Liebherr Crane BAT 410 Operating Manual SN 115925 – PDF DOWNLOAD
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Liebherr Crane BAT 410 Operating Manual SN 115925 – PDF DOWNLOAD
Language : English
Pages : 1022
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Liebherr Crane BAT 410 Operating Manual SN 115925 – PDF DOWNLOAD
Appropriate use:
The supplied equipment determines the possible applications of the machine.
The machine is only designed and constructed for the intended use stated and
described in the operation manual.
The machine may only be operated in an admissible setup condition and in the
mode corresponding to the use.
Special machine tasks that deviate from the tasks described in the operation
manual must be coordinated with the machine manufacturer beforehand.
Intended use of the machine is a basic requirement of safe operation.
Non-observation of the intended machine use results in grave consequences:
– Life-threatening or fatal injuries.
– Severe damage to the machine, assets or contamination of the environment for
which the manufacturer of the machine cannot be held liable.
– Loss of warranty and guarantee claims.
Utilization not described in the operation manual must be authorized in writing by
the manufacturer. Any other use of the machine without written consent of the
manufacturer is deemed inappropriate use.
Appropriate use of the machine is exclusively defined as follows:
– Utilization in working ranges and under the conditions of use listed and
described in the operation manual.
– Use of exchangeable equipment provided or approved by the machine manufacturer.
– Moving the machine without load with rigging equipment in line with the admissible
load chart with supervision of a signalman.
– Moving the machine with lifted load in line with the admissible load chart with
supervision of a signalman.
– A signalman must observe traveling of the machine within the admissible traveling
range with suspended and admissible load and in admissible position of
the uppercarriage and the leader.
– Application of various drilling methods described in the operation manual under
consideration of the respective admissible leader tilt.
Appropriate use the machine observing the following specifications and requirements:
– Complete safety equipment is installed and functioning properly.
– All maintenance and repair work stated in the maintenance and inspection plan
of the operation manual was performed according to specifications by qualified
maintenance personnel or authorized qualified personnel.
– All safety instructions in this operation manual are being observed.
– All valid national and international safety regulations (e.g. oil or gas industry)
are observed by the operator, if applicable.
– The operating materials listed in the operation manual are being used.
– All persons involved meet the requirements on staff according to the operation
manual.
– All persons involved meet their responsibilities according to the operation
manual.
– The technical information values are being observed.
– Load charts are being observed.
– Operational restrictions are being observed.
– Intended and inappropriate use of the exchangeable equipment is being
observed.
TABLE OF CONTENTS:
Liebherr Crane BAT 410 Operating Manual SN 115925 – PDF DOWNLOAD
Operating manual BAT 410....................................................................................................................................................................................... 1 Foreword................................................................................................................................................................................................... 3 Notes regarding the documentation.......................................................................................................................................................................... 5 Contents................................................................................................................................................................................................... 11 1 Product description...................................................................................................................................................................................... 17 1.1 Type plate......................................................................................................................................................................................... 17 1.2 Declaration of conformity.......................................................................................................................................................................... 18 1.3 Intended use....................................................................................................................................................................................... 19 1.4 Inappropriate use.................................................................................................................................................................................. 20 1.5 Machine............................................................................................................................................................................................ 21 1.5.1 Rotary drive................................................................................................................................................................................. 21 1.5.2 Rotary drive dimensions...................................................................................................................................................................... 22 1.5.3 Operating weight............................................................................................................................................................................. 22 1.5.4 Application conditions....................................................................................................................................................................... 23 1.5.5 Rotary drive................................................................................................................................................................................. 23 1.5.6 Safety devices............................................................................................................................................................................... 24 2 Safety instructions...................................................................................................................................................................................... 27 2.1 Technical condition of the machine................................................................................................................................................................. 27 2.2 Danger zone........................................................................................................................................................................................ 27 2.3 Safety signs on the machine........................................................................................................................................................................ 28 2.4 Meaning of the safety signs........................................................................................................................................................................ 28 2.4.1 Mandatory signs.............................................................................................................................................................................. 28 2.4.2 Prohibition signs............................................................................................................................................................................ 29 2.4.3 Warning signs................................................................................................................................................................................ 30 2.4.4 Rescue signs................................................................................................................................................................................. 32 2.4.5 Fire protection signs........................................................................................................................................................................ 33 2.5 Meaning of machine-specific signs.................................................................................................................................................................. 33 2.5.1 Safety signs................................................................................................................................................................................. 33 2.5.2 Notice signs................................................................................................................................................................................. 34 3 Control and operating elements........................................................................................................................................................................... 41 4 Operation................................................................................................................................................................................................ 45 4.1 Checks before start up............................................................................................................................................................................. 45 4.1.1 Inspection tour.............................................................................................................................................................................. 45 4.2 Operation.......................................................................................................................................................................................... 47 4.2.1 Accessing and staying on the platform*....................................................................................................................................................... 47 5 Operational faults, diagnosis............................................................................................................................................................................ 51 6 Assembly and dismantling................................................................................................................................................................................. 55 6.1 Implementation directions.......................................................................................................................................................................... 55 6.2 Locking elements - overview........................................................................................................................................................................ 