LIEBHERR HS 8100 HD Operator’s Manual SN184998 – PDF DOWNLOAD

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LIEBHERR HS 8100 HD Operator’s Manual SN184998 – PDF DOWNLOAD

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LIEBHERR HS 8100 HD Operator’s Manual SN184998 – PDF DOWNLOAD

Language : English
Pages : 1294
Downloadable : Yes
File Type : PDF

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LIEBHERR HS 8100 HD Operator’s Manual SN184998 – 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.

TABLE OF CONTENTS:

LIEBHERR HS 8100 HD Operator’s Manual SN184998 – PDF DOWNLOAD

Operator's manual..........................................................................................................................................................................................   1
	Foreword...............................................................................................................................................................................................   3
	Notes regarding the documentation......................................................................................................................................................................   5
	Technical terms and abbreviations......................................................................................................................................................................  11
	Contents...............................................................................................................................................................................................  13
	1 Product description..................................................................................................................................................................................  43
		1.1 Type plate.....................................................................................................................................................................................  44
		1.2 Declaration of conformity......................................................................................................................................................................  46
		1.3 Appropriate use................................................................................................................................................................................  47
		1.4 Inappropriate use..............................................................................................................................................................................  49
		1.5 Use of machine with load moment limitation and hoist limit switches............................................................................................................................  51
		1.6 Service life classification....................................................................................................................................................................  52
		1.7 Load chart in dependence on working equipment..................................................................................................................................................  53
			1.7.1 Casing oscillator and grab (grab mode)...................................................................................................................................................  54
			1.7.2 Dynamic soil compaction..................................................................................................................................................................  57
			1.7.3 Dragline operation.......................................................................................................................................................................  58
			1.7.4 Slurry wall grab.........................................................................................................................................................................  60
		1.8 Machine........................................................................................................................................................................................  64
			1.8.1 Machine overview.........................................................................................................................................................................  64
			1.8.2 Technical data...........................................................................................................................................................................  64
			1.8.3 Safety devices...........................................................................................................................................................................  69
			1.8.4 Monitoring installations.................................................................................................................................................................  70
		1.9 Basic machine..................................................................................................................................................................................  71
			1.9.1 Basic machine overview...................................................................................................................................................................  71
			1.9.2 A-frame1.................................................................................................................................................................................  75
			1.9.3 Pendant straps on A-frame1...............................................................................................................................................................  76
			1.9.4 Uppercarriage............................................................................................................................................................................  77
			1.9.5 Cabin....................................................................................................................................................................................  79
			1.9.6 Central power unit.......................................................................................................................................................................  81
			1.9.7 Undercarriage............................................................................................................................................................................  83
			1.9.8 Crawler side frame.......................................................................................................................................................................  84
			1.9.9 Platforms on uppercarriage...............................................................................................................................................................  86
			1.9.10 Electrohydraulic platforms* on uppercarriage............................................................................................................................................  87
			1.9.11 Adapter for casing oscillator...........................................................................................................................................................  91
			1.9.12 Carbody counterweight...................................................................................................................................................................  92
			1.9.13 Rear counterweight......................................................................................................................................................................  93
		1.10 Information about boom designation............................................................................................................................................................  97
		1.11 Main boom overview............................................................................................................................................................................  99
		1.12 Main boom 1311.24............................................................................................................................................................................. 100
			1.12.1 Main boom base section 1311.24.......................................................................................................................................................... 100
			1.12.2 Main boom section 1311.24 3 m........................................................................................................................................................... 101
			1.12.3 Main boom section 1311.24 6 m........................................................................................................................................................... 103
			1.12.4 Main boom head 1311.24.................................................................................................................................................................. 104
			1.12.5 Hoist rope tagline...................................................................................................................................................................... 105
			1.12.6 Pendant ropes on main boom 1311.24...................................................................................................................................................... 108
			1.12.7 Components for hydraulic slurry wall grab* on main boom 1311.24......................................................................................................................... 110
		1.13 Short boom.................................................................................................................................................................................... 121
			1.13.1 Short boom 1311.22...................................................................................................................................................................... 121
			1.13.2 Short boom 1307.24...................................................................................................................................................................... 126
			1.13.3 Short boom 1307.24 with short boom-A-frame1............................................................................................................................................. 130
		1.14 Auxiliary jib* (25 t)......................................................................................................................................................................... 141
		1.15 Rope fixing point............................................................................................................................................................................. 143
			1.15.1 Rope fixing point on main boom head..................................................................................................................................................... 143
			1.15.2 Rope lock............................................................................................................................................................................... 144
			1.15.3 Cross block............................................................................................................................................................................. 145
			1.15.4 Link plate.............................................................................................................................................................................. 146
			1.15.5 Pin for rope fixing point............................................................................................................................................................... 147
		1.16 Pulley block/hook*............................................................................................................................................................................ 148
			1.16.1 Pulley block 100 t...................................................................................................................................................................... 148
			1.16.2 Pulley block 50 t....................................................................................................................................................................... 150
			1.16.3 Pulley block 40 t....................................................................................................................................................................... 151
			1.16.4 Hook 25 t............................................................................................................................................................................... 152
			1.16.5 Hook 20 t............................................................................................................................................................................... 153
		1.17 Emergency descent rescue equipment*........................................................................................................................................................... 155
		1.18 Safety barrier*............................................................................................................................................................................... 156
		1.19 Armrests* for operator's seat................................................................................................................................................................. 157
		1.20 Catwalks*..................................................................................................................................................................................... 158
			1.20.1 Catwalks on main boom base section...................................................................................................................................................... 158
			1.20.2 Catwalks on main boom sections.......................................................................................................................................................... 159
			1.20.3 Catwalks on main boom head.............................................................................................................................................................. 160
		1.21 Tagline winch* 3 t............................................................................................................................................................................ 161
		1.22 Fuel refueling pump*.......................................................................................................................................................................... 163
		1.23 Urea refueling pump*.......................................................................................................................................................................... 164
		1.24 Uppercarriage handrail........................................................................................................................................................................ 165
			1.24.1 Self-closing doors* on uppercarriage handrail........................................................................................................................................... 166
		1.25 Safety guard* for cabin....................................................................................................................................................................... 167
		1.26 Vandalism protection*......................................................................................................................................................................... 168
			1.26.1 Top cover............................................................................................................................................................................... 169
			1.26.2 Rear cover.............................................................................................................................................................................. 170
			1.26.3 Front cover............................................................................................................................................................................. 171
			1.26.4 Right front cover....................................................................................................................................................................... 172
			1.26.5 Right rear cover........................................................................................................................................................................ 173
			1.26.6 Left front cover........................................................................................................................................................................ 174
			1.26.7 Left rear cover......................................................................................................................................................................... 175
			1.26.8 Mounts for front cover.................................................................................................................................................................. 176
			1.26.9 Locking bar............................................................................................................................................................................. 177
		1.27 Fire extinguishing system*.................................................................................................................................................................... 178
		1.28 External power supply*........................................................................................................................................................................ 179
			1.28.1 External power supply obstacle warning light............................................................................................................................................ 179
			1.28.2 External supply low temperature package................................................................................................................................................. 179
		1.29 Radio remote control*......................................................................................................................................................................... 180
		1.30 Grab rope guide*.............................................................................................................................................................................. 183
			1.30.1 Bracket for grab rope guide............................................................................................................................................................. 184
		1.31 GSM/GPRS/GPS modem............................................................................................................................................................................ 186
		1.32 Virtual Private Network (VPN)*................................................................................................................................................................ 187
			1.32.1 Cisco 3G VPN router..................................................................................................................................................................... 187
			1.32.2 Power unit.............................................................................................................................................................................. 188
			1.32.3 Cisco 3G antenna........................................................................................................................................................................ 188
			1.32.4 Vodafone 3G VPN router.................................................................................................................................................................. 189
			1.32.5 SIM card................................................................................................................................................................................ 189
		1.33 Ventilation, heating and air-conditioning..................................................................................................................................................... 190
			1.33.1 Cooling circuit......................................................................................................................................................................... 191
			1.33.2 Heating circuit......................................................................................................................................................................... 196
			1.33.3 Auxiliary air heating*.................................................................................................................................................................. 199
			1.33.4 Electric components..................................................................................................................................................................... 201
			1.33.5 Mechanic components..................................................................................................................................................................... 204
		1.34 Aircraft warning light*....................................................................................................................................................................... 206
		1.35 Auxiliary winch*.............................................................................................................................................................................. 207
		1.36 Auxiliary winch 8 t........................................................................................................................................................................... 208
		1.37 Cable remote control.......................................................................................................................................................................... 210
		1.38 Fixed cabin elevation......................................................................................................................................................................... 212
			1.38.1 Cabin elevation......................................................................................................................................................................... 212
			1.38.2 Cabin platform.......................................................................................................................................................................... 213
