Liebherr Crawler Crane HS 895 HD Operating manual SN 188182 – PDF DOWNLOAD

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Liebherr Crawler Crane HS 895 HD Operating manual SN 188182 – PDF DOWNLOAD

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Liebherr Crawler Crane HS 895 HD Operating manual SN 188182 – PDF DOWNLOAD

Language : English
Pages : 681
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Liebherr Crawler Crane HS 895 HD Operating manual SN 188182 – PDF DOWNLOAD

1. INTRODUCTION
1.1 Foreword

The hydraulic crawler crane, HS 895 HD with Litronic-control is setting new standards in excavator
manufacture.
• The basic machine
– has been developed for continuous operation in tough building-site conditions,
– has been conceived around the modular design,
– allows versatile combinations and mounting of accessories in order that the crawler crane is in
optimal operating configuration to suit every application.
• A higher degree of cost-effectiveness and economy is thus guaranteed for the user, as the number
of machines can be kept to a minimum.
• The Litronic-control combines advantages of the most up-to-date control technology with hydraulic
power transmission. Functions such as electronic engine speed sensing, energy-saving pressure
compensation, extensive diagnosis possibilities as well as automised procedures and operation
data recording are thus possible.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Liebherr Crawler Crane HS 895 HD Operating manual SN 188182 – PDF DOWNLOAD

1. INTRODUCTION............................................................. 23
	1.1 Foreword............................................................ 23
	1.2 Using the documentation............................................. 24
		1.2.1 How is this operating manual structured in volume 1?.......... 24
		1.2.2 System prerequisites of the computer for utilisation of th.... 25
		1.2.3 Actual condition of the documentation......................... 25
		1.2.4 Storing the documentation..................................... 25
	1.3 Machine license..................................................... 26
	1.4 Impressum........................................................... 29
	1.5 Conversion tables................................................... 30
		1.5.1 Length........................................................ 30
		1.5.2 Surface area.................................................. 30
		1.5.3 Weight (mass)................................................. 31
		1.5.4 Volume........................................................ 31
		1.5.5 Pressure...................................................... 31
		1.5.6 Temperature................................................... 32
		1.5.7 Speed......................................................... 32
		1.5.8 Force......................................................... 32
		1.5.9 Torque........................................................ 32
		1.5.10 Output....................................................... 33
	1.6 Certificate of conformity........................................... 34
2. PRODUCT DESCRIPTION...................................................... 39
	2.1 General............................................................. 39
		2.1.1 What should you be aware of when reading the operating man.... 39
	2.2 Applications of the machine......................................... 40
		2.2.1 Equipment rating.............................................. 41
		2.2.2 Explanatory notes on the equipment rating..................... 42
		2.2.3 Use as directed............................................... 42
		2.2.4 Use not as directed........................................... 43
	2.3 Machine summary..................................................... 45
	2.4 Boom................................................................ 46
	2.5 Uppercarriage....................................................... 48
		2.5.1 Central power unit............................................ 50
		2.5.2 Pump equipment................................................ 52
	2.6 Undercarriage....................................................... 54
	2.7 Counterweight....................................................... 55
		2.7.1 Central counterweight *....................................... 57
	2.8 Summary of hydraulic cylinders...................................... 58
	2.9 Technical data...................................................... 59
		2.9.1 Dimensions and weights........................................ 59
		2.9.2 Operating conditions.......................................... 65
		2.9.3 Emissions..................................................... 66
		2.9.4 Engine aggregate.............................................. 66
		2.9.5 Hydraulic system.............................................. 66
		2.9.6 Winches....................................................... 67
		2.9.7 Swing gear.................................................... 68
		2.9.8 Crawler....................................................... 68
		2.9.9 Control....................................................... 68
3. SAFETY REGULATIONS....................................................... 73
	3.1 General............................................................. 73
		3.1.1 Danger symbols................................................ 74
		3.1.2 Use as directed............................................... 75
		3.1.3 Areas of responsibility....................................... 75
	3.2 Personal requirements of the machine operator....................... 76
	3.3 Personal protective gear............................................ 77
	3.4 Working area........................................................ 78
	3.5 Safety and monitoring devices....................................... 79
		3.5.1 Safety devices................................................ 79
		3.5.2 Monitoring devices............................................ 80
	3.6 Safety signs on the crawler crane................................... 81
		3.6.1 Meaning of safety signs....................................... 84
	3.7 Machine-specific dangers............................................ 86
		3.7.1 Injuries resulting from operating machinery................... 86
		3.7.2 Injuries due to hydraulic energy.............................. 88
		3.7.3 Risk of burns................................................. 89
		3.7.4 Risk of chemical burns........................................ 90