56 6.2.1 Split pin.................................................................................................................................................................................... 56 6.2.2 Linchpin..................................................................................................................................................................................... 57 6.2.3 Spring cotter pin............................................................................................................................................................................ 58 6.2.4 Safety pin................................................................................................................................................................................... 59 6.2.5 Locking washers.............................................................................................................................................................................. 61 6.3 Rotary drive....................................................................................................................................................................................... 62 6.3.1 Installing the rotary drive.................................................................................................................................................................. 62 7 Transport................................................................................................................................................................................................ 65 7.1 Loading the machine................................................................................................................................................................................ 65 8 Maintenance.............................................................................................................................................................................................. 69 8.1 Maintenance and inspection schedule................................................................................................................................................................ 69 8.2 Lubricants and consumables......................................................................................................................................................................... 72 8.2.1 Filling capacity table....................................................................................................................................................................... 72 8.2.2 Lubrication chart............................................................................................................................................................................ 73 8.2.3 Hydraulic oil................................................................................................................................................................................ 76 8.2.4 Preservation medium (anti-corrosion coating)................................................................................................................................................. 77 8.3 Rotary gearbox..................................................................................................................................................................................... 80 8.3.1 Checking the gearbox oil level............................................................................................................................................................... 80 8.3.2 Topping up gearbox oil....................................................................................................................................................................... 80 8.3.3 Draining the gearbox oil..................................................................................................................................................................... 81 8.3.4 Checking for leaks........................................................................................................................................................................... 82 8.3.5 Checking fastening screws.................................................................................................................................................................... 82 8.3.6 Lubricate gearbox............................................................................................................................................................................ 83 8.4 Cam bar............................................................................................................................................................................................ 84 8.4.1 Checking the tab strips...................................................................................................................................................................... 84 8.5 Kelly shock absorber............................................................................................................................................................................... 85 8.5.1 Checking the hydraulic buffers............................................................................................................................................................... 85 8.5.2 Check the Kelly shock absorber support ring.................................................................................................................................................. 85 Index...................................................................................................................................................................................................... 87 Operator's manual LB 36-410.................................................................................................................................................................................... 89 Foreword................................................................................................................................................................................................... 97 Notes regarding the documentation.......................................................................................................................................................................... 99 Technical terms and abbreviations.......................................................................................................................................................................... 105 Contents................................................................................................................................................................................................... 107 1 Product description...................................................................................................................................................................................... 129 1.1 Type plate......................................................................................................................................................................................... 129 1.2 Declaration of conformity.......................................................................................................................................................................... 130 1.3 Installation declarations*......................................................................................................................................................................... 131 1.4 Appropriate use.................................................................................................................................................................................... 132 1.5 Inappropriate use.................................................................................................................................................................................. 133 1.6 Load charts........................................................................................................................................................................................ 135 1.7 Machine............................................................................................................................................................................................ 136 1.7.1 Machine overview............................................................................................................................................................................. 136 1.7.2 Machine dimensions........................................................................................................................................................................... 137 1.7.3 Technical data............................................................................................................................................................................... 141 1.7.4 Safety equipment............................................................................................................................................................................. 146 1.7.5 Monitoring installations..................................................................................................................................................................... 147 1.8 Carrier machine.................................................................................................................................................................................... 148 1.8.1 Carrier machine overview..................................................................................................................................................................... 148 1.8.2 Uppercarriage................................................................................................................................................................................ 150 1.8.3 Undercarriage................................................................................................................................................................................ 154 1.8.4 Counterweight................................................................................................................................................................................ 154 1.9 Drilling rig....................................................................................................................................................................................... 160 1.9.1 Drilling rig overview........................................................................................................................................................................ 160 1.9.2 Leader....................................................................................................................................................................................... 161 1.9.3 Leader top................................................................................................................................................................................... 168 1.9.4 Equipment and tool........................................................................................................................................................................... 172 1.10 Diesel particle filter*........................................................................................................................................................................... 