			1.38.3 Ladder.................................................................................................................................................................................. 214
			1.38.4 Handrail................................................................................................................................................................................ 216
		1.39 Hydraulic cabin elevation*.................................................................................................................................................................... 218
		1.40 Leak oil return*.............................................................................................................................................................................. 220
		1.41 Assembly platform* for main boom base section................................................................................................................................................. 221
			1.41.1 Assembly platform....................................................................................................................................................................... 222
			1.41.2 Ladder for assembly platform............................................................................................................................................................ 223
		1.42 Ladder* for uppercarriage..................................................................................................................................................................... 224
		1.43 Reading light* for cabin...................................................................................................................................................................... 225
		1.44 Litronic control system....................................................................................................................................................................... 226
		1.45 Emergency operation control*.................................................................................................................................................................. 227
		1.46 Visual motion warning device*................................................................................................................................................................. 228
		1.47 Process data recording (PDE)*................................................................................................................................................................. 230
		1.48 Process data report (PDR)*.................................................................................................................................................................... 231
		1.49 Rope reeving winch* 17.5 kN................................................................................................................................................................... 232
		1.50 Falling object protection* for cab............................................................................................................................................................ 234
		1.51 Foldable falling object protection* for cabin................................................................................................................................................. 236
		1.52 Verticality assistant* for slurry wall grab................................................................................................................................................... 238
			1.52.1 Verticality sensor...................................................................................................................................................................... 238
			1.52.2 Charging station for verticality sensor................................................................................................................................................. 240
		1.53 Monitoring system*............................................................................................................................................................................ 241
			1.53.1 Angle of view for rear camera and right camera.......................................................................................................................................... 241
			1.53.2 Quad monitor............................................................................................................................................................................ 242
			1.53.3 Camera.................................................................................................................................................................................. 244
		1.54 Central lubrication system.................................................................................................................................................................... 246
		1.55 Additional headlight*......................................................................................................................................................................... 247
			1.55.1 Headlight on uppercarriage.............................................................................................................................................................. 247
			1.55.2 Headlight on cabin...................................................................................................................................................................... 248
			1.55.3 Headlight on A-frame1................................................................................................................................................................... 250
			1.55.4 Adjustable headlight on main boom base section.......................................................................................................................................... 251
		1.56 Headlight on main boom........................................................................................................................................................................ 253
			1.56.1 High-pressure sodium vapor lamp......................................................................................................................................................... 253
			1.56.2 LED headlight........................................................................................................................................................................... 255
	2 Safety instructions.................................................................................................................................................................................. 259
		2.1 Safe operation of machine...................................................................................................................................................................... 259
			2.1.1 Personnel selection...................................................................................................................................................................... 259
			2.1.2 Safe system of work...................................................................................................................................................................... 259
			2.1.3 Maintenance.............................................................................................................................................................................. 260
		2.2 Areas of responsibility........................................................................................................................................................................ 261
			2.2.1 Manufacturer............................................................................................................................................................................. 261
			2.2.2 Owner.................................................................................................................................................................................... 261
			2.2.3 Machine operator......................................................................................................................................................................... 262
			2.2.4 Slinger.................................................................................................................................................................................. 262
			2.2.5 Signaller................................................................................................................................................................................ 263
			2.2.6 Maintenance personnel.................................................................................................................................................................... 263
			2.2.7 Installation personnel and disassembly personnel......................................................................................................................................... 263
			2.2.8 Helper................................................................................................................................................................................... 264
			2.2.9 Liebherr service personnel............................................................................................................................................................... 264
			2.2.10 Certified and institutionally authorized persons........................................................................................................................................ 264
		2.3 Requirements to personnel...................................................................................................................................................................... 265
			2.3.1 Machine operator......................................................................................................................................................................... 265
			2.3.2 Slinger.................................................................................................................................................................................. 265
			2.3.3 Signaller................................................................................................................................................................................ 266
			2.3.4 Maintenance personnel.................................................................................................................................................................... 266
			2.3.5 Installation personnel and disassembly personnel......................................................................................................................................... 266
			2.3.6 Helper................................................................................................................................................................................... 267
			2.3.7 Liebherr service personnel............................................................................................................................................................... 267
			2.3.8 Certified and institutionally authorized persons......................................................................................................................................... 267
		2.4 Personal protective equipment.................................................................................................................................................................. 268
		2.5 Workplace...................................................................................................................................................................................... 268
		2.6 Danger zone.................................................................................................................................................................................... 269
		2.8 Safety signs on the machine.................................................................................................................................................................... 271
		2.9 Meaning of safety signs........................................................................................................................................................................ 275
			2.9.1 Mandatory action sign.................................................................................................................................................................... 275
			2.9.2 Prohibition sign......................................................................................................................................................................... 276
			2.9.3 Warning signs............................................................................................................................................................................ 278
			2.9.4 Safe condition sign...................................................................................................................................................................... 280
			2.9.5 Fire equipment sign...................................................................................................................................................................... 280
		2.10 Meaning of machine-specific signs............................................................................................................................................................. 280
			2.10.1 Safety signs............................................................................................................................................................................ 280
			2.10.2 Notice signs............................................................................................................................................................................ 282
		2.11 Hazards....................................................................................................................................................................................... 285
			2.11.1 Mechanical action....................................................................................................................................................................... 285
			2.11.2 Electrical energy....................................................................................................................................................................... 285
			2.11.3 Hydraulic energy........................................................................................................................................................................ 286
			2.11.4 Burns................................................................................................................................................................................... 287
			2.11.5 Chemical burns.......................................................................................................................................................................... 288
			2.11.6 Fire and explosion...................................................................................................................................................................... 288
			2.11.7 Poisoning and suffocation............................................................................................................................................................... 289
			2.11.8 Electromagnetic influence............................................................................................................................................................... 290
			2.11.9 Exposure to wind........................................................................................................................................................................ 290
			2.11.10 Advertising banner on main boom........................................................................................................................................................ 297
			2.11.11 Snow load and ice load................................................................................................................................................................. 298
			2.11.12 Load-bearing capacity of the ground.................................................................................................................................................... 299
			2.11.13 Lightning strike....................................................................................................................................................................... 300
			2.11.14 Overhead lines......................................................................................................................................................................... 301
			2.11.15 Environment............................................................................................................................................................................ 303
		2.12 What to do in dangerous situations............................................................................................................................................................ 304
			2.12.1 Procedure in event of current transfer.................................................................................................................................................. 304
			2.12.2 How to respond in the event of a fire................................................................................................................................................... 305
			2.12.3 Firefighting............................................................................................................................................................................ 306
		2.13 Working at heights............................................................................................................................................................................ 308
		2.14 Use on floating structures.................................................................................................................................................................... 308
			2.14.1 Operating machine on floating structures................................................................................................................................................ 308
			2.14.2 Transporting machine on floating structures............................................................................................................................................. 309
			2.14.3 Increased corrosion susceptibility of machine on floating structures.................................................................................................................... 310
		2.15 Use at low temperatures....................................................................................................................................................................... 310
			2.15.1 Operation of machine down to -20 °C (standard).......................................................................................................................................... 311
			2.15.2 Operation of the machine down to -25 °C*................................................................................................................................................ 311
			2.15.3 Operation of the machine down to -40 °C*................................................................................................................................................ 311
		2.16 Hand signal................................................................................................................................................................................... 312
			2.16.1 General hand signals according to BGV A8................................................................................................................................................ 313
			2.16.2 Special hand signals when using sling gear.............................................................................................................................................. 315
			2.16.3 Hand signals for object handling operation according to ASME/ANSI B30.5................................................................................................................. 318
	3 Control and operating elements....................................................................................................................................................................... 325
		3.1 Operating elements on undercarriage............................................................................................................................................................ 326
		3.2 Operating elements on uppercarriage............................................................................................................................................................ 327
		3.3 Cabin.......................................................................................................................................................................................... 328
		3.4 Left control lever............................................................................................................................................................................. 329
			3.4.1 Left control lever....................................................................................................................................................................... 329
		3.5 Right control lever............................................................................................................................................................................ 339
			3.5.1 Right control lever...................................................................................................................................................................... 339
			3.5.2 Right double T-lever..................................................................................................................................................................... 348
		3.6 Pedals and levers.............................................................................................................................................................................. 353
		3.7 Spirit level................................................................................................................................................................................... 355
		3.8 Control panel X11.............................................................................................................................................................................. 356
