Liebherr Crawler Crane HS 855 HD Operating Manual SN 184872 – PDF DOWNLOAD

Description

Liebherr Crawler Crane HS 855 HD Operating Manual SN 184872 – PDF DOWNLOAD

FILE DETAILS:

Liebherr Crawler Crane HS 855 HD Operating Manual SN 184872 – PDF DOWNLOAD

Language : English
Pages : 1167
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Liebherr Crawler Crane HS 855 HD Operating Manual SN 184872 – PDF DOWNLOAD

INTRODUCTION:
1.1 Foreword:
The Liebherr name not only stands for products and services. It has become well known for ideas
and innovations. For progress, which has proven itself in the market.
We continuously expand and improve our wide variety of product and service offering with great
intensity. To do so, the constant cooperation and the experience exchange with our customers and
business partners all over the world is a prerequisite. For that reason we are thankfull for every
suggestion and recommendation for improvement.

The documentation for this machine is handled customer-specific.
Please inform our Service Dept.,
– when you sell your machine,
– when you buy one from a previous owner,
– when you decommission one.

How are the Operating instructions set up?

• The operating instructions consist of individual, continuously numbered chapters. These chapters are
  filed in the yellow register of the ring binder.
• The chapter overview at the beginning of the Operating instructions provides quick orientation. The
  subsequent index provides information about the set up of the individual chapters.
• A short description of contents is noted at the beginning of the followings chapters under the General
  heading . At the end of each chapter is a page to enter notes.
• The numbering of pages, charts and certain, large-sized illustrations contains the actual chapter
  number as prefix. For example, the page number 2 – 10 designates the 10th page in chapter 2 PRODUCT DESCRIPTION.

* Optional accessories
A multitude of optional additional equipment is available for the machine. Every description, which
affects such optional additional equipment is marked with a * symbol in the Operating instructions.

TABLE OF CONTENTS:

