Description
Liebherr LTM 1200-5.1 Operating Instructions Manual
This is the complete original operating manual for the Liebherr LTM 1200-5.1 mobile crane with telescopic boom. Issued under BAL No. 21002-03-02 by Liebherr-Werk Ehingen GmbH, this 1566-page document is the definitive reference for safe operation, setup, and maintenance of the LTM 1200-5.1 five-axle crane. It covers every phase of the crane’s working life, from daily pre-start checks and travel procedures through to counterweight ballasting, telescopic boom operation, folding jib assembly, and recurring inspection requirements.
File Details
- Manual type: Original Operating Manual
- Brand: Liebherr
- Model: LTM 1200-5.1
- Document number: BAL No. 21002-03-02
- Manufacturer: Liebherr-Werk Ehingen GmbH
- Language: English
- Page count: 1566
- File format: PDF
Chapters Covered
- Description of Crane – crane components, chassis, superstructure, telescopic boom, auxiliary boom, technical data, dimensions, support, tires, axle loads, speeds, lifting heights
- Safety – traffic regulations, break-in instructions, job planning, danger zone, emergency exit, personal protective equipment, fall arrest systems, rescuing assembly personnel, crane cab, heated components, operating site selection, slopes and ditches, ground load bearing capacity, support, alignment, external power supply, grounding, transmitters, thunderstorms, wind influences, lifting with two cranes, hand signals, working with a load, personnel lifting, welding on load, travel and crane operation, ladders, signs on the crane, antifall guards, access to the crane, working in low temperatures
- Crane Chassis Operation – operating and control instruments, driver’s cab, axle pressure, center console, keyboard, display unit, vehicle frame, inspections before travel, seatbelt, trip recorder, axle suspension system, level regulation, travel operation, starting and stopping the engine, travel speed, idling speed, parking brake, service brake, retarder, automatic transmission, indicators, Tempomat, Temposet, creeper gear, differential locks, steering, ending travel, crane at the job site, supporting the crane, support plates, leaving the job site, towing the crane, transport of crane and crane components
- Operation of Crane Superstructure – operating and control instruments, LMB emergency operation, control consoles, touch displays, LICCON computer system, set up program, crane operation program, support force monitoring, telescoping program, working range limitation, speed reduction master switch, slewing gear operating mode, sliding beam monitoring, ECO-Mode, Power-Save and Stand-by mode, crane start up, inspections, crane driver’s seat, control helm, step, crane cab, hydraulic oil preheating, starting and stopping engine, indicator lights, monitoring functions, window wiper and washer, engine regulation, hook block, safety equipment, quick test crane geometry, overload protection, safety devices, crane operation, luffing, lifting/lowering, turning, telescoping, rope reeling, wire ropes, hoist rope lug, moveable back pulley, reeling hoist rope, hook block, load hook, hoist limit switch weight, wedge lock, auxiliary block, counterweight, working with a load, two hook operation, auxiliary boom, folding jib, fixed lattice jib, luffing lattice jib, lifting a joint load, procedure for shut off of crane movements
- Equipment – safety technical notes for assembly and disassembly, checking retaining elements, rope pulleys, checking ropes, control measures, dangerous conditions without shut off, transporting components, pneumatic springs, manual rope winches, weights, guy rods, auxiliary guying, bypassing overload protection, bypassing hoist top shut off, assembly/disassembly, erection/take down, folding jib TK 800, hoist gear 2, boom nose, auxiliary boom, telescopic boom disassembly/assembly, sliding beam disassembly/assembly, hook blocks, telescopic boom extension, Bluetooth Terminal (BTT)