		3.9 Control panel X12.............................................................................................................................................................................. 358
		3.10 Control panel X22............................................................................................................................................................................. 360
		3.11 Control panel X22 for slurry wall grab HSG 5-18............................................................................................................................................... 362
		3.12 Control panel X23............................................................................................................................................................................. 365
		3.13 Control panel X25............................................................................................................................................................................. 370
		3.14 Monitor....................................................................................................................................................................................... 374
			3.14.1 Status bar.............................................................................................................................................................................. 374
			3.14.2 Display section......................................................................................................................................................................... 382
			3.14.3 Menu bar................................................................................................................................................................................ 382
			3.14.4 Submenu bar............................................................................................................................................................................. 384
		3.15 Start screen.................................................................................................................................................................................. 385
		3.16 Operation screen.............................................................................................................................................................................. 386
			3.16.1 Operation screen - lifting gear......................................................................................................................................................... 386
			3.16.2 Operation screen - dynamic soil compaction.............................................................................................................................................. 393
			3.16.3 Operation screen - vibrator............................................................................................................................................................. 395
			3.16.4 Operation screen - hammer............................................................................................................................................................... 397
			3.16.5 Operation screen - mechanical grab...................................................................................................................................................... 398
			3.16.6 Operation screen - hydraulic grab....................................................................................................................................................... 400
			3.16.7 Operation screen - slurry wall grab Leffer.............................................................................................................................................. 402
			3.16.8 Operation screen - slurry wall grab Soletanche Bachy.................................................................................................................................... 406
			3.16.9 Operation screen - slurry wall grab Kelly............................................................................................................................................... 407
			3.16.10 Operation screen - slurry wall grab HSG 5-18........................................................................................................................................... 408
			3.16.11 Operation screen - dragline............................................................................................................................................................ 409
		3.17 Power unit screen............................................................................................................................................................................. 411
		3.18 Operating hours screen........................................................................................................................................................................ 419
		3.19 Setup screen.................................................................................................................................................................................. 422
			3.19.1 Boom configuration screen............................................................................................................................................................... 424
			3.19.2 Boom configuration1 screen.............................................................................................................................................................. 425
			3.19.3 Load chart screen....................................................................................................................................................................... 429
		3.20 Working range limitation screen............................................................................................................................................................... 431
			3.20.1 Working range limitation screen......................................................................................................................................................... 431
			3.20.2 Lift height limitation screen........................................................................................................................................................... 436
			3.20.3 Lift height limitation for dragline screen.............................................................................................................................................. 438
		3.21 Information screen............................................................................................................................................................................ 440
			3.21.1 Winch1/winch2 screen.................................................................................................................................................................... 440
			3.21.2 Crawler and swing gear screen........................................................................................................................................................... 444
			3.21.3 Main boom winch screen.................................................................................................................................................................. 446
		3.22 Access control screen......................................................................................................................................................................... 447
			3.22.1 Without retrofit kit access control (black ignition keys)............................................................................................................................... 447
			3.22.2 Without retrofit kit access control (blue ignition keys)................................................................................................................................ 448
			3.22.3 With retrofit kit access control (red and blue ignition keys)*.......................................................................................................................... 449
		3.23 Mode screen................................................................................................................................................................................... 452
		3.24 Settings screen............................................................................................................................................................................... 455
			3.24.1 Settings screen......................................................................................................................................................................... 455
			3.24.2 Units screen............................................................................................................................................................................ 458
			3.24.3 Dynamic soil compaction screen.......................................................................................................................................................... 461
			3.24.4 Vibrator screen......................................................................................................................................................................... 463
			3.24.5 Hammer screen........................................................................................................................................................................... 464
			3.24.6 Mechanical grab screen.................................................................................................................................................................. 465
			3.24.7 Hydraulic grab screen................................................................................................................................................................... 468
			3.24.8 Slurry wall grab Leffer screen.......................................................................................................................................................... 471
			3.24.9 Slurry wall grab HSG 5-18 screen........................................................................................................................................................ 472
			3.24.10 Dragline screen........................................................................................................................................................................ 473
			3.24.11 Litronic test system screen............................................................................................................................................................ 475
		3.25 Error message screen.......................................................................................................................................................................... 479
		3.26 Radio remote control*......................................................................................................................................................................... 481
			3.26.1 Operating elements...................................................................................................................................................................... 482
			3.26.2 Monitor................................................................................................................................................................................. 487
		3.27 Cable remote control.......................................................................................................................................................................... 496
			3.27.1 Cable remote control on uppercarriage................................................................................................................................................... 496
			3.27.2 Cable remote control on undercarriage................................................................................................................................................... 496
			3.27.3 Cable remote control on cabin platform.................................................................................................................................................. 497
		3.28 Emergency control system*..................................................................................................................................................................... 499
		3.29 Auxiliary heating*............................................................................................................................................................................ 501
		3.30 Monitoring system*............................................................................................................................................................................ 502
			3.30.1 Quad monitor............................................................................................................................................................................ 502
			3.30.2 Control panel Zoom camera............................................................................................................................................................... 503
		3.31 Refueling pumps............................................................................................................................................................................... 505
			3.31.1 Control panel Fuel refueling pump....................................................................................................................................................... 505
			3.31.2 Control panel Urea refueling pump*...................................................................................................................................................... 506
		3.32 Central lubrication*.......................................................................................................................................................................... 507
		3.33 Additional headlights*........................................................................................................................................................................ 508
			3.33.1 Cabin................................................................................................................................................................................... 508
	4 Operation............................................................................................................................................................................................ 513
		4.1 Checks before startup.......................................................................................................................................................................... 513
			4.1.1 Inspecting machine....................................................................................................................................................................... 514
			4.1.2 Checking position of main battery switch................................................................................................................................................. 514
		4.2 Startup........................................................................................................................................................................................ 515
			4.2.1 Adjusting operator's seat................................................................................................................................................................ 515
			4.2.2 Switching on ignition.................................................................................................................................................................... 515
			4.2.3 Confirming existing setup................................................................................................................................................................ 515
			4.2.4 Checking fuel fill level................................................................................................................................................................. 516
			4.2.5 Checking urea solution fill level........................................................................................................................................................ 516
			4.2.6 Checking shut-off element Hydraulic oil tank............................................................................................................................................. 516
			4.2.7 Starting diesel engine................................................................................................................................................................... 517
			4.2.8 Adjusting rotational speed of diesel engine.............................................................................................................................................. 518
			4.2.9 Setting constant rotational speed........................................................................................................................................................ 520
			4.2.10 Releasing operating elements in the cabin............................................................................................................................................... 522
			4.2.11 Checking tilting-back support cylinder.................................................................................................................................................. 522
		4.3 Control panels................................................................................................................................................................................. 523
			4.3.1 Setting control panel X25* or control panel X26*......................................................................................................................................... 523
		4.4 Operator's seat................................................................................................................................................................................ 525
			4.4.1 Adjusting control stand horizontally..................................................................................................................................................... 526
			4.4.2 Adjusting operator's seat................................................................................................................................................................ 526
			4.4.3 Adjusting damping........................................................................................................................................................................ 530
			4.4.4 Adjusting ergonomics*.................................................................................................................................................................... 531
			4.4.5 Safety belt*............................................................................................................................................................................. 533
		4.5 Lighting....................................................................................................................................................................................... 534
			4.5.1 Operating the floodlights on the uppercarriage........................................................................................................................................... 534
			4.5.2 Operating additional floodlights......................................................................................................................................................... 534
			4.5.3 Operating cabin lighting................................................................................................................................................................. 535
			4.5.4 Operating the engine compartment lighting................................................................................................................................................ 535
		4.6 Windshield washer system....................................................................................................................................................................... 536
			4.6.1 Operating windshield wiper............................................................................................................................................................... 536
			4.6.2 Operating windshield washer system....................................................................................................................................................... 537
		4.7 Ventilation, heating and cooling............................................................................................................................................................... 538
			4.7.1 Setting air vent......................................................................................................................................................................... 540
			4.7.2 Adjusting lamella vents.................................................................................................................................................................. 541
			4.7.3 Setting recirculated air or fresh air.................................................................................................................................................... 541
			4.7.4 Operating ventilation.................................................................................................................................................................... 541
			4.7.5 Using heating............................................................................................................................................................................ 542
			4.7.6 Switching on or switching off air conditioner............................................................................................................................................ 542
			4.7.7 Operating external air conditioner*...................................................................................................................................................... 542
			4.7.8 Auxiliary heating*....................................................................................................................................................................... 550
		4.8 Additional cabin equipment..................................................................................................................................................................... 553
			4.8.1 Operating the signal horn................................................................................................................................................................ 553