Liebherr Crawler Crane HS 855 HD Operating Manual SN 184872 – PDF DOWNLOAD

1. INTRODUCTION.............................................................  29
	1.1 Foreword............................................................  29
	1.2 Handling of documentation...........................................  30
		1.2.1 How are the Operating instructions set up?....................  31
		1.2.2 System requirements of the computer for use of CD-ROMs........  31
		1.2.3 Storage of documentation......................................  31
		1.2.4 Current status of documentation...............................  32
		1.2.5 Display conventions...........................................  33
		1.2.6 Symbols.......................................................  34
	1.3 Legal notice........................................................  36
	1.4 Conversion tables...................................................  37
		1.4.1 Length........................................................  37
		1.4.2 Surface area..................................................  37
		1.4.3 Weight (Mass).................................................  38
		1.4.4 Volume........................................................  38
		1.4.5 Pressure......................................................  38
		1.4.6 Temperature...................................................  39
		1.4.7 Speed.........................................................  39
		1.4.8 Force.........................................................  39
		1.4.9 Torque........................................................  39
		1.4.10 Performance..................................................  40
	1.5 Declaration of conformity...........................................  41
2. PRODUCT DESCRIPTION......................................................  47
	2.1 General.............................................................  47
	2.2 Intended use........................................................  48
		2.2.1 State-of-the-art technology...................................  49
		2.2.2 Machine classification........................................  49
		2.2.3 Appropriate use...............................................  51
		2.2.4 Inappropriate use.............................................  53
	2.3 Machine summary.....................................................  55
	2.4 Boom................................................................  56
		2.4.1 Information on boom designations..............................  56
		2.4.2 Main boom.....................................................  57
		2.4.3 Boom with carbon-fiber pendant straps Boom section 3 m [10....  66
	2.5 Uppercarriage.......................................................  70
		2.5.1 Central aggregate.............................................  72
		2.5.2 Diesel engine.................................................  74
	2.6 Undercarriage.......................................................  75
	2.7 Counterweight.......................................................  77
		2.7.1 Rear counterweight............................................  77
		2.7.2 Central counterweight *.......................................  78
	2.8 Summary of hydraulic cylinders......................................  79
	2.9 Technical data......................................................  81
	2.10 Technical data.....................................................  82
		2.10.1 Dimensions and weights.......................................  82
		2.10.2 Operating conditions.........................................  87
		2.10.3 Emissions....................................................  87
		2.10.4 Engine.......................................................  88
		2.10.5 Hydraulic system.............................................  88
		2.10.6 Winches......................................................  89
		2.10.7 Swing........................................................  90
		2.10.8 Crawlers.....................................................  90
		2.10.9 Control system...............................................  90
3. SAFETY INSTRUCTIONS......................................................  97
	3.1 Technical condition of the machine..................................  97
	3.2 Areas of responsibility.............................................  98
		3.2.1 Manufacturer..................................................  98
		3.2.2 Owner.........................................................  98
		3.2.3 Machine operator..............................................  98
		3.2.4 Rigger........................................................  98
		3.2.5 Signalman.....................................................  99
		3.2.6 Maintenance personnel.........................................  99
	3.3 Requirements of personnel........................................... 100
		3.3.1 Machine operator.............................................. 100
		3.3.2 Rigger........................................................ 100
		3.3.3 Signalman..................................................... 100
		3.3.4 Maintenance personnel......................................... 101
	3.4 Personal protective gear............................................ 102
	3.5 Work area........................................................... 103
		3.5.1 Danger area................................................... 104
	3.6 Safety and monitoring devices....................................... 105
		3.6.1 Safety devices................................................ 105
		3.6.2 Monitoring devices............................................ 107
	3.7 Safety signs on the machine......................................... 109
	3.8 Meaning of the safety signs......................................... 113
		3.8.1 Prohibition signs............................................. 113
		3.8.2 Warning signs................................................. 113
		3.8.3 Fire protection signs......................................... 115
		3.8.4 Mandatory signs............................................... 115
	3.9 Meaning of the machine-specific safety signs........................ 117
	3.10 Hazards............................................................ 119
		3.10.1 Mechanical action............................................ 119
		3.10.2 Electrical energy............................................ 120
		3.10.3 Hydraulic energy............................................. 121
		3.10.4 Burns........................................................ 122
		3.10.5 Chemical burns............................................... 123
		3.10.6 Fire and explosion........................................... 124
		3.10.7 Poisoning and suffocation.................................... 125
		3.10.8 Electromagnetic influence.................................... 126
		3.10.9 Exposure to wind............................................. 127
		3.10.10 Snow and ice loads.......................................... 131
		3.10.11 Ground bearing strength..................................... 131
		3.10.12 Lightning strikes........................................... 132
		3.10.13 Overhead power lines........................................ 133
		3.10.14 Excavation work............................................. 136
		3.10.15 Environment................................................. 138
	3.11 What to do in dangerous situations................................. 139
		3.11.1 How to respond in the event of a current transfer............ 139
		3.11.2 Procedure in the event of fire............................... 141
		3.11.3 Firefighting................................................. 141
	3.12 Advertising banners on the main boom............................... 145
	3.13 Working at heights................................................. 147
	3.14 Application on floating devices.................................... 149
		3.14.1 Operation of the machine on floating devices DANGER !........ 150
		3.14.2 Transport of the machine on floating devices................. 151
		3.14.3 Higher risk of machine corrosion on floating devices......... 151
	3.15 Use at low temperatures............................................ 152
		3.15.1 Operation of the machine down to -20 °C (-4 °F) (standard.... 153
		3.15.2 Operation of the machine down to -25 °C (-13 °F)............. 153
		3.15.3 Operation of the machine down to -40 °C (-40 °F)............. 153
	3.16 Hand signals....................................................... 154
		3.16.1 General hand signals in accordance with BGV A8............... 155
		3.16.2 Special hand signals for attachment operations............... 157
		3.16.3 Hand signals for lifting operations in accordance with AS.... 160
4. CONTROLS................................................................. 169
	4.1 General............................................................. 169
	4.2 Operating elements on the undercarriage............................. 170
	4.3 Operating elements on the uppercarriage............................. 171
	4.4 Operator's cab...................................................... 172
