse list
Schild Sicherungsaufstellung
I
<
drawing no.:
ZekJinungsnr.:
5048 600 00 00 061 009
ident. no.:
Idenlnr.:
983605214
assemljly group
locaton
Ort
slieel
47
of
von
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completed checklist to be filed^in crane file
Ausgefüllte Einstellungsanweisung verbleibt
im
Kranal<t
identification
Bezeichnung
=DS+4A-S03
=DS+4A-S22
=DS+4A-S23
=DS+4D-S01-08
=DS+4E-S01-10
=DS+4E-S20
=DS+4E-S21
=DS+4H-S01-04
=DS+4H-S21
=DS+4H-S22
=DS+4H-S23
=DS+4H-S24
=DS+4H-S25
=DS+4H-S26
=DS+4H-S27
=DS+4H-S28
sheet/col.
Blatt/Pfad
/12.B3
/17.C2
/37.C3
/31.B2
/19.B3
/36.B2
/36.D2
/18.A2
/17.B7
/33.B2
/33.B3
/17.B5
/17.B6
/34.B2
/34.B3
/18.B7
commissioning
eng.
Monteur
recommended adjustment
Einstellung Soll
Functionstest
Funl<tionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
Functionstest
Funktionstest
as built adjustment teststand
Einstellung
Ist
Prüfstand
name
Name
signature
Unters.
signature
Unterschrift
as built adjustment yard
Einstellung Ist Übergabe
date
Datum
signature
Unters.
order no.:
Auftraqsnr.:
n i o d . n o . :
A n d . N r . :
i s s u e d
E i s l e l l
n a m e a p g i o v e d
N a n a g e p i ü f l
L I E B H E R R - W E R K N E N Z I N G G I VIB H
A - 6 7 1 0 N E N Z I N G
C o p y r i g h t ( c l
C h e c k l i s t e l e c t ri c s a f e t y d e v i c e s
C h e c k l i s t e E l. S i c h e r h e it s e in n c h t u n g e n
I 4 I •
d r a w i n g n o . :
Z e k J i n u n a s n r . :
5048 600 00 00 0 6 1 009
i d e n t . n o . :
i d en l n r . :
983605214
a s s e m b l y g r o u p
A n l a g e
l o c a t i o n
O i l
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A
B
C
-
D
E
F
1 2 1 3 1 4 1 5
^
09
40665
mo d m;
And Nr.:
modification index
Änderungsinc
revision
i
Revision
1
date
Datum
mod.no.:
And. Nr.:
19.02.04
33721
mod /pages
Ander.Æ^tgn
1
3
4
11
12
13
15
23
52
07.03.05
dae
Daum
Iwngac
name
Name
issued
Erslel
appoved
gepiiifl
revision
«
Revision
^
date
Datum
mod.no.:
And. Nr.:
24.02.04
33801
mod./pages
Änder.:/Seiten
1
11
13
15
18
52
04.02.04
Ivmgaci
revision q
Revision
^
date
Datum
mod.no.:
And. Nr.:
09.03.04
34029
mod./pages
Änder.:/Serten
1
11
53
revision i
Revision
^
date
Datum
mod.no.:
And. Nr.:
29.03.04
34328
mod./pages
Ander.:/Seiten
1
54
UEBHERR-WERK NENZING GMBH
A-6710 NENZING
Copyright
(c)
Urtieberrecht (c)
revision
r
Revision '^
date
Datum
mod.no.:
And. Nr.:
03.05.04
35242
mod./pa9es
Andef.:/Seiten
1
11
19
20
46
51
ex
revision
«
Revision
D
date
Datum
mod.no.:
And. Nr.:
19.05.04
35591
mod./pages
Ander.:/Seiten
1
41
51
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1 2 1 3 1 4 1 5
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date
Datum
mod.no.:
And. Nr.:
03.12.04
39412
mod
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1
12
17
18
19
20
30
32
35
36
37
38
40
41
42
43
44
51
1
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date
Datum
mod.no.:
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19
20
30
32
35
36
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38
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42
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date
Datum
mod.no.:
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07.03.05
40665
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I H ^
1 E L . N R S H O O K G fl Rf lG E
2 C O M P O N E N T S I D E N T I F I C R T I O N
3
KEY FOR
R H R T S L I S T
4 O U T L I N E E L E C T R I C
5 W I R I N G D I R G R R M
N R S f l U X I L I R R Y H O I S T
1 3 M O U N T I N G P L A T E XI
H S N I T C H U N I T X20
