Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-05-02 – PDF DOWNLOAD

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Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-05-02 – PDF DOWNLOAD

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Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-05-02 – PDF DOWNLOAD

Language : English
Pages : 1680
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-05-02 – PDF DOWNLOAD

Preface:
General:
This crane was built according to the state of technology and recognized safety technical regulations.
Despite that, dangers to body and life for the user and / or third persons or damage to the crane and /
or other material assets can occur.
This crane may only be used:
– in impeccable technical condition.
– for destined use.
– by trained personnel, which acts in a safety and danger conscious way.
– when no safety relevant problems are present.
– when no modifications were made on the crane.
Any problems, which could affect safety must be fixed immediately.
Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen GmbH.
Data recording device:
This crane is equipped with a data recording device. Among others, the following data is recorded:
– Date and time of day
– Entered configuration of the crane
– Actual load
– Percentage of utilization of the crane
– Working radius
– Main boom angle, luffing jib angle
– Total telescopic boom length, length of each telescopic section
– Every actuation of bypass devices
The recorded data can be read with a respective software.
Safety and warning notes:
Safety and warning notes are directed to all persons who work with the crane.
The terms DANGER, WARNING, CAUTION and NOTICE used in the crane documentation are intended
to point out certain rules of conduct to all persons working with the crane.

TABLE OF CONTENTS:

Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-05-02 – PDF DOWNLOAD

Operating instructions...............................................................................   1
	Preface..........................................................................................   2
	Contents.........................................................................................  11
	1 Description of crane...........................................................................  21
		1.01 Terminology.............................................................................  22
			1  Crane components......................................................................  23
			2  Auxiliary boom........................................................................  25
		1.02 Product description.....................................................................  26
			1  Crane chassis.........................................................................  27
			2  Crane superstructure..................................................................  28
			3  Auxiliary equipment...................................................................  30
		1.03 Technical data..........................................................................  32
			1  Dimensions............................................................................  33
			2  Support...............................................................................  33
			3  Tires.................................................................................  34
			4  Weights...............................................................................  34
			5  Workplace-related emission value......................................................  35
			6  Vibrations............................................................................  35
			7  Speeds................................................................................  35
			8  Ropes.................................................................................  36
			9  Lifting heights.......................................................................  36
	2 Safety.........................................................................................  41
		2.01 Traffic regulations.....................................................................  42
			1  Traffic regulations...................................................................  43
		2.01.10 General traffic regulations..........................................................  44
			1  General traffic regulations...........................................................  45
		2.01.20 National traffic regulations.........................................................  48
			1  National traffic regulations..........................................................  49
		2.02 Break-in instructions...................................................................  50
			1  Break-in instructions.................................................................  51
		2.03 Job planning............................................................................  52
			1  Planning crane operation..............................................................  53
		2.04 General safety technical guidelines.....................................................  54
			1  General...............................................................................  55
			2  Emergency exit........................................................................  63
			3  Checking the rigging and fastening points.............................................  67
			4  Personal protective equipment.........................................................  69
			5  Use of single-stranded height safety equipment, illustration 1........................  74
			6  Use of double-stranded height safety equipment, illustration 2........................  74
			7  Securing the assembly personnel against falling.......................................  74
			8  Rescuing the assembly personnel.......................................................  76
			9  Documentation.........................................................................  76
			10  Identification.......................................................................  76
			11  Crane operator responsibilities......................................................  76
			12  Selecting the location, illustrations 1 to 3.........................................  83
			13  Slopes and excavations, illustrations 4 and 5........................................  86
			14  Permissible ground pressures.........................................................  86
			15  Support..............................................................................  88
			16  Checking the safety measures.........................................................  91
			17  Endangering air traffic..............................................................  91
			18  Grounding............................................................................  92
			19  Consideration of wind conditions.....................................................  92
			20  Working in the vicinity of transmitters.............................................. 101
			21  Joint lifting of a load with two cranes.............................................. 102
			22  Working ranges of several cranes overlap............................................. 103
			23  Hand signals for guidance............................................................ 103
			24  Crane operation with a load.......................................................... 112
			25  Lifting of personnel................................................................. 115
			26  Crane operation in case of thunderstorms............................................. 116
			27  Safety notes for external power feed (100 V AC to 400 V AC).......................... 117
			28  Welding work on the load............................................................. 117