		3.7.5 Fire and explosion hazards.................................... 91
		3.7.6 Risk of poisoning and asphyxiation............................ 94
		3.7.7 Safety Precaution for using refrigerants...................... 95
		3.7.8 Electromagnetic influences.................................... 97
		3.7.9 Endangering the environment................................... 98
	3.8 Additional dangers.................................................. 99
		3.8.1 Effects of wind and storms WARNING! If the maximum permiss.... 99
		3.8.2 Ground conditions on the site.................................103
		3.8.3 Snow and ice loads............................................104
		3.8.4 Lightning strikes.............................................105
		3.8.5 Overhead power lines..........................................106
		3.8.6 Underground pipes and cables..................................115
	3.9 Safety precautions for the machine operator.........................120
	3.10 Safety precautions for maintenance and repair personnel............120
	3.11 Safety precautions for construction site personnel.................121
		3.11.1 Signalman....................................................121
		3.11.2 Rigger.......................................................123
		3.11.3 Hand signals.................................................123
4. CONTROL AND OPERATING ELE- MENTS.........................................135
	4.1 General.............................................................135
	4.2 Operating elements on the undercarriage.............................136
	4.3 Operating elements on the uppercarriage.............................137
	4.4 Operator's cab......................................................138
		4.4.1 Summary of operator's cab.....................................138
		4.4.2 Summary of the control stand..................................140
		4.4.3 Summary of the control stand from above.......................142
	4.5 LCD screen..........................................................145
	4.6 Overview of the LCD screen..........................................147
		4.6.1 Main areas of the screen......................................147
		4.6.2 Description of the main areas of the screen...................147
		4.6.3 Sequence of mode screens......................................149
		4.6.4 Left-hand control panel (X11).................................151
	4.7 Left-hand control panel (X12).......................................154
	4.8 Right-hand control panel (X23)......................................156
	4.9 Litronic service panel..............................................160
		4.9.1 Emergency shut-down switch....................................162
		4.9.2 Left-hand switch lever........................................163
		4.9.3 Right-hand switch lever.......................................163
		4.9.4 Pedal arrangement.............................................163
	4.10 Crawler crane operation - auxiliary functions......................164
		4.10.1 Adjusting operating elements.................................164
		4.10.2 Operator's seat..............................................165
		4.10.3 LCD-display screen adjustments...............................166
		4.10.4 Windshield wiper.............................................166
		4.10.5 Heating and air conditioning *...............................168
		4.10.6 Inside lighting in uppercarriage.............................170
		4.10.7 Cab lighting.................................................170
		4.10.8 Radio........................................................170
		4.10.9 Horn.........................................................170
		4.10.10 Cigarette lighter / socket in the cab.......................170
		4.10.11 Cabin adjustment cylinder *.................................171
		4.10.12 Cab height adjustment *.....................................171
	4.11 Operator guidance on the display screen............................173
	4.12 Start-up screen....................................................173
	4.13 Set-up screens.....................................................175
		4.13.1 Set-up screen 1 for main boom................................176
		4.13.2 Set-up screen 3 for main boom with fixed fly jib.............182
		4.13.3 Example of a load capacity chart for load moment limitati....184
	4.14 "Mode screen" page.................................................186
	4.15 "Power unit monitoring" screen.....................................193
	4.16 "Fault monitor" screen.............................................196
5. OPERATION................................................................201
	5.1 General.............................................................201
	5.2 Safety regulations for operation....................................201
		5.2.1 Notes on safe operation.......................................201
		5.2.2 Safety regulations for start-up...............................202
		5.2.3 Safety regulations for excavator operation....................202
		5.2.4 Safety regulations for lifting gear operation of the crawl....202
		5.2.5 Safety regulations for travel operation.......................203
		5.2.6 Safety regulations for shutting down the crawler crane........203
	5.3 Checks before start-up..............................................204
		5.3.1 Tour of inspection............................................204
	5.4 Checks before starting CAUTION ! Please note the safety regu........205
		5.4.1 Engine oil level..............................................205
		5.4.2 Gear oil level................................................205
		5.4.3 Coolant level.................................................205
		5.4.4 Fuel system...................................................207
		5.4.5 Tank level of fuel tank.......................................207
		5.4.6 Checking oil level in the hydraulic tank......................208
		5.4.7 Shut off slide valve on the hydraulic tank....................208
		5.4.8 Electrical system.............................................209
		5.4.9 Battery main switch...........................................209
		5.4.10 Inspection of maintenance tasks..............................209
	5.5 Adjusting operating elements........................................211
	5.6 Switching on control DANGER ! Faulty operation can lead to s........211
		5.6.1 Ignition switch...............................................211
		5.6.2 Parking position..............................................212
