Liebherr CBW 45(40)32/20(24.4)27.5 ST Cargo Deck Crane Instruction & Maintenance Manual Volume 1

Description

Liebherr CBW 45(40)32/20(24.4)27.5 ST Cargo Deck Crane Instruction & Maintenance Manual — Volume 1

This is Volume 1 of the documentation set released for the Liebherr CBW 45(40)32/20(24,4)27,5 ST cargo deck crane under order number 162 211. It is the combined instruction and maintenance volume: the part that tells the operator how the crane is started, controlled and shut down, and the part that tells the service technician how the hydraulic system, gearboxes, disc brakes, ropes, slewing ring and electrical equipment are kept in condition. Everything from the pre-start checks through to the 2000-hour annual service is contained in this single file.

File Details

• Manual type: Instruction / Maintenance Manual (Volume 1 of a three-volume set)
• Brand: Liebherr
• Model: CBW 45(40)32/20(24,4)27,5 ST cargo deck crane
• Order number: 162 211
• Language: English
• Page count: 104 pages
• File format: PDF

Liebherr splits the documentation for this crane into Volume 1 (Instruction / Maintenance), Volume 2 (Technical Information) and Volume 3 (Spare Parts List). This listing covers Volume 1 only — the operating and maintenance volume — and it is written for both the crane operator and the trained service technician working on the machine.

Chapters Covered

• 1. Preface
  • To the Owner
  • General Information — crane serial number, spare parts and repairs, preservation, welding operations
  • Crane Application and Operation — intended operation, use of professional personnel, environmental conditions, foreseeable misuses
  • Conversion Table (SI units)
  • Standard Hand Signals for Controlling Crane Operations
  • General Hints and Advice for Crane Operation
  • General Safety Rules
  • Explanation of Safety Signs — prohibition, warning, mandatory and rescue signs
  • Liebherr World-Wide Service Organization
• 2. General Description
  • Arrangement of the Main Parts of the Crane
  • Slewing Column
  • Jib
  • Technical Description of the Crane — general, hoisting system, luffing system, slewing system, power regulation, crane control, heating, cooling, operator’s cabin
  • Safety Devices — hydraulic brakes, additional protection of the jib motion, overpressure protection, emergency stop buttons, limit switches, emergency hand pump, emergency descent
  • Emergency Descent procedure
  • Load Diagram
  • Layout of the Operator’s Cabin
  • Explanation of Control Elements — joystick jib/slew motion, joystick hoist motion
  • Switch Unit X20
  • Controls on the Switch Cabinet X1
  • Preparations for Crane Operation — start up from parking position, shut down for work break, starting up after a work break, shut down for parking position
  • Crane Operation — hook lifting and lowering, slewing left and right, jib lifting and lowering
• 3. Maintenance
  • General and Maintenance Intervals
  • High Adhesion Lubricant or Underwater Grease
  • Disposal of Used Materials
  • Special Safety Regulations — general maintenance safety, fire and explosion prevention, handling and disposal instructions, lubricants and oils, maintenance of oil coolers, hydraulic oil filling
  • Maintenance of Hydraulic System — general, filter elements, hydraulic fluid, flushing of hydraulic circuit and prefilling the pumps, hydraulic lines and hoses, valve and filter plate aggregate room, return flow filter hydraulic oil tank
  • Pressure Accumulators — general, safety instructions, accumulator types in the crane
  • Liebherr Condition Monitoring — techniques employed, oil sample / oil exchange, taking an oil sample, condition monitoring report
  • Gearboxes — slewing gearboxes, hoist winch gearbox
  • Multiple Disc Brakes
  • Instructions for Use of Crane Ropes — selection of wire ropes, rope installation, maintenance, inspection, untwisting of hoist ropes, discard criteria
  • Replacement of Ropes — reeving hoist gear, layout of rope reeving, rope fix points
  • Rope Pulleys — general layout, storage, transport, during operation, inspection and maintenance, chemical resistance of LAMIGAMID rope pulleys
  • Roller Slewing Ring
  • Electrical System — maintenance, wet cleaning
  • Maintenance Instructions for Slip Ring Unit — terminal box, power section, signal section, cable insulation
  • Lubrication and Greasing Diagram
  • Maintenance Lists — every 10 hrs / daily, every 50 hrs / weekly, first 100 hrs / after 2 weeks, first 500 hrs / after 3 months, every 500 hrs / every 3 months, first 1000 hrs / after 6 months, every 2000 hrs / every year
  • Service Spare-Parts and Standard Tools
  • Table of Lubricants

