Liebherr Mobile Crane LTM1095-5.1 Operations Manual Sn 044228 – PDF DOWNLOAD

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Liebherr Mobile Crane LTM1095-5.1 Operations Manual

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Liebherr Mobile Crane LTM1095-5.1 Operations Manual 

Language: English
Size: 18.9 MB
Pages: 1524
Format: PDF
Downloadable: YES
Serial No : 044228

DESCRIPTION:

Liebherr Mobile Crane LTM1095-5.1 Operations Manual 

FOREWORD:

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.

TABLE OF CONTENTS:

Liebherr Mobile Crane LTM1095-5.1 Operations Manual 

Operating instructions..........................................................................   1
	1.00 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 Additional equipment..............................................................  29
		1.03 Technical data.....................................................................  30
			1 Dimensions........................................................................  31
			2 Suspension path and incline.......................................................  31
			3 Stabilizers.......................................................................  31
			4 Tires.............................................................................  32
			5 Weights...........................................................................  32
			6 Workplace-related emission value..................................................  33
			7 Vibrations........................................................................  33
			8 Speeds............................................................................  33
			9 Ropes.............................................................................  35
			10 Hoisting heights.................................................................  35
	2.00 Safety.................................................................................  41
		2.01 Traffic regulations................................................................  42
			1 Traffic regulations...............................................................  43
		2.02 Break-in instructions..............................................................  44
			1 Break-in instructions.............................................................  45
		2.03 Job planning.......................................................................  46
			1 Planning crane operation..........................................................  47
		2.04 General safety technical guidelines................................................  48
			1 General...........................................................................  49
			2 Emergency exit....................................................................  55
			3 Checking the rigging and fastening points.........................................  59
			4 Personal protective equipment.....................................................  61
			5 Use of single-stranded height safety equipment, illustration 1....................  67
			6 Use of double-stranded height safety equipment, illustration 2....................  67
			7 Securing the assembly personnel against falling...................................  67
			8 Rescuing the assembly personnel...................................................  69
			9 Documentation.....................................................................  69
			10 Identification...................................................................  69
			11 Requirements for the crane operator..............................................  69
			12 Selecting the location, illustrations 1 to 3.....................................  75
			13 Slopes and excavations, illustrations 4 and 5....................................  78
			14 Permissible ground pressures.....................................................  78
			15 Supporting.......................................................................  83
			16 Checking the safety measures.....................................................  84
			17 Endangering air traffic..........................................................  84
			18 Grounding........................................................................  85
			19 Consideration of wind conditions.................................................  85
			20 Working in the vicinity of transmitters..........................................  93
			21 Dangers when working together with several cranes................................  95
			22 Hand signals for guidance........................................................  96
			23 Crane operation with a load...................................................... 103
			24 Lifting of personnel............................................................. 106
			25 Crane operation in case of thunderstorms......................................... 107
			26 Safety instructions for external power supply (230 V AC)......................... 108
			27 Welding work on the load......................................................... 108
			28 Interruption of crane operation.................................................. 109
			29 Resuming crane operation......................................................... 109
			30 Ending crane operation........................................................... 110
			31 Turning / driving in reverse..................................................... 110
			32 Parking the vehicle.............................................................. 110
			33 Safety guidelines for ladders.................................................... 113
		2.05 Signs on the crane................................................................. 119
			1 Warning signs..................................................................... 121
			2 Command and prohibition signs..................................................... 127
			3 Notice signs...................................................................... 131
		2.06 Antifall guards on the crane....................................................... 136
			1 Fall arresters on the crane....................................................... 137
			2 Providing a ladder................................................................ 139
			3 Attachment and fastening points................................................... 141
			4 Railings on the crane superstructure.............................................. 147
		2.10 General safety technical notes for driving with dolly.............................. 148
			1 Travel operation with dolly....................................................... 149
	3.00 Crane chassis operation................................................................ 159
		3.01 Operating and monitoring instruments on the crane chassis.......................... 160
			1 General operating elements........................................................ 161
			2 Control elements DTCO trip recorder*.............................................. 165
			3 Operating elements on camera-monitor*............................................. 167
			4 Keyboard.......................................................................... 169
			5 Display unit...................................................................... 173
			6 Grounding the mobile crane........................................................ 179
		3.02 Before starting to travel.......................................................... 180
			1 General checks before starting to travel.......................................... 181
			2 Work station - Driver's cab....................................................... 187
		3.03 Axle suspension system............................................................. 196
			1 Crane vehicle axles suspended..................................................... 197