			4.8.2 Operating the safety lever............................................................................................................................................................... 553
			4.8.3 Operating the radio...................................................................................................................................................................... 554
			4.8.4 Using the ashtray........................................................................................................................................................................ 555
			4.8.5 Using the cigarette lighter.............................................................................................................................................................. 556
		4.9 Cab tilting device*............................................................................................................................................................................ 557
			4.9.1 Operating the cab tilting device......................................................................................................................................................... 557
		4.10 Hydraulic cabin elevation..................................................................................................................................................................... 558
			4.10.1 Operating hydraulic cabin elevation..................................................................................................................................................... 558
		4.11 Central lubrication*.......................................................................................................................................................................... 561
			4.11.1 Set lubrication time.................................................................................................................................................................... 561
			4.11.2 Set pause time.......................................................................................................................................................................... 561
			4.11.3 Interim lubrication..................................................................................................................................................................... 561
		4.12 Mode.......................................................................................................................................................................................... 562
			4.12.1 Switching off assembly functions........................................................................................................................................................ 562
			4.12.2 Selecting mode.......................................................................................................................................................................... 562
		4.13 Setting setup................................................................................................................................................................................. 564
			4.13.1 Selecting setup screen.................................................................................................................................................................. 564
			4.13.2 Selecting and changing the basic machine configuration.................................................................................................................................. 565
			4.13.3 Selecting and changing the main boom configuration...................................................................................................................................... 566
			4.13.4 Selecting rope safety................................................................................................................................................................... 568
			4.13.5 Calculating load chart.................................................................................................................................................................. 569
			4.13.6 Exiting setup screen.................................................................................................................................................................... 570
		4.14 Load moment limitation (LML).................................................................................................................................................................. 571
			4.14.1 General................................................................................................................................................................................. 571
			4.14.2 Load moment limitation self-lock........................................................................................................................................................ 573
			4.14.3 Load moment limitation shut-down........................................................................................................................................................ 575
		4.15 Calculating load charts online................................................................................................................................................................ 577
			4.15.1 Calculating load chart.................................................................................................................................................................. 577
		4.16 Set the load capacity display to zero (taring)................................................................................................................................................ 578
			4.16.1 Setting the load display of winch1 or winch2 to zero.................................................................................................................................... 578
		4.17 Single hook operation/twin hook operation..................................................................................................................................................... 579
			4.17.1 Single hook operation with one winch on one load hook................................................................................................................................... 581
			4.17.2 Single hook operation with two winches on one load hook................................................................................................................................. 581
			4.17.3 Single hook operation with two winches on two load hooks................................................................................................................................ 582
			4.17.4 Twin hook operation with two load hooks on two loads.................................................................................................................................... 584
			4.17.5 Twin hook operation with two load hooks on one load..................................................................................................................................... 585
		4.18 Crawler....................................................................................................................................................................................... 587
			4.18.1 Setting the crawler speed*.............................................................................................................................................................. 587
			4.18.2 Operating the crawler................................................................................................................................................................... 587
			4.18.3 Locking or unlocking the crawler........................................................................................................................................................ 591
		4.19 Swing gear.................................................................................................................................................................................... 593
			4.19.1 Setting swing gear speed................................................................................................................................................................ 593
			4.19.2 Switching on or switching off swing gear free-turn...................................................................................................................................... 593
			4.19.3 Operating swing gear.................................................................................................................................................................... 594
			4.19.4 Locking or unlocking swing gear......................................................................................................................................................... 595
		4.20 Main boom..................................................................................................................................................................................... 597
			4.20.1 Selecting the speed level of boom adjustment............................................................................................................................................ 597
			4.20.2 Operating the main boom................................................................................................................................................................. 597
			4.20.3 Locking or unlocking the boom adjustment................................................................................................................................................ 601
		4.21 Winch1/winch2................................................................................................................................................................................. 602
			4.21.1 Operating winch1........................................................................................................................................................................ 602
			4.21.2 Operating winch2........................................................................................................................................................................ 604
			4.21.3 Locking or unlocking winch1/winch2...................................................................................................................................................... 606
		4.22 Free-fall operation*.......................................................................................................................................................................... 607
			4.22.1 Releasing free-fall operation........................................................................................................................................................... 607
			4.22.2 Releasing secured free-fall operation................................................................................................................................................... 608
			4.22.3 Releasing unsecured free-fall operation................................................................................................................................................. 608
			4.22.4 Switching on free-fall of winch1........................................................................................................................................................ 609
			4.22.5 Switching on free-fall of winch2........................................................................................................................................................ 611
			4.22.6 Operating secured free-fall operation................................................................................................................................................... 613
			4.22.7 Operating unsecured free-fall operation................................................................................................................................................. 615
			4.22.8 Switching off free-fall of winches...................................................................................................................................................... 617
			4.22.9 Locking free-fall operation............................................................................................................................................................. 617
			4.22.10 Interconnecting* pedals................................................................................................................................................................ 618
		4.23 Winch synchronization*........................................................................................................................................................................ 627
			4.23.1 Switching on winch synchronization...................................................................................................................................................... 627
			4.23.2 Operating winch synchronization......................................................................................................................................................... 628
			4.23.3 Switching off winch synchronization..................................................................................................................................................... 630
		4.24 Object handling mode.......................................................................................................................................................................... 631
			4.24.1 Selecting object handling mode.......................................................................................................................................................... 631
			4.24.2 Operating winch1........................................................................................................................................................................ 631
			4.24.3 Operating winch2........................................................................................................................................................................ 633
		4.25 Mechanical grab mode.......................................................................................................................................................................... 636
			4.25.1 Selecting mechanical grab mode.......................................................................................................................................................... 636
			4.25.2 Selecting winch1 or winch2 as hoisting winch............................................................................................................................................ 636
			4.25.3 Operating mechanical grab with winch synchronization.................................................................................................................................... 637
		4.26 Hydraulic grab mode........................................................................................................................................................................... 642
			4.26.1 Selecting hydraulic grab mode........................................................................................................................................................... 642
			4.26.2 Setting hydraulic grab.................................................................................................................................................................. 642
			4.26.3 Operating hydraulic grab................................................................................................................................................................ 643
		4.27 Hammer mode*.................................................................................................................................................................................. 650
			4.27.1 Hammer.................................................................................................................................................................................. 650
			4.27.2 Rigging hammer.......................................................................................................................................................................... 652
			4.27.3 Selecting hammer mode................................................................................................................................................................... 652
			4.27.4 Adjusting hammer........................................................................................................................................................................ 652
			4.27.5 Switching on hammer..................................................................................................................................................................... 653
			4.27.6 Adjusting delivery rate................................................................................................................................................................. 654
			4.27.7 Switching off hammer.................................................................................................................................................................... 654
		4.28 Dragline mode................................................................................................................................................................................. 655
			4.28.1 Selecting dragline mode................................................................................................................................................................. 655
			4.28.2 Setting position of dragline to zero.................................................................................................................................................... 655
			4.28.3 Interlock control*...................................................................................................................................................................... 656
		4.29 “Dynamic soil compaction” mode................................................................................................................................................................ 659
			4.29.1 Selecting “dynamic soil compaction” mode................................................................................................................................................ 660
			4.29.2 Selecting piling control for winch1 and/or winch2....................................................................................................................................... 661
			4.29.3 Setting piling control.................................................................................................................................................................. 662
			4.29.4 Switching on piling control............................................................................................................................................................. 663
			4.29.5 Switching off piling control............................................................................................................................................................ 663
			4.29.6 Stopping piling control................................................................................................................................................................. 664
			4.29.7 Resetting settings of piling control.................................................................................................................................................... 665
		4.30 Vibrator mode*................................................................................................................................................................................ 666
			4.30.1 Vibrator................................................................................................................................................................................ 666
			4.30.2 Selecting vibrator mode................................................................................................................................................................. 668
			4.30.3 Setting vibrator mode................................................................................................................................................................... 669
			4.30.4 Closing clamp........................................................................................................................................................................... 670
			4.30.5 Switching on vibrator mode.............................................................................................................................................................. 670
			4.30.6 Adjusting delivery rate................................................................................................................................................................. 671
			4.30.7 Adjusting eccentric..................................................................................................................................................................... 672
			4.30.8 Switching off vibrator.................................................................................................................................................................. 672
			4.30.9 Opening clamp........................................................................................................................................................................... 672
		4.31 Slurry wall grab mode Leffer*................................................................................................................................................................. 673
			4.31.1 Selecting slurry wall grab Leffer mode.................................................................................................................................................. 673
			4.31.2 Adjusting slurry wall grab Leffer....................................................................................................................................................... 673
			4.31.3 Operating hose drums and cable drum..................................................................................................................................................... 674
			4.31.4 Operating slurry wall grab mode Leffer.................................................................................................................................................. 675
			4.31.5 Slack rope cut-out...................................................................................................................................................................... 701
