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Liebherr Crawler Crane LR 1160 Operator’s manual SN134237 – PDF DOWNLOAD
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Description
Liebherr Crawler Crane LR 1160 Operator’s manual SN134237 – PDF DOWNLOAD
FILE DETAILS:
Liebherr Crawler Crane LR 1160 Operator’s manual SN134237 – PDF DOWNLOAD
Language : English
Pages : 1616
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Liebherr Crawler Crane LR 1160 Operator’s manual SN134237 – PDF DOWNLOAD
- Foreword The name Liebherr doesn’t just stand for products and services. It has become a byword for ideas and innovations. For progress which has proved its worth in the marketplace.
- We constantly strive to extend and improve our diverse range of products and services. This requires ongoing cooperation and sharing of experience with our customers and business partners throughout the world.
- We are therefore grateful for any ideas and suggestions for improvements. Inform Liebherr customer service if the machine is sold or bought by a previous owner
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Liebherr Crawler Crane LR 1160 Operator’s manual SN134237 – PDF DOWNLOAD
Operator's manual.............................................................................................................................................................................................. 1 Foreword................................................................................................................................................................................................... 3 Notes regarding the documentation.......................................................................................................................................................................... 5 Technical terms and abbreviations.......................................................................................................................................................................... 11 Contents................................................................................................................................................................................................... 13 1 Product description...................................................................................................................................................................................... 47 1.1 Type label......................................................................................................................................................................................... 47 1.2 Declaration of conformity.......................................................................................................................................................................... 49 1.3 Intended use....................................................................................................................................................................................... 50 1.4 Special modes of operation......................................................................................................................................................................... 52 1.5 Inappropriate use.................................................................................................................................................................................. 53 1.6 Machine............................................................................................................................................................................................ 55 1.6.1 Machine overview............................................................................................................................................................................. 55 1.6.2 Technical data............................................................................................................................................................................... 55 1.6.3 Safety devices............................................................................................................................................................................... 60 1.6.4 Monitoring installations..................................................................................................................................................................... 61 1.7 Basic machine...................................................................................................................................................................................... 63 1.7.1 Basic machine overview....................................................................................................................................................................... 63 1.7.2 A-frame1..................................................................................................................................................................................... 67 1.7.3 Pendant straps on A-frame1................................................................................................................................................................... 68 1.7.4 Uppercarriage................................................................................................................................................................................ 69 1.7.5 Cabin........................................................................................................................................................................................ 72 1.7.6 Central power unit........................................................................................................................................................................... 73 1.7.7 Platform on uppercarriage.................................................................................................................................................................... 75 1.7.8 Undercarriage................................................................................................................................................................................ 76 1.7.9 Crawler side frame........................................................................................................................................................................... 78 1.7.10 Platforms on undercarriage.................................................................................................................................................................. 80 1.7.11 Carbody counterweight....................................................................................................................................................................... 86 1.7.12 Rear counterweight.......................................................................................................................................................................... 88 1.8 Information about boom designation................................................................................................................................................................. 92 1.9 Main boom - overview............................................................................................................................................................................... 95 1.10 Main boom 2018.................................................................................................................................................................................... 96 1.10.1 Main boom base section 2018.23.............................................................................................................................................................. 96 1.10.2 Main boom section 2018.20 3 m............................................................................................................................................................... 98 1.10.3 Main boom section 2018.20 6 m............................................................................................................................................................... 99 1.10.4 Main boom section 2018.20 11.7 m............................................................................................................................................................ 101 1.10.5 Main boom head section 2018.20.............................................................................................................................................................. 103 1.10.6 Rope guide.................................................................................................................................................................................. 105 1.10.7 Mid-point suspension on main boom 2018...................................................................................................................................................... 108 1.10.8 Pendant straps on main boom 2018............................................................................................................................................................ 113 1.11 Reducing piece overview........................................................................................................................................................................... 120 1.12 Reducing adapter 2018/1713........................................................................................................................................................................ 121 1.12.1 2018/1713.20 reducing piece 12 m............................................................................................................................................................ 121 1.12.2 Main boom section 1713.22 1 m............................................................................................................................................................... 123 1.12.3 Mid-point suspension on reducing adapter 2018/1713.......................................................................................................................................... 125 1.12.4 Pendant straps on reducing piece 2018/1713.................................................................................................................................................. 137 1.13 Reducing adapter 2018/1309........................................................................................................................................................................ 139 1.13.1 2018/1309.20 reducing piece 7.2 m........................................................................................................................................................... 139 1.13.2 Mid-point suspension on reducing adapter 2018/1309.......................................................................................................................................... 141 1.13.3 Pendant straps on reducing piece 2018/1309.................................................................................................................................................. 153 1.14 Fixed jib - overview.............................................................................................................................................................................. 155 1.15 1008 fixed jib.................................................................................................................................................................................... 156 1.15.1 Jib base section 1008.20.................................................................................................................................................................... 156 1.15.2 1008.17 jib section 3 m..................................................................................................................................................................... 157 1.15.3 1008.17 jib section 6 m..................................................................................................................................................................... 159 1.15.4 1008.20 jib head section.................................................................................................................................................................... 160 1.15.5 Pendant straps on fixed jib 1008............................................................................................................................................................ 161 1.16 Fixed jib 0806.................................................................................................................................................................................... 166 1.16.1 Jib base section 0806.16.................................................................................................................................................................... 166 1.16.2 Jib section 0806.15 3 m..................................................................................................................................................................... 167 1.16.3 Jib section 0806.15 6 m..................................................................................................................................................................... 168 1.16.4 Jib head section 0806.16.................................................................................................................................................................... 169 1.16.5 Mid-point suspension on fixed jib 0806...................................................................................................................................................... 171 1.16.6 Pendant straps on fixed jib 0806............................................................................................................................................................ 174 1.17 Luffing jib - overview............................................................................................................................................................................ 180 1.18 1713 luffing jib.................................................................................................................................................................................. 181 1.18.1 Jib base section 1713.22.................................................................................................................................................................... 181 1.18.2 Jib section 1713.18 3 m..................................................................................................................................................................... 183 1.18.3 Jib section 1713.18 6 m..................................................................................................................................................................... 184 1.18.4 Jib section 1713.18 12 m.................................................................................................................................................................... 185 1.18.5 Jib head section 1713.21.................................................................................................................................................................... 187 1.18.6 Mid-point suspension on luffing jib 1713.................................................................................................................................................... 188 1.18.7 Pendant straps on luffing jib 1713.......................................................................................................................................................... 193 1.19 1309 luffing jib.................................................................................................................................................................................. 200 1.19.1 Jib base section 1309.22.................................................................................................................................................................... 200 1.19.2 Jib section 1309.20 3 m..................................................................................................................................................................... 201 1.19.3 1309.20 jib section 6 m..................................................................................................................................................................... 203 1.19.4 1309.20 jib section 11.7 m.................................................................................................................................................................. 204 1.19.5 1309.22 jib head section.................................................................................................................................................................... 205 1.19.6 Mid-point suspension on luffing jib 1309.................................................................................................................................................... 207 1.19.7 Pendant straps on luffing jib 1309.......................................................................................................................................................... 213 1.20 Midfall overview.................................................................................................................................................................................. 219 1.21 1713.31 Midfall................................................................................................................................................................................... 220 1.21.1 Midfall 1713.31............................................................................................................................................................................. 220 1.21.2 Mid-point suspension on midfall 1713.31..................................................................................................................................................... 222 1.21.3 Pendant straps on midfall 1713.31........................................................................................................................................................... 222 1.22 1309.32 Midfall................................................................................................................................................................................... 224 1.22.1 Midfall 1309.32............................................................................................................................................................................. 224 1.22.2 Mid-point suspension on midfall 1309.32..................................................................................................................................................... 226 1.22.3 Pendant straps on midfall 1309.32........................................................................................................................................................... 226 1.23 Auxiliary jib* (36 t)............................................................................................................................................................................. 228 1.24 Auxiliary jib* (15 t)............................................................................................................................................................................. 231 1.25 Rope fixing point................................................................................................................................................................................. 233 1.25.1 Main boom head.............................................................................................................................................................................. 233 1.25.2 Fixed jib head section...................................................................................................................................................................... 234 1.25.3 Luffing jib head section.................................................................................................................................................................... 235 1.25.4 Auxiliary jib (36 t) on main boom head...................................................................................................................................................... 236 1.25.5 Auxiliary jib (15 t) on jib head section.................................................................................................................................................... 236 1.25.6 Midfall..................................................................................................................................................................................... 237 1.25.7 Pocket lock................................................................................................................................................................................. 237 1.25.8 Cross link.................................................................................................................................................................................. 239 1.25.9 Pin for rope fixing point................................................................................................................................................................... 240 1.26 Pulley block/hook*................................................................................................................................................................................ 241 1.26.1 Pulley block (160 t)........................................................................................................................................................................ 241 1.26.2 Pulley block (100 t)........................................................................................................................................................................ 243 1.26.3 Pulley block (80 t)......................................................................................................................................................................... 245 1.26.4 Pulley block (40 t)......................................................................................................................................................................... 247 1.26.5 Hook (12.5 t)............................................................................................................................................................................... 249 1.27 Emergency descent rescue equipment*............................................................................................................................................................... 251 1.28 Safety barrier*................................................................................................................................................................................... 252 1.29 Suction flap*..................................................................................................................................................................................... 253 1.30 Armrests* for operator's seat..................................................................................................................................................................... 254 1.31 Vertical Line Finder* assistance system........................................................................................................................................................... 255 1.32 Outside mirror*................................................................................................................................................................................... 257 1.33 Tagline winch*.................................................................................................................................................................................... 258 1.34 Fuel refueling pump*.............................................................................................................................................................................. 260 1.35 Cab roof protection guard*........................................................................................................................................................................ 261 1.36 Lightning rods*................................................................................................................................................................................... 262 1.37 External power supply*............................................................................................................................................................................ 263 1.37.1 External power supply aircraft warning light................................................................................................................................................ 263 1.37.2 External supply low temperature package..................................................................................................................................................... 265 1.38 Radio remote control*............................................................................................................................................................................. 268 1.39 Foot pedal adjuster*.............................................................................................................................................................................. 271 1.40 GSM/GPRS/GPS modem................................................................................................................................................................................ 