			2 Crane vehicle axles blocked....................................................... 199
			3 Level regulation.................................................................. 201
		3.04 Travel operation................................................................... 214
			1 Driving conditions of the crane................................................... 215
			2 Starting and stopping the engine.................................................. 221
			3 Driving........................................................................... 229
			4 Differential locks................................................................ 271
			5 Steering.......................................................................... 277
		3.05 Crane at the job site.............................................................. 283
			1 General........................................................................... 285
			2 The Bluetooth™ Terminal (BTT)..................................................... 293
			3 Supporting from the crane operator's cab.......................................... 329
			4 Before leaving the jobsite........................................................ 349
		3.07 Towing the crane................................................................... 350
			1 Towing............................................................................ 351
		3.80 Transport of crane and crane components............................................ 352
			1 Transporting the crane............................................................ 353
	4.00 Operation of crane superstructure...................................................... 361
		4.01 Operating and monitoring instruments on the crane superstructure................... 362
			1 Operating and control instruments................................................. 363
			2 Operating elements on camera - monitor*........................................... 367
			3 Operating elements on control consoles............................................ 369
			4 Operating elements on the operating and control unit (BKE)........................ 409
		4.02 LICCON computer system............................................................. 416
			1 General........................................................................... 417
			2 LICCON computer system boot up.................................................... 419
			3 Operating elements of the LICCON computer system.................................. 421
			4 “Set up” program.................................................................. 425
			5 “Crane operation” program......................................................... 443
			6 “Telescoping” program............................................................. 503
			7 The “Working range limitation” program*........................................... 507
			8 The “Support force monitoring” program*........................................... 509
			9 The settings window “Speed reduction master switch”............................... 517
			10 Power-Save and Stand-by mode in the LICCON computer system....................... 525
		4.03 Crane start up and taking the crane out of service................................. 530
			1 Checks before start up............................................................ 531
			2 Work station - Crane operator's cab............................................... 535
			3 Preheating the hydraulic oil*..................................................... 549
			4 Starting and stopping the engine.................................................. 551
			5 Engine regulation from the crane driver's cab..................................... 571
			6 LICCON computer system after engine start......................................... 575
		4.04 Safety equipment................................................................... 578
			1 General........................................................................... 579
			2 Quick test Crane geometry......................................................... 579
			3 Quick test Overload protection.................................................... 579
			4 LICCON computer system............................................................ 580
			5 Safety devices on the crane....................................................... 585
		4.05 Crane operation.................................................................... 596
			1 General........................................................................... 597
			2 LICCON computer system............................................................ 603
			3 Luffing........................................................................... 605
			4 Lifting / lowering................................................................ 611
			5 Turning........................................................................... 617
			6 Telescoping....................................................................... 625
		4.06 Rope reeving....................................................................... 652
			1 Wire ropes and rope end connections............................................... 653
			2 Reeving the hoist rope with the auxiliary reeving rope............................ 655
			3 Reeving the hook block in and out................................................. 659
			4 Securing and removing the load hook*.............................................. 665
			5 Attaching / removing the hoist limit switch weight................................ 669
			6 Assembling / disassembling the wedge lock......................................... 673
			7 Crane operation with auxiliary block* on the telescopic boom...................... 675
			8 Rope reeving...................................................................... 675
		4.07 Counterweight...................................................................... 676
			1 General........................................................................... 677
			2 Assembly.......................................................................... 687
			3 Disassembly of the counterweight plates........................................... 693
		4.08 Working with a load................................................................ 700
			1 Technical safety instructions for working with a load............................. 701
			2 Checks before starting to work with the crane..................................... 702
			3 Crane movement - Telescoping...................................................... 703
			4 Taking on a load.................................................................. 705
			5 Crane operation................................................................... 709
		4.10 Driving from the crane operator's cab.............................................. 711
			1 General........................................................................... 713
			2 Brakes............................................................................ 721
			3 Travel operation.................................................................. 725
			4 Differential locks................................................................ 739
			5 Steering.......................................................................... 745
		4.15 Reeving plans...................................................................... 750
			1 Reeving plans..................................................................... 751
		4.20 Procedure for shut off of crane movements.......................................... 764
			1 General........................................................................... 765
			2 Instructions for resuming crane movements for cranes with CE mark................. 767
			3 Instructions for resuming crane movements for cranes without CE mark.............. 801
	5.00 Equipment.............................................................................. 835