		4.4.1 Operator's cab overview....................................... 172
		4.4.2 Control stand overview........................................ 174
		4.4.3 Overview of control stand from above.......................... 176
	4.5 Overview of the LCD screen.......................................... 179
		4.5.1 Main areas of the screen...................................... 179
		4.5.2 Description of the main areas of the screen................... 179
		4.5.3 Sequence of mode screens...................................... 181
	4.6 Left-hand control panel (X12)....................................... 183
	4.7 Left-hand control panel (X11)....................................... 185
	4.8 Litronic service panel on the LCD screen............................ 187
		4.8.1 Menu bar...................................................... 187
		4.8.2 Keyboard menu................................................. 188
	4.9 Right-hand control panel (X23)...................................... 190
	4.10 Right-hand control panel (X23) (optional).......................... 195
		4.10.1 Emergency shut-down switch................................... 201
		4.10.2 Joysticks, pedals, handwheels................................ 202
	4.11 Operating the machine - auxiliary functions........................ 204
		4.11.1 Adjusting the controls....................................... 204
		4.11.2 Driver's seat................................................ 205
		4.11.3 LCD screen adjustments....................................... 206
		4.11.4 Windshield wiper............................................. 206
		4.11.5 Interior lighting in the superstructure...................... 208
		4.11.6 Cab lighting................................................. 208
		4.11.7 Radio........................................................ 208
		4.11.8 Hooter....................................................... 208
		4.11.9 Cigarette lighter............................................ 208
		4.11.10 Cab adjustment cylinder *................................... 209
		4.11.11 Cab height adjustment *..................................... 209
	4.12 Operator guidance on the display screen............................ 211
	4.13 Start-up screen.................................................... 211
	4.14 Set-up screens..................................................... 212
		4.14.1 Set-up screen 1 for main boom................................ 213
		4.14.2 Set-up screen 3 for main boom with fixed fly jib............. 219
		4.14.3 Example of a load capacity chart for load moment limitati.... 221
	4.15 "Mode screen" page................................................. 223
	4.16 "Operating modes" screen........................................... 230
	4.17 "Power unit monitoring" screen..................................... 232
	4.18 Motor error message................................................ 235
		4.18.1 Serious motor error message.................................. 235
		4.18.2 General motor error message.................................. 236
	4.19 "Fault monitor" screen............................................. 237
5. OPERATION................................................................ 245
	5.1 General............................................................. 245
	5.2 Operating instructions.............................................. 245
		5.2.1 Safe working with the duty cycle crawler crane................ 245
		5.2.2 Using the electronic load moment limiter*..................... 246
		5.2.3 Resetting the load capacity display to zero (taring).......... 247
		5.2.4 Line pull limitation*......................................... 247
		5.2.5 Emergency shut-down button.................................... 247
		5.2.6 Operating the safety lever.................................... 248
	5.3 Inspections before start-up......................................... 249
		5.3.1 Tour of inspection............................................ 249
		5.3.2 Inspection duties............................................. 249
	5.4 Daily start up...................................................... 252
		5.4.1 Battery main switch........................................... 252
		5.4.2 Switch on ignition............................................ 252
		5.4.3 Programming set-up *.......................................... 252
		5.4.4 Checking the fuel level....................................... 256
		5.4.5 Refueling the machine......................................... 256
		5.4.6 Select operating mode......................................... 257
		5.4.7 Select operating mode on the left hand con- trol desk (X12.... 259
		5.4.8 Select an operating mode in the "Operating modes" screen...... 263
	5.5 Starting the diesel engine.......................................... 266
		5.5.1 Adjusting the engine RPM...................................... 267
		5.5.2 Setting the constant engine RPM............................... 270
		5.5.3 Lowering safety lever......................................... 272
	5.6 Operating the crawler crane - Main functions........................ 273
		5.6.1 Checks before beginning work.................................. 274
		5.6.2 Adjust main boom.............................................. 275
		5.6.3 Actuating hoisting winches.................................... 277
		5.6.4 Actuating swing gear.......................................... 281
		5.6.5 Swing gear free-swing......................................... 284
	5.7 A-frame position.................................................... 286
		5.7.1 Actuate crawler............................................... 288
		5.7.2 Adjust cylinder............................................... 291
	5.8 Litronic ® test system.............................................. 294
		5.8.1 Properties.................................................... 294
		5.8.2 General....................................................... 294
		5.8.3 Starting the Litronic ® test system........................... 295
		5.8.4 The menus..................................................... 296
		5.8.5 Main menu..................................................... 296
		5.8.6 INPUT/OUTPUT menu............................................. 297
		5.8.7 MEMORY menu................................................... 297
		5.8.8 SELECT menu................................................... 298
		5.8.9 CORRECTION menu............................................... 301
		5.8.10 MESSAGES menu................................................ 302
		5.8.11 SPECIAL FUNCTIONS menu....................................... 303
	5.9 Crawler crane operation - auxiliary functions....................... 308
		5.9.1 Adjusting operating elements.................................. 308
		5.9.2 Operator's seat............................................... 309
		5.9.3 LCD-display screen adjustments................................ 310
		5.9.4 Windshield wiper.............................................. 310
		5.9.5 Heating and air conditioning *................................ 312
		5.9.6 Inside lighting in uppercarriage.............................. 314
		5.9.7 Cab lighting.................................................. 314
		5.9.8 Radio......................................................... 314
		5.9.9 Horn.......................................................... 314
		5.9.10 Cigarette lighter / socket in the cab........................ 314
		5.9.11 Cabin adjustment cylinder *.................................. 315
		5.9.12 Cab height adjustment *...................................... 315
	5.10 Machine operation - operating modes................................ 316
		5.10.1 Crane operation.............................................. 316
		5.10.2 Free-fall operation.......................................... 321
		5.10.3 Working in free-fall operation............................... 328
		5.10.4 Shutting down free-fall operation............................ 329
		5.10.5 Winch standstill monitoring.................................. 329
		5.10.6 Lowering control (SWG-control) *............................. 331
		5.10.7 Interlock control system *................................... 333
		5.10.8 Winch synchronisation*....................................... 335
		5.10.9 Grapple control *............................................ 337
		5.10.10 Pile driver control/chisel control *........................ 338
		5.10.11 Casing oscillator *......................................... 344
	5.11 Shutting down the machine.......................................... 347
		5.11.1 Parking position............................................. 347
		5.11.2 Switch off diesel engine..................................... 349
		5.11.3 Parking position of ignition start switch.................... 349
		5.11.4 Checks when leaving crawler crane............................ 350
	5.12 Emergency operation control........................................ 351
		5.12.1 Functions of the control desk................................ 352
		5.12.2 Using the emergency operation controller..................... 353
6. ASSEMBLY AND DISASSEMBLY................................................. 361