Read as a whole, this Liebherr CBW 45(40)32/20(24.4)27.5 ST instruction and maintenance manual gives the reader a complete working picture of the crane. The general description explains how the slewing column is laid out over its three levels, where the hoist winch, hydraulic oil cooler and jib pivot sit, and how the hoisting, luffing and slewing circuits are each built around their own axial piston pump. The control chapter then maps every switch, pilot light and joystick on switch unit X20 and switch cabinet X1 to its function, including the motor-on and motor-off sequence and the park position bypass for the jib. The maintenance half of the file is the part that gets used repeatedly: it explains how the pressure filter, oil cooler filter and return flow filter are exchanged, how gear oil levels are read on the sight glass and dipstick, how the multiple disc brakes are laid out, how wire ropes are inspected and discarded, and how the roller slewing ring bolts are pretensioned. A condition monitoring chapter with sampling instructions and a spectroscopic metal analysis reference table closes the technical content, followed by the maintenance lists that turn all of it into a schedule.

Practical Coverage Inside

Several sections are worth calling out because of how much workshop time they save. The hydraulic maintenance chapter includes cross-section illustrations of the pressure filter and return flow filter assemblies with the safety bypass valve and dirt indicator called out, plus step-by-step element replacement with the O-ring and sealing ring positions. The rope chapter goes well beyond a simple inspection note — it covers correct uncoiling direction, reel-to-drum geometry, pretensioning of multi-layer reeling, untwisting procedures with illustrated direction-of-twist references, and a full page of discard criteria with photographic examples of strand breakage, basket distortion, kinking and diameter reduction. The gearbox sections give separate filling, level-check and drainage points for the slewing gearboxes and the hoist winch gearbox, including the reminder that maximum oil level in the winch should reach the centre line only.

Safety Content

Safety is threaded through the whole volume rather than confined to one chapter. The general safety rules set out the daily inspection routine, the rule against leaving a suspended load, clearance and signalman requirements, and the procedure for a damaged jib. The electrical and hydraulic safety device descriptions list the emergency stop button locations at switch unit X20, switch cabinet X1 and the ascent ladder, the gear cam limit switches on the hoist and luffing systems, the hose fracture safety valves at the luffing cylinders, and the emergency hand pump for lowering a load during a total blackout. The emergency descent procedure from the cabin front window is illustrated step by step with the rescue harness. There is also a full page of prohibition, warning, mandatory and rescue signage reproduced in the format used on the crane itself.

Maintenance Schedules

The maintenance lists are organised by interval and by function group, so a technician can work straight down the column for the interval due. Daily items cover the gear rim of the main slewing bearing, rope condition, hydraulic leaktightness and control panel function. Weekly items cover greasing lines, hoist winch gear oil level, slewing gear box oil levels and the main pressure, temperature and level sensor cables. The 100-hour, 500-hour, 1000-hour and 2000-hour lists add filter element replacement, oil sampling, pressure adjustment checks, rope pulley inspection, slip ring brush checks, hydraulic motor tooth profile wear checks and the two-yearly pressure accumulator check.

Reference Data Included

A load diagram for the crane is reproduced in the general description, showing the 4-fall operation curve across the working radius range. The lubrication and greasing diagram identifies every point on the crane that requires grease or oil, and the table of lubricants at the end of the volume lists recommended products by number and application alongside the equivalent products from a wide range of lubricant suppliers. Filling quantities are given for the hydraulic oil tank, hoisting winch and slewing gear boxes.

Who This Volume Suits

This manual is the right document for a chief engineer or deck officer responsible for a CBW 45(40)32/20(24.4)27.5 ST crane on board, for a shore-side workshop maintaining one, and for a service technician who needs the correct procedure, the correct fluid and the correct interval before touching the machine. It is also useful as a reference for anyone specifying replacement filters, ropes or lubricants, since the filter assembly drawings, rope construction details and lubricant table all sit in the same volume.

Get the Liebherr CBW 45(40)32/20(24.4)27.5 ST Instruction and Maintenance Manual

With this manual on hand you can carry out the routine daily and weekly checks correctly, work through the 100-hour, 500-hour, 1000-hour and 2000-hour service lists without guessing, replace hydraulic filter elements and return flow filter elements to the right procedure, judge wire rope condition against the actual discard criteria instead of a rule of thumb, set gear oil levels at the correct marks, and follow the emergency descent and emergency stop procedures exactly as written. Getting those procedures and specifications right is what keeps a cargo deck crane lifting safely and keeps the maintenance record clean.

IMAGES PREVIEW

The file is delivered as an instant PDF download — no shipping, no waiting for a parcel. Open it on a laptop, tablet or phone at the crane, or print the pages you need for the workshop or the engine room. Once downloaded, it stays with you for the life of the crane.