180 1.11 By-pass flow filter system*....................................................................................................................................................................... 181 1.12 Refueling pump*................................................................................................................................................................................... 182 1.13 Fuelling system* pressure filter.................................................................................................................................................................. 183 1.14 External power supply*............................................................................................................................................................................ 184 1.14.1 External power supply obstacle warning light................................................................................................................................................ 184 1.14.2 External supply low temperature package..................................................................................................................................................... 185 1.15 Cab roof protection guard*........................................................................................................................................................................ 188 1.16 Falling object protection* for cab................................................................................................................................................................ 189 1.17 Safety guard* for falling object protection....................................................................................................................................................... 191 1.18 Front falling object protection*.................................................................................................................................................................. 192 1.19 Vandalism protection*............................................................................................................................................................................. 193 1.19.1 Top cover................................................................................................................................................................................... 194 1.19.2 Rear cover.................................................................................................................................................................................. 195 1.19.3 Front cover................................................................................................................................................................................. 196 1.19.4 Right front cover........................................................................................................................................................................... 197 1.19.5 Right rear cover............................................................................................................................................................................ 199 1.19.6 Left front cover............................................................................................................................................................................ 200 1.19.7 Left rear cover............................................................................................................................................................................. 201 1.19.8 Brackets for front cover.................................................................................................................................................................... 202 1.19.9 Barrier rod................................................................................................................................................................................. 202 1.20 Ventilation, heating and air-conditioning......................................................................................................................................................... 204 1.20.1 Cooling circuit............................................................................................................................................................................. 204 1.20.2 Heating circuit............................................................................................................................................................................. 207 1.20.3 Auxiliary air heating*...................................................................................................................................................................... 207 1.20.4 Fuel pre-filter heating..................................................................................................................................................................... 210 1.21 Socket* in cabin.................................................................................................................................................................................. 211 1.22 GSM/GPRS/GPS modem*............................................................................................................................................................................... 212 1.23 Litronic control system........................................................................................................................................................................... 213 1.24 Loading and installation radio remote control*.................................................................................................................................................... 214 1.25 Process data recording (PDE)*..................................................................................................................................................................... 217 1.26 Process data report (PDR)*........................................................................................................................................................................ 218 1.27 Ladder on uppercarriage........................................................................................................................................................................... 219 1.28 Additional floodlights*........................................................................................................................................................................... 220 1.29 Obstacle warning light*........................................................................................................................................................................... 221 1.30 Video surveillance system*........................................................................................................................................................................ 222 1.30.1 Monitor..................................................................................................................................................................................... 222 1.30.2 Reversing camera*........................................................................................................................................................................... 223 1.30.3 Camera winches.............................................................................................................................................................................. 224 1.31 Central lubrication*.............................................................................................................................................................................. 225 1.31.1 Central lubrication leader track............................................................................................................................................................ 225 1.31.2 Central lubrication swing ring tooth flank, bearing and kinematics.......................................................................................................................... 225 2 Safety instructions...................................................................................................................................................................................... 229 2.1 Safe operation of the machine...................................................................................................................................................................... 229 2.1.1 Personnel selection.......................................................................................................................................................................... 229 2.1.2 Safe system of work.......................................................................................................................................................................... 229 2.1.3 Preventive maintenance....................................................................................................................................................................... 230 2.2 Areas of responsibility............................................................................................................................................................................ 231 2.2.1 Manufacturer................................................................................................................................................................................. 231 2.2.2 Owner........................................................................................................................................................................................ 231 2.2.3 Machine operator............................................................................................................................................................................. 232 2.2.4 Slinger...................................................................................................................................................................................... 232 2.2.5 Signaller.................................................................................................................................................................................... 233 2.2.6 Maintenance personnel........................................................................................................................................................................ 233 2.2.7 Installation personnel and disassembly personnel............................................................................................................................................. 233 2.2.8 Helper....................................................................................................................................................................................... 234 2.2.9 Liebherr service personnel................................................................................................................................................................... 