		5.6.3 Working floodlight............................................212
		5.6.4 Programming set-up............................................213
	5.7 Starting the diesel engine..........................................217
		5.7.1 Prerequisites.................................................217
		5.7.2 Starting in extreme external temperatures.....................220
	5.8 Adjusting engine speed..............................................220
		5.8.1 Adjustment of engine speed....................................220
		5.8.2 Constant speed................................................220
		5.8.3 Automatic idle................................................220
		5.8.4 Gas pedal *...................................................221
		5.8.5 Electronic limited load regulation............................221
	5.9 Operation...........................................................222
		5.9.1 Operation types...............................................222
		5.9.2 Litronic control..............................................222
		5.9.3 Simultaneous movements........................................223
		5.9.4 Maximum lifting capacities....................................223
		5.9.5 Line-pull limitation *........................................223
		5.9.6 Operation with the load moment limitation *...................224
		5.9.7 Safety lever control..........................................224
		5.9.8 Vibrator selection switch lever...............................224
		5.9.9 Operating crawler crane - main functions......................225
		5.9.10 Checks before beginning work ATTENTION ! Do not operate t....226
	5.10 Actuate swing gear.................................................228
		5.10.1 General......................................................228
		5.10.2 Swing speed..................................................228
		5.10.3 Functional mode..............................................228
	5.11 Free swing gear....................................................230
		5.11.1 General......................................................230
		5.11.2 Free swing gear On...........................................230
		5.11.3 Key-operated free swing gear.................................231
		5.11.4 Functional use...............................................231
		5.11.5 Free swing gear Off..........................................231
	5.12 Adjusting main boom................................................232
		5.12.1 Functional use...............................................232
		5.12.2 Shut-down....................................................232
		5.12.3 Assembly operation...........................................233
	5.13 Moving the machine.................................................234
	5.14 Crawler high gear *................................................238
	5.15 Actuating winches..................................................239
		5.15.1 General......................................................239
		5.15.2 Functional use...............................................239
		5.15.3 Shut-down....................................................239
		5.15.4 Assembly operation...........................................240
	5.16 High gear winches *................................................240
		5.16.1 General......................................................240
		5.16.2 Pre-selection................................................240
	5.17 Lifting mode.......................................................241
		5.17.1 Operating the hoisting winches...............................241
		5.17.2 Lifting loads with the main boom head using runner attach....244
		5.17.3 Lifting loads with the tip boom (runner).....................245
		5.17.4 Lifting loads with the main boom head with fixed fly jib ....246
		5.17.5 Twin hook operation..........................................248
		5.17.6 Combined two-hook operation with fixed fly jib...............255
	5.18 Operating heating..................................................259
		5.18.1 Heating operation............................................260
		5.18.2 Fresh air operation..........................................260
	5.19 Inclining operator's cab *.........................................261
		5.19.1 General......................................................261
	5.20 Hydraulic cab elevation............................................263
		5.20.1 Product description..........................................263
		5.20.2 Safety guidelines............................................264
		5.20.3 Assembly.....................................................268
		5.20.4 Operation....................................................273
		5.20.5 Disassembly..................................................275
		5.20.6 Maintenance..................................................276
	5.21 Excavator operation ATTENTION ! The safety regulations in c........278
		5.21.1 Counterweight................................................278
	5.22 Lifting gear operation with excavator equipment ATTENTION !........279
		5.22.1 Prerequisites................................................279
		5.22.2 Hoist rope reeving...........................................279
		5.22.3 Free-fall operation..........................................280
		5.22.4 Working in free-fall operation...............................286
		5.22.5 Shutting down free-fall operation............................287
		5.22.6 Winch standstill monitoring..................................287
	5.23 Shutting down the crawler crane....................................288
		5.23.1 Emergency Off key ATTENTION ! Upon actuation of an Emerge....288
	5.24 Parking position WARNING ! The crawler crane is to be suffi........289
		5.24.1 Short breaks in operation....................................289
		5.24.2 Longer breaks in operation...................................289
	5.25 Actuating refuelling pumps.........................................290
		5.25.1 General......................................................290
		5.25.2 Refuelling...................................................290
	5.26 Emergency control *................................................291
		5.26.1 General......................................................291
		5.26.2 Notes on safety..............................................291
		5.26.3 Pre-selecting Emergency control..............................291
		5.26.4 Using emergency control......................................293