- Additional Equipment – heater, engine preheating, air conditioning systems for driver’s cab and crane operator’s cab, emergency take-down, emergency operation of support, variable support, chart overview assembly/disassembly on variable support
- Service and Maintenance – general safety, warranty and coverage, Liebherr Service, oil and lubricant analysis, cleaning, disposal, maintenance intervals for crane chassis, crane superstructure, and crane boom, maintenance guidelines for crane chassis, crane superstructure, and crane boom, fill quantities, lubrication schedule, service fluids and lubricants
- Inspections of Cranes – periodic crane inspections, inspection of carrying crane structures, steel structures, repair welding, test points, inspection of rope feed mechanism, locking system of telescopic boom, safety ropes and anchor points, load handling equipment, assembly aids, fastening equipment, diaphragm reservoir, relapse cylinders, rope pulleys, carrier rollers, extension conditions of sliding beams, function of overload protection, roller slewing ring connection, mounting of load bearing equipment, tele extension, change over pulleys, oil and fuel reservoirs, inspection of winches, inspection of crane wire ropes, inspection of load hooks, inspection of hydraulic hose lines, inspection of pneumatic brake system, inspection of ladders, weighing procedure for mobile cranes, inspection chart for cranes
- Attachment – foreword, update confirmation, customer information
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Liebherr LTM 1200-5.1 Mobile Crane Operating Instructions Manual – 1566 Page PDF” are as follows:
+Operating instructionsp. 1
Prefacep. 2
Contentsp. 11
+1 Description of cranep. 23
+1.01 Terminologyp. 24
1 Crane componentsp. 25
2 Auxiliary boomp. 27
+1.02 Product descriptionp. 28
1 Crane chassisp. 29
2 Crane superstructurep. 30
3 Auxiliary equipmentp. 32
+1.03 Technical datap. 34
1 Dimensionsp. 35
2 Suspension path and inclinep. 36
3 Supportp. 37
4 Tiresp. 37
5 Axle loadsp. 38
6 Noise emissionp. 38
7 Vibrationsp. 38
8 Speedsp. 38
9 Crane ropesp. 39
10 Lifting heightsp. 40
+2 Safetyp. 43
+2.01 Traffic regulationsp. 44
1 Traffic regulationsp. 45
+2.01.10 General traffic regulationsp. 46
1 General traffic regulationsp. 47
+2.01.20 National traffic regulationsp. 50
1 National traffic regulationsp. 51
+2.02 Break-in instructionsp. 52
1 First commissioningp. 53
+2.03 Job planningp. 54
1 Planning Crane operationp. 55
+2.04 General safety technical guidelinesp. 56
1 Danger zone of cranep. 57
2 Traffic endangerment and environmental damagep. 57
3 Endangering air trafficp. 57
4 Movement on the cranep. 58
5 Emergency exitp. 58
6 Personal protective equipmentp. 61
7 Securing persons to prevent them from fallingp. 66
8 Rescuing the assembly personnelp. 68
9 Crane cab with retractable / extendable stepp. 69
10 Crane cab with incline adjustmentp. 70
11 Safety barp. 71
12 Closing the windowsp. 72
13 Rigging and fastening pointsp. 73
14 Heated crane componentsp. 74
15 Crane operator responsibilitiesp. 74
16 Selecting the operating sitep. 76
17 Slopes and ditchesp. 80
18 Load burdens on the ground due to crane operationp. 83
19 Supportp. 87
20 Aligning the cranep. 89
21 Checking the safety measuresp. 90
22 Safety guidelines in case of external power supplyp. 91
23 Groundingp. 91
24 Working in the vicinity of transmittersp. 93
25 Crane operation in case of thunderstormsp. 94
26 Wind influencesp. 95
27 Lifting a load with two cranesp. 101
28 Working ranges overlapp. 103
29 Hand signals for guidancep. 103
30 Crane operation with a loadp. 112
31 Lifting of personnelp. 115
32 Securing personnel on shut off cranep. 116
33 Welding work on the loadp. 118
34 Travel and crane operationp. 119
+2.04.10 Laddersp. 124
1 Safety guidelinesp. 125
2 Safety signsp. 125
3 Ladder inspectionp. 129
4 User guidelinesp. 129
5 Ladder accessp. 130
+2.05 Signs on the cranep. 142
+2.05.10 Labeling of load lifting equipmentp. 176