			4.31.6 Mooring free-fall....................................................................................................................................................................... 703
		4.32 Slurry wall grab Soletanche Bachy mode........................................................................................................................................................ 712
			4.32.1 Selecting slurry wall grab Soletanche Bachy mode........................................................................................................................................ 712
			4.32.2 Adjusting slurry wall grab Soletanche Bachy............................................................................................................................................. 712
			4.32.3 Operating slurry wall grab Soletanche Bachy............................................................................................................................................. 713
		4.33 Slurry wall grab Soilmec mode................................................................................................................................................................. 718
			4.33.1 Selecting slurry wall grab Soilmec mode................................................................................................................................................. 718
			4.33.2 Adjusting slurry wall grab Soilmec...................................................................................................................................................... 718
			4.33.3 Operating slurry wall grab Soilmec...................................................................................................................................................... 719
		4.34 Slurry wall grab HSG 5-18 mode................................................................................................................................................................ 726
			4.34.1 Selecting slurry wall grab HSG 5-18 mode................................................................................................................................................ 726
			4.34.2 Adjusting slurry wall grab HSG 5-18..................................................................................................................................................... 726
			4.34.3 Operating hose drum..................................................................................................................................................................... 727
			4.34.4 Operating main boom..................................................................................................................................................................... 728
			4.34.5 Operating “slurry wall grab HSG 5-18”................................................................................................................................................... 730
		4.35 Casing oscillator*............................................................................................................................................................................ 734
			4.35.1 Connecting the casing oscillator........................................................................................................................................................ 734
			4.35.2 Activating and deactivating the casing oscillator - standard mode (without ecological control*)......................................................................................... 735
			4.35.3 Activating and deactivating the casing oscillator - standard mode (with ecological control*)............................................................................................ 735
			4.35.4 Activating and deactivating the casing oscillator - ecological mode (with ecological control*).......................................................................................... 735
			4.35.5 Adjusting the casing oscillator......................................................................................................................................................... 736
		4.36 Lowering control.............................................................................................................................................................................. 737
			4.36.1 Switching on lowering control........................................................................................................................................................... 737
			4.36.2 Operating the lowering control.......................................................................................................................................................... 737
			4.36.3 Switching off lowering control.......................................................................................................................................................... 739
		4.37 “GRAB MATIC” assistance system*............................................................................................................................................................... 740
			4.37.1 Setting grab geometry................................................................................................................................................................... 741
			4.37.2 Setting slack rope cut-out.............................................................................................................................................................. 743
			4.37.3 Setting reference point for rope measuring system....................................................................................................................................... 743
			4.37.4 Switching on or switching off slack rope cut-out........................................................................................................................................ 743
			4.37.5 Setting insertion depth................................................................................................................................................................. 744
			4.37.6 Switching on or switching off maximum grab depth........................................................................................................................................ 747
			4.37.7 Operating mechanical grab............................................................................................................................................................... 748
			4.37.8 Operating hydraulic grab................................................................................................................................................................ 748
			4.37.9 Operating grab with alternative control lever assignment................................................................................................................................ 748
		4.38 Load recorder*................................................................................................................................................................................ 753
			4.38.1 Setting trigger points.................................................................................................................................................................. 753
			4.38.2 Operating load recorder................................................................................................................................................................. 753
		4.39 Working range limitation...................................................................................................................................................................... 756
			4.39.1 Operating edge limitation............................................................................................................................................................... 756
			4.39.2 Operating sector limitation............................................................................................................................................................. 758
			4.39.3 Operating radius limitation............................................................................................................................................................. 759
			4.39.4 Operating swing range limitation........................................................................................................................................................ 762
			4.39.5 Operating lift height limitation........................................................................................................................................................ 763
			4.39.6 Operating lift height limitation for dragline........................................................................................................................................... 765
			4.39.7 Unlocking swing gear and boom after operating crawler................................................................................................................................... 767
			4.39.8 Resetting working range limitations..................................................................................................................................................... 767
		4.40 Rope reeving winch............................................................................................................................................................................ 768
			4.40.1 Setting the rope reeving winch to free-wheel............................................................................................................................................ 768
			4.40.2 Deactivating rope reeving winch free-fall............................................................................................................................................... 769
			4.40.3 Reeving the rope of the rope reeving winch.............................................................................................................................................. 769
		4.41 Tagline winch*................................................................................................................................................................................ 770
			4.41.1 Putting tagline winch into operation.................................................................................................................................................... 770
			4.41.2 Switching on or switching off tagline winch............................................................................................................................................. 772
			4.41.3 Switching on or switching off tagline winch in assembly function........................................................................................................................ 772
			4.41.4 Setting constant tension of tagline winch............................................................................................................................................... 772
			4.41.5 Setting pulling force of tagline winch.................................................................................................................................................. 773
			4.41.6 Switching on or switching off max. pulling force of tagline winch....................................................................................................................... 774
			4.41.7 Switching on or switching off tagline winch free-turn................................................................................................................................... 774
			4.41.8 Decommissioning tagline winch........................................................................................................................................................... 775
		4.42 Radio remote control*......................................................................................................................................................................... 776
			4.42.1 Battery................................................................................................................................................................................. 776
			4.42.2 Battery charger......................................................................................................................................................................... 776
			4.42.3 Starting machine with radio remote control.............................................................................................................................................. 778
		4.43 Constant pull winch1 and winch2............................................................................................................................................................... 784
			4.43.1 Operating constant pull................................................................................................................................................................. 784
		4.44 Refueling machine............................................................................................................................................................................. 786
			4.44.1 Refueling with fuel from tank vehicle................................................................................................................................................... 786
			4.44.2 Filling machine with fuel from fuel refueling pump...................................................................................................................................... 787
			4.44.3 Filling up with urea solution*.......................................................................................................................................................... 788
			4.44.4 Filling up with urea solution* with urea refueling pump*................................................................................................................................ 789
		4.45 Inclination display........................................................................................................................................................................... 791
			4.45.1 Operating the inclinometer.............................................................................................................................................................. 791
		4.46 Verticality assistant* for slurry wall grab................................................................................................................................................... 792
			4.46.1 Charging verticality sensor............................................................................................................................................................. 792
			4.46.2 Attaching verticality sensor to slurry wall grab........................................................................................................................................ 794
		4.47 Rope measuring system*........................................................................................................................................................................ 797
			4.47.1 Initializing rope measuring system...................................................................................................................................................... 797
			4.47.2 Programming layer change................................................................................................................................................................ 797
		4.48 Automatic stop system of diesel engine*....................................................................................................................................................... 799
			4.48.1 Switching on or switching off automatic stop system of diesel engine.................................................................................................................... 799
		4.49 ECO mode*..................................................................................................................................................................................... 801
			4.49.1 ECO mode operation...................................................................................................................................................................... 801
		4.50 Sensitive lift*............................................................................................................................................................................... 802
			4.50.1 Switching on or switching off sensitive lift............................................................................................................................................ 802
			4.50.2 Operating sensitive lift................................................................................................................................................................ 802
		4.51 Emergency stop................................................................................................................................................................................ 803
			4.51.1 Using emergency stop.................................................................................................................................................................... 803
		4.52 Shutdown...................................................................................................................................................................................... 805
			4.52.1 Short work interruption................................................................................................................................................................. 805
			4.52.2 Long work interruption.................................................................................................................................................................. 806
			4.52.3 Switching off main battery switch....................................................................................................................................................... 807
		4.53 Hydraulic emergency mode*..................................................................................................................................................................... 808
			4.53.1 Winch 2 emergency mode.................................................................................................................................................................. 808
			4.53.2 Main boom adjusting winch emergency mode................................................................................................................................................ 810
			4.53.3 Swing emergency mode.................................................................................................................................................................... 811
		4.54 Emergency control system*..................................................................................................................................................................... 814
			4.54.1 Operating the emergency control system.................................................................................................................................................. 814
		4.55 Disposal...................................................................................................................................................................................... 815
			4.55.1 Disposing of machine.................................................................................................................................................................... 815
	5 Operational faults, diagnosis........................................................................................................................................................................ 819
		5.1 Malfunctions................................................................................................................................................................................... 819
			5.1.1 Detecting errors......................................................................................................................................................................... 819
			5.1.2 Error displays on monitor................................................................................................................................................................ 820
			5.1.3 Troubleshooting.......................................................................................................................................................................... 823
		5.2 Litronic testing system........................................................................................................................................................................ 825
			5.2.1 Litronic test system overview............................................................................................................................................................ 825
			5.2.2 Screens.................................................................................................................................................................................. 826
			5.2.3 Starting the Litronic testing system..................................................................................................................................................... 832
		5.3 Fuses.......................................................................................................................................................................................... 833
			5.3.1 List of fuses............................................................................................................................................................................ 833
			5.3.2 Checking fuses........................................................................................................................................................................... 835
			5.3.3 Changing fuses........................................................................................................................................................................... 837
	6 Operational planning................................................................................................................................................................................. 841
		6.1 Assembly site.................................................................................................................................................................................. 841
		6.2 Tools required................................................................................................................................................................................. 842