234 2.2.10 Certified and institutionally authorized persons............................................................................................................................................ 234 2.3 Requirements to personnel.......................................................................................................................................................................... 235 2.3.1 Machine operator............................................................................................................................................................................. 235 2.3.2 Slinger...................................................................................................................................................................................... 235 2.3.3 Signaller.................................................................................................................................................................................... 236 2.3.4 Maintenance personnel........................................................................................................................................................................ 236 2.3.5 Installation personnel and disassembly personnel............................................................................................................................................. 236 2.3.6 Helper....................................................................................................................................................................................... 237 2.3.7 Liebherr service personnel................................................................................................................................................................... 237 2.3.8 Certified and institutionally authorized persons............................................................................................................................................. 237 2.4 Personal protective equipment...................................................................................................................................................................... 238 2.5 Workplace.......................................................................................................................................................................................... 238 2.6 Danger zone........................................................................................................................................................................................ 239 2.6.1 Danger zone in drilling mode................................................................................................................................................................. 240 2.6.2 Danger zone when moving the machine.......................................................................................................................................................... 240 2.6.3 Danger zone in transport position............................................................................................................................................................ 241 2.7 Safety signs on machine............................................................................................................................................................................ 241 2.8 Safety signs on the machine (US market)............................................................................................................................................................ 242 2.9 Meaning of safety signs............................................................................................................................................................................ 245 2.9.1 Mandatory action sign........................................................................................................................................................................ 245 2.9.2 Prohibition sign............................................................................................................................................................................. 246 2.9.3 Warning signs................................................................................................................................................................................ 247 2.9.4 Safe condition sign.......................................................................................................................................................................... 249 2.9.5 Fire equipment sign.......................................................................................................................................................................... 250 2.10 Meanings of machine-specific signs................................................................................................................................................................ 250 2.11 Notice signs...................................................................................................................................................................................... 251 2.12 Hazards........................................................................................................................................................................................... 253 2.12.1 Mechanical action........................................................................................................................................................................... 253 2.12.2 Electrical energy........................................................................................................................................................................... 254 2.12.3 Hydraulic energy............................................................................................................................................................................ 255 2.12.4 Burns....................................................................................................................................................................................... 255 2.12.5 Chemical burns.............................................................................................................................................................................. 256 2.12.6 Fire and explosion.......................................................................................................................................................................... 257 2.12.7 Poisoning and suffocation................................................................................................................................................................... 258 2.12.8 Electromagnetic influence................................................................................................................................................................... 259 2.12.9 Exposure to wind............................................................................................................................................................................ 259 2.12.10 Snow load and ice load..................................................................................................................................................................... 261 2.12.11 Load-bearing capacity of the ground........................................................................................................................................................ 261 2.12.12 Lightning strike........................................................................................................................................................................... 262 2.12.13 Overhead lines............................................................................................................................................................................. 263 2.12.14 Earthwork.................................................................................................................................................................................. 265 2.12.15 Environment................................................................................................................................................................................ 266 2.13 What to do in dangerous situations................................................................................................................................................................ 267 2.13.1 How to respond in the event of a current transfer........................................................................................................................................... 267 2.13.2 How to respond in the event of a fire....................................................................................................................................................... 268 2.13.3 Firefighting................................................................................................................................................................................ 269 2.14 Working at heights................................................................................................................................................................................ 271 2.15 Use at low temperatures........................................................................................................................................................................... 271 2.15.1 Operation of the machine down to -20 °C (-4 °F) (standard).................................................................................................................................. 272 2.15.2 Operation of the machine down to -25 °C (-13 °F)*........................................................................................................................................... 272 2.15.3 Operation of the machine down to -40 °C (-40 °F)*........................................................................................................................................... 272 2.16 Hand signals...................................................................................................................................................................................... 273 2.16.1 General hand signals in accordance with BGV A8.............................................................................................................................................. 273 2.16.2 Special hand signals for sling gear application............................................................................................................................................. 276 2.16.3 Hand signals for lifting gear application in accordance with ASME/ANSI B30.5................................................................................................................ 279 3 Control and operating elements........................................................................................................................................................................... 