272 1.41 Virtual Private Network (VPN)*.................................................................................................................................................................... 273 1.41.1 Cisco 3G VPN router......................................................................................................................................................................... 273 1.41.2 Power unit.................................................................................................................................................................................. 274 1.41.3 Cisco 3G antenna............................................................................................................................................................................ 274 1.41.4 Vodafone 3G VPN router...................................................................................................................................................................... 275 1.41.5 SIM card.................................................................................................................................................................................... 275 1.42 Hook fixing point *............................................................................................................................................................................... 276 1.43 Handrail* / wide steps*........................................................................................................................................................................... 278 1.44 Ventilation, heating and air-conditioning......................................................................................................................................................... 279 1.44.1 Cooling circuit............................................................................................................................................................................. 280 1.44.2 Heating circuit............................................................................................................................................................................. 285 1.44.3 Auxiliary air heating*...................................................................................................................................................................... 288 1.44.4 Electric components......................................................................................................................................................................... 290 1.44.5 Mechanic components......................................................................................................................................................................... 293 1.45 Aircraft warning light*........................................................................................................................................................................... 295 1.46 Third hoist limit switch*......................................................................................................................................................................... 296 1.47 Hoist limit switch clamp* for auxiliary jib (36 t)................................................................................................................................................ 297 1.48 Cabin handrail*................................................................................................................................................................................... 298 1.48.1 Cabin handrail variant 1 with undercarriage with carbody counterweight...................................................................................................................... 299 1.48.2 Cabin handrail variant 1 with undercarriage without carbody counterweight................................................................................................................... 300 1.48.3 Cabin handrail variant 2 with undercarriage with carbody counterweight...................................................................................................................... 302 1.48.4 Cabin handrail variant 2 with undercarriage without carbody counterweight................................................................................................................... 304 1.49 Cable remote control.............................................................................................................................................................................. 307 1.50 Catwalks* for boom................................................................................................................................................................................ 309 1.51 Leak oil return*.................................................................................................................................................................................. 311 1.52 Ladder* for boom.................................................................................................................................................................................. 312 1.53 Ladder* for uppercarriage......................................................................................................................................................................... 314 1.54 Reading light* for cabin.......................................................................................................................................................................... 315 1.55 Litronic control system........................................................................................................................................................................... 316 1.56 Retrofit kits* for operation with two ropes over the jib head section............................................................................................................................. 317 1.56.1 Retrofit kit for luffing jibs 1008 / 1309 / 1713 / 1916 / 2316.............................................................................................................................. 317 1.56.2 Retrofit kit for 1008 fixed jib............................................................................................................................................................. 318 1.56.3 Retrofit kit for 0806 fixed jib............................................................................................................................................................. 319 1.57 Luffing jib luffing winch as auxiliary winch*..................................................................................................................................................... 320 1.58 By-pass flow filter system*....................................................................................................................................................................... 321 1.59 Emergency operation control*...................................................................................................................................................................... 322 1.60 Visual motion warning device*..................................................................................................................................................................... 323 1.61 Process data recording (PDE)*..................................................................................................................................................................... 325 1.62 Process data report (PDR)*........................................................................................................................................................................ 326 1.63 Pump wear indicator*.............................................................................................................................................................................. 327 1.64 Quick-action couplings* on jib luffing winch...................................................................................................................................................... 329 1.65 Socket* in cabin.................................................................................................................................................................................. 331 1.66 Falling object protection* for cabin.............................................................................................................................................................. 332 1.66.1 Foldable falling object protection*......................................................................................................................................................... 332 1.66.2 Fixed falling object protection............................................................................................................................................................. 334 1.67 Vandalism protection*............................................................................................................................................................................. 336 1.67.1 Top cover................................................................................................................................................................................... 337 1.67.2 Rear cover.................................................................................................................................................................................. 338 1.67.3 Front cover................................................................................................................................................................................. 339 1.67.4 Right front cover........................................................................................................................................................................... 340 1.67.5 Right rear cover............................................................................................................................................................................ 341 1.67.6 Left front cover............................................................................................................................................................................ 342 1.67.7 Left rear cover............................................................................................................................................................................. 343 1.67.8 Brackets for front cover.................................................................................................................................................................... 344 1.67.9 Barrier rod................................................................................................................................................................................. 345 1.68 Video monitoring system*.......................................................................................................................................................................... 346 1.68.1 Cabin overview.............................................................................................................................................................................. 346 1.68.2 Machine overview............................................................................................................................................................................ 347 1.68.3 Video surveillance - basic device........................................................................................................................................................... 348 1.68.4 Video surveillance - boom................................................................................................................................................................... 350 1.68.5 Quad monitor................................................................................................................................................................................ 351 1.68.6 Camera...................................................................................................................................................................................... 352 1.68.7 Control panel zoom camera................................................................................................................................................................... 354 1.68.8 Zoom camera................................................................................................................................................................................. 355 1.68.9 Mounts...................................................................................................................................................................................... 356 1.68.10 Camera cable in main boom base section..................................................................................................................................................... 361 1.68.11 Zoom camera in main boom head.............................................................................................................................................................. 362 1.68.12 Zoom camera in fixed jib head.............................................................................................................................................................. 363 1.68.13 Zoom camera in luffing jib head............................................................................................................................................................ 365 1.68.14 Zoom camera in auxiliary jib 36 t.......................................................................................................................................................... 366 1.68.15 Zoom camera in auxiliary jib 15 t.......................................................................................................................................................... 366 1.68.16 Foot pedal* for zoom camera................................................................................................................................................................ 368 1.69 Central lubrication system........................................................................................................................................................................ 369 1.70 Additional floodlights*........................................................................................................................................................................... 370 1.70.1 Floodlights on uppercarriage................................................................................................................................................................ 370 1.70.2 Floodlight on cabin......................................................................................................................................................................... 372 1.70.3 Adjustable floodlights on main boom base section............................................................................................................................................ 373 1.70.4 Floodlights on main boom.................................................................................................................................................................... 374 1.70.5 Floodlight with LED om main boom head*...................................................................................................................................................... 379 1.70.6 Floodlight with high-pressure sodium vapor lamp on jib head section......................................................................................................................... 380 2 Safety instructions...................................................................................................................................................................................... 385 2.1 Safe operation of the machine...................................................................................................................................................................... 385 2.1.1 Personnel selection.......................................................................................................................................................................... 385 2.1.2 Safe system of work.......................................................................................................................................................................... 385 2.1.3 Preventive maintenance....................................................................................................................................................................... 386 2.2 Areas of responsibility............................................................................................................................................................................ 387 2.2.1 Manufacturer................................................................................................................................................................................. 387 2.2.2 Owner........................................................................................................................................................................................ 387 2.2.3 Machine operator............................................................................................................................................................................. 388 2.2.4 Slinger...................................................................................................................................................................................... 388 2.2.5 Signaller.................................................................................................................................................................................... 389 2.2.6 Maintenance personnel........................................................................................................................................................................ 389 2.2.7 Installation personnel and disassembly personnel............................................................................................................................................. 389 2.2.8 Helper....................................................................................................................................................................................... 390 2.2.9 Liebherr service personnel................................................................................................................................................................... 390 2.2.10 Certified and institutionally authorized persons............................................................................................................................................ 390 2.3 Requirements to personnel.......................................................................................................................................................................... 391 2.3.1 Machine operator............................................................................................................................................................................. 391 2.3.2 Slinger...................................................................................................................................................................................... 391 2.3.3 Signaller.................................................................................................................................................................................... 392 2.3.4 Maintenance personnel........................................................................................................................................................................ 392 2.3.5 Installation personnel and disassembly personnel............................................................................................................................................. 392 2.3.6 Helper....................................................................................................................................................................................... 393 2.3.7 Liebherr service personnel................................................................................................................................................................... 393 2.3.8 Certified and institutionally authorized persons............................................................................................................................................. 393 2.4 Personal protective equipment...................................................................................................................................................................... 394 2.5 Workplace.......................................................................................................................................................................................... 394 2.6 Danger zone........................................................................................................................................................................................ 395 2.7 Safety signs on the machine........................................................................................................................................................................ 397 2.8 Safety signs on the machine (US market)............................................................................................................................................................ 401 2.9 Meaning of safety signs............................................................................................................................................................................ 406 2.9.1 Mandatory action sign........................................................................................................................................................................ 407 2.9.2 Prohibition sign............................................................................................................................................................................. 408 2.9.3 Warning signs................................................................................................................................................................................ 409 2.9.4 Safe condition sign.......................................................................................................................................................................... 411 2.9.5 Fire equipment sign.......................................................................................................................................................................... 411 2.10 Meaning of machine-specific signs................................................................................................................................................................. 412 2.10.1 Safety signs................................................................................................................................................................................ 412 2.10.2 Notice signs................................................................................................................................................................................ 413 2.11 Hazards........................................................................................................................................................................................... 417 2.11.1 Mechanical action........................................................................................................................................................................... 417 2.11.2 Electrical energy........................................................................................................................................................................... 418 2.11.3 Hydraulic energy............................................................................................................................................................................ 418 2.11.4 Burns....................................................................................................................................................................................... 419 2.11.5 Chemical burns.............................................................................................................................................................................. 420 2.11.6 Fire and explosion.......................................................................................................................................................................... 421 2.11.7 Poisoning and suffocation................................................................................................................................................................... 422 2.11.8 Electromagnetic influence................................................................................................................................................................... 422 2.11.9 Exposure to wind............................................................................................................................................................................ 423 2.11.10 Snow load and ice load..................................................................................................................................................................... 428 2.11.11 Ground condition and load-bearing capacity................................................................................................................................................. 