6. ASSEMBLY AND DISASSEMBLY.................................................297
	6.1 General.............................................................297
	6.2 Application planning................................................297
	6.3 Application types...................................................299
		6.3.1 Excavator operation...........................................299
		6.3.2 Lifting gear operation with excavator equipment...............299
		6.3.3 Assembly lengths for main boom................................299
		6.3.4 Defining the set-up...........................................309
		6.3.5 Assembling and preparing the transport equipment..............309
	6.4 Safety regulations for assembly and disassembly.....................311
	6.5 Mounting mode.......................................................312
		6.5.1 General.......................................................312
		6.5.2 Preselecting mounting mode Mounting mode is selected with ....312
		6.5.3 Mounting mode display.........................................312
		6.5.4 Operation in mounting mode....................................312
	6.6 Prerequisites for assembly..........................................313
		6.6.1 Transport position of basic machine...........................313
	6.7 Order of assembly stages............................................314
	6.8 Mounting noise-protection covers....................................315
	6.9 Installing exhaust limit pipe.......................................316
		6.9.1 Swiveling the cab to the working position.....................317
		6.9.2 Fitting the turnbuckle........................................320
	6.10 Adjusting the A-frame..............................................322
		6.10.1 General......................................................322
	6.11 Folding A-frame forwards...........................................324
		6.11.1 Folding A-frame backwards....................................324
	6.12 Extending support cylinder.........................................325
		6.12.1 Safety regulations for the supporting procedure..............326
		6.12.2 Supporting the basic machine.................................326
	6.13 Assembling the crawler.............................................329
		6.13.1 General......................................................329
		6.13.2 Angle indicator *............................................329
		6.13.3 Notes on safety for crawler assembly.........................330
		6.13.4 Prerequisites for assembly...................................330
		6.13.5 Assembly of first crawler....................................332
		6.13.6 Assembly of second crawler...................................334
	6.14 Mounting ladders, platforms and roof grids *.......................338
		6.14.1 Platforms around the operator's cab..........................338
		6.14.2 Platforms on the uppercarriage...............................338
		6.14.3 Roof grid operator's cab *...................................338
	6.15 Mounting central counterweight *...................................339
	6.16 Preparing the counterweight........................................341
		6.16.1 General......................................................341
		6.16.2 Prerequisites for assembly...................................342
		6.16.3 Assembly.....................................................342
	6.17 Mounting counterweight.............................................344
	6.18 Assembling the main boom...........................................347
		6.18.1 General......................................................347
		6.18.2 Bolting the sections.........................................350
		6.18.3 Pendant straps on main boom..................................351
		6.18.4 Main boom intermediate tensioners *..........................363
		6.18.5 Rope guide *.................................................365
	6.19 Attach the main boom pivot piece...................................366
		6.19.1 General......................................................366
		6.19.2 Attaching to the superstructure..............................367
	6.20 Main boom tilting-back supports....................................369
		6.20.1 General......................................................369
	6.21 Attaching the main boom............................................370
		6.21.1 General......................................................370
		6.21.2 Attaching the main boom......................................372
	6.22 Connecting electrics and hydraulics *..............................375
		6.22.1 Required hoisting rope length................................377
	6.23 Installing hoist rope..............................................378
		6.23.1 General......................................................378
		6.23.2 Procedure....................................................378
	6.24 Reeve the cable....................................................379
	6.25 Rope luffing winch *...............................................381
		6.25.1 General......................................................381
		6.25.2 Arrangement of components....................................381
		6.25.3 Rope reeving.................................................382
		6.25.4 Switching on rope luffing winch..............................382
		6.25.5 Switching off rope luffing winch.............................382
	6.26 Erect the main boom................................................383
		6.26.1 Prerequisites for erection 1.) Erecting requirements Befo....383
		6.26.2 Erecting procedure 1.) Lifting the main boom Slowly lift ....385
		6.26.3 Cancelling assembly mode.....................................386
	6.27 Disassembly........................................................387
		6.27.1 General......................................................387
		6.27.2 Prerequisites for disassembly................................387
	6.28 Order of disassembly stages........................................388
	6.29 Laying down the main boom..........................................389
		6.29.1 General......................................................389
		6.29.2 Procedure when laying down the main boom.....................391
		6.29.3 Disassembly of load hook PROCEDURE 1.) Disassembly of hoi....392
		6.29.4 Pull out hoist rope..........................................392
	6.30 Dismantling the main boom..........................................392
		6.30.1 General......................................................392