287 3.1 Operating elements on undercarriage................................................................................................................................................................ 287 3.2 Operating elements on the uppercarriage............................................................................................................................................................ 288 3.3 Cabin.............................................................................................................................................................................................. 289 3.4 Left control lever................................................................................................................................................................................. 291 3.4.1 Function assignment buttons of left control lever............................................................................................................................................ 291 3.4.2 Function assignment movement direction of left control lever................................................................................................................................. 293 3.5 Right control lever................................................................................................................................................................................ 296 3.5.1 Function assignment of right control lever buttons........................................................................................................................................... 296 3.5.2 Function assignment of right control lever movement directions............................................................................................................................... 301 3.6 Foot pedals and hand levers........................................................................................................................................................................ 304 3.7 Circular bubble.................................................................................................................................................................................... 305 3.8 Control panel X11.................................................................................................................................................................................. 306 3.9 Control panel X12.................................................................................................................................................................................. 308 3.10 Control panel X23................................................................................................................................................................................. 310 3.11 Control panel X25................................................................................................................................................................................. 314 3.12 Concrete pump control panel....................................................................................................................................................................... 319 3.13 Monitor........................................................................................................................................................................................... 321 3.13.1 Status bar.................................................................................................................................................................................. 321 3.13.2 Display section............................................................................................................................................................................. 327 3.13.3 Menu bar.................................................................................................................................................................................... 327 3.13.4 Submenu bar................................................................................................................................................................................. 328 3.14 Start screen...................................................................................................................................................................................... 330 3.15 Mode screen....................................................................................................................................................................................... 331 3.15.1 Kelly drilling.............................................................................................................................................................................. 331 3.15.2 CFA drilling................................................................................................................................................................................ 337 3.15.3 FOW drilling................................................................................................................................................................................ 342 3.15.4 Full displacement drilling.................................................................................................................................................................. 346 3.15.5 Soil mixing................................................................................................................................................................................. 351 3.15.6 Down-the-hole drilling...................................................................................................................................................................... 355 3.16 Power unit screen................................................................................................................................................................................. 360 3.17 Screen "Operating hours".......................................................................................................................................................................... 367 3.18 Swing limitation* screen.......................................................................................................................................................................... 370 3.19 Screen Access control............................................................................................................................................................................. 371 3.19.1 Without retrofit kit access control (black ignition keys)................................................................................................................................... 371 3.19.2 Without retrofit kit access control (blue ignition keys).................................................................................................................................... 372 3.19.3 With retrofit kit access control (red and blue ignition keys)*.............................................................................................................................. 373 3.20 Mode screen....................................................................................................................................................................................... 376 3.21 Settings screen................................................................................................................................................................................... 378 3.21.1 Screen "Settings - components".............................................................................................................................................................. 378 3.21.2 Screen "Settings - accessory equipment"..................................................................................................................................................... 382 3.21.3 Settings - units screen..................................................................................................................................................................... 386 3.21.4 Screen Settings - Litronic testing system................................................................................................................................................... 389 3.22 Screen "Error messages"........................................................................................................................................................................... 393 3.23 Auxiliary heating*................................................................................................................................................................................ 395 3.24 Video surveillance system*........................................................................................................................................................................ 396 3.24.1 Monitor..................................................................................................................................................................................... 396 3.25 Loading and installation radio remote control*.................................................................................................................................................... 397 3.25.1 Operating elements.......................................................................................................................................................................... 398 3.25.2 Monitor..................................................................................................................................................................................... 406 3.26 Control panel for track width adjustment of crawler side frame*................................................................................................................................... 412 3.27 Central lubrication*.............................................................................................................................................................................. 413 4 Operation................................................................................................................................................................................................ 417 4.1 Control panels..................................................................................................................................................................................... 418 4.1.1 Setting control panel X25* or control panel X26*............................................................................................................................................. 418 4.2 Operator's seat.................................................................................................................................................................................... 420 4.2.1 Adjusting the control stand horizontally..................................................................................................................................................... 