429 2.11.12 Lightning strike........................................................................................................................................................................... 430 2.11.13 Overhead lines............................................................................................................................................................................. 431 2.11.14 Environment................................................................................................................................................................................ 433 2.12 What to do in dangerous situations................................................................................................................................................................ 434 2.12.1 Procedure in event of current transfer...................................................................................................................................................... 434 2.12.2 How to respond in the event of a fire....................................................................................................................................................... 435 2.12.3 Firefighting................................................................................................................................................................................ 436 2.13 Working at heights................................................................................................................................................................................ 438 2.14 Utilization on floating constructions............................................................................................................................................................. 438 2.14.1 Operating the machine on floating constructions............................................................................................................................................. 439 2.14.2 Operating the machine on floating structure................................................................................................................................................. 439 2.14.3 Increased corrosion susceptibility of the machine on floating structures.................................................................................................................... 440 2.15 Use at low temperatures........................................................................................................................................................................... 440 2.15.1 Operation of the machine down to -20 °C (standard).......................................................................................................................................... 441 2.15.2 Operation of the machine down to -25 °C*.................................................................................................................................................... 441 2.15.3 Operation of the machine down to -40 °C*.................................................................................................................................................... 442 2.16 Hand signals...................................................................................................................................................................................... 442 2.16.1 General hand signals in accordance with BGV A8.............................................................................................................................................. 443 2.16.2 Special hand signals for sling gear application............................................................................................................................................. 445 2.16.3 Hand signals for lifting gear application in accordance with ASME/ANSI B30.5................................................................................................................ 448 3 Control and operating elements........................................................................................................................................................................... 455 3.1 Operating elements on the undercarriage............................................................................................................................................................ 456 3.2 Operating elements on uppercarriage................................................................................................................................................................ 457 3.3 Cabin.............................................................................................................................................................................................. 458 3.4 Left control lever................................................................................................................................................................................. 459 3.4.1 Left control lever........................................................................................................................................................................... 459 3.4.2 Left control lever........................................................................................................................................................................... 464 3.5 Right control lever................................................................................................................................................................................ 470 3.5.1 Right control lever.......................................................................................................................................................................... 470 3.5.2 Right double T-lever......................................................................................................................................................................... 477 3.6 Foot pedals and hand levers........................................................................................................................................................................ 484 3.7 Circular bubble.................................................................................................................................................................................... 486 3.8 Operating hours counter............................................................................................................................................................................ 487 3.8.2 Additional operating hours counter*.......................................................................................................................................................... 487 3.9 Control panel X11.................................................................................................................................................................................. 488 3.10 Control panel X12................................................................................................................................................................................. 490 3.11 Control panel X23................................................................................................................................................................................. 492 3.12 Monitor........................................................................................................................................................................................... 495 3.12.1 Status bar.................................................................................................................................................................................. 495 3.12.2 Display section............................................................................................................................................................................. 503 3.12.3 Menu bar.................................................................................................................................................................................... 503 3.12.4 Submenu bar................................................................................................................................................................................. 505 3.13 Screen Start...................................................................................................................................................................................... 506 3.14 Operation screen.................................................................................................................................................................................. 507 3.15 Power unit screen................................................................................................................................................................................. 516 3.16 Operating hours screen............................................................................................................................................................................ 523 3.17 Setup screen...................................................................................................................................................................................... 526 3.17.1 Setup - boom configuration screen........................................................................................................................................................... 528 3.17.2 Setup - boom configuration 1 screen......................................................................................................................................................... 529 3.17.3 Setup - boom configuration 2 screen......................................................................................................................................................... 532 3.17.4 Setup - boom configuration 3 screen......................................................................................................................................................... 535 3.17.5 Setup - boom configuration 4 screen......................................................................................................................................................... 540 3.17.6 Setup - boom configuration 5 screen......................................................................................................................................................... 544 3.17.7 Setup - load chart screen................................................................................................................................................................... 549 3.18 Screen Working range limitation................................................................................................................................................................... 551 3.18.1 Screen Working range limitation - working range limitation.................................................................................................................................. 551 3.18.2 Screen Working range limitation - lifting height limitation................................................................................................................................. 558 3.19 Screen Access control............................................................................................................................................................................. 561 3.19.1 Without retrofit kit access control (black ignition keys)................................................................................................................................... 561 3.19.2 Without retrofit kit access control (blue ignition keys).................................................................................................................................... 562 3.19.3 With retrofit kit access control (red and blue ignition keys)*.............................................................................................................................. 563 3.20 Mode screen....................................................................................................................................................................................... 566 3.21 Settings screen................................................................................................................................................................................... 568 3.21.1 Screen Settings - components................................................................................................................................................................ 568 3.21.2 Settings - units screen..................................................................................................................................................................... 571 3.21.3 Litronic test system screen................................................................................................................................................................. 574 3.22 Error messages screen............................................................................................................................................................................. 579 3.23 Cable remote control.............................................................................................................................................................................. 581 3.23.1 Cable remote control on uppercarriage....................................................................................................................................................... 581 3.23.2 Cable remote control on undercarriage....................................................................................................................................................... 581 3.24 Radio remote control*............................................................................................................................................................................. 583 3.24.1 Operating elements.......................................................................................................................................................................... 583 3.24.2 Monitor..................................................................................................................................................................................... 592 3.25 Emergency operation control*...................................................................................................................................................................... 601 3.26 Control unit external air conditioning system*.................................................................................................................................................... 603 3.27 Auxiliary heating* control unit................................................................................................................................................................... 605 3.28 Video monitoring system*.......................................................................................................................................................................... 606 3.28.1 Quad monitor................................................................................................................................................................................ 606 3.28.2 Control panel zoom camera................................................................................................................................................................... 607 3.29 Central lubrication*.............................................................................................................................................................................. 609 3.30 Additional floodlights*........................................................................................................................................................................... 610 3.30.1 Cabin....................................................................................................................................................................................... 610 4 Operation................................................................................................................................................................................................ 615 4.1 Checks before startup.............................................................................................................................................................................. 615 4.1.1 Inspecting the machine....................................................................................................................................................................... 616 4.1.2 Checking position of main battery switch..................................................................................................................................................... 616 4.2 Startup............................................................................................................................................................................................ 617 4.2.1 Adjusting the operator's seat................................................................................................................................................................ 617 4.2.2 Switching on the ignition.................................................................................................................................................................... 617 4.2.3 Confirming the existing setup................................................................................................................................................................ 617 4.2.4 Checking the fuel fill level................................................................................................................................................................. 618 4.2.5 Checking the urea solution fill level........................................................................................................................................................ 618 4.2.6 Checking the hydraulic oil tank gate valve................................................................................................................................................... 618 4.2.7 Starting the diesel engine................................................................................................................................................................... 619 4.2.8 Adjusting the diesel engine RPM.............................................................................................................................................................. 620 4.2.9 Setting the constant engine RPM.............................................................................................................................................................. 622 4.2.10 Lowering the safety lever................................................................................................................................................................... 624 4.2.11 Checking the tilting-back support cylinder.................................................................................................................................................. 624 4.3 Control panels..................................................................................................................................................................................... 625 4.3.1 Setting control panel X25* or control panel X26*............................................................................................................................................. 625 4.4 Operator's seat.................................................................................................................................................................................... 627 4.4.1 Adjusting the control stand horizontally..................................................................................................................................................... 628 4.4.2 Adjusting the operator's seat................................................................................................................................................................ 628 4.4.3 Adjusting the dampening...................................................................................................................................................................... 632 4.4.4 Adjusting the ergonomics*.................................................................................................................................................................... 633 4.4.5 Safety belt*................................................................................................................................................................................. 635 4.5 Lighting........................................................................................................................................................................................... 636 4.5.1 Operating the floodlights on the uppercarriage............................................................................................................................................... 636 4.5.2 Operating additional floodlights............................................................................................................................................................. 636 4.5.3 Operating cabin lighting..................................................................................................................................................................... 637 4.5.4 Operating the engine compartment lighting.................................................................................................................................................... 637 4.6 Windscreen wiper system............................................................................................................................................................................ 638 4.6.1 Operating the windscreen wipers.............................................................................................................................................................. 638 4.6.2 Operating the windscreen washer system....................................................................................................................................................... 639 4.7 Ventilation, heating and air-conditioning.......................................................................................................................................................... 640 4.7.1 Setting the air vent......................................................................................................................................................................... 642 4.7.2 Adjusting the lamella vents.................................................................................................................................................................. 643 4.7.3 Setting recirculated air or fresh air........................................................................................................................................................ 643 4.7.4 Operating the ventilation.................................................................................................................................................................... 643 4.7.5 Using the heater............................................................................................................................................................................. 644 4.7.6 Turning the air conditioning system on or off................................................................................................................................................ 644 4.7.7 Operating the external air conditioning system*.............................................................................................................................................. 645 4.7.8 Auxiliary heating*........................................................................................................................................................................... 652 4.8 Additional cab equipment........................................................................................................................................................................... 656 4.8.1 Using the horn............................................................................................................................................................................... 656 4.8.2 Operating the safety lever................................................................................................................................................................... 656 4.8.3 Operating the radio.......................................................................................................................................................................... 657 4.8.4 Using the ashtray............................................................................................................................................................................ 658 4.8.5 Using the cigarette lighter.................................................................................................................................................................. 659 4.9 Cab tilting device*................................................................................................................................................................................ 