1 Identifications on the hook block or load hooksp. 177
2 Identifications on single hook or double hookp. 178
3 Identifications on auxiliary weightsp. 179
+2.06 Antifall guards on the cranep. 182
1 Safety guidelinesp. 183
2 Transporting the ladderp. 184
3 Ladder on telescopic boomp. 185
4 Ladder on auxiliary boomp. 187
5 Fall protection equipment on counterweightp. 188
6 Fall protection equipment on the crane superstructurep. 190
7 Folding the platform into tank position / operating positionp. 194
+2.07 Access to the cranep. 196
1 Ascent and descent on the crane chassisp. 197
2 Walking and stepping surfacesp. 206
+2.08 Working in low temperaturesp. 208
1 Working in low temperaturesp. 209
2 Working in ambient temperatures up to -40°Cp. 209
3 Working in ambient temperatures below -40°Cp. 215
+3 Crane chassis operationp. 217
+3.01 Operating and control instruments on the crane chassisp. 218
1 Driver's cabp. 219
2 Axle pressurep. 222
3 Center consolep. 223
4 Keyboardp. 225
5 Display unitp. 234
6 Vehicle framep. 243
+3.02 Before starting to travelp. 244
1 Inspectionsp. 245
2 Before starting to drivep. 252
3 Seatbeltp. 255
4 Trip recorder *p. 255
+3.03 Axle suspension systemp. 258
1 Crane vehicle axles suspendedp. 259
2 Crane vehicle axles blockedp. 263
3 Level regulationp. 267
+3.04 Travel operationp. 284
1 Travel conditionsp. 285
2 Starting the enginep. 286
3 Turning the engine offp. 287
4 Travel speedp. 290
5 Idling speedp. 290
6 Applying the parking brakep. 293
7 Service brakep. 295
8 Retarderp. 295
9 Automatic transmissionp. 297
10 Indicatorsp. 305
11 Tempomatp. 313
12 Temposetp. 317
13 Creeper gearp. 320
14 Differential locksp. 323
15 Steeringp. 325
16 Ending travelp. 332
+3.05 Crane at the job sitep. 336
1 Descriptionp. 337
2 Controlling the axle suspensionp. 338
3 Supporting the cranep. 340
4 Installing the support platesp. 354
5 Leaving the job sitep. 357
+3.07 Towing the cranep. 360
1 Safety notes for towingp. 361
2 Defective enginep. 361
3 Defective transmissionp. 362
4 Defective distributor gearp. 364
5 Defective axle(s)p. 365
+3.80 Transport of crane and crane componentsp. 366
1 Transporting the cranep. 367
+4 Operation of crane superstructurep. 375
+4.01 Operating and control instruments on the crane superstructurep. 376
1 Operating and control instrumentsp. 377
2 Operating elements LMB emergency operationp. 383
3 Operating elements on control consolesp. 385
4 Operating elements on the operating and control unit (BKE)p. 417
+4.02 LICCON computer systemp. 424
1 Generalp. 424
2 System start of the LICCON computer systemp. 426
3 Operating elements of the LICCON computer systemp. 427
4 The set up programp. 429
5 The Crane operation programp. 437
6 The Support force monitoring program *p. 478
7 The Telescoping programp. 482
8 The Working range limitation program *p. 491
9 Speed reduction master switchp. 495
10 Setting the operating mode of the slewing gearp. 499
11 Sliding beam monitoring without shut off of crane movement *p. 500
12 Sliding beam monitoring with shut off of crane movement *p. 502
13 ECO-Mode *p. 506
14 Power-Save mode and Stand-by mode in the LICCON computer systemp. 511
+4.03 Crane start up and taking the crane out of servicep. 514
1 Inspectionsp. 515
2 Crane driver's seatp. 518
3 Control helmp. 519
4 Stepp. 521
5 Crane cabp. 522
6 Hydraulic oil preheating *p. 525
7 LICCON computer systemp. 527
8 Starting the enginep. 530
9 Turning the engine offp. 532
10 Indicator lightsp. 534
11 Monitoring functionsp. 534
12 Window wiper / window washer systemp. 536
13 Engine regulationp. 538
14 Hook blockp. 540
+4.04 Safety equipmentp. 546
1 Generalp. 547
2 Quick test Crane geometryp. 547
3 Quick test Overload protectionp. 547
4 LICCON computer systemp. 547
5 Safety devices on the cranep. 553
+4.05 Crane operationp. 564
1 Descriptionp. 565
2 Safety guidelinesp. 565
3 Prerequisites for crane operationp. 566
4 Master switchp. 566
5 Pinning Crane superstructurep. 572
6 Master switch assignmentp. 573
7 Luffingp. 574