421 4.2.2 Adjusting the operator's seat................................................................................................................................................................ 421 4.2.3 Adjusting the dampening...................................................................................................................................................................... 425 4.2.4 Adjusting the ergonomics*.................................................................................................................................................................... 426 4.2.5 Safety belt*................................................................................................................................................................................. 428 4.3 Lighting........................................................................................................................................................................................... 429 4.3.1 Operating the floodlights on the uppercarriage............................................................................................................................................... 429 4.3.2 Operating cabin lighting..................................................................................................................................................................... 430 4.3.3 Operating the engine compartment lighting.................................................................................................................................................... 430 4.4 Windscreen wiper system............................................................................................................................................................................ 431 4.4.1 Operating the windscreen wipers.............................................................................................................................................................. 431 4.4.2 Operating the windscreen washer system....................................................................................................................................................... 432 4.5 Ventilation, heating and air-conditioning.......................................................................................................................................................... 433 4.5.1 Setting the air vent......................................................................................................................................................................... 435 4.5.2 Adjusting the lamella vents.................................................................................................................................................................. 436 4.5.3 Setting recirculated air or fresh air........................................................................................................................................................ 436 4.5.4 Operating the ventilation.................................................................................................................................................................... 436 4.5.5 Using the heater............................................................................................................................................................................. 437 4.5.6 Turning the air conditioning system on or off................................................................................................................................................ 437 4.5.7 Auxiliary heating*........................................................................................................................................................................... 437 4.6 Additional cab equipment........................................................................................................................................................................... 441 4.6.1 Using the horn............................................................................................................................................................................... 441 4.6.2 Operating the safety lever................................................................................................................................................................... 441 4.6.3 Operating the radio.......................................................................................................................................................................... 442 4.6.4 Using the ashtray............................................................................................................................................................................ 443 4.6.5 Using the cigarette lighter.................................................................................................................................................................. 443 4.7 Central lubrication*............................................................................................................................................................................... 444 4.7.1 Operating the leader track* central lubrication and rotary drive* central lubrication........................................................................................................ 444 4.8 Additional power unit*............................................................................................................................................................................. 445 4.8.1 Operating the compressor*.................................................................................................................................................................... 445 4.8.2 Operating the generator*..................................................................................................................................................................... 445 4.9 Video surveillance system*......................................................................................................................................................................... 446 4.9.1 Operating the video surveillance system...................................................................................................................................................... 446 4.10 Checks before start-up............................................................................................................................................................................ 447 4.10.1 Inspecting the machine...................................................................................................................................................................... 447 4.10.2 Checking the fuel level..................................................................................................................................................................... 448 4.10.3 Checking the urea level..................................................................................................................................................................... 448 4.10.4 Checking the hydraulic oil tank gate valve.................................................................................................................................................. 449 4.10.5 Checking the main battery switch............................................................................................................................................................ 449 4.11 Startup........................................................................................................................................................................................... 450 4.11.1 Cabin roof protection guard* and falling object protection*................................................................................................................................. 450 4.11.2 Adjusting the operator's seat............................................................................................................................................................... 450 4.11.3 Switching on the ignition................................................................................................................................................................... 450 4.11.4 Selecting mode.............................................................................................................................................................................. 451 4.11.5 Starting the diesel engine.................................................................................................................................................................. 452 4.11.6 Adjusting the engine RPM.................................................................................................................................................................... 453 4.11.7 Setting the constant engine RPM............................................................................................................................................................. 454 4.11.8 Lowering the safety lever................................................................................................................................................................... 454 4.11.9 Unlocking the functions..................................................................................................................................................................... 455 4.12 Loading and installation radio remote control*.................................................................................................................................................... 456 4.12.1 rechargeable battery........................................................................................................................................................................ 456 4.12.2 battery charger............................................................................................................................................................................. 456 4.12.3 Starting the machine with the loading and installation radio remote control................................................................................................................. 458 4.13 Crawler........................................................................................................................................................................................... 464 4.13.1 Traveling with lowered leader............................................................................................................................................................... 465 4.13.2 Traveling with erected leader............................................................................................................................................................... 465 4.13.3 Traveling with a load....................................................................................................................................................................... 465 4.13.4 Operating the crawler....................................................................................................................................................................... 