660 4.9.1 Tilting the cabin............................................................................................................................................................................ 660 4.10 Central lubrication*.............................................................................................................................................................................. 661 4.10.1 Set lubrication time........................................................................................................................................................................ 661 4.10.2 Set pause time.............................................................................................................................................................................. 661 4.10.3 Interim lubrication......................................................................................................................................................................... 661 4.11 Mode.............................................................................................................................................................................................. 662 4.11.1 Switching on or switching off assembly functions............................................................................................................................................ 662 4.11.2 Selecting mode.............................................................................................................................................................................. 662 4.12 Programming the setup............................................................................................................................................................................. 664 4.12.1 Call up the Setup screen.................................................................................................................................................................... 664 4.12.2 Selecting and changing settings............................................................................................................................................................. 665 4.12.3 Calculating the revised set-up.............................................................................................................................................................. 665 4.12.4 Checking the programed setup................................................................................................................................................................ 666 4.13 Load moment limitation (LML)...................................................................................................................................................................... 667 4.13.1 General..................................................................................................................................................................................... 667 4.13.2 Load moment limitation self-lock............................................................................................................................................................ 670 4.13.3 Load moment limitation shut-off (CE load chart)............................................................................................................................................. 672 4.13.4 Load moment limitation shut-off (ANSI load chart)........................................................................................................................................... 673 4.14 Calculating load charts online.................................................................................................................................................................... 675 4.14.1 Calculating load charts..................................................................................................................................................................... 675 4.14.2 Boom configuration 4 - load position 1...................................................................................................................................................... 676 4.14.3 Boom configuration 4 - load position 2...................................................................................................................................................... 677 4.14.4 Boom configuration 5 - load position 1...................................................................................................................................................... 678 4.14.5 Boom configuration 5 - load position 3...................................................................................................................................................... 679 4.14.6 Boom configuration 6 - load position 2...................................................................................................................................................... 680 4.14.7 Boom configuration 8 - load position 1...................................................................................................................................................... 681 4.14.8 Boom configuration 8 - load position 2...................................................................................................................................................... 682 4.14.9 Boom configuration 9 - load position 1...................................................................................................................................................... 683 4.14.10 Boom configuration 9 - load position 2..................................................................................................................................................... 684 4.15 Set the load capacity display to zero (taring).................................................................................................................................................... 685 4.15.1 Setting the load display of winch1 or winch2 to zero........................................................................................................................................ 685 4.16 Single hook operation/twin hook operation......................................................................................................................................................... 686 4.16.1 Single hook operation with one winch on one hook............................................................................................................................................ 688 4.16.2 Single hook operation with two winches on one hook.......................................................................................................................................... 690 4.16.3 Single hook operation with two winches on two hooks......................................................................................................................................... 691 4.16.4 Twin hook operation with two hooks on two loads............................................................................................................................................. 697 4.16.5 Twin hook operation with two hooks on one load.............................................................................................................................................. 699 4.17 Crawlers.......................................................................................................................................................................................... 703 4.17.1 Setting the crawler speed................................................................................................................................................................... 703 4.17.2 Operating the travel gear................................................................................................................................................................... 703 4.17.3 Locking or unlocking the crawler............................................................................................................................................................ 707 4.18 Swing gear........................................................................................................................................................................................ 709 4.18.1 Setting the swing speed..................................................................................................................................................................... 709 4.18.2 Turning the swing gear free-wheel on or off................................................................................................................................................. 710 4.18.3 Operating the swing gear.................................................................................................................................................................... 711 4.18.4 Locking or unlocking the swing gear......................................................................................................................................................... 714 4.19 Main boom......................................................................................................................................................................................... 715 4.19.1 Operating the main boom..................................................................................................................................................................... 715 4.19.2 Locking or unlocking the main boom.......................................................................................................................................................... 719 4.20 Jib............................................................................................................................................................................................... 720 4.20.1 Selecting the jib........................................................................................................................................................................... 720 4.20.2 Operating the jib........................................................................................................................................................................... 721 4.21 Winch 1/Winch 2................................................................................................................................................................................... 726 4.21.1 Operating winch 1........................................................................................................................................................................... 726 4.21.2 Operating winch 2........................................................................................................................................................................... 730 4.21.3 Locking or unlocking winch1/winch2.......................................................................................................................................................... 734 4.22 Free-fall operation*.............................................................................................................................................................................. 736 4.22.1 Switching on free-fall operation............................................................................................................................................................ 736 4.22.2 Selecting free-fall mode.................................................................................................................................................................... 737 4.22.3 Operating free-fall operation............................................................................................................................................................... 738 4.22.4 Switching off free-fall operation........................................................................................................................................................... 741 4.23 Winch synchronization*............................................................................................................................................................................ 742 4.23.1 Activating winch synchronization............................................................................................................................................................ 742 4.23.2 Operating the winch synchronization......................................................................................................................................................... 743 4.23.3 Deactivating winch synchronization.......................................................................................................................................................... 745 4.24 Foundation works mode*............................................................................................................................................................................ 746 4.24.1 Vibrator.................................................................................................................................................................................... 746 4.24.2 Depth vibrator.............................................................................................................................................................................. 748 4.24.3 Hammer...................................................................................................................................................................................... 750 4.24.4 Select foundation works mode................................................................................................................................................................ 753 4.25 Blocked crawlers*................................................................................................................................................................................. 754 4.25.1 Driving onto the support plates............................................................................................................................................................. 755 4.25.2 Working with Blocked Crawlers............................................................................................................................................................... 756 4.26 Assembly cylinder *............................................................................................................................................................................... 758 4.26.1 Select assembly cylinder.................................................................................................................................................................... 758 4.26.2 Operating the assembly cylinder............................................................................................................................................................. 758 4.27 Filling the machine with fuel..................................................................................................................................................................... 761 4.27.1 Filling the fuel tank....................................................................................................................................................................... 761 4.27.2 Filling up with urea solution*.............................................................................................................................................................. 762 4.28 Radio remote control*............................................................................................................................................................................. 763 4.28.1 Battery..................................................................................................................................................................................... 763 4.28.2 Battery charger............................................................................................................................................................................. 763 4.28.3 Starting the machine with the radio remote control.......................................................................................................................................... 765 4.29 Rope measuring system*............................................................................................................................................................................ 771 4.29.1 Setting the rope length to zero............................................................................................................................................................. 771 4.29.2 Calibrating the rope measuring system....................................................................................................................................................... 771 4.30 Ground pressure display*.......................................................................................................................................................................... 773 4.30.1 Operating the ground pressure display....................................................................................................................................................... 773 4.31 Inclination display*.............................................................................................................................................................................. 774 4.31.1 Operating the inclinometer.................................................................................................................................................................. 774 4.32 Load recorder*.................................................................................................................................................................................... 775 4.32.1 Setting trigger points...................................................................................................................................................................... 775 4.32.2 Operating the load recorder................................................................................................................................................................. 775 4.33 Working range limitation*......................................................................................................................................................................... 778 4.33.1 Operating the edge limitation............................................................................................................................................................... 778 4.33.2 Operating the sector limitation............................................................................................................................................................. 780 4.33.3 Operating the radius limitation............................................................................................................................................................. 782 4.33.4 Operating the swing range limitation........................................................................................................................................................ 786 4.33.5 Operating the lifting height limitation..................................................................................................................................................... 787 4.33.6 Cancelling the stop after crawler operation................................................................................................................................................. 789 4.33.7 Resetting limitations....................................................................................................................................................................... 789 4.34 Assistance system horizontal load path*........................................................................................................................................................... 790 4.34.1 Activating horizontal load path............................................................................................................................................................. 790 4.34.2 Activating horizontal load path............................................................................................................................................................. 791 4.34.3 Deactivating horizontal load path........................................................................................................................................................... 793 4.35 Assistance system Vertical Line Finder*........................................................................................................................................................... 794 4.35.1 Setting offsets of the Vertical Line Finder to zero......................................................................................................................................... 794 4.35.2 Activating the positioning of boom head above load's center of gravity...................................................................................................................... 794 4.35.3 Positioning boom head above load's center of gravity........................................................................................................................................ 794 4.35.4 Deactivating positioning of boom head above load's center of gravity........................................................................................................................ 795 4.36 Rope reeving winch................................................................................................................................................................................ 796 4.36.1 Setting the rope reeving winch to free-wheel................................................................................................................................................ 796 4.36.2 Deactivating rope reeving winch free-fall................................................................................................................................................... 797 4.36.3 Reeving the rope of the rope reeving winch.................................................................................................................................................. 797 4.37 Tagline winch*.................................................................................................................................................................................... 798 4.37.1 Putting the tagline winch into operation.................................................................................................................................................... 798 4.37.2 Turn the tagline winch on or off............................................................................................................................................................ 799 4.37.3 Set the constant tension of the tagline winch............................................................................................................................................... 799 4.37.4 Setting the pull force of the tagline winch................................................................................................................................................. 800 4.37.5 Select maximum pull force of the tagline winch.............................................................................................................................................. 801 4.37.6 Turning tagline winch free-wheel on or off.................................................................................................................................................. 801 4.38 Luffing jib luffing winch as auxiliary winch*..................................................................................................................................................... 803 4.38.1 Use as jib luffing winch.................................................................................................................................................................... 803 4.38.2 Use as leader height adjusting winch........................................................................................................................................................ 804 4.38.3 Use as auxiliary winch...................................................................................................................................................................... 804 4.39 Diesel engine automatic stop system*.............................................................................................................................................................. 805 4.39.1 Switching the diesel engine automatic stop system on or off................................................................................................................................. 805 4.40 ECO mode*......................................................................................................................................................................................... 806 4.40.1 ECO mode operation.......................................................................................................................................................................... 806 4.41 Sensitive lift*................................................................................................................................................................................... 