	6.1 General............................................................. 361
	6.2 Application planning................................................ 362
		6.2.1 Determine the working area.................................... 362
		6.2.2 Determine set-up stage........................................ 372
		6.2.3 Arrange and prepare the equipment for transport............... 372
	6.3 Safety regulations for assembly and dismantling..................... 373
		6.3.1 Requirements for the erecting team............................ 373
		6.3.2 Requirements for the site..................................... 373
		6.3.3 Rules for executing the work.................................. 374
	6.4 Notes for assembly operation........................................ 375
		6.4.1 Operation in assembly operation............................... 375
	6.5 Assembling the basic machine........................................ 376
		6.5.1 Prerequisites................................................. 376
		6.5.2 Overview of assembly stages................................... 376
		6.5.3 Prepare assembly operation.................................... 381
		6.5.4 Starting assembly mode........................................ 383
		6.5.5 Removing the superstructure locking........................... 387
		6.5.6 Prepare assembly crane........................................ 388
		6.5.7 Supporting and unloading the basic machine *.................. 390
		6.5.8 Mounting the crawler *........................................ 390
		6.5.9 Move the device with a narrow track gauge (transport posit.... 391
		6.5.10 Drive machine from flat-bed trailer.......................... 392
		6.5.11 Adjusting crawler track carrier to operating track........... 393
		6.5.12 Mount walkways and platforms................................. 397
		6.5.13 Mounting center counterweight*............................... 398
		6.5.14 Assembling the rear counterweight............................ 401
		6.5.15 Lash counterweight plates with base plate.................... 405
		6.5.16 Lifting the rear counterweight............................... 407
		6.5.17 Bolting the rear counterweight............................... 411
	6.6 Assembling the main boom............................................ 413
		6.6.1 Prerequisites................................................. 413
		6.6.2 Overview of assembly steps.................................... 413
		6.6.3 Unload and position the heavy boom head....................... 414
		6.6.4 Assembling main boom.......................................... 414
		6.6.5 Assemble main boom retaining cables........................... 417
		6.6.6 Anchoring rods on main boom................................... 423
		6.6.7 Pendant ropes for 1313.2 boom................................. 429
		6.6.8 Main boom intermediate tensioning *........................... 430
		6.6.9 Hoisting rope steadying *..................................... 433
		6.6.10 Rope guide *................................................. 433
		6.6.11 Completing main boom assembly................................ 434
		6.6.12 Mounting main boom onto foot................................. 435
	6.7 Reeve the cable..................................................... 439
		6.7.1 Luffing hoist cable........................................... 441
		6.7.2 Cable reeving diagrams........................................ 445
		6.7.3 Connecting the electrics *.................................... 447
		6.7.4 Hoist limit switch *.......................................... 450
		6.7.5 Mounting main boom............................................ 452
		6.7.6 Procedure during assembly..................................... 454
		6.7.7 De-selection of assembly operation............................ 455
	6.8 Conversion.......................................................... 456
		6.8.1 Time-saving conversion of the main boom....................... 456
	6.9 Detaching the main boom............................................. 459
		6.9.1 Prerequisites................................................. 459
		6.9.2 Overview of dismantling stages................................ 459
		6.9.3 Preparations in lifting operation............................. 460
		6.9.4 Selecting assembly mode....................................... 460
		6.9.5 Setting down main boom........................................ 461
		6.9.6 Procedure during setting down................................. 463
		6.9.7 Disconnect electrics *........................................ 464
		6.9.8 Pull out hoist cables......................................... 466
		6.9.9 Disassemble main boom from foot............................... 467
		6.9.10 Disassemble main boom........................................ 471
	6.10 Dismantling the basic machine...................................... 472
		6.10.1 Prerequisites................................................ 472
		6.10.2 Overview of dismantling stages............................... 473
		6.10.3 Setting down the rear counterweight.......................... 475
		6.10.4 Removing the lashing of the counterweight plates............. 477
		6.10.5 Dismantling and loading the rear counterweight............... 478
		6.10.6 Disassembling center counterweight*.......................... 481
		6.10.7 Preparing disassembly of crawler *........................... 482
		6.10.8 Supporting basic machine *................................... 482
		6.10.9 Lifting and loading crawler from undercarriage *............. 483
		6.10.10 Loading basic machine *..................................... 483
		6.10.11 Removing ladders and platforms.............................. 483
		6.10.12 Adjust crawler track carriers to transport track width...... 484
		6.10.13 Manoeuvring machine onto flat-bed trailer................... 487
		6.10.14 Disassembling assembly crane................................ 488
		6.10.15 Fitting the superstructure lock............................. 489
		6.10.16 Taking the basic machine out of operation................... 491
		6.10.17 Transporting basic machine with flat-bed trailer............ 492
		6.10.18 Transporting the attachment................................. 494
		6.10.19 Loading the basic machine with an auxiliary crane........... 495
		6.10.20 Transporting overseas....................................... 498
7. MAINTENANCE.............................................................. 505
	7.1 General............................................................. 505
		7.1.1 Lubricants.................................................... 506
		7.1.2 Welding work.................................................. 506
		7.1.3 Cylinder...................................................... 506
	7.2 Maintenance chart................................................... 507
		7.2.1 Work to be carried out........................................ 507
	7.3 Diesel engine....................................................... 523
		7.3.1 Checking engine oil level..................................... 523
	7.4 Fuel system......................................................... 524
		7.4.1 Arrangement of components..................................... 524
		7.4.2 Draining condensed water on the water sepa- rator............. 525
		7.4.3 Bleeding the fuel system...................................... 525
	7.5 Cooling system...................................................... 526
		7.5.1 Checking the coolant level.................................... 527
	7.6 The dry air filter.................................................. 528
		7.6.1 Assembly of dry air filters................................... 528
		7.6.2 General....................................................... 529
	7.7 Splitter box........................................................ 530
		7.7.1 General....................................................... 530
		7.7.2 Checking gear oil............................................. 530
		7.7.3 Filling gear oil.............................................. 530
		7.7.4 Gear oil cooler............................................... 530
	7.8 Lubrication of bearings............................................. 531
	7.9 Swing gears......................................................... 532
		7.9.1 Checking the oil level........................................ 533
	7.10 Swing ring......................................................... 534
		7.10.1 Toothing..................................................... 534
		7.10.2 Lubricating the ball tracks.................................. 535
		7.10.3 Lubrication procedure........................................ 535
		7.10.4 Checking the hydraulic rotary transmission................... 535
	7.11 Crawler gear....................................................... 536
		7.11.1 General...................................................... 536
		7.11.2 Checking the oil level....................................... 536
	7.12 Crawlers........................................................... 537
		7.12.1 Cleaning and maintaining the crawlers........................ 537