466 4.13.5 Traveling straight ahead.................................................................................................................................................................... 468 4.14 Swing............................................................................................................................................................................................. 471 4.14.1 Operating the swing......................................................................................................................................................................... 471 4.14.2 Setting the swing speed..................................................................................................................................................................... 471 4.14.3 Setting the swing limitation*............................................................................................................................................................... 472 4.15 Leader............................................................................................................................................................................................ 483 4.15.1 Tilting the leader.......................................................................................................................................................................... 483 4.15.2 Adjusting the leader radius................................................................................................................................................................. 486 4.15.3 Operating the leader support................................................................................................................................................................ 488 4.16 First automatic leader adjustment................................................................................................................................................................. 492 4.16.1 Entering the first nominal value for the leader tilt........................................................................................................................................ 492 4.16.2 Operating the first automatic leader adjustment............................................................................................................................................. 494 4.17 Second automatic leader adjustment................................................................................................................................................................ 496 4.17.1 Entering the second nominal value for leader tilt........................................................................................................................................... 496 4.17.2 Operating the second automatic leader adjustment............................................................................................................................................ 498 4.18 Auxiliary winch................................................................................................................................................................................... 499 4.18.1 Operating the auxiliary winch............................................................................................................................................................... 499 4.19 Additional winch*................................................................................................................................................................................. 503 4.19.1 Operating the additional winch.............................................................................................................................................................. 503 4.20 Kelly winch....................................................................................................................................................................................... 505 4.20.1 Operating the Kelly winch................................................................................................................................................................... 505 4.21 Kelly winch rope measuring system*................................................................................................................................................................ 509 4.21.1 Initializing the rope measuring system...................................................................................................................................................... 509 4.21.2 Programming the rope measuring system....................................................................................................................................................... 511 4.22 Kelly winch free-wheel............................................................................................................................................................................ 513 4.22.1 Activating Kelly winch free-wheel........................................................................................................................................................... 513 4.22.2 Operating Kelly winch free-wheel............................................................................................................................................................ 514 4.22.3 Deactivating Kelly winch free-wheel......................................................................................................................................................... 515 4.22.4 Activating unsecured Kelly winch free-wheel................................................................................................................................................. 515 4.22.5 Deactivating unsecured Kelly winch free-wheel............................................................................................................................................... 516 4.23 Universal carriage................................................................................................................................................................................ 517 4.23.1 Operating the universal carriage............................................................................................................................................................ 517 4.24 Parallel mode*.................................................................................................................................................................................... 525 4.24.1 Activating parallel mode.................................................................................................................................................................... 525 4.24.2 Moving the universal carriage............................................................................................................................................................... 527 4.24.3 Deactivating parallel mode.................................................................................................................................................................. 527 4.25 Drilling operation................................................................................................................................................................................ 528 4.25.1 Setting the speed range..................................................................................................................................................................... 528 4.25.2 Saving drilling movement.................................................................................................................................................................... 531 4.25.3 Switching on the load moment limiter*....................................................................................................................................................... 531 4.25.4 Bypassing the torque limitation*............................................................................................................................................................ 531 4.25.5 Limiting the drilling speed................................................................................................................................................................. 532 4.25.6 Vibrate rotary drive........................................................................................................................................................................ 533 4.25.7 Operating auger cleaner..................................................................................................................................................................... 533 4.25.8 Operating the lower pile guide.............................................................................................................................................................. 534 4.26 Kelly drilling*................................................................................................................................................................................... 536 4.26.1 Preselecting Kelly drilling................................................................................................................................................................. 536 4.26.2 Setting the rotary drive.................................................................................................................................................................... 537 4.26.3 Turning the rotary drive.................................................................................................................................................................... 539 4.27 CFA drilling*..................................................................................................................................................................................... 541 4.27.1 Selecting CFA drilling...................................................................................................................................................................... 541 4.27.2 Setting the rotary drive.................................................................................................................................................................... 542 4.27.3 Turning the rotary drive to the right....................................................................................................................................................... 545 4.28 FOW drilling*..................................................................................................................................................................................... 546 4.28.1 Preselecting FOW drilling................................................................................................................................................................... 546 4.28.2 Setting the rotary drive.................................................................................................................................................................... 547 4.28.3 Actuating rotary drive1 (auger)............................................................................................................................................................. 