			6.2.1 Assembling the machine with the self-assembly system..................................................................................................................................... 842
			6.2.2 Assembling the machine without the self-assembly system.................................................................................................................................. 842
		6.3 Positioning load hook or pulley block.......................................................................................................................................................... 843
		6.4 Restrictions due to wind....................................................................................................................................................................... 844
			6.4.1 Reducing the load........................................................................................................................................................................ 844
			6.4.2 Lay down boom............................................................................................................................................................................ 844
		6.5 Traveling on gradients......................................................................................................................................................................... 845
			6.5.1 Permitted gradient for main boom 1311.24 (+ auxiliary jib*).............................................................................................................................. 846
		6.6 Lifting accessory and sling gear............................................................................................................................................................... 848
	7 Assembly and dismantling............................................................................................................................................................................. 851
		7.1 Explanation of symbols used.................................................................................................................................................................... 851
		7.2 Implementing provisions for assembly/disassembly............................................................................................................................................... 853
		7.3 Locking elements overview...................................................................................................................................................................... 854
			7.3.1 Split pin................................................................................................................................................................................ 854
			7.3.2 Linchpin................................................................................................................................................................................. 855
			7.3.3 Spring cotter pin........................................................................................................................................................................ 856
			7.3.4 Locking spring........................................................................................................................................................................... 857
			7.3.5 Locking washers.......................................................................................................................................................................... 859
			7.3.6 Self-locking nuts........................................................................................................................................................................ 860
		7.4 Assembling the basic machine................................................................................................................................................................... 861
			7.4.1 Accessing cabin with ladder.............................................................................................................................................................. 861
			7.4.2 Moving cabin platforms* into working position............................................................................................................................................ 862
			7.4.3 Moving the platforms into working position............................................................................................................................................... 866
			7.4.4 Moving electrohydraulic platforms* into working position................................................................................................................................. 871
			7.4.5 Mounting the ladder on the uppercarriage................................................................................................................................................. 879
			7.4.6 Mounting uppercarriage handrail.......................................................................................................................................................... 880
			7.4.7 Putting the load moment limiter lamp and flashing light into working position............................................................................................................ 887
			7.4.8 Fitting the exhaust pipe................................................................................................................................................................. 887
			7.4.9 Checking the position of the bypass plug................................................................................................................................................. 890
			7.4.10 Putting the machine into operation...................................................................................................................................................... 891
			7.4.11 Switching on assembly functions......................................................................................................................................................... 891
			7.4.12 Switching on cylinder adjustment functions.............................................................................................................................................. 892
			7.4.13 Extend the tilting back support cylinders............................................................................................................................................... 892
			7.4.14 Remove round sling between boom base section and A-frame 1.............................................................................................................................. 892
			7.4.15 Erecting A-frame1....................................................................................................................................................................... 892
			7.4.16 Removing the uppercarriage locking device............................................................................................................................................... 894
			7.4.17 Stow away uppercarriage locking device.................................................................................................................................................. 895
			7.4.18 Unloading basic machine with mounted crawler side frames................................................................................................................................ 896
			7.4.19 Unloading basic machine without mounted crawler side frames............................................................................................................................. 904
			7.4.20 Using the machine as assembly crane..................................................................................................................................................... 932
			7.4.21 Attaching carbody counterweight......................................................................................................................................................... 934
			7.4.22 Fitting the rear counterweight.......................................................................................................................................................... 939
		7.5 Main boom 1311.24.............................................................................................................................................................................. 949
			7.5.1 Configuration of main boom............................................................................................................................................................... 949
			7.5.2 Overview of main boom 1311.24 pendant ropes.............................................................................................................................................. 950
			7.5.3 Reeving plan for object handling operation............................................................................................................................................... 951
			7.5.4 Reeving diagram grab mode................................................................................................................................................................ 957
			7.5.5 Reeving diagram dragline bucket mode..................................................................................................................................................... 958
		7.6 Assembling the main boom....................................................................................................................................................................... 960
			7.6.1 Programming the setup.................................................................................................................................................................... 960
			7.6.2 Unloading and positioning the main boom components....................................................................................................................................... 960
			7.6.3 Pinning main boom components............................................................................................................................................................. 961
			7.6.4 Installing hoist rope tagline............................................................................................................................................................ 964
			7.6.5 Pinning the pendant ropes................................................................................................................................................................ 966
			7.6.6 Pinning main boom base section to main boom.............................................................................................................................................. 966
			7.6.7 Pinning base of pendant straps on A-frame1 to main boom pendant ropes.................................................................................................................... 969
			7.6.8 Installing the auxiliary jib ( 25 t) on the main boom head............................................................................................................................... 970
			7.6.9 Connect the electric cables.............................................................................................................................................................. 975
			7.6.10 Installing the obstacle warning light................................................................................................................................................... 975
			7.6.11 Installing anemometer................................................................................................................................................................... 977
			7.6.12 Installing bracket of hoist limit switch................................................................................................................................................ 979
			7.6.13 Rope reeving............................................................................................................................................................................ 980
			7.6.14 Installing the rope fixing point........................................................................................................................................................ 980
			7.6.15 Installing weight of hoist limit switch................................................................................................................................................. 982
			7.6.16 Erecting the main boom.................................................................................................................................................................. 985
			7.6.17 Switching off assembly functions........................................................................................................................................................ 988
			7.6.18 Checking the main boom limit switch plate for proper adjustment......................................................................................................................... 989
		7.7 Short boom..................................................................................................................................................................................... 991
			7.7.1 Short boom 1311.22....................................................................................................................................................................... 991
			7.7.2 Short boom 1307.24....................................................................................................................................................................... 995
			7.7.3 Short boom 1307.24 with short boom-A-frame1.............................................................................................................................................. 997
		7.8 Assembling short boom..........................................................................................................................................................................1000
			7.8.1 Pinning main boom base section to short boom.............................................................................................................................................1000
			7.8.2 Pinning base of pendant straps on A-frame1 to short boom pendant ropes...................................................................................................................1001
		7.9 Adjusting the track............................................................................................................................................................................1004
			7.9.1 Preparing the machine....................................................................................................................................................................1004
			7.9.2 Adjusting track from narrow to wide......................................................................................................................................................1005
			7.9.3 Converting from narrow to wide track.....................................................................................................................................................1010
			7.10.1 Grab rope guide.........................................................................................................................................................................1011
		7.11 Fixed cabin elevation.........................................................................................................................................................................1013
			7.11.1 Moving fixed cabin elevation to working position........................................................................................................................................1013
			7.11.2 Moving fixed cabin elevation into transport position....................................................................................................................................1019
		7.12 Vandalism protection*.........................................................................................................................................................................1020
			7.12.1 Installing the vandalism protection.....................................................................................................................................................1020
		7.13 Assembling the machine without a self-assembly system.........................................................................................................................................1022
			7.13.1 Specific procedure when no jacks are available..........................................................................................................................................1022
			7.13.2 Specific procedure with no counterweight hoisting cylinder..............................................................................................................................1022
			7.13.3 Specific procedure with no assembly cylinder............................................................................................................................................1024
		7.14 Disassembling main boom.......................................................................................................................................................................1025
			7.14.1 Brief summary...........................................................................................................................................................................1025
		7.15 Disassembling basic machine...................................................................................................................................................................1028
			7.15.1 Brief summary...........................................................................................................................................................................1028
	8 Transport............................................................................................................................................................................................1031
		8.1 Loading the basic machine with an assist crane.................................................................................................................................................1031
			8.1.1 Loading basic machine with crawler side frame, carbody counterweight and rear counterweight 17.3 t.......................................................................................1032
			8.1.2 Loading the basic machine with crawler side frame, without carbody counterweight and rear counterweight..................................................................................1033
			8.1.3 Loading the basic machine without crawler side frame, carbody counterweight and rear counterweight.......................................................................................1035
		8.2 Driving the basic machine onto the transport vehicle...........................................................................................................................................1038
		8.3 Transporting the basic machine with a transport vehicle........................................................................................................................................1039
			8.3.1 Transporting the basic machine with crawler side frame with a transport vehicle..........................................................................................................1039
			8.3.2 Transporting the basic machine with crawler side frame with a transport vehicle..........................................................................................................1041
			8.3.3 Transporting the basic machine without crawler side frame with a transport vehicle.......................................................................................................1044
		8.4 Transporting boom components...................................................................................................................................................................1047
			8.4.1 Inserting pins into transport brackets...................................................................................................................................................1047
			8.4.2 Lashing pendant ropes in transport position..............................................................................................................................................1048
			8.4.3 Moving rope bracket into transport position..............................................................................................................................................1048
	9 Maintenance..........................................................................................................................................................................................1051
		9.1 Maintenance and inspection schedule............................................................................................................................................................1051
		9.2 Lubricants and consumables.....................................................................................................................................................................1065
			9.2.1 Lubrication diagram......................................................................................................................................................................1066
			9.2.2 Filling capacity table...................................................................................................................................................................1068
			9.2.3 Lubricant table..........................................................................................................................................................................1069
			9.2.4 Lubricant for diesel engine..............................................................................................................................................................1072
			9.2.5 Fuel.....................................................................................................................................................................................1072
			9.2.6 Urea solution............................................................................................................................................................................1072
			9.2.7 Diesel engine coolant....................................................................................................................................................................1073