			29  Travel and crane operation........................................................... 118
		2.04.10 Ladders.............................................................................. 122
			1  Technical safety instructions......................................................... 123
			2  User guidelines....................................................................... 123
			3  Safety signs.......................................................................... 124
		2.05 Signs on the crane...................................................................... 130
			1  Signs................................................................................. 131
		2.05.10 Labeling of load lifting equipment................................................... 162
			1  Identifications on the hook block or load hooks....................................... 163
			2  Identifications on single hook or double hook......................................... 164
			3  Identifications on auxiliary weights.................................................. 165
		2.06 Antifall guards on the crane............................................................ 168
			1  Personal protective equipment......................................................... 169
			2  Preparing the ladder.................................................................. 171
			3  Attachment and fastening points....................................................... 173
			4  Railings on the crane superstructure.................................................. 177
		2.07 Access to the crane..................................................................... 178
			1  Components on the crane............................................................... 179
			2  Ascent and descent on the crane chassis............................................... 183
			3  Walking and stepping surfaces......................................................... 193
		2.08 Working in low temperatures............................................................. 194
			1  Working in low temperatures........................................................... 195
			2  Working in ambient temperatures up to -40°C........................................... 195
			3  Working in ambient temperatures below -40°C........................................... 201
	3 Crane chassis operation........................................................................ 203
		3.01 Operating and control instruments on the crane chassis.................................. 204
			1  Operating and monitoring elements..................................................... 205
			2  Camera - monitor *.................................................................... 211
			3  Trip recorder *....................................................................... 213
			4  Keyboard.............................................................................. 215
			5  Display unit.......................................................................... 223
		3.02 Before starting to travel............................................................... 232
			1  General checks before starting to travel.............................................. 233
			2  Work station - Driver's cab........................................................... 241
		3.03 Axle suspension system.................................................................. 250
			1  Crane vehicle axles suspended......................................................... 251
			2  Crane vehicle axles blocked........................................................... 255
			3  Level regulation...................................................................... 259
		3.04 Travel operation........................................................................ 270
			1  Driving configurations of the crane................................................... 271
			2  Starting and stopping the engine...................................................... 275
			3  Driving the crane vehicle............................................................. 281
			4  Creeper gear (off-road gear / maneuvering or taxiing mode)............................ 319
			5  Differential locks.................................................................... 325
			6  Steering.............................................................................. 331
		3.05 Crane support........................................................................... 338
			1  General............................................................................... 339
			2  Bluetooth™ Terminal (BTT)............................................................. 347
			3  Supporting from the crane operator's cab.............................................. 383
			4  Before leaving the jobsite............................................................ 403
		3.07 Towing the crane........................................................................ 404
			1  Towing................................................................................ 405
		3.80 Transport of crane and crane components................................................. 406
			1  Transporting the crane................................................................ 407
	4 Operation of crane superstructure.............................................................. 415
		4.01 Operating and control instruments on the crane superstructure........................... 416
			1  Operating and control instruments..................................................... 417
			2  Operating elements on camera - monitor *.............................................. 421
			3  Operating elements on control consoles................................................ 423
			4  Operating elements on the operating and control unit (BKE)............................ 453
		4.02 LICCON computer system.................................................................. 460
			1  General............................................................................... 461
			2  LICCON computer system boot up........................................................ 463
			3  Operating elements of the LICCON computer system...................................... 465
			4  „Set up“ program...................................................................... 469
			5  „Crane operation“ program............................................................. 487
			6  „Telescoping“ program................................................................. 551
			7  The „Working range limitation“ program *.............................................. 555
			8  The „Support force monitoring“ program *.............................................. 557
			9  The settings window „Speed reduction master switch“................................... 565
			10  Power-Save and Stand-by mode in the LICCON computer system........................... 573
		4.03 Crane start up and taking the crane out of service...................................... 578
			1  Checks before start up................................................................ 579
			2  Work station - Crane operatorʼs cab................................................... 585
			3  Preheating the hydraulic oil with the Hydraulic oil preheating *...................... 601
			4  Starting the engines from the crane operatorʼs cab.................................... 605
			5  Engine regulation from the crane driverʼs cab......................................... 617
			6  Detaching / attaching the hook block on the fastening point........................... 621
			7  LICCON computer system after engine start............................................. 633
		4.04 Safety equipment........................................................................ 636