8 Lifting / loweringp. 576
9 Turningp. 580
10 Telescopingp. 585
+4.06 Rope reevingp. 596
1 Wire ropes and rope end connectionsp. 597
2 Hoist rope lug *p. 597
3 Moveable back pulley *p. 601
4 Reeving the hoist ropep. 602
5 Reeving the hook block in and outp. 607
6 Attaching and removing the load hook *p. 610
7 Attaching / removing the hoist limit switch weightp. 613
8 Assembling / disassembling the wedge lockp. 615
9 Auxiliary block * on telescopic boomp. 617
10 Rope reevingp. 618
+4.07 Counterweightp. 620
1 Generalp. 621
2 Assemblyp. 627
3 Disassembly of the counterweight platesp. 633
+4.08 Working with a loadp. 640
1 Safety technical instructions for working with a loadp. 641
2 Checks before starting to work with the cranep. 641
3 Crane movement – Telescopingp. 642
4 Taking on a loadp. 645
5 Crane operationp. 651
+4.12 Two hook operationp. 654
1 Auxiliary boomp. 655
2 Hook operationp. 659
3 Two hook operation monitored / Two hook operation not monitoredp. 662
4 Safety guidelinesp. 663
5 Boom nose on telescopic boomp. 665
6 Auxiliary jib on telescopic boomp. 666
7 Folding jibp. 667
8 Strong lattice jibp. 669
9 Fixed lattice jibp. 670
10 Boom nose on fixed lattice jibp. 671
11 Auxiliary jib on fixed lattice jibp. 672
12 Luffing lattice jibp. 674
13 Boom nose on luffing lattice jibp. 675
14 Auxiliary jib on luffing lattice jibp. 676
15 Lifting a joint loadp. 678
+4.20 Procedure for shut off of crane movementsp. 682
1 Generalp. 683
2 Instructions to resume the crane movementp. 699
+5 Equipmentp. 739
+5.01 Safety technical notes for assembly and disassemblyp. 740
1 Checking the retaining elementsp. 741
2 Rope pulleysp. 741
3 Checking the ropesp. 741
4 Control measuresp. 742
5 Dangerous conditions without shut offp. 745
6 Transporting componentsp. 745
7 Pneumatic springs for assembly support of componentsp. 745
8 Manual rope winches for assembly support of componentsp. 746
9 Weightsp. 746
10 Guy rodsp. 746
11 Auxiliary guyingp. 747
12 Bypassing the overload protectionp. 747
13 Bypassing the hoist top shut offp. 749
14 Assembly / disassemblyp. 750
15 Erection / take downp. 795
+5.02 Folding jib – TKp. 800
1 Generalp. 801
2 Assembling the folding jibp. 815
3 Reeving the hoist ropep. 845
4 Changing the mechanical folding jib from 0° to 22.5° or 45°p. 847
5 Hydraulic connectionsp. 859
6 Electrical connectionsp. 867
7 Erectionp. 875
8 Adjusting the folding jib angle hydraulically *p. 877
9 Changing the mechanical folding jib from 22.5° or 45° to 0°p. 879
10 Unreeving the hoist ropep. 887
11 Removing the folding jibp. 889
+5.09 Hoist gear 2p. 912
1 Generalp. 913
2 Assemblyp. 913
3 Disassemblyp. 915
+5.10 Boom nosep. 916
1 Generalp. 917
2 Assemblyp. 919
3 Disassemblyp. 925
+5.12 Auxiliary boomp. 930
1 Generalp. 931
2 Assembling the auxiliary boomp. 935
3 Reeving in the hoist ropep. 959
4 Changing the mechanical auxiliary boom from 0° to 22.5° or 45°p. 961
5 Hydraulic connectionsp. 967
6 Electrical connectionsp. 969
7 Erectionp. 973
8 Adjusting the auxiliary boom angle hydraulically *p. 975
9 Changing the mechanical auxiliary boom from 22.5° or 45° to 0°p. 977
10 Unreeving the hoist ropep. 981
11 Disassembling the auxiliary boomp. 983
+5.14 Telescopic boom disassembly / assembly, luffing cylinder on the crane superstructurep. 1004
1 Generalp. 1005
2 Disassemblyp. 1007
3 Assemblyp. 1021
+5.17 Sliding beam disassembly / assemblyp. 1032
1 Generalp. 1033
2 Install the covers *p. 1034
3 Remove sliding beams with auxiliary crane *p. 1037
4 Removing the rear sliding beams with own crane *p. 1039
5 Installing the sliding beams with the auxiliary crane *p. 1047
6 Installing the rear sliding beams with own crane *p. 1049
+5.19 Hook blocksp. 1056
1 Procedure in case of slack ropep. 1057
2 Hook block overviewp. 1059
3 Transporting the hook block / load hookp. 1061
4 Installing the single blocksp. 1063
5 Removing the single blocksp. 1067
+5.25 Telescopic boom extensionp. 1070
1 Generalp. 1071
2 Assemblyp. 1073