			9.2.8 Hydraulic oil............................................................................................................................................................................1073
			9.2.9 Preservation medium (anti-corrosion coating).............................................................................................................................................1074
			9.2.10 Liebherr oil analysis set...............................................................................................................................................................1076
		9.3 Work instructions for preventive maintenance...................................................................................................................................................1078
		9.4 Diesel engine D934/D936/D944/D946 A7-04 (see operator's manual of the engine manufacturer on CD)...............................................................................................1080
			9.4.1 Checking motor oil level.................................................................................................................................................................1080
		9.5 Diesel engine D934/D936/D944/D946 A7-00 or D934/D936/D944/D946 A7-03 (see operator's manual of the engine manufacturer on CD)..................................................................1081
			9.5.1 Checking motor oil level.................................................................................................................................................................1081
		9.6 Fuel tank......................................................................................................................................................................................1082
			9.6.1 Draining water and sediments.............................................................................................................................................................1082
		9.7 Air filter system..............................................................................................................................................................................1083
			9.7.1 Checking for function of negative pressure indicator.....................................................................................................................................1083
			9.7.2 Cleaning the dust extraction valve of air filter.........................................................................................................................................1083
			9.7.3 Exchanging dry air filter main element and dry air filter safety element.................................................................................................................1084
		9.8 Exhaust aftertreatment system* (see operator's manual of the engine manufacturer on CD)........................................................................................................1086
			9.8.1 Checking air tanks for condensation......................................................................................................................................................1086
			9.8.2 Replacing cartridge of air dryer.........................................................................................................................................................1086
		9.9 Distribution gearbox...........................................................................................................................................................................1089
			9.9.1 Checking the gearbox oil level...........................................................................................................................................................1089
			9.9.2 Topping up gearbox oil...................................................................................................................................................................1090
			9.9.3 Checking the venting valve...............................................................................................................................................................1091
		9.10 Swing gear....................................................................................................................................................................................1092
			9.10.1 Checking gearbox oil level..............................................................................................................................................................1092
			9.10.2 Topping up gearbox oil..................................................................................................................................................................1092
		9.11 Rotary joint..................................................................................................................................................................................1094
			9.11.1 Lubricating external teeth..............................................................................................................................................................1094
			9.11.2 Lubricating the bearing races via the central lubrication point.........................................................................................................................1094
		9.12 Winch1/winch2.................................................................................................................................................................................1096
			9.12.1 Checking the gearbox oil level..........................................................................................................................................................1096
			9.12.2 Topping up gearbox oil..................................................................................................................................................................1097
			9.12.3 Lubricating counter bearings............................................................................................................................................................1097
			9.12.4 Checking the rope end fastening for tight fit...........................................................................................................................................1098
		9.13 Boom luffing winches..........................................................................................................................................................................1099
			9.13.1 Checking gearbox oil level..............................................................................................................................................................1099
			9.13.2 Topping up gearbox oil..................................................................................................................................................................1100
			9.13.3 Lubricating counter bearings............................................................................................................................................................1100
			9.13.4 Checking rope end fastening for tight fit...............................................................................................................................................1101
		9.14 Rope reeving winch............................................................................................................................................................................1102
			9.14.1 Lubricating the counter bearing.........................................................................................................................................................1102
			9.14.2 Checking rope end attachment for tight fit when starting up rope reeving winch..........................................................................................................1102
		9.15 Tagline winch.................................................................................................................................................................................1103
			9.15.1 Checking the gearbox oil level..........................................................................................................................................................1103
			9.15.2 Topping up the gearbox oil..............................................................................................................................................................1104
			9.15.3 Lubricating the rope bracket on the boom base section and checking pulleys for damage...................................................................................................1104
			9.15.4 Checking the rope end fastening for tight fit...........................................................................................................................................1105
		9.16 Crawler.......................................................................................................................................................................................1106
			9.16.1 Checking gearbox oil level..............................................................................................................................................................1106
			9.16.2 Checking gearbox and hydraulic screw connections for leak tightness.....................................................................................................................1107
			9.16.3 Cleaning crawler........................................................................................................................................................................1107
			9.16.4 Checking locking screws of struts on crawler side frames for tight fit on telescopic undercarriages.....................................................................................1107
			9.16.5 Checking chain tension..................................................................................................................................................................1109
			9.16.6 Adjusting chain tension.................................................................................................................................................................1110
			9.16.7 Retightening chain......................................................................................................................................................................1111
			9.16.8 Relaxing chain..........................................................................................................................................................................1112
			9.16.9 Tightening base plate screws............................................................................................................................................................1113
			9.16.10 Checking locking screws of track pads axes.............................................................................................................................................1114
		9.17 Sling gear....................................................................................................................................................................................1115
			9.17.1 Checking transport lashing und round sling for wear (in accordance with EN 1492-2)......................................................................................................1115
			9.17.2 Checking round steel chains for wear and damage.........................................................................................................................................1115
		9.18 Hook/pulley block.............................................................................................................................................................................1116
			9.18.1 Checking all hooks/pulley blocks for damage, wear, corrosion and widening of the hook aperture..........................................................................................1116
			9.18.2 Lubricating bearings and axels..........................................................................................................................................................1116
			9.18.3 Check that the safety catch is present and working properly.............................................................................................................................1117
		9.19 Hydraulic system..............................................................................................................................................................................1118
			9.19.1 Checking hydraulic system for leak tightness............................................................................................................................................1118
			9.19.2 Checking hydraulic oil cooler for contamination.........................................................................................................................................1118
			9.19.3 Changing pressure filter................................................................................................................................................................1119
		9.20 Hydraulic oil tank............................................................................................................................................................................1121
			9.20.1 Checking hydraulic oil level in hydraulic oil tank using sight glasses..................................................................................................................1121
			9.20.2 Carrying out hydraulic oil analysis.....................................................................................................................................................1124
			9.20.3 Fill in hydraulic oil through return filter.............................................................................................................................................1124
			9.20.4 Draining hydraulic oil..................................................................................................................................................................1125
			9.20.5 Cleaning magnetic rod in return filter..................................................................................................................................................1126
			9.20.6 Exchanging return filter................................................................................................................................................................1128
		9.21 Hydraulic cylinder............................................................................................................................................................................1130
			9.21.1 Checking hydraulic cylinder for leak tightness and tight fit............................................................................................................................1130
			9.21.2 Protecting piston rods of hydraulic cylinders from corrosion............................................................................................................................1130
			9.21.3 Preserving piston rods of hydraulic cylinders in case of longer periods of standstill...................................................................................................1130
		9.22 Hydraulic lines...............................................................................................................................................................................1131
			9.22.1 Visual inspection of hydraulic lines (hydraulic hoses, hydraulic pipes).................................................................................................................1131
		9.23 Bypass filter system..........................................................................................................................................................................1132
			9.23.1 Checking the bypass filter system.......................................................................................................................................................1132
			9.23.2 Changing the filter elements............................................................................................................................................................1132
		9.24 Electrical system.............................................................................................................................................................................1135
			9.24.1 Checking cable guides and cable connections for chafe marks.............................................................................................................................1135
		9.25 Batteries.....................................................................................................................................................................................1136
			9.25.1 Checking fill level of battery..........................................................................................................................................................1136
		9.26 Lighting......................................................................................................................................................................................1138
			9.26.1 Checking that the cabin lighting, floodlights and auxiliary floodlights are working properly............................................................................................1138
			9.26.2 Changing the cab lamp light bulb........................................................................................................................................................1138
			9.26.3 Changing the bulbs of floodlights on the cabin and on the uppercarriage.................................................................................................................1138
			9.26.4 Changing the bulbs of floodlights on main boom base section.............................................................................................................................1141
		9.27 Rope measuring system.........................................................................................................................................................................1145
			9.27.1 Checking rope measuring system and height adjustment of all winches (if available) for correct function.................................................................................1145
			9.27.2 Readjusting layer change when changing ropes............................................................................................................................................1145
		9.28 Limit switches................................................................................................................................................................................1146
			9.28.1 Checking hoist limit switches, boom limit switches and, if necessary, limit switches of the piling and drilling rig to ensure they are working correctly................................1146
		9.29 Mechanical inclinometer.......................................................................................................................................................................1147
			9.29.1 Checking that the mechanical inclinometer is working properly...........................................................................................................................1147
		9.30 Emergency stop................................................................................................................................................................................1148
			9.30.1 Checking for function emergency stop....................................................................................................................................................1148
		9.31 Aircraft warning light*.......................................................................................................................................................................1149
			9.31.1 Checking aircraft warning light for function and damage, check mains cable and plug (if available) for damage...........................................................................1149
		9.32 Fire extinguisher.............................................................................................................................................................................1150
			9.32.1 Checking seals and inspection due dates on fire extinguishers...........................................................................................................................1150
		9.33 Personal protective equipment.................................................................................................................................................................1151
			9.33.1 Checking personal protective gear.......................................................................................................................................................1151
		9.34 Safety sign...................................................................................................................................................................................1152
			9.34.1 Checking safety signs on machine for completeness, damage and legibility................................................................................................................1152
		9.35 Access systems and railings...................................................................................................................................................................1153
			9.35.1 Checking ladders, steps, platforms, and ascents for wear, damage and anti-slip surfaces.................................................................................................1153
			9.35.2 Checking latches and hand rails for wear and damage.....................................................................................................................................1153
			9.35.3 Checking the spring tension of railing doors............................................................................................................................................1153
			9.35.4 Setting the spring tension of railing doors.............................................................................................................................................1154
			9.35.5 Checking the function of the railing stabilization......................................................................................................................................1156
		9.36 Steel structure...............................................................................................................................................................................1158