15 C O N N E C T I O N P L A N
18 C A B L E R E G I S T E R
1 9 M O D I F I C A T I O N I N D E X
INHFfLTSVERZEICHNIS
E L . N R S HR K E N G R R R G E
G E R R T E B E Z E I C H N Ü N G
B T Ü C K L I S T E N S C H L Ü S S E L
Ü E B E R S I C H T E L E K T R I K
S C H H L T P L R N
N R S H I L F S H U B
M O N T A G E T R F E L
XI
S C H f l L T E R E I N H E I T X30
R N S C H L U S S P L A N
K H B E L L I S T E
H E N D E R U N G S I N D E X
LOCRTIONS :
XI SWITCH CRBINET CRANE CONTROL
X20 SWITCH UNIT
X59 JUNCTION BOX
4 DEVICE OUTSIDE
EINBflUORTE :
S ch a l t sch ra n k K ra n s t e u e ru n g
B ch a l t e re in h e i t
Klemmdase
Gerät außen
L I E B H E R R - N E R K N E N Z I N G G E S . H B H
R - G ? I 0 N E N Z I N G
Copyright Ic)
issued
E rs t e l l t
approved
geprüft
15.05.
3 0 . 0 5 . 0 0
Datum/date
Hunuiai
l i u n k l t Ø
Name/name
name/Benennunn
E L . N R S - H O O K G flR R G E
E L . N R S - H R K E N G f l R R G E
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LECTRICni COMPONENTS IDENTIFICHTION
CTT
C R B L E S
W 20
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FB
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boom
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d r i ve rs ca b in
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base column
hoist ing gear
cab in
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su p e r s t ru c t u re
g i rd e r
slewing head
s t r u t
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tank
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B
C
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G
H
K
M
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T
V
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whip ho ist ing gear
tugger winch
closing winch
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V e n t i l e
L IE B H E R R - W E R K N E N Z I N G G E S .M B H
f l - 6 7 1 0 N E N Z I N G
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Ic)
issued
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C O M P O N E N TS I D E N T I F I C f l T I
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name
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STÜCKLISTENSCHLÜSSEL
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issued
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approved
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Name/rune
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O U T L I N E E L E C T R I C
U E B E R 5 I C H T E L E K T R I K
date
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INDEX
:
1 EL.NRS- POWER MRNflGEMENT SYSTEM PASSIV E
2 CRANE CONTROL
3 WIRING DIRGRflM
1 MOUNTING PLATE XI
6 SWITCH UNIT -X20
7 CONNECTION LIST
8 MODIFICATION INDEX
LOCHTIONS :
XI
X10
X20
•1
SNITCH CABINET CRHNE
SLIP RING COLUMN
CONTROL DESK
DEVICE OUTSIDE
CONTROL
INHALTSVERZEICHNIS
:
EL.NRS-POWER MANAGEMENT SYSTEM PASSIV
KRHNSTEUERUNG
STROMLRUFPLAN
MONTAGETRFEL XI
SCHRLTEREINHEIT -X20
ANSCHLÜSSPLAN
AENDERUNGSINDEX
^
CRANE TYPE
Krantyp :
ORDER NO.:
Ru f tragsnr.:
CUSTOMER ;
Kunde :
CBN 5TRNDRRD
EINBflUORTE
Bchaltschrank Kransteuerung
Schleif ringkörper
Steuerstand
Gerät außen
L IE B H E R R - W E R K N E N Z I N G GES.
f l - G ? l 0 N E N Z I N G
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10.11.03
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E L . N R S P O N E R M f l N R G E HE N T S Y S T E M P A S S I V E
E L . N R S P O W E R H fl N HG E N E N T S Y S T E M P A S SI V
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