		6.30.2 Dismantling the main boom....................................394
	6.31 Retracting the main boom tilting-back supports.....................396
		6.31.1 General......................................................396
	6.32 Dismantling the main boom pivot piece..............................397
		6.32.1 General......................................................397
		6.32.2 Detaching from basic machine.................................398
	6.33 Disassembling the main boom........................................399
		6.33.1 Prerequisites................................................399
		6.33.2 Procedure....................................................399
	6.34 Disassembling counterweight........................................400
	6.35 Dismantling counterweight..........................................402
		6.35.1 Prerequisites................................................403
		6.35.2 Dismantling the counterweight................................403
	6.36 Dismantling the central counterweight *............................405
	6.37 Dismantling the platforms..........................................406
		6.37.1 Platforms around the cab.....................................406
		6.37.2 Platforms on the superstructure..............................406
	6.38 Disassembling crawler..............................................407
		6.38.1 General......................................................407
		6.38.2 Notes on safety for crawler disassembly......................408
		6.38.3 Prerequisites for disassembly................................408
		6.38.4 Disassembly of first crawler.................................410
		6.38.5 Disassembly of second crawler................................411
	6.39 Loading basic machine..............................................412
		6.39.1 General......................................................412
	6.40 Folding back the A-frame...........................................413
		6.40.1 General......................................................413
		6.40.2 Procedure....................................................413
		6.40.3 Swiveling the cab to the transport position..................415
	6.41 Bringing noise-protection covers into transport position...........417
	6.42 Dismantling exhaust limit pipe.....................................418
	6.43 Transport..........................................................419
		6.43.1 Safety regulations for loading and unloading.................419
		6.43.2 Transport position of basic machine..........................420
	6.44 Overseas transport.................................................421
	6.45 Loading the basic machine with an auxiliary crane..................422
		6.45.1 General......................................................422
		6.45.2 Loading procedure............................................425
	6.46 Secure the basic machine to prevent it from sliding about..........427
		6.46.1 General......................................................427
7. MAINTENANCE..............................................................433
	7.1 General.............................................................433
		7.1.1 Lubricants....................................................434
		7.1.2 Welding work..................................................434
		7.1.3 Cylinder......................................................434
	7.2 Maintenance chart...................................................435
		7.2.1 Work to be carried out........................................435
	7.3 Diesel engine.......................................................454
		7.3.1 Check engine oil level........................................454
		7.3.2 Changing engine oil...........................................454
		7.3.3 Changing engine oil filter....................................454
		7.3.4 Greasing spur gear on flywheel................................455
		7.3.5 Motor fastening screws........................................455
		7.3.6 Changing the oil separator....................................455
	7.4 Fuel system (MAN engine)............................................457
		7.4.1 Check the water separator on the fuel prefilter, drain off....458
		7.4.2 Draining condensate from the fuel filter......................460
		7.4.3 Draining condensate from the fuel tank........................462
		7.4.4 Cleaning the fuel prefilter...................................464
		7.4.5 Replacing the fuel filter.....................................466
		7.4.6 Bleeding the fuel system......................................468
	7.5 Cooling system......................................................471
		7.5.1 Check coolant level...........................................472
		7.5.2 Checking the cooling system...................................472
		7.5.3 Changing the coolant..........................................472
		7.5.4 Draining coolant..............................................473
		7.5.5 Filling coolant...............................................473
		7.5.6 Temperature regulation........................................474
	7.6 V-belts.............................................................475
		7.6.1 Checking V-belts..............................................475
		7.6.2 Adjusting V-belt tension (fig. 20)............................475
		7.6.3 Changing V-belts..............................................475
	7.7 Measuring device for V-belt tension.................................476
	7.8 Dry-air filter......................................................477
		7.8.1 General.......................................................478
		7.8.2 Cleaning the filter cartridge.................................478
		7.8.3 Dry cleaning..................................................478
	7.9 Gear inspection.....................................................479
		7.9.1 Inspection intervals..........................................479
		7.9.2 Checking oil amount...........................................479
		7.9.3 Checking oil colouring........................................479
		7.9.4 Checking for hardened foreign bodies..........................479
		7.9.5 Notes for rinsing gears.......................................479
		7.9.6 Overall assessment............................................480
	7.10 Splitter box.......................................................481
		7.10.1 General......................................................481
		7.10.2 Checking gear oil............................................481