	7.13 Guide wheels....................................................... 538
		7.13.1 Overview of the crawler tensioning systems................... 538
	7.14 Checking the chain tension......................................... 540
		7.14.1 Tensioning the chain with grease tensioner................... 540
		7.14.2 Floor plates................................................. 541
		7.14.3 Track adjustment and disassembly of the crawler track car.... 544
	7.15 Winches 1 + 2...................................................... 545
		7.15.1 General...................................................... 545
		7.15.2 Winches 1 + 2 overall view................................... 546
		7.15.3 Lubrication of winches 1 + 2................................. 547
	7.16 Main boom luffing winch............................................ 548
		7.16.1 General...................................................... 548
		7.16.2 Checking the oil level....................................... 549
		7.16.3 Lubrication of the main boom luffing winch................... 549
	7.17 Fly-jib adjusting winch / auxiliary winch*......................... 550
		7.17.1 General...................................................... 550
		7.17.2 Checking the oil level....................................... 551
		7.17.3 Lubrication of the auxiliary winch *......................... 551
	7.18 Ropes and pulleys.................................................. 553
		7.18.1 Checking the rope against end of service life criteria....... 553
		7.18.2 Check the rope for diameter shrinkage........................ 554
		7.18.3 Check for rope deformations.................................. 555
		7.18.4 Check ropes for corrosion.................................... 556
		7.18.5 Check ropes for abrasion..................................... 557
		7.18.6 Check ropes for the effects of heat.......................... 557
		7.18.7 Check the rope for number of permitted wire breaks........... 559
		7.18.8 Selecting a rope............................................. 562
		7.18.9 Storing ropes................................................ 566
		7.18.10 Transporting ropes.......................................... 567
		7.18.11 Checking the rope drive..................................... 567
		7.18.12 Winding ropes............................................... 572
		7.18.13 Luffing ropes............................................... 574
		7.18.14 Lubricating ropes........................................... 576
		7.18.15 Check rope suspension and rope fixation..................... 576
		7.18.16 Checking the pocket locks................................... 577
		7.18.17 Checking the rope fixation and rope thimble................. 578
	7.19 Hydraulic system................................................... 580
		7.19.1 Check the hydraulic system for leaks......................... 580
	7.20 Hydraulic oil tank................................................. 581
		7.20.1 Checking the level in the hydraulic oil tank using the si.... 581
		7.20.2 Filling with hydraulic oil................................... 582
		7.20.3 Draining the hydraulic oil................................... 583
		7.20.4 Cleaning the magnetic rod in the return filter............... 584
	7.21 Hydraulic filter................................................... 586
		7.21.1 Changing the pressure filter................................. 586
	7.22 Electrical system.................................................. 587
		7.22.1 General...................................................... 587
		7.22.2 Wet cleaning................................................. 587
		7.22.3 Batteries.................................................... 587
		7.22.4 Boom limit switch............................................ 589
		7.22.5 Hoist limit switch........................................... 589
		7.22.6 Slip ring unit *............................................. 589
	7.23 Maintenance boom................................................... 590
		7.23.1 Boom foot.................................................... 590
		7.23.2 Boom intermediate pieces..................................... 590
		7.23.3 Checking the boom bolting and retaining rod connections...... 591
	7.24 Pulleys............................................................ 592
		7.24.1 Pulleys on the uppercarriage................................. 592
		7.24.2 Pulleys on A - frame 1....................................... 592
		7.24.3 Cable guide on the boom *.................................... 592
	7.25 Maintenance of S-boom head......................................... 593
		7.25.1 Pulleys on the S-boom head................................... 593
		7.25.2 Electrical components on the S-boom head..................... 594
	7.26 Load hooks......................................................... 594
		7.26.1 Load hook with one or more pulleys........................... 594
		7.26.2 Single hooks................................................. 594
	7.27 Maintenance of the counterweight................................... 595
		7.27.1 Rear counterweight........................................... 595
		7.27.2 Central ballast *............................................ 595
	7.28 Maintenance of the hydraulic cylinders............................. 596
	7.29 Heating and ventilation............................................ 597
	7.30 Windshield washing system.......................................... 598
	7.31 Transport straps and slings........................................ 598
		7.31.1 General...................................................... 598
	7.32 Filling quantities................................................. 599
	7.33 Lubrication chart.................................................. 600
	7.34 Maintaining the CFK pendant straps................................. 603
		7.34.1 Arrangement of pendant straps................................ 604
		7.34.2 Checking the pendant straps.................................. 604
		7.34.3 Checks....................................................... 604
		7.34.4 Wear to the protective sheath................................ 605
		7.34.5 Checking the pendant strap bushes............................ 605
		7.34.6 Parallel flanges............................................. 605
		7.34.7 Checking the connecting pins................................. 606
		7.34.8 Inspecting the coupling links................................ 606
		7.34.9 Replacing the pendant straps................................. 606
		7.34.10 Transporting the pendant straps............................. 606
	7.35 Lubrication chart.................................................. 608
	7.36 Hydraulic oil...................................................... 612
		7.36.1 Initial filling.............................................. 612
		7.36.2 Mixing....................................................... 612
	7.37 Diesel fuels....................................................... 614
	7.38 Diesel engine lubricating oils..................................... 615
	7.39 Diesel engine coolant.............................................. 617
	7.40 Repair-welding..................................................... 620
	7.41 Machine care....................................................... 621
		7.41.1 Hydraulic cylinders.......................................... 621
		7.41.2 Cleaning the machine......................................... 622
	7.42 Preservation of the machine........................................ 623
		7.42.1 Maintenance of the preservation.............................. 624
		7.42.2 Storing the machine for up to 7 months....................... 632
		7.42.3 Storing the machine for more than 7 months................... 638
		7.42.4 Immobilization............................................... 638
		7.42.5 Resale....................................................... 638
	7.43 Preservation medium (anti-corrosion coating)....................... 639
8. REPAIR WORK.............................................................. 647
	8.1 General............................................................. 647
	8.2 Steel chains........................................................ 647
		8.2.1 General....................................................... 647
		8.2.2 Special steel grades.......................................... 647
	8.3 Fire extinguishers.................................................. 648
	8.4 Personal protective equipment....................................... 648
	8.5 Preservation guidelines............................................. 648
	8.6 Selling the machine - decommission- ing - salvaging................. 648
	8.7 Change cables....................................................... 649
		8.7.1 Select cables................................................. 650
		8.7.2 Pull in cables................................................ 651
		8.7.3 Fit on the cable of winch1/winch2 with attached main boom..... 653
9. OPTIONS.................................................................. 669
	9.1 3-coil-limit switch................................................. 670