807 4.41.1 Switching on or switching off function sensitive lift....................................................................................................................................... 807 4.41.2 Sensitive lift operation.................................................................................................................................................................... 807 4.42 Abseil rescue equipment*.......................................................................................................................................................................... 808 4.42.1 Using abseil rescue equipment............................................................................................................................................................... 808 4.43 Emergency stop.................................................................................................................................................................................... 810 4.43.1 Using emergency stop........................................................................................................................................................................ 810 4.44 Shutdown.......................................................................................................................................................................................... 811 4.44.1 Short work interruption..................................................................................................................................................................... 811 4.44.2 Long work interruption...................................................................................................................................................................... 812 4.44.3 Switching off battery main switch........................................................................................................................................................... 813 4.45 Hydraulic emergency mode*......................................................................................................................................................................... 814 4.45.1 Winch 2 emergency mode...................................................................................................................................................................... 814 4.45.2 Main boom adjusting winch emergency mode.................................................................................................................................................... 816 4.45.3 Swing emergency mode........................................................................................................................................................................ 817 4.46 Emergency operation control*...................................................................................................................................................................... 820 4.46.1 Operating the emergency control............................................................................................................................................................. 820 5 Operational faults, diagnosis............................................................................................................................................................................ 825 5.1 Malfunctions....................................................................................................................................................................................... 825 5.1.1 Identifying faults........................................................................................................................................................................... 825 5.1.2 Error displays on monitor.................................................................................................................................................................... 825 5.1.3 Troubleshooting.............................................................................................................................................................................. 830 5.2 Litronic testing system............................................................................................................................................................................ 831 5.2.1 Litronic testing system overview............................................................................................................................................................. 831 5.2.2 Screen pages................................................................................................................................................................................. 832 5.2.3 Starting the Litronic testing system......................................................................................................................................................... 838 5.3 Fuses.............................................................................................................................................................................................. 839 5.3.1 List of fuses................................................................................................................................................................................ 839 5.3.2 Checking fuses............................................................................................................................................................................... 841 5.3.3 Changing fuses............................................................................................................................................................................... 843 6 Operational planning..................................................................................................................................................................................... 847 6.1 Assembly site...................................................................................................................................................................................... 847 6.2 Tools required..................................................................................................................................................................................... 849 6.2.1 Machine with self-assembly system............................................................................................................................................................ 849 6.2.2 Machine without self-assembly system......................................................................................................................................................... 849 6.3 Required length of winch1/winch2 rope.............................................................................................................................................................. 850 6.3.1 Calculating the length of winch1/winch2 rope................................................................................................................................................. 850 6.4 Choosing the correct hook or pulley block.......................................................................................................................................................... 852 6.5 Positioning the hook or pulley block............................................................................................................................................................... 854 6.6 Restrictions due to exposure to wind............................................................................................................................................................... 855 6.6.1 Erecting the boom............................................................................................................................................................................ 855 6.6.2 Reducing the load............................................................................................................................................................................ 855 6.6.3 Parking positions of boom configurations..................................................................................................................................................... 863 6.6.4 Lay down boom................................................................................................................................................................................ 866 6.7 Traveling on gradients............................................................................................................................................................................. 868 6.8 Rigging material................................................................................................................................................................................... 887 6.8.1 4-strand round sling gear with chain shortening devices...................................................................................................................................... 888 6.8.2 Round slings................................................................................................................................................................................. 888 6.8.3 Shackle...................................................................................................................................................................................... 889 6.8.4 Other lifting devices........................................................................................................................................................................ 889 7 Assembly and dismantling................................................................................................................................................................................. 893 7.1 Explanation of symbols used........................................................................................................................................................................ 893 7.2 Work instructions for assembly/disassembly......................................................................................................................................................... 895 7.3 Locking elements - overview........................................................................................................................................................................ 896 7.3.1 Split pin.................................................................................................................................................................................... 896 7.3.2 Linchpin..................................................................................................................................................................................... 897 7.3.3 Spring plug.................................................................................................................................................................................. 898 7.3.4 Locking spring............................................................................................................................................................................... 899 7.3.5 Locking washers.............................................................................................................................................................................. 901 7.3.6 Self-locking nuts............................................................................................................................................................................ 902 7.4 Assembling the basic machine....................................................................................................................................................................... 903 7.4.1 Notes........................................................................................................................................................................................ 903 7.4.2 Moving cabin platforms* into working position................................................................................................................................................ 903 7.4.3 Swivel the cab to the working position....................................................................................................................................................... 907 7.4.4 Mounting the cabin handrail*................................................................................................................................................................. 909 7.4.5 Ladder for cabin............................................................................................................................................................................. 925 7.4.6 Putting the load moment limiter lamp and flashing light into working position................................................................................................................ 928 7.4.7 Mounting the boom walkway on the uppercarriage............................................................................................................................................... 928 7.4.8 Mounting the ladder on the uppercarriage..................................................................................................................................................... 929 7.4.9 Mounting the uppercarriage railing........................................................................................................................................................... 930 7.4.10 Fitting the exhaust pipe.................................................................................................................................................................... 935 7.4.11 Checking the position of the bypass plug.................................................................................................................................................... 937 7.4.12 Putting the machine into operation.......................................................................................................................................................... 938 7.4.13 Switching on assembly mode functions........................................................................................................................................................ 939 7.4.14 Switching on cylinder adjustment functions.................................................................................................................................................. 939 7.4.15 Removing the uppercarriage locking device................................................................................................................................................... 939 7.4.16 Stow away uppercarriage locking device...................................................................................................................................................... 940 7.4.17 Extend the tilting back support cylinders................................................................................................................................................... 940 7.4.18 Erecting A-frame 1.......................................................................................................................................................................... 940 7.4.19 Unloading the machine....................................................................................................................................................................... 943 7.4.20 Rigging and lifting the main boom base section.............................................................................................................................................. 953 7.4.21 Attaching the main boom base section to the uppercarriage................................................................................................................................... 956 7.4.22 Connecting hydraulic lines to the uppercarriage............................................................................................................................................. 959 7.4.23 Connecting electric cables to the uppercarriage............................................................................................................................................. 963 7.4.24 Bolting the equalizer on A-frame1 to the main boom boom base section........................................................................................................................ 965 7.4.25 Detach the assembly cylinder from the main boom base section................................................................................................................................ 966 7.4.26 Installing crawler side frame............................................................................................................................................................... 970 7.4.27 Connecting hydraulic lines of the crawler................................................................................................................................................... 982 7.4.28 Unfolding steps from transport position..................................................................................................................................................... 985 7.4.29 Move the jack into the transport position................................................................................................................................................... 985 7.4.30 Using the machine as assembly crane......................................................................................................................................................... 989 7.4.31 Attaching the carbody counterweight......................................................................................................................................................... 991 7.4.32 Installing platform on undercarriage........................................................................................................................................................ 995 7.4.33 Fitting the rear counterweight..............................................................................................................................................................1002 7.5 Main boom 2018.....................................................................................................................................................................................1014 7.5.1 Configuration of main boom...................................................................................................................................................................1014 7.5.2 Lengths of mid-point suspensions.............................................................................................................................................................1015 7.5.3 Overview of main boom 2018 pendant straps....................................................................................................................................................1016 7.5.4 Reeving diagrams for one rope across main boom head 2018 (load position 1)...................................................................................................................1018 7.5.5 Reeving diagrams for two ropes across main boom head 2018 (load position1)...................................................................................................................1021 7.5.6 Reeving diagrams for one rope across auxiliary jib (36 t) on main boom head 2018 (load position1)............................................................................................1024 7.5.7 Reeving diagrams for two ropes across auxiliary jib (36 t) and main boom head 2018 (load position 1).........................................................................................1026 7.5.8 Reeving diagram - jib luffing winch as auxiliary winch.......................................................................................................................................1027 7.6 Assembling the main boom...........................................................................................................................................................................1029 7.6.1 Notes........................................................................................................................................................................................1029 7.6.2 Programming the setup........................................................................................................................................................................1029 7.6.3 Unloading and positioning the main boom section..............................................................................................................................................1029 7.6.4 Mounting ladder* for boom....................................................................................................................................................................1030 7.6.5 Pinning the main boom head to the main boom sections.........................................................................................................................................1032 7.6.6 Connecting catwalks* for booms...............................................................................................................................................................1034 7.6.7 Connecting and checking boom fall arrest*....................................................................................................................................................1036 7.6.8 Installing the rope guide....................................................................................................................................................................1036 7.6.9 Pinning pendant straps.......................................................................................................................................................................1038 7.6.10 Installing jib backstay straps..............................................................................................................................................................1039 7.6.11 Installing the mid-point suspension.........................................................................................................................................................1040 7.6.12 Bolting the main boom base section to the main boom.........................................................................................................................................1043 7.6.13 Bolting the equalizer on A-frame1 to the main boom pendant straps...........................................................................................................................1045 7.6.14 Installing auxiliary jib (36 t) on main boom head...........................................................................................................................................1045 7.6.15 Installing hoist limit switch on auxiliary jib (36 t).......................................................................................................................................1049 7.6.16 Installing second rope pulley* for triple reeving of auxiliary jib (36 t)...................................................................................................................1049 7.6.17 Connect the electric cables.................................................................................................................................................................1050 7.6.18 Installing the aircraft warning light.......................................................................................................................................................1051 7.6.19 Installing anemometer.......................................................................................................................................................................1052 7.6.20 Moving the lightning rods* into working position............................................................................................................................................1054 7.6.21 Rope reeving................................................................................................................................................................................1056 7.6.22 Installing the rope fixing point............................................................................................................................................................1065 7.6.23 Installing the hoist limit switch...........................................................................................................................................................1070 7.6.24 Erecting the main boom......................................................................................................................................................................1075 7.6.25 Switching off assembly functions............................................................................................................................................................1079 7.6.26 Checking the main boom limit switch plate for proper adjustment.............................................................................................................................1080 7.7 Main boom 2018 + Reducing adapter 2018/1713........................................................................................................................................................1082 7.7.1 Configuration of main boom...................................................................................................................................................................1082 7.7.2 Lengths of mid-point