			1  General............................................................................... 637
			2  Quick test Crane geometry............................................................. 637
			3  Quick test Overload protection........................................................ 637
			4  LICCON computer system................................................................ 637
			5  Safety devices on the crane........................................................... 643
		4.05 Crane operation......................................................................... 654
			1  General............................................................................... 655
			2  LICCON computer system................................................................ 661
			3  Luffing............................................................................... 663
			4  Lifting / lowering.................................................................... 669
			5  Turning............................................................................... 675
			6  Telescoping........................................................................... 687
		4.06 Rope reeving............................................................................ 714
			1  Wire ropes and rope end connections................................................... 715
			2  Reeving the hoist rope with the auxiliary reeving rope................................ 717
			3  Reeving the hook block in and out..................................................... 721
			4  Securing and removing the load hook *................................................. 727
			5  Attaching / removing the hoist limit switch weight.................................... 731
			6  Assembling / disassembling the wedge lock............................................. 735
			7  Crane operation with auxiliary block * on the telescopic boom......................... 737
			8  Rope reeving.......................................................................... 737
		4.07 Counterweight........................................................................... 738
			1  General............................................................................... 739
			2  Assembly.............................................................................. 745
			3  Disassembly of the counterweight plates............................................... 751
		4.08 Working with a load..................................................................... 758
			1  Safety technical instructions for working with a load................................. 759
			2  Checks before starting to work with the crane......................................... 759
			3  Crane movement-Telescoping............................................................ 760
			4  Taking on a load...................................................................... 763
			5  Crane operation....................................................................... 769
		4.12 Two hook operation...................................................................... 772
			1  Operating modes....................................................................... 773
			2  Operation with boom nose * on the telescopic boom..................................... 773
			3  Operation with boom nose * on lattice jib............................................. 775
			4  „Two hook operation“ with auxiliary boom *............................................ 777
		4.15 Reeving plans........................................................................... 782
			1  Reeving plans......................................................................... 783
		4.20 Procedure for shut off of crane movements............................................... 800
			1  General............................................................................... 801
			2  Instructions to resume the crane movement............................................. 817
	5 Equipment...................................................................................... 857
		5.01 Safety technical notes for assembly and disassembly..................................... 858
			1  Checking the retaining elements....................................................... 859
			2  Rope pulleys.......................................................................... 859
			3  Checking the ropes.................................................................... 859
			4  Control measures...................................................................... 860
			5  Dangerous conditions without shut off................................................. 862
			6  Transporting components............................................................... 862
			7  Pneumatic springs for assembly support of components.................................. 863
			8  Manual rope winches for assembly support of components................................ 863
			9  Weights............................................................................... 864
			10  Guy rods............................................................................. 864
			11  Auxiliary guying..................................................................... 864
			12  Bypassing the overload protection.................................................... 865
			13  Bypassing the hoist top shut off..................................................... 867
			14  Assembly / disassembly............................................................... 869
			15  Erection / take down................................................................. 906
		5.02 Folding jib - TK........................................................................ 910
			1  General............................................................................... 911
			2  Assembling the folding jib............................................................ 925
			3  Reeving the hoist rope................................................................ 955
			4  Changing the mechanical folding jib from 0° to 22.5° or 45°........................... 957
			5  Hydraulic connections................................................................. 969
			6  Electrical connections................................................................ 977
			7  Erection.............................................................................. 985
			8  Adjusting the folding jib angle hydraulically *....................................... 987
			9  Changing the mechanical folding jib from 22.5° or 45° to 0°........................... 989
			10  Unreeving the hoist rope............................................................. 997
			11  Removing the folding jib............................................................. 999
		5.09 Hoist gear 2............................................................................1022
			1  General...............................................................................1023
			2  Assembly..............................................................................1023
			3  Disassembly...........................................................................1025
		5.10 Boom nose...............................................................................1026
			1  General...............................................................................1027
			2  Assembly..............................................................................1029
			3  Disassembly...........................................................................1035
		5.12 Auxiliary boom..........................................................................1040
			1  General...............................................................................1041
			2  Assembling the auxiliary boom.........................................................1045