		9.1.1 General....................................................... 670
		9.1.2 Adjusting 3-coil-limit switch................................. 670
	9.2 Heating and air conditioning system................................. 671
		9.2.1 General....................................................... 671
		9.2.2 Air conditioning system units................................. 671
		9.2.3 Operation..................................................... 672
		9.2.4 Information on the use of the heating and air conditioning.... 673
	9.3 Outreach limitation................................................. 675
		9.3.1 Adjusting the boom outreach limitation........................ 676
		9.3.2 Check outreach limitation*.................................... 676
	9.4 Inclination display................................................. 677
		9.4.1 Operating the inclinometer.................................... 677
	9.5 Refuelling pump..................................................... 679
		9.5.1 General....................................................... 680
		9.5.2 Refuelling.................................................... 680
	9.6 Diagonal protection set............................................. 682
		9.6.1 General....................................................... 682
	9.7 Slewing gear limitation............................................. 683
		9.7.1 Setting slewing gear limitation............................... 685
		9.7.2 Check slewing gear limitation................................. 688
		9.7.3 Cancel slewing gear limitation*............................... 688
	9.8 Pressure filter refuelling system................................... 689
		9.8.1 General....................................................... 689
	9.9 GSM/GPRS/GPS modem.................................................. 690
	9.10 Helicopter-warning light........................................... 691
	9.11 Helicopter light................................................... 695
	9.12 Limiting the lifting height........................................ 700
		9.12.1 Setting the lifting height limit............................. 701
		9.12.2 Deactivating the lifting height limiter...................... 701
	9.13 Cold weather kit................................................... 703
		9.13.1 General...................................................... 703
		9.13.2 Off-duty heating General..................................... 704
		9.13.3 Heating the hydraulic oil.................................... 705
	9.14 Constant tension winch 1 and 2..................................... 707
		9.14.1 Function..................................................... 707
	9.15 Standby heater..................................................... 709
		9.15.1 General...................................................... 709
	9.16 Flow meter......................................................... 710
		9.16.1 Description of parts......................................... 710
		9.16.2 Operation.................................................... 711
		9.16.3 Maintenance.................................................. 711
	9.17 Shut-off slide valve on the hydraulic tank with limit switc........ 713
		9.17.1 General...................................................... 713
		9.17.2 Functioning.................................................. 713
	9.18 Shut-off valve on hydraulic tank with limit switch and disp........ 714
		9.18.1 General...................................................... 714
		9.18.2 Function..................................................... 715
	9.19 Supplemental heaters............................................... 716
	9.20 Grab rope guide.................................................... 717
	9.21 Hydraulic cab inclination.......................................... 719
		9.21.1 Operating elements of the hydraulic cab inclination.......... 719
		9.21.2 Interlock control............................................ 721
	9.22 Check point indication............................................. 723
		9.22.1 General...................................................... 723
	9.23 Bypass filter...................................................... 724
		9.23.1 General...................................................... 724
		9.23.2 Functioning.................................................. 724
		9.23.3 Maintenance.................................................. 724
	9.24 Orthopaedic driver's seat.......................................... 725
		9.24.1 General...................................................... 725
	9.25 Process data acquisition (PDE)..................................... 726
		9.25.1 General...................................................... 726
		9.25.2 Data evaluation.............................................. 727
		9.25.3 PDE monitor.................................................. 728
		9.25.4 Operation.................................................... 738
		9.25.5 Data organization............................................ 741
		9.25.6 Printer...................................................... 742
	9.26 Pump wear indication............................................... 743
		9.26.1 Check chip control........................................... 745
	9.27 Rope bow........................................................... 746
		9.27.1 General...................................................... 746
		9.27.2 Mounting rope bows........................................... 746
	9.28 Rope length metering............................................... 748
		9.28.1 General...................................................... 748
		9.28.2 Displays in the mode screen.................................. 748
		9.28.3 Programming rope length...................................... 748
	9.29 Load moment limiter signal column.................................. 751
	9.30 Central lubrication of the swing ring bearings..................... 753
		9.30.1 General...................................................... 753
		9.30.2 Filling the grease reservoir................................. 754
		9.30.3 Time interval programming.................................... 754
		9.30.4 Function..................................................... 755
		9.30.5 Maintenance of the central lubrication system................ 755
	9.31 Central lubrication of the tooth flanks of the swing ring.......... 756
		9.31.1 General...................................................... 756
		9.31.2 Filling the grease reservoir................................. 757
		9.31.3 Time interval programming.................................... 757
		9.31.4 Function..................................................... 758
		9.31.5 Maintenance of the central lubrication system................ 758
	9.32 Central lubrication of the swing ring bearings and/or tooth........ 759
		9.32.1 General...................................................... 759
		9.32.2 Filling the grease reservoir................................. 760
		9.32.3 Programming the time intervals............................... 760
	9.33 Function........................................................... 761
		9.33.1 Monitoring................................................... 761
		9.33.2 Maintenance of the central lubrication system................ 762
	9.34 Boom catwalks...................................................... 763
		9.34.1 Fitting steel boom catwalks.................................. 763
		9.34.2 Fitting CFRP boom catwalks................................... 766
	9.35 Line pull limitation............................................... 769
		9.35.1 Switching on line pull limitation............................ 769
		9.35.2 Switching off line pull limitation........................... 770
	9.36 Winch synchronisation.............................................. 771
		9.36.1 Switching on and operating winch synchronisation............. 772
	9.37 Rock guard (variant 1)............................................. 776
		9.37.1 Use.......................................................... 776
	9.38 Rock guard (variant 2)............................................. 777
		9.38.1 Use.......................................................... 777
	9.39 Rock guard (variant 3)............................................. 778
		9.39.1 Use.......................................................... 778
	9.40 Video monitoring system............................................ 779
		9.40.1 Monitor...................................................... 779
		9.40.2 Control panel................................................ 781
		9.40.3 Camera....................................................... 783
	9.41 Hydraulic grab..................................................... 786
		9.41.1 General...................................................... 786
		9.41.2 Connecting the grab.......................................... 787
		9.41.3 Operational controls......................................... 789
		9.41.4 Right-hand control panel (X23)............................... 791
		9.41.5 Select grab mode............................................. 794
		9.41.6 Soilmec grab indicator....................................... 797