suspensions.............................................................................................................................................................1083 7.7.3 Overview of main boom 2018 pendant straps + reducing adapter 2018/1713.......................................................................................................................1085 7.7.4 Reeving diagrams for one rope across main boom head 1713 (load position1)....................................................................................................................1087 7.7.5 Reeving diagrams for two ropes across main boom head 1713 (load position1)...................................................................................................................1088 7.8 Main boom 2018 + Reducing adapter 2018/1309........................................................................................................................................................1090 7.8.1 Configuration of main boom...................................................................................................................................................................1090 7.8.2 Lengths of mid-point suspensions.............................................................................................................................................................1093 7.8.3 Overview of main boom 2018 pendant straps + reducing adapter 2018/1309.......................................................................................................................1096 7.8.4 Reeving diagrams for one rope across main boom head 1309 (load position 1)...................................................................................................................1098 7.8.5 Reeving diagrams for two ropes across main boom head 1309 (load position 1)..................................................................................................................1099 7.9 Assembling the main boom + reducing piece..........................................................................................................................................................1101 7.9.1 Notes........................................................................................................................................................................................1101 7.9.2 Installing reducing adapter..................................................................................................................................................................1101 7.9.3 Installing mid-point suspension..............................................................................................................................................................1102 7.9.4 Moving the lightning rods* into working position.............................................................................................................................................1107 7.9.5 Reeving the rope.............................................................................................................................................................................1109 7.10 Fixed jib 1008....................................................................................................................................................................................1118 7.10.1 Configuration of jib........................................................................................................................................................................1118 7.10.2 Configuration of main boom..................................................................................................................................................................1118 7.10.3 Overview of pendant straps on fixed jib 1008................................................................................................................................................1119 7.10.4 Reeving diagrams for one rope across jib head 1008 (load position1).........................................................................................................................1121 7.10.5 Reeving diagrams for two ropes across jib head 1008 (load position1)........................................................................................................................1122 7.10.6 Reeving diagrams for one rope across main boom head 2018 (load position 2)..................................................................................................................1123 7.11 Fixed jib 0806....................................................................................................................................................................................1127 7.11.1 Configuration of jib........................................................................................................................................................................1127 7.11.2 Lengths of jib mid-point suspensions........................................................................................................................................................1127 7.11.3 Configuration of main boom..................................................................................................................................................................1128 7.11.4 Overview of pendant straps on fixed jib 0806................................................................................................................................................1128 7.11.5 Reeving diagrams for one rope across jib head 0806 (load position1).........................................................................................................................1130 7.11.6 Reeving diagrams for two ropes across jib head section 0806 (load position1)................................................................................................................1131 7.11.7 Reeving diagrams for one rope across main boom head 2018 (load position 2)..................................................................................................................1132 7.12 Assembling the fixed jib..........................................................................................................................................................................1136 7.12.1 Notes.......................................................................................................................................................................................1136 7.12.2 Programming the setup.......................................................................................................................................................................1136 7.12.3 Unloading and positioning jib components....................................................................................................................................................1136 7.12.4 Pinning jib head section and jib section....................................................................................................................................................1137 7.12.5 Installing the jib base section.............................................................................................................................................................1138 7.12.6 Pinning the jib to the jib base section.....................................................................................................................................................1141 7.12.7 Installing the mid-point suspensions (jib 0806).............................................................................................................................................1141 7.12.8 Pinning the pendant straps..................................................................................................................................................................1144 7.12.9 Mounting connecting links on main boom head.................................................................................................................................................1144 7.12.10 Attaching the main boom (self-assembly system).............................................................................................................................................1146 7.12.11 Pinning A-frame2 base of pendant straps with main boom.....................................................................................................................................1146 7.12.12 Connect the electric cables................................................................................................................................................................1147 7.12.13 Installing the aircraft warning light......................................................................................................................................................1148 7.12.14 Installing anemometer......................................................................................................................................................................1150 7.12.15 Moving the lightning rods* into working position...........................................................................................................................................1152 7.12.16 Rope reeving...............................................................................................................................................................................1155 7.12.17 Attaching the rope fixing point............................................................................................................................................................1163 7.12.18 Installing the hoist limit switch..........................................................................................................................................................1167 7.12.19 Bypassing unused hoist limit switches......................................................................................................................................................1174 7.12.20 Erecting main boom with fixed jib..........................................................................................................................................................1175 7.12.21 Switching off assembly functions...........................................................................................................................................................1178 7.12.22 Checking the main boom limit switch plate for proper adjustment............................................................................................................................1179 7.13 Luffing jib 1713..................................................................................................................................................................................1181 7.13.1 Configuration of jib........................................................................................................................................................................1181 7.13.2 Lengths of jib mid-point suspensions........................................................................................................................................................1182 7.13.3 Configuration of main boom..................................................................................................................................................................1183 7.13.4 Overview of pendant straps on luffing jib 1713..............................................................................................................................................1184 7.13.5 Reeving diagram A-frame2/A-frame3...........................................................................................................................................................1186 7.13.6 Reeving diagrams for one rope across jib head section 1713 (load position 1)................................................................................................................1187 7.13.7 Reeving diagrams for two ropes across jib head section 2316, 1916, 1713, 1309, 1008 (load position1)........................................................................................1188 7.13.8 Reeving diagrams for one rope across main boom head 2018 (load position 2)..................................................................................................................1190 7.13.9 Reeving diagrams for one rope across auxiliary jib (15 t) on jib head section 1916, 1713, 1309, 1008 (load position1).......................................................................1194 7.14 1309 luffing jib..................................................................................................................................................................................1195 7.14.1 Configuration of jib........................................................................................................................................................................1195 7.14.2 Lengths of jib mid-point suspensions........................................................................................................................................................1196 7.14.3 Configuration of main boom..................................................................................................................................................................1197 7.14.4 Overview of pendant straps on 1309 luffing jib..............................................................................................................................................1198 7.14.5 Rope reeving system for A-frame 2/A-frame 3.................................................................................................................................................1200 7.14.6 Reeving diagrams for one rope across jib head section 1309 (load position 1)................................................................................................................1201 7.14.7 Reeving diagrams for two ropes across jib head section 2316, 1916, 1713, 1309, 1008 (load position1)........................................................................................1202 7.14.8 Reeving diagrams for one rope across main boom head 2018 (load position 2)..................................................................................................................1204 7.14.9 Reeving diagrams for one rope across auxiliary jib (15 t) to jib head section 1916, 1713, 1309, 1008 (load position 1)......................................................................1208 7.15 Assemble the luffing jib..........................................................................................................................................................................1209 7.15.1 Notes.......................................................................................................................................................................................1209 7.15.2 Programming the setup.......................................................................................................................................................................1209 7.15.3 Unloading and positioning jib components....................................................................................................................................................1209 7.15.4 Installing auxiliary jib (15 t) on jib head section.........................................................................................................................................1210 7.15.5 Pinning jib head section and jib section....................................................................................................................................................1212 7.15.6 Installing the jib base section.............................................................................................................................................................1213 7.15.7 Checking the pressure in the accumulator of the hydraulic tilting-back supports.............................................................................................................1216 7.15.8 Installing main boom (self-assembly system).................................................................................................................................................1216 7.15.9 Connect A-frame2 with the rope of winch1/winch2.............................................................................................................................................1216 7.15.10 Reeving A-frame2/A-frame 3.................................................................................................................................................................1217 7.15.11 Erecting A-frame2/A-frame3 with rope of winch1/winch2 and pinning hydraulic tilting-back supports..........................................................................................1219 7.15.12 Pinning A-frame2 equalizer to jib backstay straps..........................................................................................................................................1221 7.15.13 Connecting the base of pendant straps on A-frame3 to the jib base section..................................................................................................................1223 7.15.14 Bolting the jib base section to the jib....................................................................................................................................................1225 7.15.15 Pinning A-frame3 equalizer with jib pendant straps.........................................................................................................................................1226 7.15.16 Installing mid-point suspension............................................................................................................................................................1226 7.15.17 Pinning pendant straps.....................................................................................................................................................................1230 7.15.18 Connect the electric cables................................................................................................................................................................1231 7.15.19 Installing the aircraft warning light......................................................................................................................................................1232 7.15.20 Installing anemometer......................................................................................................................................................................1233 7.15.21 Moving the lightning rods* into working position...........................................................................................................................................1235 7.15.22 Rope reeving...............................................................................................................................................................................1238 7.15.23 Installing the rope fixing point...........................................................................................................................................................1248 7.15.24 Installing the hoist limit switch..........................................................................................................................................................1253 7.15.25 Bypassing unused hoist limit switches......................................................................................................................................................1261 7.15.26 Erecting the main boom with luffing jib....................................................................................................................................................1262 7.15.27 Switching off assembly functions...........................................................................................................................................................1267 7.15.28 Checking the top jib limit switch for function.............................................................................................................................................1268 7.15.29 Checking the jib limit switch plate for proper adjustment..................................................................................................................................1270 7.16 1713 luffing jib + 1713 midfall...................................................................................................................................................................1272 7.16.1 Configuration of jib........................................................................................................................................................................1272 7.16.2 Lengths of jib mid-point suspensions........................................................................................................................................................1273 7.16.3 Configuration of main boom..................................................................................................................................................................1274 7.16.4 Pendant straps of luffing jib 1713 + midfall 1713 - overview................................................................................................................................1274 7.16.5 Reeving diagrams for one rope across jib head section 1713 (load position 1)................................................................................................................1277 7.16.6 Reeving diagrams for one rope across midfall 1713 (load position3)..........................................................................................................................1279 7.17 1309 luffing jib + 1309 Midfall...................................................................................................................................................................1281 7.17.1 Configuration of jib........................................................................................................................................................................1281 7.17.2 Lengths of jib mid-point suspensions........................................................................................................................................................1282 7.17.3 Configuration of main boom..................................................................................................................................................................1283 7.17.4 Pendant straps of 1309 luffing jib + 1309 Midfall overview..................................................................................................................................1284 7.17.5 Reeving diagrams for one rope across jib head section 1309 (load position 1)................................................................................................................1286 7.17.6 Reeving diagrams for one rope across midfall 1309 (load position3)..........................................................................................................................1288 7.18 Assembling the luffing jib + Midfall..............................................................................................................................................................1290 7.18.1 Notes.......................................................................................................................................................................................1290 7.18.2 Installing the midfall......................................................................................................................................................................1290 7.19 Adjusting track...................................................................................................................................................................................1296 7.19.1 Converting from wide track to narrow track..................................................................................................................................................1296 7.19.2 Converting from narrow track to wide track..................................................................................................................................................1309 7.20 Vandalism protection*.............................................................................................................................................................................1310 7.20.1 Installing the vandalism protection.........................................................................................................................................................1310 7.21 Jib luffing winch*................................................................................................................................................................................1312 7.21.1 Fixing rope end.............................................................................................................................................................................1312 7.21.2 Lashing the jib luffing winch...............................................................................................................................................................1312 7.21.3 Installation of jib luffing winch...........................................................................................................................................................1313 7.21.4 Connect hydraulic lines.....................................................................................................................................................................1314 7.21.5 Connect the electric