			3  Reeving in the hoist rope.............................................................1069
			4  Changing the mechanical auxiliary boom from 0° to 22.5° or 45°........................1071
			5  Hydraulic connections.................................................................1077
			6  Electrical connections................................................................1079
			7  Erection..............................................................................1083
			8  Adjusting the auxiliary boom angle hydraulically *....................................1085
			9  Changing the mechanical auxiliary boom from 22.5° or 45° to 0°........................1087
			10  Unreeving the hoist rope.............................................................1091
			11  Disassembling the auxiliary boom.....................................................1093
		5.14 Telescopic boom disassembly / assembly, luffing cylinder on the crane superstructure....1114
			1  General...............................................................................1115
			2  Removal of telescopic boom............................................................1115
			3  Installation of telescopic boom.......................................................1127
			4  Retracting the luffing cylinder with removed telescopic boom..........................1137
		5.17 Sliding beam disassembly / assembly.....................................................1138
			1  General...............................................................................1139
			2  Remove sliding beams with auxiliary crane *...........................................1141
			3  Removing the rear sliding beams with own crane *......................................1143
			4  Installing the sliding beams with the auxiliary crane *...............................1151
			5  Installing the rear sliding beams with own crane *....................................1153
		5.19 Hook blocks.............................................................................1160
			1  Minimum required hook block weight....................................................1161
			2  Procedure in case of slack rope.......................................................1164
			3  Hook block overview...................................................................1167
			4  Transporting the hook block / load hook...............................................1169
			5  Installing the single blocks..........................................................1171
			6  Removing the single blocks............................................................1175
		5.25 Telescopic boom extension...............................................................1178
			1  General...............................................................................1179
			2  Assembly..............................................................................1181
			3  Establishing the electrical / hydraulic connections...................................1183
			4  Erection..............................................................................1183
			5  Disassembly...........................................................................1185
		5.31 Bluetooth™ Terminal (BTT)...............................................................1188
			1  Display / operating element Bluetooth™ Terminal.......................................1189
			2  The Bluetooth™ Terminal (BTT) is plugged into the instrument console..................1205
			3  The Bluetooth™ Terminal (BTT) removed from its charging cradle........................1213
			4  Operation of the Bluetooth™ Terminal (BTT)............................................1249
	6 Additional equipment...........................................................................1255
		6.01 Heater / engine preheating / Air conditioning system Driver’s cab.......................1256
			1  Heating the driver's cab..............................................................1257
			2  Maintaining the engine independent heater.............................................1279
		6.02 Heater / engine preheating / Air conditioning system Crane operator’s cab...............1282
			1  Heating the crane operator's cab......................................................1283
			2  Menu „Climate control settings“.......................................................1283
			3  Maintaining the engine independent heater.............................................1317
		6.04 Support beam monitoring / sliding beam monitoring.......................................1320
			1  General...............................................................................1321
			2  Support bases.........................................................................1321
			3  Working with the LICCON sliding beam monitoring *.....................................1322
		6.05 Emergency take-down.....................................................................1324
			1  Emergency control.....................................................................1325
		6.07 Emergency operation of support..........................................................1328
			1  Emergency operation of support........................................................1329
	7 Service and maintenance........................................................................1333
		7.01 Maintenance and service - General.......................................................1334
			1  Technical safety instructions.........................................................1335
			2  Warranty and coverage.................................................................1338
			3  Liebherr Service......................................................................1339
			4  Oil and lubricant analysis............................................................1340
			5  Cleaning..............................................................................1341
			6  Disposal..............................................................................1342
		7.02 Maintenance intervals - Crane chassis...................................................1344
			1  Crane chassis maintenance and inspection schedule.....................................1345
		7.03 Maintanance intervals - Crane superstructure............................................1352
			1  Crane superstructure maintenance and inspection schedule..............................1353
		7.03.50 Maintenance intervals - Crane boom...................................................1360
			1  Crane boom maintenance and inspection schedule........................................1361
		7.04 Maintenance guidelines - Crane chassis..................................................1366
			1  Diesel engine.........................................................................1367
			2  Coolant system........................................................................1371
			3  Air filter system.....................................................................1375
			4  Fuel system...........................................................................1377
			5  Urea system *.........................................................................1381
			6  Exhaust system........................................................................1383
			7  Automatic transmission................................................................1385
			8  Distributor gear......................................................................1389
			9  Axles.................................................................................1391
			10  Tires................................................................................1393
			11  Driverʼs cab.........................................................................1411
			12  Auxiliary heater *...................................................................1415