3 Establishing the electrical / hydraulic connectionsp. 1075
4 Erectionp. 1075
5 Disassemblyp. 1077
+5.31 Bluetooth Terminal (BTT)p. 1080
1 Technical safety instructionsp. 1081
2 Description of functionp. 1082
3 BTT Operating elementsp. 1082
4 BTT System startp. 1083
5 BTT: Button blockp. 1085
6 BTT: EMERGENCY STOP switchp. 1086
7 Settings and condition displays on the BTTp. 1087
8 Turning the BTT on / off / overp. 1088
9 Orienting the BTT to the cranep. 1090
10 BTT Menu overviewp. 1092
11 Menu Driven distance and operating hoursp. 1097
12 MenuAuxiliary heater Crane chassis *p. 1101
13 Incline display in driver's cab menup. 1103
14 Menu Engine operation crane chassis / crane superstructurep. 1105
15 Menu Support the crane / Support automaticp. 1113
16 MenuAxle suspension *p. 1117
17 Menu Sliding the sliding beam / supporting the cranep. 1122
18 Menu Assembly functions crane superstructurep. 1126
19 Menu Test systemp. 1134
+6 Additional equipmentp. 1137
+6.01 Heater / engine preheating / Air conditioning system Driver’s cabp. 1138
1 Climate control systemsp. 1139
2 Safety guidelinesp. 1139
3 Heaterp. 1140
4 Climate control system *p. 1144
5 Auxiliary heater *p. 1146
6 Maintenance Heaterp. 1150
7 Maintenance Auxiliary heater *p. 1151
+6.02 Heater / engine preheating / Air conditioning system Crane operator’s cabp. 1154
1 Climate control systemsp. 1155
2 Safety guidelinesp. 1155
3 Climate controlp. 1156
4 Climate control system *p. 1163
5 Auxiliary heater *p. 1164
6 Maintenance Heaterp. 1171
7 Maintenance Auxiliary heater *p. 1172
+6.05 Emergency take-downp. 1174
1 Emergency controlp. 1175
+6.07 Emergency operation of supportp. 1178
1 Emergency operation of supportp. 1179
+6.26 Variable supportp. 1182
1 Safety guidelinesp. 1183
2 Descriptionp. 1183
3 Assembling / disassembling the auxiliary boomp. 1183
4 Set up program with variable supportp. 1187
5 Crane operation program with variable supportp. 1191
6 Crane operation with variable supportp. 1195
+6.26.05 Chart overview Assembly / disassembly on variable supportp. 1196
1 Chart overview Support variation AV1p. 1197
2 Chart overview Support variation AV2p. 1197
3 Chart overview Support variation AV3p. 1197
6.26.10 Charts Assembly / disassembly on variable supportp. 1198
+7 Service and maintenancep. 1201
+7.01 Maintenance and service – Generalp. 1202
1 Technical safety instructionsp. 1203
2 Warranty and coveragep. 1207
3 Liebherr Servicep. 1207
4 Oil and lubricant analysisp. 1208
5 Cleaningp. 1209
6 Disposalp. 1210
+7.02 Maintenance intervals – Crane chassisp. 1212
1 Maintenance and inspection schedulep. 1213
+7.03 Maintanance intervals – Crane superstructurep. 1222
1 Maintenance and inspection schedulep. 1223
+7.03.50 Maintenance intervals – Crane boomp. 1232
1 Maintenance and inspection schedulep. 1233
+7.04 Maintenance guidelines – Crane chassisp. 1240
1 Safety guidelinesp. 1241
2 Driver's cabp. 1241
3 Diesel enginep. 1245
4 Cooling systemp. 1248
5 Air filter systemp. 1250
6 Fuel systemp. 1250
7 Urea system *p. 1257
8 Exhaust systemp. 1260
9 Transmissionp. 1261
10 Travel drivep. 1265
11 Axlesp. 1267
12 Steeringp. 1271
13 Tiresp. 1272
14 Auxiliary heater *p. 1287
15 Hydraulic systemp. 1288
16 Hydraulic hose linesp. 1293
17 Compressed air and brake systemp. 1294
18 Electrical systemp. 1295
19 Laddersp. 1299
20 Window cleaning systemp. 1300
21 Camera cleaning systemp. 1301
+7.05 Maintenance guidelines – Crane superstructurep. 1304
1 Enginep. 1305
2 Cooling systemp. 1307
3 Fuel systemp. 1309
4 Urea system *p. 1316
5 Central lubrication systemp. 1318
6 Slewing ring connectionp. 1322
7 Slewing gearp. 1323
8 Hoist gear(s)p. 1325
9 Auxiliary heater *p. 1327
10 Ventilationp. 1330
11 Hydraulic systemp. 1330
12 Hydraulic hose linesp. 1333
13 Servicing the air dryerp. 1333
14 Electrical systemp. 1334
15 Laddersp. 1334
+7.05.50 Maintenance guidelines – Crane boomp. 1336
1 Telescopic boomp. 1337
2 Rope pulleys and guide pulleysp. 1339
3 Crane ropesp. 1340
+7.06 Fill quantities, lubrication schedulep. 1354