		7.10.3 Draining gear oil WARNING ! There is danger of burning du....482
		7.10.4 Filling gear oil.............................................482
		7.10.5 Service recommendation duties................................482
		7.10.6 Gear oil cooler..............................................482
	7.11 Winches 1 + 2......................................................483
		7.11.1 General......................................................483
		7.11.2 Check gear oil level.........................................483
		7.11.3 Changing gear oil............................................483
		7.11.4 Service recommendation.......................................484
		7.11.5 Free-fall brake (optional)...................................484
		7.11.6 Checking wear of hydraulic motor and drive planetary unit....485
		7.11.7 Proximity indicators.........................................485
		7.11.8 Deflection pulley............................................485
	7.12 Main boom luffing winch............................................486
		7.12.1 General......................................................486
		7.12.2 Checking oil level...........................................486
		7.12.3 Changing gear oil............................................487
		7.12.4 Service recommendation.......................................487
	7.13 Swing gears........................................................488
		7.13.1 Checking oil level...........................................488
		7.13.2 Draining gear oil............................................488
		7.13.3 Recommendation of service tasks..............................488
		7.13.4 Swing gear assembly..........................................489
	7.14 Swing ring.........................................................490
		7.14.1 Gear teeth...................................................490
		7.14.2 Fastening screws.............................................490
		7.14.3 Lubricating the ball track...................................490
		7.14.4 Lubrication procedure........................................490
		7.14.5 Inspection of hydraulic rotary transmission..................490
	7.15 Travel gears.......................................................491
		7.15.1 General......................................................491
		7.15.2 Checking the oil level.......................................491
		7.15.3 Changing gear oil............................................492
		7.15.4 Checking condition of travel gears...........................492
		7.15.5 Service recommendation.......................................492
	7.16 Crawler............................................................493
		7.16.1 Tensioning crawler track.....................................493
		7.16.2 Tensioning crawler chain.....................................494
		7.16.3 Idlers.......................................................494
		7.16.4 Track pads...................................................494
		7.16.5 Cleaning the crawler track...................................494
	7.17 Crawlers...........................................................495
		7.17.1 Cleaning and maintaining the crawlers........................495
	7.18 Guide wheels.......................................................496
		7.18.1 Overview of the crawler tensioning systems...................496
	7.19 Checking the chain tension.........................................498
		7.19.1 Tensioning the chain with grease tensioner...................498
		7.19.2 Floor plates.................................................499
	7.20 Hydraulic system...................................................503
		7.20.1 Check the hydraulic system for leaks.........................503
	7.21 Hydraulic oil tank.................................................504
		7.21.1 Checking the level in the hydraulic oil tank using the si....504
		7.21.2 Filling with hydraulic oil...................................505
		7.21.3 Draining the hydraulic oil...................................506
		7.21.4 Cleaning the magnetic rod in the return filter...............507
	7.22 Hydraulic filter...................................................509
		7.22.1 Changing the pressure filter.................................509
	7.23 Ropes and pulleys..................................................511
		7.23.1 Checking the rope against end of service life criteria.......511
		7.23.2 Check the rope for diameter shrinkage........................512
		7.23.3 Check for rope deformations..................................513
		7.23.4 Check ropes for corrosion....................................514
		7.23.5 Check ropes for abrasion.....................................515
		7.23.6 Check ropes for the effects of heat..........................515
		7.23.7 Check the rope for number of permitted wire breaks...........517
		7.23.8 Selecting a rope.............................................520
		7.23.9 Storing ropes................................................524
		7.23.10 Transporting ropes..........................................525
		7.23.11 Checking the rope drive.....................................525
		7.23.12 Winding ropes...............................................530
		7.23.13 Luffing ropes...............................................532
		7.23.14 Lubricating ropes...........................................534
		7.23.15 Check rope suspension and rope fixation.....................534
		7.23.16 Checking the pocket locks...................................535
		7.23.17 Checking the rope fixation and rope thimble.................536
	7.24 Steel pendant straps...............................................539
		7.24.1 Check the pendant straps and pins for damage and wear, an....539
		7.24.2 Check the pin connections throughout the pendant straps s....540
		7.24.3 Protect the steel pendant straps, connecting links and pi....540
		7.24.4 Check the connecting links of the pendant straps for dama....540
	7.25 Carbon-fiber pendant straps........................................541
		7.25.1 Arrangement of the carbon-fiber pendant straps...............542
		7.25.2 Check the carbon-fiber pendant straps........................542
		7.25.3 Checks.......................................................542
		7.25.4 Wear to the protective sheath................................543
		7.25.5 Checking the carbon-fiber pendant strap bush.................543
		7.25.6 Parallel flanges.............................................543
		7.25.7 Check the carbon-fiber pendant straps and connecting pins....544