			13  Hydraulic system.....................................................................1417
			14  Hydraulic hose lines.................................................................1421
			15  Compressed air and brake system......................................................1424
			16  Electrical system....................................................................1425
			17  Ladders..............................................................................1429
		7.05 Maintenance guidelines - Crane superstructure...........................................1432
			1  Diesel engine.........................................................................1433
			2  Coolant system........................................................................1437
			3  Air filter system.....................................................................1441
			4  Fuel system...........................................................................1443
			5  Urea system *.........................................................................1447
			6  Exhaust system........................................................................1451
			7  Pump distributor gear.................................................................1453
			8  Central lubrication system............................................................1455
			9  Slewing ring connection...............................................................1465
			10  Slewing gear(s)......................................................................1467
			11  Hoist gear(s)........................................................................1469
			12  Auxiliary heater *...................................................................1475
			13  Hydraulic system.....................................................................1481
			14  Hydraulic hose lines.................................................................1484
			15  Electrical system....................................................................1484
		7.05.50 Maintenance guidelines - Crane boom..................................................1486
			1  Telescopic boom.......................................................................1487
		7.06 Fill quantities, lubrication schedule...................................................1490
			1  Fill quantities.......................................................................1491
			2  Lubrication schedule..................................................................1492
		7.06 Fill quantities, lubrication schedule...................................................1494
			1  Fill quantities.......................................................................1495
			2  Lubrication schedule..................................................................1499
		7.07 Service fluids and lubricants...........................................................1504
			1  Specified service items and lubricants for Liebherr cranes............................1505
	8 Inspections of cranes..........................................................................1513
		8.01 Periodic crane inspections..............................................................1514
			1  General...............................................................................1515
			2  Inspection of carrying crane structures, especially steel structures..................1516
			3  Inspecting the hoist and retracting winches...........................................1589
			4  Inspecting the load hooks.............................................................1601
			5  Inspection of the rope feed mechanism in the telescopic boom..........................1603
			6  Inspection of locking system of telescopic boom.......................................1605
			7  Inspection of safety ropes and anchor points..........................................1607
			8  Inspection of membrane accumulator....................................................1609
			9  Inspection of relapse cylinders.......................................................1609
			10  Inspection of the safety controls on the relapse cylinders...........................1610
			11  Inspection of rope pulleys...........................................................1610
			12  Inspecting the function of the overload protection...................................1610
			13  Inspecting the roller slewing ring connection........................................1610
			14  Inspection of the mounting of the load bearing equipment.............................1611
			15  Inspection of the tele extension with eccentric, illustration 1......................1613
			16  Inspection of change over pulleys, illustration 2....................................1613
			17  Inspection of the oil and fuel reservoirs............................................1613
			18  Inspection of the auxiliary reeving winch, recovery winch and spare gear winch.......1613
			19  Appendix.............................................................................1613
		8.04 Inspection of crane wire ropes..........................................................1622
			1  Introduction..........................................................................1623
			2  Wire rope.............................................................................1623
			3  Operating behavior of steel ropes.....................................................1629
			4  Condition of equipment that is functionally associated with the rope..................1630
			5  Rope inspection log...................................................................1630
			6  Rope storage and marking..............................................................1630
			7  Wire ropes and rope end connections...................................................1630
			8  Twisting caused by stretching in rotation-resistant ropes and its remedy..............1635
			9  Appendix 1............................................................................1639
			10  Appendix 2...........................................................................1641
			11  Appendix 3...........................................................................1643
			12  Appendix 4...........................................................................1643
		8.06 Inspection of hydraulic hose lines......................................................1646
			1  Hydraulic hose lines..................................................................1647
		8.07 Inspection of pneumatic brake system for disk brakes....................................1650
			1  General...............................................................................1651
			2  Visual inspection.....................................................................1651
			3  Function and performance test.........................................................1651
			4  Internal inspection of the wheel brake................................................1653
	90 Appendix......................................................................................1657
		90.01 Foreword to appendix...................................................................1658
			1  Preface...............................................................................1659
		90.05 Update confirmation....................................................................1660
			1  Update confirmation...................................................................1661
			2  Customer information..................................................................1661
	Index............................................................................................1663

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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