1 Fill quantitiesp. 1355
2 Lubrication schedulep. 1356
+7.07 Service fluids and lubricantsp. 1358
1 Specified service fluids and lubricants for Liebherr cranesp. 1359
+8 Inspections of cranesp. 1367
+8.01 Periodic crane inspectionsp. 1368
1 General informationp. 1369
2 Inspection of carrying crane structures, especially steel structuresp. 1370
3 Inspection of the rope feed mechanism in the telescopic boomp. 1444
4 Inspection of locking system of telescopic boomp. 1446
5 Inspection of safety ropes and anchor pointsp. 1448
6 Inspection of load handling equipment and assembly aidsp. 1450
7 Inspection of fastening equipmentp. 1451
8 Inspection of diaphragm reservoirp. 1451
9 Inspection of relapse cylindersp. 1451
10 Inspection of rope pulleysp. 1452
11 Inspection of carrier rollersp. 1452
12 Inspection of extension conditions of sliding beamsp. 1454
13 Inspection of the function of the overload protectionp. 1454
14 Inspection of the roller slewing ring connectionp. 1454
15 Inspection of the mounting of the load bearing equipmentp. 1454
16 Inspection of the tele extension with eccentric, illustration 1p. 1456
17 Inspection of change over pulleys, illustration 2p. 1456
18 Inspection of the oil and fuel reservoirsp. 1456
+8.03 Inspection of winchesp. 1458
1 Inspecting the hoist and retracting winchesp. 1459
2 Inspection of the auxiliary reeving winch, recovery winch and spare wheel winchp. 1461
3 Monitoring the winchesp. 1461
+8.04 Inspection of crane wire ropesp. 1470
1 Importance of inspectionp. 1471
2 Personal protective equipmentp. 1471
3 Qualification Inspection personnelp. 1471
4 Unscheduled inspectionp. 1471
5 Intervalsp. 1471
6 Areasp. 1472
7 Documentation of inspection resultsp. 1473
8 Wire ropes and rope end connectionsp. 1473
9 Degree of severityp. 1475
10 Abbreviations Rope diameterp. 1475
11 Distortions and mechanical damagep. 1475
12 Removal criteria Overviewp. 1475
13 Checking for broken strandsp. 1476
14 Determining the number of broken wiresp. 1477
15 Checking of rope diameterp. 1481
16 Checking for corrosionp. 1483
17 Corkscrew-like distortionp. 1486
18 Basket formationp. 1487
19 Protruding, distorted insert or strandp. 1487
20 Loop formationp. 1488
21 Kinking or rope loops pulled closedp. 1489
22 Bucklesp. 1490
23 Effects of heat, arcsp. 1491
24 Combined degree of severityp. 1491
25 Flatteningsp. 1491
26 Current checklistp. 1494
+8.05 Inspection of load hooksp. 1496
1 Safety guidelinesp. 1497
2 Inspection intervalsp. 1497
3 Inspecting and monitoring the load hookp. 1497
+8.06 Inspection of hydraulic hose linesp. 1500
1 Safety guidelinesp. 1501
2 Inspection intervalsp. 1501
3 Checking the end of the service lifep. 1501
4 Inspecting the hydraulic hose lines for damagep. 1502
5 Inspecting the hydraulic hose lines for leaksp. 1503
6 Documenting the inspectionp. 1503
7 Replacing hydraulic hose linesp. 1503
+8.07 Inspection of pneumatic brake system for disk brakes (system pressure: 10 bar)p. 1506
1 Safety guidelinesp. 1507
2 Guidelinesp. 1507
3 Visual inspectionp. 1508
4 Function testp. 1509
5 Performance testp. 1509
6 Checking the brake padsp. 1510
7 Checking the brake discsp. 1512
+8.17 Inspection of laddersp. 1516
1 Safety guidelinesp. 1517
2 Inspection intervalsp. 1517
3 Inspecting laddersp. 1517
4 Inspection sheet and check listp. 1517
+8.80 Weighing procedure for mobile cranesp. 1522
1 Weighing errorp. 1523
2 Symbolp. 1523
3 Weighing the mobile cranep. 1523
+8.90 Inspection chart for cranesp. 1530
1 Inspection chart for recurring inspections of Liebherr cranesp. 1531
+90 Attachmentp. 1541
+90.01 Foreword to attachmentp. 1542
+90.05 Update confirmationp. 1544
1 Update confirmationp. 1545
2 Customer informationp. 1545
Indexp. 1547
What This Manual Provides