		7.25.8 Check the connecting links of the carbon-fiber pendant st....544
		7.25.9 Lubricating the connecting links.............................545
		7.25.10 Lubrication pins............................................545
		7.25.11 Replacing the carbon-fiber pendant straps...................545
		7.25.12 Transporting the carbon-fiber pendant straps................545
	7.26 Pendant ropes......................................................547
		7.26.1 Protect the pendant ropes, connecting links and pins from....547
	7.27 Maintenance of boom components.....................................549
		7.27.1 main boom pivot piece........................................549
		7.27.2 Boom intermediate pieces.....................................549
		7.27.3 Checking the boom bolting and the anchor- ing rod connect....549
		7.27.4 Checking the A-frame.........................................549
	7.28 Checking boom components...........................................550
		7.28.1 General......................................................550
		7.28.2 Boom diagonals:..............................................550
		7.28.3 Rope pulleys on the superstructure...........................551
		7.28.4 Rope pulleys on A-frame......................................551
		7.28.5 Main boom limit switch.......................................552
		7.28.6 Main boom head...............................................552
		7.28.7 Hoisting limit switch *......................................552
		7.28.8 Load hook....................................................553
	7.29 Maintenance counterweight..........................................554
	7.30 Electrical system..................................................555
		7.30.1 General......................................................555
		7.30.2 Wet cleaning.................................................555
		7.30.3 Electrical rotary transmission *.............................555
		7.30.4 Batteries....................................................556
	7.31 Heating and ventilation............................................557
	7.32 Windshield washing system..........................................557
	7.33 Transport straps and slings........................................558
		7.33.1 General......................................................558
	7.34 Lubrication of bearings............................................558
	7.35 Maintenance of the rope luffing winch..............................559
		7.35.1 General......................................................559
		7.35.2 Technical data: Maximum rope pull 13.4 kN (1.3 t) [3010 l....559
		7.35.3 Changing gear oil............................................559
		7.35.4 Lubricating rope luffing winch...............................559
	7.36 Fuel and lubricants................................................560
		7.36.1 General......................................................560
	7.37 Lubrication plan...................................................561
	7.38 Capacities.........................................................563
	7.39 Lubrication chart..................................................564
	7.40 Hydraulic oil......................................................568
		7.40.1 Initial filling..............................................568
		7.40.2 Mixing.......................................................568
	7.41 Diesel fuels.......................................................570
	7.42 Diesel engine lubricating oils.....................................571
	7.43 Diesel engine coolant..............................................573
	7.44 Repair-welding.....................................................576
	7.45 Machine care.......................................................577
		7.45.1 Hydraulic cylinders..........................................577
		7.45.2 Cleaning the machine.........................................578
	7.46 Preservation of the machine........................................579
		7.46.1 Maintenance of the preservation..............................580
		7.46.2 Storing the machine for up to 7 months.......................588
		7.46.3 Storing the machine for more than 7 months...................594
		7.46.4 Immobilization...............................................594
		7.46.5 Resale.......................................................594
	7.47 Preservation medium (anti-corrosion coating).......................595
8. REPAIR WORK..............................................................601
	8.1 General.............................................................601
	8.2 Safety regulations..................................................601
	8.3 Changing ropes......................................................602
		8.3.1 Notes on safety...............................................602
		8.3.2 Instructions for the reeving of wire cables...................602
		8.3.3 Mounting ropes................................................603
	8.4 Changing ropes of winches 1 + 2.....................................604
		8.4.1 General.......................................................604
		8.4.2 Procedure 1.) Laying down main boom It is necessary when c....605
	8.5 Change rope on main boom luffing winch..............................605
		8.5.1 General DANGER ! Changing of the main boom luffing ropes c....605
		8.5.2 Preparing for rope change.....................................605
		8.5.3 Reeving plan main boom luffing winch..........................606
		8.5.4 Procedure for rope change 1.) Loosen main boom luffing rop....607
	8.6 Luffing plans.......................................................608
		8.6.1 Hook operation with one winch.................................608
	8.7 Rope mounting *.....................................................611
		8.7.1 General.......................................................611
9. OPTIONS..................................................................615
	9.1 General.............................................................615
	9.2 Air conditioning....................................................617
		9.2.1 General.......................................................617
		9.2.2 Air conditioning operating elements...........................617
		9.2.3 Notes on air conditioning operation...........................618
		9.2.4 Safety guidelines for handling cooling agent for air condi....619
		9.2.5 Components of the air conditioning system.....................621
		9.2.6 Maintenance of the air conditioning system....................621