		9.41.7 Operating the grab........................................... 798
		9.41.8 Settings..................................................... 799
		9.41.9 Deselecting Soilmec grab..................................... 805
		9.41.10 Maintenance of the additional grab.......................... 805
	9.42 Mini cutter........................................................ 806
		9.42.1 General...................................................... 806
		9.42.2 Controls..................................................... 807
		9.42.3 Connecting the mini cutter................................... 809
		9.42.4 Operating the mini cutter.................................... 810
		9.42.5 Mini cutter maintenance...................................... 813
		9.42.6 Removing the mini cutter..................................... 813
	9.43 Rope separating bracket, boom head stabilisers..................... 814
		9.43.1 Ðeneral...................................................... 814
		9.43.2 Arrangement.................................................. 814
	9.44 Additional searchlights............................................ 815
		9.44.1 Floodlight on the superstructure............................. 815
	9.45 Air compressor..................................................... 817
		9.45.1 General...................................................... 817
		9.45.2 Start-up..................................................... 818
		9.45.3 Operating the air compressor................................. 818
	9.46 Slurry wall grab................................................... 820
		9.46.1 General...................................................... 820
		9.46.2 Connecting the grab.......................................... 824
		9.46.3 Operating elements........................................... 825
		9.46.4 Selecting grab operation mode................................ 831
		9.46.5 "Grab" screen................................................ 834
		9.46.6 Operating the grab........................................... 836
		9.46.7 Grab free-fall within slow-down height*...................... 846
		9.46.8 Deselecting the grab......................................... 850
		9.46.9 Detaching the grab........................................... 850
		9.46.10 Grab maintenance............................................ 851
	9.47 Magnetic system.................................................... 852
	9.48 Vibratory hammer................................................... 853
		9.48.1 General...................................................... 853
		9.48.2 Controls..................................................... 854
		9.48.3 Connecting the hydraulic system.............................. 856
		9.48.4 Select vibratory operation................................... 858
		9.48.5 "Vibratory hammer operation" screen.......................... 861
		9.48.6 Settings..................................................... 862
		9.48.7 Operating the vibratory hammer............................... 864
		9.48.8 Deselecting "Vibratory hammer operation"..................... 867
		9.48.9 Maintenance of the attached vibratory hammer................. 867
	9.49 Concrete cutter mode............................................... 868
		9.49.1 General...................................................... 868
		9.49.2 Connecting the concrete cutters.............................. 870
	9.50 Right-hand control panel (X23)..................................... 871
		9.50.1 Selecting the concrete cutters............................... 873
		9.50.2 Concrete cutter mode display................................. 876
		9.50.3 Controlling the concrete cutters............................. 878
		9.50.4 Switching between the joystick and the but- tons on the j.... 879
		9.50.5 Maintaining the concrete cutters............................. 880
		9.50.6 Releasing the hydraulic oil.................................. 881
	9.51 Hammer............................................................. 883
		9.51.1 Controls..................................................... 884
		9.51.2 Connecting the hydraulic system.............................. 886
		9.51.3 Select hammer operation...................................... 887
		9.51.4 "Hammer operation" screen.................................... 891
		9.51.5 Settings..................................................... 892
		9.51.6 Operating the hammer......................................... 894
		9.51.7 Deselecting "Hammer operation"............................... 895
		9.51.8 Maintenance of the attached hammer........................... 895
	9.52 Leader............................................................. 897
		9.52.1 General...................................................... 897
		9.52.2 Operating modes.............................................. 898
		9.52.3 Assembly and dismantling..................................... 898
		9.52.4 Controls..................................................... 899
		9.52.5 "Leader operation" screen.................................... 903
		9.52.6 Connecting the electrical and hydraulic systems.............. 905
		9.52.7 "Leader drop prevention" safety monitor...................... 907
		9.52.8 Operating the leader with additional panel X25............... 909
		9.52.9 Platform adjustment winch.................................... 913
		9.52.10 General..................................................... 913
		9.52.11 Leader height adjusting winch............................... 914
		9.52.12 General..................................................... 914
		9.52.13 Left-hand control lever..................................... 914
		9.52.14 Automatic inclination system................................ 915
		9.52.15 General..................................................... 915
		9.52.16 Mooring..................................................... 916
		9.52.17 Yo-Yo operation............................................. 917
		9.52.18 Contact pressure control.................................... 918
		9.52.19 Mooring for leader adjustment............................... 920
		9.52.20 Enabling constant tension................................... 920
	9.53 Grab mode.......................................................... 921
		9.53.1 General...................................................... 921
		9.53.2 Connecting the grab.......................................... 921
		9.53.3 Grab operation selection..................................... 921
		9.53.4 Selecting grab mode.......................................... 922
		9.53.5 Operating the grab........................................... 925
	9.54 Concrete crusher................................................... 927
		9.54.1 General...................................................... 927
	9.55 Function lock...................................................... 929
	9.56 Roof railing....................................................... 930
		9.56.1 Location..................................................... 930
		9.56.2 Fastening.................................................... 931
		9.56.3 Chopper bar.................................................. 931
	9.57 Steadying winch.................................................... 932
		9.57.1 General...................................................... 932
		9.57.2 Technical data............................................... 933
		9.57.3 Checks before start-up....................................... 933
		9.57.4 Working with the steadying winch............................. 934
		9.57.5 Maintenance of the steadying winch........................... 938
	9.58 Orange peel grab................................................... 940
		9.58.1 Connecting the grab.......................................... 944
		9.58.2 Selecting the grab........................................... 945
		9.58.3 "Grab operation mode" display field.......................... 947
		9.58.4 Set the delivery rate and working pressure for grab opera.... 950
	9.59 Auxiliary winch.................................................... 952
		9.59.1 General...................................................... 952
		9.59.2 Operating the auxiliary winch................................ 953
	9.60 Self-loading system................................................ 955
		9.60.1 Extending the assembly cylinder.............................. 955
		9.60.2 Supporting and unloading the basic machine................... 957
		9.60.3 Attach the crawler side frame................................ 965
		9.60.4 Preparing for disassembly of the crawler track carrier....... 987
		9.60.5 Support basic machine........................................ 988
		9.60.6 Removing the crawler track carrier from the undercarriage.... 994
		9.60.7 Loading the basic machine....................................1003
	9.61 Fixed jib..........................................................1006
		9.61.1 Fixed jib on heavy boom head (system no.: 1311.22)...........1007
		9.61.2 Set-up screen 3 for main boom with fixed jib.................1011
		9.61.3 Attach the jib base section..................................1021