The Liebherr LTM 1200-5.1 operating instructions is far more than a quick-start guide. It is the complete operational and maintenance reference for this 200-tonne class five-axle telescopic crane. Every procedure a crane operator, rigger, or maintenance technician needs is documented in sequence: how to level and support the crane correctly, how to configure the LICCON overload protection for a given boom and counterweight combination, how to safely telescope the boom through its 13.2 m to 72 m range, how to assemble and adjust the folding jib, and how to interpret the acoustic and optical warning systems when a crane movement is shut off.
Beyond day-to-day operation, the manual goes deep into the systems that keep the LTM 1200-5.1 stable and controllable. The axle suspension and level regulation chapters explain how to block and suspend the hydro-pneumatic suspension for travel versus crane operation, how to use the automatic and manual level controls, and how the BTT and touch displays are used to control sliding beams and support cylinders. The superstructure section covers the full LICCON computer system, including the set-up program, crane operation program, telescoping program, working range limitation, ECO-Mode, and the support force monitoring function.
Key Systems and Procedures Covered
Engine and drivetrain information spans the Liebherr D 946 A7-04 and D 946 A7-03 chassis engines along with the D 944 A7-04 superstructure engine, the ZF 12 AS 2530 automatic transmission, distributor gear, and the 10×6 drive configuration with differential locks. The steering chapter details the ZF Servocom two-circuit hydro steering with speed-dependent rear axle steering. Brake content covers the all-wheel servo air brake, ABS, spring-loaded parking brake, Intarder, and eddy current retarder.
Load handling equipment is documented in full: hook blocks, load hooks, wedge locks, hoist limit switch weights, auxiliary blocks on the telescopic boom, and the complete rope reeling procedures. Counterweight assembly and disassembly is explained step by step, including ballasting cylinder operation, turntable lock pinning, and the correct angles for picking up and setting down counterweight plates. The two hook operation chapter covers permitted hook configurations for the telescopic boom, auxiliary jib, folding jib, strong lattice jib, fixed lattice jib, and luffing lattice jib.
For maintenance planning, the manual provides detailed inspection schedules separated by crane chassis, crane superstructure, and crane boom, with intervals based on operating hours, driven mileage, and calendar time. Individual maintenance guidelines explain how to check oil levels, replace filters, bleed fuel systems, service the cooling system, inspect hydraulic hose lines, and check brake pads and discs. The wire rope inspection chapter follows structured removal criteria and includes a current checklist for documenting rope condition.
Who This Manual Is For
This operating instructions manual is written for crane operators, rigging crews, maintenance technicians, and fleet managers responsible for the Liebherr LTM 1200-5.1. It supports safe crane setup, correct load chart use, proper telescoping and luffing sequences, accurate counterweight configuration, and compliance with inspection intervals. Because the LTM 1200-5.1 is a five-axle mobile crane with a complex LICCON control system, having the original operating procedures on hand is essential for avoiding overload conditions, incorrect support configurations, and unsafe crane movements.
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This Liebherr LTM 1200-5.1 operating instructions manual is delivered as a PDF download immediately after purchase. No shipping, no waiting for a physical book. The file can be viewed on any device, searched for specific procedures or specifications, and printed for workshop or cab use. Whether you are setting up the crane on a new job site, troubleshooting a LICCON message, or planning the next inspection interval, this 1566-page manual gives you the complete original reference in a portable, accessible format.
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