			9.36.1 Checking the machine steel structure for damage, cracks.................................................................................................................................1158
			9.36.2 Repairs on the steel structure..........................................................................................................................................................1159
		9.37 Main boom.....................................................................................................................................................................................1161
			9.37.1 Checking main boom base section, main boom section und main boom head for damage und wear...............................................................................................1161
			9.37.2 Main boom base section: checking knuckle pin and locking elements for tight fit.........................................................................................................1162
			9.37.3 Main boom base section: lubricating knuckle pin.........................................................................................................................................1162
			9.37.4 Main boom base section or A-frame1: Checking function of mechanical angle indicator for boom............................................................................................1164
			9.37.5 Checking main boom head for function and damage.........................................................................................................................................1165
			9.37.6 Checking anemometer and hoist limit switch for function and tight fit...................................................................................................................1165
			9.37.7 Checking auxiliary jib for function and damage..........................................................................................................................................1166
			9.37.8 Checking components on main boom for tight fit; checking that screws, pins and locking elements are present and not damaged.............................................................1167
		9.38 A-frame1......................................................................................................................................................................................1168
			9.38.1 Checking A-frame 1......................................................................................................................................................................1168
			9.38.2 Lubricating the bearings on A-frame 1...................................................................................................................................................1168
		9.39 Steel pendant straps..........................................................................................................................................................................1170
			9.39.1 Checking steel pendant straps and pins for damage and wear and check that locking springs and split pins are present....................................................................1170
			9.39.2 Checking the ease of movement of pin connections in the entire pendant strap strand.....................................................................................................1171
			9.39.3 Protecting steel pendant straps, connecting links and pins from corrosion...............................................................................................................1171
			9.39.4 Checking connecting links for damage and wear...........................................................................................................................................1171
			9.39.5 Checking tension load cells for damage and wear, checking electricity connections for tight fit.........................................................................................1171
		9.40 Pendant ropes.................................................................................................................................................................................1173
			9.40.1 Performing visual inspection of pendant rope deterioration or mechanical damage.........................................................................................................1173
			9.40.2 Checking tension load cells for damage and wear, checking electricity connections for tight fit.........................................................................................1173
			9.40.3 Checking pendant ropes for end of service life..........................................................................................................................................1173
			9.40.4 Protecting pendant ropes, end terminations and pins against corrosion...................................................................................................................1178
			9.40.5 Replacing pendant ropes (after 6000 h or after 5 years).................................................................................................................................1178
		9.41 Counterweight.................................................................................................................................................................................1179
			9.41.1 Checking tension rod screw lock for correct position / color coding.....................................................................................................................1179
			9.41.2 Checking the screws of the rear counterweight tie-down for tight fit....................................................................................................................1179
			9.41.3 Checking the rear counterweight, fixing lugs and round steel chains for damage, wear and secure fit.....................................................................................1180
			9.41.4 Checking locking elements for availability, damage, wear and tight fit..................................................................................................................1180
			9.41.5 Checking the function of the pin connection cylinder and limit switch (if available)....................................................................................................1180
			9.41.6 Checking counterweight supports (pins, link plates) for damage and wear.................................................................................................................1180
		9.42 Lubrication system............................................................................................................................................................................1181
			9.42.1 Checking the operation of the central lubrication for the swing ring tooth flanks.......................................................................................................1181
			9.42.2 Checking the operation of the central lubrication for the swing ring bearing............................................................................................................1182
			9.42.3 Checking the fill level of the lubrication pumps........................................................................................................................................1182
			9.42.4 Checking the time intervals of the lubrication pumps....................................................................................................................................1183
			9.42.5 Checking the lubrication points.........................................................................................................................................................1183
		9.43 Ropes and end connections.....................................................................................................................................................................1184
			9.43.1 Structure of a rope.....................................................................................................................................................................1184
			9.43.2 Visual inspection of ropes and end connections for deterioration of condition or mechanical damage......................................................................................1184
			9.43.3 Checking ropes for lubrication..........................................................................................................................................................1184
			9.43.4 Lubricating ropes.......................................................................................................................................................................1185
			9.43.5 Checking ropes and end connections for discard criteria.................................................................................................................................1185
			9.43.6 Storing ropes...........................................................................................................................................................................1198
			9.43.7 Transporting ropes......................................................................................................................................................................1198
			9.43.8 Selecting a rope........................................................................................................................................................................1199
			9.43.9 Unwinding rope from rope reel...........................................................................................................................................................1201
			9.43.10 Laying on rope.........................................................................................................................................................................1203
		9.44 Rope drum.....................................................................................................................................................................................1214
			9.44.1 Checking rope tensioning pulleys* of rope drum for wear.................................................................................................................................1214
			9.44.2 Checking groove diameter of rope drum...................................................................................................................................................1214
			9.44.3 Checking rope drum for slack rope layers................................................................................................................................................1215
		9.45 Rope pulleys..................................................................................................................................................................................1216
			9.45.1 Structure of a rope pulley..............................................................................................................................................................1216
			9.45.2 Checking groove diameter of rope pulley.................................................................................................................................................1216
			9.45.3 Checking bottom of groove diameter of rope pulley.......................................................................................................................................1217
			9.45.4 Checking web width of rope pulley.......................................................................................................................................................1218
			9.45.5 Checking bottom of groove of rope pulley for sharp edges................................................................................................................................1219
			9.45.6 Checking rope pulleys for damage........................................................................................................................................................1219
			9.45.7 Checking rope pulley bearings...........................................................................................................................................................1220
			9.45.8 Lubricating rope pulley bearings........................................................................................................................................................1220
			9.45.9 Checking position of bearing and locking ring...........................................................................................................................................1220
			9.45.10 Cleaning plastic rope pulley...........................................................................................................................................................1221
		9.46 Rope suspension and rope attachment...........................................................................................................................................................1222
			9.46.1 Checking rope suspensions (rope clamps, rope thimbles) for wire breaks, absence of corrosion and tight fit of screw connections.........................................................1222
			9.46.2 Checking pocket locks...................................................................................................................................................................1223
			9.46.3 Checking pressed termination for cracks.................................................................................................................................................1224
			9.46.4 Checking rope fixing point..............................................................................................................................................................1225
		9.47 Cabin.........................................................................................................................................................................................1226
			9.47.1 Removing cabin roof protection guard or fixed falling object protection*................................................................................................................1226
			9.47.2 Opening foldable falling object protection*.............................................................................................................................................1227
			9.47.3 Checking windows of cabin for damage....................................................................................................................................................1227
			9.47.4 Cleaning cabin windows..................................................................................................................................................................1228
			9.47.5 Checking function of cabin door and door lock...........................................................................................................................................1228
			9.47.6 Checking cabin roof protection guard or falling object protection* for damage and locking in case of foldable falling object protection.................................................1229
			9.47.7 Lubricating falling object protection*..................................................................................................................................................1230
			9.47.8 Replacing windshield wiper..............................................................................................................................................................1230
			9.47.9 Filling windshield washer system........................................................................................................................................................1231
			9.47.10 Checking exterior mirrors and interior mirrors for damage..............................................................................................................................1232
			9.47.11 Checking hydraulic cabin tilting device for function and damage........................................................................................................................1232
			9.47.12 Checking hydraulic cabin elevation for function and damage.............................................................................................................................1233
			9.47.13 Cleaning or replacing filter insert in cabin...........................................................................................................................................1234
		9.48 Ventilation, heating and cooling..............................................................................................................................................................1236
			9.48.1 Checking recirculated air filter for contamination......................................................................................................................................1236
			9.48.2 Replacing recirculated air filter.......................................................................................................................................................1240
			9.48.3 Checking fresh air filter for contamination.............................................................................................................................................1245
			9.48.4 Replacing fresh air filter..............................................................................................................................................................1246
			9.48.5 Checking coolant filling in sight glass.................................................................................................................................................1250
			9.48.6 Checking condenser for contamination....................................................................................................................................................1251
			9.48.7 Checking condenser for loose leads, loos screws and corrosion...........................................................................................................................1252
			9.48.8 Checking fan on condenser for function, tight fit and damage............................................................................................................................1252
			9.48.9 Checking climatic box for contamination.................................................................................................................................................1253
			9.48.10 Checking dryer for damage and corrosion................................................................................................................................................1254
			9.48.11 Starting ventilation, heating, air conditioner, external air conditioner* and auxiliary heating system* and ensuring that sufficient antifreeze has been added to the water circuit....1254
			9.48.12 Replacing fuel filter of auxiliary water heating*......................................................................................................................................1257
		9.49 Slurry wall grab..............................................................................................................................................................................1259
			9.49.1 Check correct function of slurry wall grab..............................................................................................................................................1259
		9.50 Hoses, cables.................................................................................................................................................................................1260
			9.50.1 Checking hose winches, traps, cable winches, hose guides, cable guides, rope pulley cables and hose reels with scraper for damage and correct attachment................................1260
			9.50.2 Checking cable drums and hose reels on boom head for ease of movement...................................................................................................................1260
			9.50.3 Greasing hose winch bearing at the central lubrication point............................................................................................................................1260
			9.50.4 Hose winch drive: Checking oil level....................................................................................................................................................1260
		9.51 Grab rope guide...............................................................................................................................................................................1261
			9.51.1 Lubricating grab rope guide.............................................................................................................................................................1261
			9.51.2 Checking grab rope guide for wear and damage............................................................................................................................................1261
		9.52 Vibrator cooling..............................................................................................................................................................................1262
			9.52.1 Checking vibrator cooling for correct function..........................................................................................................................................1262
		9.53 Compressor*...................................................................................................................................................................................1263
			9.53.1 Checking the oil level and draining condensate from the air container...................................................................................................................1263
		9.54 Machine care..................................................................................................................................................................................1264
			9.54.1 Cleaning machinery compartment..........................................................................................................................................................1264
			9.54.2 Cleaning machine........................................................................................................................................................................1265
			9.54.3 Preserving machine......................................................................................................................................................................1266
	Index..................................................................................................................................................................................................1279

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