	9.3 Boom catwalks.......................................................624
		9.3.1 General.......................................................624
		9.3.2 Mounting boom catwalks........................................624
	9.4 Rope bow............................................................625
		9.4.1 General.......................................................625
		9.4.2 Mounting rope bows............................................625
	9.5 Diagonal protection set.............................................626
		9.5.1 General.......................................................626
	9.6 3-coil-limit switch.................................................627
		9.6.1 General.......................................................627
		9.6.2 Adjusting 3-coil-limit switch.................................627
	9.7 Hoist limit switch..................................................628
		9.7.1 General.......................................................628
		9.7.2 Mounting hoist limit switch...................................628
		9.7.3 Hoist limit switch actuated...................................628
		9.7.4 Bridging hoist limit switch...................................629
	9.8 Cable length dimensions.............................................630
		9.8.1 General.......................................................630
		9.8.2 Displays in operation diagram.................................630
		9.8.3 Programming cable length......................................630
		9.8.4 Lowering control (SWG-control) *..............................632
		9.8.5 Interlock control.............................................634
	9.9 Winch synchronization...............................................636
		9.9.1 General.......................................................636
		9.9.2 Switching on winch synchronization............................636
		9.9.3 Switching off winch synchronization...........................636
	9.10 Casing oscillator..................................................637
		9.10.1 General......................................................637
		9.10.2 Prerequisites................................................637
		9.10.3 Attach casing oscillator.....................................637
		9.10.4 Switching on casing oscillator...............................638
		9.10.5 Page "Casing oscillator".....................................639
		9.10.6 Adjustment possibilities.....................................640
		9.10.7 Economy switching............................................641
		9.10.8 Switching off casing oscillator..............................641
	9.11 Steadying winch....................................................643
		9.11.1 General......................................................643
		9.11.2 Assembling steadying winch...................................643
		9.11.3 Fixing rope for steadying winch..............................644
		9.11.4 Adjustment possibilities.....................................645
		9.11.5 Switching on steadying winch.................................646
		9.11.6 Working with the steadying winch.............................647
		9.11.7 Switching off steadying winch................................648
		9.11.8 Maintenance of steadying winch General.......................648
	9.12 Central lubrication of tooth flanks................................651
		9.12.1 General......................................................651
		9.12.2 Filling the grease container.................................652
		9.12.3 Time interval programming....................................652
		9.12.4 Function.....................................................653
		9.12.5 Maintenance of the central lubricating system................653
	9.13 Central lubrication of the slewing ring bearings...................654
		9.13.1 General......................................................654
		9.13.2 Filling the grease container.................................655
		9.13.3 Time interval programming....................................655
		9.13.4 Function.....................................................656
		9.13.5 Maintenance of the central lubricating system................656
	9.14 Central lubrication of the tooth flanks of the slewing ring........657
		9.14.1 General......................................................657
		9.14.2 Filling the grease container.................................658
		9.14.3 Time interval programming....................................658
		9.14.4 Function.....................................................659
		9.14.5 Maintenance of the central lubricating system................659
	9.15 Platforms on the undercarriage.....................................661
		9.15.1 General......................................................661
		9.15.2 Location.....................................................661
	9.16 Platform with railing on the superstructure........................663
		9.16.1 General......................................................663
		9.16.2 Location.....................................................663
		9.16.3 Fastening the segments.......................................664
		9.16.4 Chopper bar..................................................664
	9.17 Roof railing.......................................................665
		9.17.1 General......................................................665
		9.17.2 Location.....................................................665
		9.17.3 Fastening....................................................666
		9.17.4 Chopper bar..................................................666
	9.18 GSM Service Modem..................................................667
	9.19 Optional floodlights on the superstructure.........................669
		9.19.1 Locations (Figure 39)........................................669
		9.19.2 Operational controls.........................................669
	9.20 Orthopedic driver's seat...........................................671
		9.20.1 General......................................................671
	9.21 Outreach limitation................................................673
		9.21.1 Adjusting the outreach limitation*...........................674
		9.21.2 Check outreach limitation*...................................674
10. APPENDIX................................................................679
	10.1 General............................................................679

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