		9.61.4 Assembling the jib (system no.: 0806.15).....................1023
		9.61.5 Attaching the jib head (system no.: 0806.16).................1023
		9.61.6 Assembling the fly jib pendant straps........................1024
		9.61.7 Intermediate tensioners on the fixed jib.....................1025
		9.61.8 Assembling the main boom.....................................1027
		9.61.9 Supporting the main boom.....................................1028
		9.61.10 Attaching connecting links to the main boom.................1029
		9.61.11 Attach the backstay straps to the connecting links..........1030
		9.61.12 Erecting the A-frame........................................1032
		9.61.13 Intermediate tensioners on the fixed jib....................1033
		9.61.14 Assembling the main boom....................................1035
		9.61.15 Supporting the main boom....................................1036
		9.61.16 Attaching connecting links to the main boom.................1037
		9.61.17 Attach the backstay straps to the connecting links..........1038
		9.61.18 Erecting the A-frame........................................1040
		9.61.19 Attaching the backstay straps to the crossbar...............1041
		9.61.20 Connecting the electrics....................................1042
		9.61.21 Luff the hoist rope.........................................1045
		9.61.22 Reeving the pulley block (or load hook) on the heavy boo....1045
		9.61.23 Reeving the pulley block/load hook on the 0806 jib head.....1046
		9.61.24 Fitting the hoist limit switch weight.......................1048
		9.61.25 Erecting a main boom + fixed jib............................1050
		9.61.26 Erecting procedure..........................................1050
		9.61.27 Erectability with fixed jib.................................1054
		9.61.28 Two-hook operation with fixed jib...........................1054
		9.61.29 Combined two-hook operation with fixed jib..................1056
		9.61.30 Setting down the fixed jib..................................1057
		9.61.31 Maintenance of the fixed jib................................1058
	9.62 Cab elevation......................................................1059
		9.62.1 General......................................................1059
		9.62.2 Signs on the cab.............................................1060
		9.62.3 Operating elements and controls..............................1061
		9.62.4 Emergency release............................................1062
		9.62.5 Using the emergency release..................................1062
		9.62.6 Maintenance and repair work under the cab....................1063
	9.63 Tip boom...........................................................1065
		9.63.1 General......................................................1066
		9.63.2 Fitting the tip boom.........................................1069
		9.63.3 Removing the tip boom........................................1074
	9.64 Maintenance of the tip boom........................................1079
	9.65 Casagrande Cutter..................................................1080
		9.65.1 General......................................................1080
		9.65.2 Connecting the cutter........................................1080
		9.65.3 Selecting the cutter.........................................1081
		9.65.4 Switching on cutting mode....................................1081
		9.65.5 Cut field....................................................1081
		9.65.6 Key assignments for additional desk X25: 9. OPTIONS )/Med....1083
		9.65.7 Joystick.....................................................1086
		9.65.8 Operating cutter.............................................1087
		9.65.9 Automatic mode...............................................1088
		9.65.10 Pressure monitoring.........................................1088
		9.65.11 Hose winches left and right.................................1089
		9.65.12 Hose reels left and right...................................1092
		9.65.13 Crowd cylinder..............................................1094
		9.65.14 Winch synchronization in cutting mode.......................1094
		9.65.15 Measuring reel..............................................1094
		9.65.16 Safety cut-out in cutting mode..............................1095
		9.65.17 Assembly mode and limit switch bypassed.....................1096
		9.65.18 LML.........................................................1096
		9.65.19 Rope tension limitation, hoist winch 1 and 2................1096
	9.66 Drilling drive.....................................................1097
		9.66.1 General......................................................1097
		9.66.2 Connecting the hydraulic system..............................1098
		9.66.3 Selecting drilling mode......................................1099
		9.66.4 "Drilling mode" screen.......................................1103
		9.66.5 Settings.....................................................1104
		9.66.6 Operating in drilling mode...................................1106
		9.66.7 Actuating the boom luffing winch in drilling mode............1107
		9.66.8 "Drilling mode" selection....................................1107
		9.66.9 Maintenance of the attached drill unit.......................1107
	9.67 Slurry wall grab for tunnel working................................1109
		9.67.1 Basic machine with short boom................................1109
		9.67.2 Product description..........................................1110
		9.67.3 Short boom 1307.24 5428 mm [17 ft 10 s.......................1110
		9.67.4 4,450 mm [14 ft 7 inch] pendant straps.......................1112
		9.67.5 Working range of short boom 52°..............................1113
		9.67.6 Working range of short boom 56°..............................1114
		9.67.7 Assembly.....................................................1115
		9.67.8 Switching off assembly mode..................................1121
		9.67.9 Check operation of A-frame and tilting-back support limit....1122
		9.67.10 Disassembling the short boom................................1125
	9.68 Hydraulic oil level too low warning signal WARNING! Ignorin........1127
		9.68.1 Monitoring the "Hydraulic oil level in the hydraulic oil ....1127
	9.69 Emergency stop switch on the counterweight.........................1129
	9.70 ECO Mode...........................................................1131
		9.70.1 Select the Engine monitoring screen..........................1131
		9.70.2 Starting Eco Mode............................................1132
		9.70.3 Switching off Eco Mode.......................................1132
	9.71 Sensitive hoisting winch 2.........................................1133
		9.71.1 Ensure that the following conditions are satisfied:..........1133
		9.71.2 Preselect sensitive hoisting.................................1133
		9.71.3 Operate sensitive hoisting...................................1133
	9.72 Warning light and horn.............................................1135
		9.72.1 General......................................................1135
		9.72.2 Function.....................................................1135
	9.73 Hydraulically folding boom walkways on uppercarriage...............1137
		9.73.1 Hydraulically folding boom walkways on uppercarriage.........1138
		9.73.2 Operating elements on uppercarriage..........................1139
		9.73.3 Move left boom walkway into working position.................1140
		9.73.4 Brackets.....................................................1141
		9.73.5 Brackets.....................................................1142
		9.73.6 Fold boom walkway into working position......................1143
		9.73.7 Boom walkway.................................................1144
		9.73.8 Bolt boom walkway in working position........................1145
		9.73.9 Bolt rear left boom walkway in working position..............1146
		9.73.10 Fold railings into working position.........................1147
		9.73.11 Railing.....................................................1148
		9.73.12 Front left ladder...........................................1149
		9.73.13 Ladder on boom walkway......................................1150
		9.73.14 Move right boom walkway into working position...............1151
		9.73.15 Folding boom walkway into working position..................1152
		9.73.16 Boom walkway................................................1153
		9.73.17 Bolt boom walkway in working position.......................1154
		9.73.18 Fold railings into working position.........................1155
		9.73.19 Railing.....................................................1156
		9.73.20 Rear right ladder...........................................1157
		9.73.21 Ladder on boom walkway......................................1158
		9.73.22 Bracket.....................................................1159
10. APPENDIX................................................................1165

Questions? Email us: [email protected]

https://vimeo.com/876650941?share=copy

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V