cables.................................................................................................................................................................1315 7.22 Time-saving reconfiguring of the main boom........................................................................................................................................................1316 7.22.1 Reconfiguring the main boom.................................................................................................................................................................1316 7.23 Lashing the machine on a floating device..........................................................................................................................................................1319 7.23.1 Rigging equipment and limit values..........................................................................................................................................................1319 7.23.2 Securing the machine against sliding........................................................................................................................................................1321 7.24 Disassembling the luffing jib + Midfall...........................................................................................................................................................1326 7.24.1 Brief summary...............................................................................................................................................................................1326 7.25 Deinstalling the luffing jib......................................................................................................................................................................1327 7.25.1 Preparing the machine.......................................................................................................................................................................1327 7.25.2 Lower jib up to load moment limitation stop.................................................................................................................................................1329 7.25.3 Lowering the jib until wheels set down on the ground or the bottom jib limit switch is triggered............................................................................................1330 7.25.4 Lower main boom and jib all the way to the ground...........................................................................................................................................1332 7.26 Dismantling the fixed jib.........................................................................................................................................................................1338 7.26.1 Brief summary...............................................................................................................................................................................1338 7.27 Disassembling main boom + reducing adapter........................................................................................................................................................1340 7.27.1 Brief summary...............................................................................................................................................................................1340 7.28 Disassembling the main boom.......................................................................................................................................................................1341 7.28.1 Brief summary...............................................................................................................................................................................1341 7.29 Disassembling the basic machine...................................................................................................................................................................1344 7.29.1 Brief summary...............................................................................................................................................................................1344 8 Transport................................................................................................................................................................................................1349 8.1 Loading the basic machine with an assist crane.....................................................................................................................................................1349 8.1.1 Loading the basic machine without crawler side frame, carbody counterweight and rear counterweight...........................................................................................1349 8.1.2 Loading the basic machine with crawler side frame............................................................................................................................................1352 8.2 Transporting the basic machine with a transport vehicle............................................................................................................................................1355 8.3 Transporting the basic machine by ship.............................................................................................................................................................1359 8.4 Transporting the boom sections.....................................................................................................................................................................1364 8.4.1 Adjusting and mounting the transport brackets for steel pendant straps.......................................................................................................................1364 8.4.2 Installing transport brackets for CF pendant straps..........................................................................................................................................1364 8.4.3 Inserting and securing pendant straps in transport bracket...................................................................................................................................1366 8.4.4 Securing the pendant straps with transport safety............................................................................................................................................1367 8.4.5 Preparing boom components for transport......................................................................................................................................................1368 8.4.6 Transporting the pendant straps..............................................................................................................................................................1370 9 Maintenance..............................................................................................................................................................................................1373 9.1 Maintenance and inspection schedule................................................................................................................................................................1373 9.2 Lubricants and consumables.........................................................................................................................................................................1387 9.2.1 Lubrication diagram..........................................................................................................................................................................1388 9.2.2 Filling capacity table.......................................................................................................................................................................1390 9.2.3 Lubrication chart............................................................................................................................................................................1391 9.2.4 Diesel engine lubricating oil................................................................................................................................................................1394 9.2.5 Fuel.........................................................................................................................................................................................1394 9.2.6 Urea solution................................................................................................................................................................................1394 9.2.7 Diesel engine coolant........................................................................................................................................................................1394 9.2.8 Hydraulic oil................................................................................................................................................................................1395 9.2.9 Preservation medium (anti-corrosion coating).................................................................................................................................................1396 9.2.10 Liebherr oil diagnosis system...............................................................................................................................................................1398 9.3 Work instructions for preventive maintenance.......................................................................................................................................................1400 9.4 Air filter system..................................................................................................................................................................................1402 9.4.1 Checking the negative pressure indicator.....................................................................................................................................................1402 9.4.2 Cleaning the air filter dust ejector.........................................................................................................................................................1403 9.4.3 Replacing the dry air filter main element and dry air filter safety element..................................................................................................................1403 9.5 Exhaust aftertreatment system* (see operating manual of the engine manufacturer on CD).............................................................................................................1405 9.5.1 Checking air cylinder for condensate.........................................................................................................................................................1405 9.5.2 Replacing air dryer cartridge................................................................................................................................................................1405 9.6 Swing gear.........................................................................................................................................................................................1408 9.6.1 Checking the gearbox oil level...............................................................................................................................................................1408 9.6.2 Topping up gearbox oil.......................................................................................................................................................................1408 9.7 Swing connection...................................................................................................................................................................................1410 9.7.1 Lubricating external teeth...................................................................................................................................................................1410 9.7.2 Lubricating the bearing races via the central lubrication point..............................................................................................................................1410 9.8 Winch1/winch2......................................................................................................................................................................................1412 9.8.1 Checking the gearbox oil level...............................................................................................................................................................1412 9.8.2 Topping up gearbox oil.......................................................................................................................................................................1413 9.8.3 Checking oil level of holding brake..........................................................................................................................................................1413 9.8.4 Changing hydraulic oil of the holding brake..................................................................................................................................................1414 9.8.5 Lubricating counter bearings.................................................................................................................................................................1417 9.8.6 Checking the rope end fastening for tight fit................................................................................................................................................1417 9.9 Boom luffing winches...............................................................................................................................................................................1418 9.9.1 Checking the gearbox oil level...............................................................................................................................................................1418 9.9.2 Topping up gearbox oil.......................................................................................................................................................................1419 9.9.3 Lubricating counter bearings.................................................................................................................................................................1419 9.9.4 Checking the rope end fastening for tight fit................................................................................................................................................1420 9.10 Rope reeving winch................................................................................................................................................................................1421 9.10.1 Lubricating the counter bearing.............................................................................................................................................................1421 9.10.2 Checking rope end attachment for tight fit when starting up rope reeving winch..............................................................................................................1421 9.11 Tagline winch.....................................................................................................................................................................................1422 9.11.1 Checking the gearbox oil level..............................................................................................................................................................1422 9.11.2 Topping up the gearbox oil..................................................................................................................................................................1423 9.11.3 Lubricating the rope bracket on the boom base section and checking pulleys for damage.......................................................................................................1423 9.11.4 Checking the rope end fastening for tight fit...............................................................................................................................................1424 9.12 Crawler...........................................................................................................................................................................................1425 9.12.1 Checking the gearbox oil level..............................................................................................................................................................1425 9.12.2 Check gearbox and hydraulic screw connections for leaks.....................................................................................................................................1426 9.12.3 Cleaning the crawler........................................................................................................................................................................1426 9.12.4 Checking locking screws on undercarriage for tight fit......................................................................................................................................1427 9.12.5 Checking the chain tension..................................................................................................................................................................1427 9.12.6 Retightening chain..........................................................................................................................................................................1430 9.12.7 Relaxing the chain..........................................................................................................................................................................1432 9.12.8 Tightening the base plate screws............................................................................................................................................................1433 9.13 Lifting device....................................................................................................................................................................................1434 9.13.1 Check transport lashing and round slings for wear (according to EN 1492-2)..................................................................................................................1434 9.13.2 Check the round steel chains for wear and damage............................................................................................................................................1434 9.14 Hook/pulley block.................................................................................................................................................................................1435 9.14.1 Checking all hooks/pulley blocks for damage, wear, corrosion and widening of the hook aperture..............................................................................................1435 9.14.2 Lubricating bearings and axels..............................................................................................................................................................1435 9.14.3 Check that the safety catch is present and working properly.................................................................................................................................1436 9.15 Hydraulic system..................................................................................................................................................................................1437 9.15.1 Check the hydraulic system for leaks........................................................................................................................................................1437 9.15.2 Checking the oil cooler for contamination...................................................................................................................................................1437 9.15.3 Changing the compressed air filter..........................................................................................................................................................1438 9.16 Hydraulic oil tank................................................................................................................................................................................1440 9.16.1 Carrying out a hydraulic oil analysis.......................................................................................................................................................1440 9.16.2 Filling with hydraulic oil..................................................................................................................................................................1440 9.16.3 Draining the hydraulic oil..................................................................................................................................................................1441 9.16.4 Cleaning the magnetic rod in the return filter..............................................................................................................................................1441 9.16.5 Exchanging return filter....................................................................................................................................................................1444 9.17 Hydraulic cylinders...............................................................................................................................................................................1446 9.17.1 Check that the hydraulic cylinder fits properly and does not leak...........................................................................................................................1446 9.17.2 Protecting the piston rods of the hydraulic cylinders from corrosion........................................................................................................................1446 9.17.3 Preserving the piston rods of the hydraulic cylinders in case of longer periods of non-use..................................................................................................1446 9.18 Hydraulic leads...................................................................................................................................................................................1447 9.18.1 Visual inspection of hydraulic leads (hydraulic hoses, hydraulic pipes).....................................................................................................................1447 9.19 Bypass filter system..............................................................................................................................................................................1448 9.19.1 Checking the bypass filter system...........................................................................................................................................................1448 9.19.2 Changing the filter elements................................................................................................................................................................1448 9.20 Batteries.........................................................................................................................................................................................1451 9.20.1 Checking the fluid level in the cells.......................................................................................................................................................1451 9.21 Lighting..........................................................................................................................................................................................1452 9.21.1 Checking the function of cabin lighting, floodlights and additional floodlight..............................................................................................................1452 9.21.2 Changing the cabin illuminant...............................................................................................................................................................1452 9.21.3 Changing the bulbs of floodlight on the cabin and on the uppercarriage......................................................................................................................1452 9.21.4 Changing the bulbs of floodlight on main boom base section..................................................................................................................................1455 9.21.5 Exchanging the bulbs of floodlights on main boom or jib head section........................................................................................................................1458 9.22 Rope measuring system.............................................................................................................................................................................1461 9.22.1 Checking the rope measuring system and height adjustment of all winches (if available) for correct function.................................................................................1461 9.22.2 Readjusting layer change when changing ropes................................................................................................................................................1461 9.23 Limit switches....................................................................................................................................................................................1462 9.23.1 Checking hoist limit switches, boom limit switches and, if necessary, limit switches of the piling and drilling rig to ensure they are working correctly....................................1462 9.24 Mechanical inclinometer...........................................................................................................................................................................1463 9.24.1 Checking that the mechanical inclinometer is working