		5.01 Safety technical guidelines for assembly and disassembly........................... 836
			1 Checking the retaining elements................................................... 837
			2 Rope pulleys...................................................................... 837
			3 Checking the ropes................................................................ 837
			4 Control measures.................................................................. 838
			5 Dangerous conditions without shut off............................................. 840
			6 Transporting components........................................................... 840
			7 Pneumatic springs for assembly support of components.............................. 841
			8 Manual rope winches for assembly support of components............................ 841
			9 Weights........................................................................... 841
			10 Guy rods......................................................................... 842
			11 Exceeding the overload protection................................................ 845
			12 Assembly / disassembly........................................................... 847
			13 Erection / take down............................................................. 873
		5.02 Folding jib - TK................................................................... 875
			1 General........................................................................... 877
			2 Assembling the folding jib........................................................ 883
			3 Reeving in the hoist rope......................................................... 907
			4 Changing over mechanical folding jib from 0° to 20° or 40°........................ 909
			5 Hydraulic connections............................................................. 929
			6 Electrical connections............................................................ 931
			7 Erection.......................................................................... 939
			8 Adjusting the folding jib angle hydraulically*.................................... 941
			9 Changing the mechanical folding jib from 20° or 40° to 0°......................... 943
			10 Unreeving the hoist rope......................................................... 959
			11 Removing the folding jib......................................................... 961
		5.09 Hoist gear 2....................................................................... 976
			1 General........................................................................... 977
			2 Assembly.......................................................................... 977
			3 Disassembly....................................................................... 979
		5.10 Boom nose.......................................................................... 980
			1 General........................................................................... 981
			2 Assembly.......................................................................... 981
			3 Disassembly....................................................................... 987
		5.12 Auxiliary boom..................................................................... 990
			1 General........................................................................... 991
			2 Assembly of the auxiliary boom.................................................... 995
			3 Erection..........................................................................1013
			4 Disassembling the auxiliary boom..................................................1015
		5.19 Hook blocks........................................................................1026
			1 Minimum required hook block weight................................................1027
			2 Procedure in case of slack rope...................................................1030
			3 Hook block overview...............................................................1033
			4 Installing the single blocks......................................................1035
			5 Removing the single blocks........................................................1039
		5.25 Telescopic boom extension..........................................................1042
			1 General...........................................................................1043
			2 Assembly..........................................................................1045
			3 Establishing the electrical / hydraulic connections...............................1047
			4 Erection..........................................................................1047
			5 Disassembly.......................................................................1049
		5.31 Bluetooth™ Terminal (BTT...........................................................1052
			1 Operating and control instruments Bluetooth™ Terminal (BTT).......................1053
			2 The Bluetooth™ Terminal back in plugged into the instrument console...............1067
			3 Bluetooth™ Terminal (BTT) removed from its charging cradle........................1073
			4 Operation of the Bluetooth™ Terminal (BTT)........................................1099
	6.00 Additional equipment...................................................................1105
		6.01 Heater / engine preheating /Air conditioning system Driver’s cab...................1106
			1 Heating the driver's cab..........................................................1107
		6.02 Heater / engine preheating /Air conditioning system Crane operat...................1128
			1 Heating the crane operator's cab..................................................1129
			2 Menu “Climate control settings”...................................................1129
		6.04 Sliding beam monitoring............................................................1164
			1 General...........................................................................1165
			2 Support bases.....................................................................1165
			3 Working with sliding beam monitoring..............................................1167
		6.05 Emergency take-down................................................................1168
			1 Emergency control.................................................................1169
		6.07 Emergency operation of support.....................................................1174
			1 Emergency operation of support....................................................1175
	7.00 Service and maintenance................................................................1179
		7.01 Maintenance and service - General..................................................1180
			1 General...........................................................................1181
			2 Cleaning and care of the crane....................................................1182
			3 Measures for work interruption or transport.......................................1183
			4 Maintenance work on the crane superstructure or boom..............................1184
			5 Maintenance and inspection guidelines.............................................1184
		7.02 Maintenance intervals - Crane chassis .............................................1188
			1 Crane chassis maintenance and inspection schedule.................................1189
		7.03 Maintanance intervals - Crane superstructure ......................................1198
			1 Crane superstructure maintenance and inspection schedule..........................1199
		7.04 Maintenance guidelines - Crane chassis.............................................1208
			1 Diesel engine.....................................................................1209
			2 Automatic transmission............................................................1215
			3 Transfer gearbox..................................................................1219