properly...............................................................................................................................1463 9.25 Emergency stop....................................................................................................................................................................................1464 9.25.1 Checking the emergency stop.................................................................................................................................................................1464 9.26 Obstacle warning light*...........................................................................................................................................................................1465 9.26.1 Check obstacle warning light for function and damage, check mains cable and plug (if available) for damage..................................................................................1465 9.27 Fire extinguishers................................................................................................................................................................................1466 9.27.1 Checking the seals and inspection dates on the fire extinguishers...........................................................................................................................1466 9.28 Personal protective equipment.....................................................................................................................................................................1467 9.28.1 Checking personal protective gear...........................................................................................................................................................1467 9.29 Safety signs......................................................................................................................................................................................1468 9.29.1 Checking safety signs on machine for completeness and legibility............................................................................................................................1468 9.30 Access systems and railings.......................................................................................................................................................................1469 9.30.1 Checking ladders, steps, platforms, and ascents for wear, damage and anti-slip surfaces.....................................................................................................1469 9.30.2 Checking latches and hand rails for wear and damage.........................................................................................................................................1469 9.30.3 Checking the spring tension of railing doors................................................................................................................................................1469 9.30.4 Setting the spring tension of railing doors.................................................................................................................................................1470 9.30.5 Checking the function of the railing stabilization..........................................................................................................................................1472 9.31 Steel structure...................................................................................................................................................................................1474 9.31.1 Checking the machine steel structure for damage, cracks.....................................................................................................................................1474 9.31.2 Repairs on the steel structure..............................................................................................................................................................1475 9.32 Main boom.........................................................................................................................................................................................1477 9.32.1 Check main boom base section, main boom head and main boom sections for damage and wear (cracks, notches, corrosion, plastic deformation, wear).............................................1477 9.32.2 Main boom base section: Check knuckle pins and locking elements for tight fit...............................................................................................................1478 9.32.3 Main boom base section: Lubricating knuckle pins............................................................................................................................................1478 9.32.4 Main boom base section or A-frame1: Checking the function of the mechanical boom angle indicator............................................................................................1479 9.32.5 Checking the main boom head for function and damage.........................................................................................................................................1480 9.32.6 Checking the anemometer for tight fit and function..........................................................................................................................................1480 9.32.7 Checking the auxiliary jib for function and damage..........................................................................................................................................1481 9.33 Jib...............................................................................................................................................................................................1482 9.33.1 Checking the jib base section, jib head section and jib sections for damage and wear........................................................................................................1482 9.33.2 Filling the accumulators for the tilting-back supports on the jib...........................................................................................................................1482 9.33.3 Checking locking flaps for ease of movement.................................................................................................................................................1488 9.33.4 Jib head section: Checking wheels for ease of movement......................................................................................................................................1489 9.33.5 Checking the anemometer for tight fit and function..........................................................................................................................................1490 9.33.6 Jib base section: Checking screw connections and pin connections for tight fit, checking that rope protection and locking springs are in place and undamaged................................1490 9.34 A-frame1..........................................................................................................................................................................................1491 9.34.1 Checking A-frame 1..........................................................................................................................................................................1491 9.34.2 Lubricating the bearings on A-frame 1.......................................................................................................................................................1491 9.34.3 Lubricating the bearings on the A-frame1 cylinder...........................................................................................................................................1492 9.35 Main boom tilting-back supports...................................................................................................................................................................1493 9.35.1 Checking pressure in main boom tilting-back supports........................................................................................................................................1493 9.36 Steel pendant straps..............................................................................................................................................................................1496 9.36.1 Checking steel pendant straps and pins for damage and wear and check that locking springs and split pins are present........................................................................1496 9.36.2 Checking the ease of movement of pin connections in the entire pendant strap strand.........................................................................................................1497 9.36.3 Protecting steel pendant straps, connecting links and pins from corrosion...................................................................................................................1497 9.36.4 Checking connecting links for damage and wear...............................................................................................................................................1497 9.36.5 Checking tension load cells for damage and wear, checking electricity connections for tight fit.............................................................................................1497 9.37 Carbon-fibre pendant straps.......................................................................................................................................................................1499 9.37.1 Checking CF pendant straps and pins for damage and wear and check that locking springs and split pins are present...........................................................................1500 9.37.2 Checking the ease of movement of pin connections in the entire pendant strap strand.........................................................................................................1502 9.37.3 Protecting CF pendant strap bushes, connecting links and pins from corrosion................................................................................................................1502 9.37.4 Checking connecting links for damage and wear...............................................................................................................................................1503 9.37.5 Checking tension load cells for damage and wear, checking electricity connections for tight fit.............................................................................................1503 9.38 Pendant ropes.....................................................................................................................................................................................1504 9.38.1 Check pendant ropes and pins for damage and wear and check that locking springs and cotter pins are present (cracks, notches, corrosion, plastic deformation, wear, lubrication, etc.)......1504 9.38.2 Protecting pendant ropes, connecting links and pins from corrosion..........................................................................................................................1504 9.38.3 Checking connecting links for damage and wear...............................................................................................................................................1505 9.39 Counterweight.....................................................................................................................................................................................1506 9.39.1 Checking the screws of the rear counterweight tie-down for tight fit (with exception of LR 1001.xx.xx)......................................................................................1506 9.39.2 Checking the rear counterweight, fixing lugs and round steel chains for damage, wear and secure fit.........................................................................................1506 9.39.3 Checking locking elements for availability, damage, wear and tight fit......................................................................................................................1507 9.39.4 Checking counterweight supports (pins, shackles) for damage and wear........................................................................................................................1507 9.40 Lubrication system................................................................................................................................................................................1508 9.40.1 Checking the function of the central lubrication system.....................................................................................................................................1508 9.40.2 Check fill level of the lubrication pump....................................................................................................................................................1508 9.40.3 Checking the time intervals of the lubrication pump.........................................................................................................................................1509 9.40.4 Checking the lubrication points.............................................................................................................................................................1509 9.41 Ropes.............................................................................................................................................................................................1510 9.41.1 Assembly of a rope..........................................................................................................................................................................1510 9.41.2 Visual inspection of the ropes for deterioration or mechanical damage.......................................................................................................................1510 9.41.3 Checking ropes for lubrication..............................................................................................................................................................1510 9.41.4 Rope lubrication............................................................................................................................................................................1511 9.41.5 Checking ropes for end of service life......................................................................................................................................................1511 9.41.6 Storing ropes...............................................................................................................................................................................1524 9.41.7 Transporting the ropes......................................................................................................................................................................1524 9.41.8 Selecting a rope............................................................................................................................................................................1525 9.41.9 Unwind rope from rope reel..................................................................................................................................................................1527 9.41.10 Laying on the rope.........................................................................................................................................................................1529 9.42 Drum..............................................................................................................................................................................................1540 9.42.1 Checking rope tensioning pulleys* of drum for wear..........................................................................................................................................1540 9.42.2 Checking the groove diameter of the drum....................................................................................................................................................1540 9.42.3 Checking drum for loose rope layers.........................................................................................................................................................1541 9.43 Rope pulleys......................................................................................................................................................................................1542 9.43.1 Assembly of a pulley........................................................................................................................................................................1542 9.43.2 Checking the groove diameter of the pulley..................................................................................................................................................1542 9.43.3 Checking the bottom of groove diameter of the pulley........................................................................................................................................1543 9.43.4 Checking the gap width of the pulley........................................................................................................................................................1544 9.43.5 Checking bottom of pulley groove for sharp edges............................................................................................................................................1545 9.43.6 Checking pulleys for damage.................................................................................................................................................................1545 9.43.7 Checking the pulley bearings................................................................................................................................................................1546 9.43.8 Lubricating the pulley bearings.............................................................................................................................................................1546 9.43.9 Checking the position of bearing and locking ring...........................................................................................................................................1546 9.43.10 Cleaning plastic pulleys...................................................................................................................................................................1547 9.44 Rope suspension and rope attachment...............................................................................................................................................................1548 9.44.1 Checking rope suspensions (rope clamps, rope thimbles) for wire breaks, absence of corrosion and tight fit of screw fittings................................................................1548 9.44.2 Checking pocket locks.......................................................................................................................................................................1549 9.44.3 Check pressed termination for cracks........................................................................................................................................................1550 9.44.4 Checking rope fixing point..................................................................................................................................................................1551 9.45 Cab...............................................................................................................................................................................................1552 9.45.1 Removing the cabin roof protection guard or fixed falling object protection*................................................................................................................1552 9.45.2 Opening foldable falling object protection*.................................................................................................................................................1553 9.45.3 Check the windows of the cab for damage.....................................................................................................................................................1553 9.45.4 Checking that the cab door and the door lock work properly..................................................................................................................................1554 9.45.5 Checking cabin roof protection guard or falling object protection* for damage and locking in case of foldable falling object protection.....................................................1554 9.45.6 Lubricating the falling object protection*..................................................................................................................................................1555 9.45.7 Replacing the windscreen wiper..............................................................................................................................................................1555 9.45.8 Filling the windscreen cleaning system......................................................................................................................................................1556 9.45.9 Checking outside mirrors and inside mirrors for damage......................................................................................................................................1557 9.45.10 Checking the operation of the hydraulic cab tilting device and for damage..................................................................................................................1557 9.45.11 Checking hydraulic cabin elevation for function and damage.................................................................................................................................1558 9.45.12 Cleaning or replacing the filter insert in the cabin.......................................................................................................................................1559 9.46 Ventilation, heating and air-conditioning.........................................................................................................................................................1561 9.46.1 Checking the recirculated air filter for contamination......................................................................................................................................1561 9.46.2 Replacing the recirculated air filter.......................................................................................................................................................1565 9.46.3 Checking fresh air filter for contamination.................................................................................................................................................1570 9.46.4 Replacing the fresh air filter..............................................................................................................................................................1571 9.46.5 Checking the coolant level in the sight glass...............................................................................................................................................1575 9.46.6 Checking the condenser for contamination....................................................................................................................................................1576 9.46.7 Checking the condenser for loose leads, loos screws and corrosion...........................................................................................................................1577 9.46.8 Checking the fan on condenser for function, tight fit and damage............................................................................................................................1577 9.46.9 Checking the climate box for contamination..................................................................................................................................................1578 9.46.10 Checking the dryer for damage and corrosion................................................................................................................................................1579 9.46.11 Starting the ventilation, heating, air conditioner, external air conditioner* and auxiliary heating system* and ensuring that sufficient antifreeze has been added to the water circuit....1579 9.46.12 Replacing the fuel filter of auxiliary water heating*......................................................................................................................................1582 9.47 HATZ diesel engine* (see operation manual of the engine manufacturer on CD).......................................................................................................................1584 9.47.1 Checking the belt drive.....................................................................................................................................................................1584 9.47.2 Replacing the belt drive including vibration damper, deflection pulley and springs..........................................................................................................1584 9.48 Machine care......................................................................................................................................................................................1585 9.48.1 Cleaning the machine........................................................................................................................................................................1585 9.48.2 Preserving the machine......................................................................................................................................................................1586 Index......................................................................................................................................................................................................1599
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