			4 Hydraulic system..................................................................1223
			5 Compressed air and brake system air dryer.........................................1233
			6 Tires / wheels....................................................................1233
			7 Axles.............................................................................1235
			8 Wheel alignment...................................................................1237
			9 Tilting the driver's cab..........................................................1239
			10 Electrical system - Lighting.....................................................1239
		7.05 Maintenance guidelines - Crane superstructure .....................................1242
			1 Crane engine......................................................................1243
			2 Hydraulic system..................................................................1251
			3 Central lubrication system........................................................1259
			4 Slewing ring connection...........................................................1267
			5 Hoist gears.......................................................................1269
			6 Slewing gear......................................................................1273
			7 Counterweight plates..............................................................1275
			8 Electrical system - Lighting......................................................1275
			9 Telescopic boom...................................................................1277
		7.06 Fill quantities, lubrication chart.................................................1280
			1 Fill quantities...................................................................1281
			2 Lubrication schedule..............................................................1285
		7.07 Service fluids and lubricants......................................................1290
			1 Specified service items and lubricants for Liebherr cranes........................1291
		7.15 Procedure in case of problems......................................................1299
			1 Procedure to follow in case of a problem..........................................1301
			2 Carrying out error diagnostics....................................................1307
			3 Measures in clear problem cases...................................................1313
			4 Measures for defective components.................................................1322
	8.00 Inspections of cranes..................................................................1333
		8.01 Periodic crane inspections.........................................................1334
			1 General...........................................................................1335
			2 Inspection of carrying crane structures, especially steel structures..............1336
			3 Inspection of tires and disk wheels...............................................1401
			4 Inspecting the hoist and luffing winches..........................................1403
			5 Inspecting load hooks.............................................................1415
			6 Inspecting the rope feed mechanics in the telescopic boom.........................1415
			7 Inspection of locking system of telescopic boom...................................1417
			8 Inspection of retaining ropes and anchor points...................................1419
			9 Inspection of membrane accumulator................................................1421
			10 Inspection of relapse cylinders..................................................1422
			11 Inspection of the safety controls on the relapse cylinders.......................1422
			12 Inspecting the cable pulleys.....................................................1422
			13 Inspecting the function of the overload protection...............................1423
			14 Inspecting the roller slewing ring connection....................................1423
			15 Inspecting the mounting of the load bearing equipment............................1423
			16 Inspection of the tele extension with eccentric, illustration 1..................1425
			17 Inspection of change over pulleys, illustration 2................................1425
			18 Inspecting the oil and fuel reservoirs...........................................1425
			19 Inspection of the auxiliary reeving winch, towing winch and spare wheel winch....1425
			20 Appendix.........................................................................1426
		8.04 Inspection of crane wire ropes.....................................................1436
			1 Introduction......................................................................1437
			2 Wire rope.........................................................................1437
			3 Operating behavior of steel ropes.................................................1443
			4 Condition of equipment that is functionally associated with the rope..............1443
			5 Rope inspection log...............................................................1443
			6 Rope storage and marking..........................................................1443
			7 Wire ropes and rope end connections...............................................1443
			8 Twisting caused by stretching in rotation-resistant ropes and its remedy..........1447
			9 Appendix 1........................................................................1451
			10 Appendix 2.......................................................................1453
			11 Appendix 3.......................................................................1455
			12 Appendix 4.......................................................................1455
		8.07 Inspection of pneumatic brake system for drum brakes ..............................1458
			1 General...........................................................................1459
			2 Visual inspection.................................................................1459
			3 Operation and performance test....................................................1459
			4 Internal inspection of the wheel brakes...........................................1460
	9.00 General notes..........................................................................1463
		9.02 Supplementary service work.........................................................1464
			1 Checks before start up............................................................1465
			2 Repair and maintenance tasks......................................................1465
			3 Important service tasks...........................................................1465
			4 Maintenance notes for replacement parts...........................................1466
			5 Recommendations for travel operation..............................................1466
			6 Disposal of fuels and lubricants..................................................1466
			7 Tires.............................................................................1466
	15.00 Driving with the equipment in place...................................................1475
		15.01 Travel mode with the equipment in place...........................................1476
			1 Measures to be taken before driving with the equipment in place...................1479
			2 Driving with the equipment in place...............................................1483
			3 Charts for driving with the equipment in place....................................1485
		15.05 Charts for driving with the equipment in place....................................1486
			1 Charts for driving with the equipment in place....................................1487
	Index.......................................................................................1515

LIEBHERR MOBILE CRANE LTM1095-5.1 OPERATIONS MANUAL SN 044228 – PDF DOWNLOAD:

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