549 4.28.4 Switching torque of rotary drive1........................................................................................................................................................... 551 4.28.5 Actuate rotary drive2 (pipe)................................................................................................................................................................ 551 4.28.6 Switching torque of rotary drive2........................................................................................................................................................... 552 4.28.7 Operating both rotary drives with one control lever......................................................................................................................................... 553 4.28.8 Actuating the relative adjustment cylinder.................................................................................................................................................. 554 4.29 Full displacement drilling*....................................................................................................................................................................... 555 4.29.1 Selecting full displacement drilling........................................................................................................................................................ 555 4.29.2 Setting the rotary drive.................................................................................................................................................................... 556 4.29.3 Turning the rotary drive to the right....................................................................................................................................................... 559 4.29.4 Retracting the concrete trunk............................................................................................................................................................... 560 4.30 Soil mixing*...................................................................................................................................................................................... 561 4.30.1 Preselecting soil mixing.................................................................................................................................................................... 561 4.30.2 Setting the rotary drive.................................................................................................................................................................... 562 4.30.3 Turning the rotary drives................................................................................................................................................................... 564 4.31 Casing oscillator*................................................................................................................................................................................ 566 4.31.1 Connecting the casing oscillator............................................................................................................................................................ 566 4.31.2 Adjusting casing oscillator................................................................................................................................................................. 569 4.31.3 Activating the casing oscillator - standard mode............................................................................................................................................ 571 4.31.4 Activating the casing oscillator - ecological mode.......................................................................................................................................... 571 4.31.5 Operating the casing oscillator............................................................................................................................................................. 572 4.31.6 Operating the casing oscillator via remote control.......................................................................................................................................... 573 4.31.7 Operating casing oscillator (variant)* via remote control................................................................................................................................... 575 4.31.8 Switching off the casing oscillator......................................................................................................................................................... 576 4.32 Reinforcement vibrator*........................................................................................................................................................................... 577 4.32.1 Operating the reinforcement vibrator........................................................................................................................................................ 577 4.32.2 Starting the automatic clamping system...................................................................................................................................................... 577 4.32.3 Switching the reinforcement vibrator on..................................................................................................................................................... 577 4.32.4 Switching the reinforcement vibrator off.................................................................................................................................................... 578 4.32.5 Opening the clamp........................................................................................................................................................................... 578 4.33 Down-the-hole drilling*........................................................................................................................................................................... 579 4.33.1 Selecting down-the-hole drilling............................................................................................................................................................ 579 4.33.2 Setting the rotary drive.................................................................................................................................................................... 579 4.33.3 Turning the rotary drive.................................................................................................................................................................... 581 4.33.4 Operating the relocation unit*.............................................................................................................................................................. 582 4.34 Filling machine with fuel......................................................................................................................................................................... 583 4.34.1 Filling machine with fuel from a tank truck................................................................................................................................................. 583 4.34.2 Filling the machine with fuel from a refueling pump......................................................................................................................................... 584 4.34.3 Filling up with urea solution*.............................................................................................................................................................. 585 4.35 Diesel engine automatic stop system*.............................................................................................................................................................. 586 4.35.1 Switching the diesel engine automatic stop system on or off................................................................................................................................. 586 4.36 Safety harness and fall arrest slider*............................................................................................................................................................ 587 4.36.1 Putting on the safety harness............................................................................................................................................................... 587 4.36.2 Function test fall arrest slider............................................................................................................................................................ 589 4.36.3 Hook up fall arrest slider.................................................................................................................................................................. 589 4.37 Shutdown.......................................................................................................................................................................................... 590 4.37.1 Short interruption of work.................................................................................................................................................................. 590 4.37.2 Long interruption of work................................................................................................................................................................... 591 4.38 Emergency stop.................................................................................................................................................................................... 593 4.38.1 Using emergency stop........................................................................................................................................................................ 593 5 Operational faults, diagnosis............................................................................................................................................................................ 597 5.1 Malfunctions....................................................................................................................................................................................... 597 5.1.1 Identifying faults........................................................................................................................................................................... 597 5.1.2 Error displays on monitor.................................................................................................................................................................... 597 5.1.3 Troubleshooting.............................................................................................................................................................................. 601 5.2 Litronic testing system............................................................................................................................................................................ 603 5.2.1 Litronic testing system overview............................................................................................................................................................. 603 5.2.2 Screen pages................................................................................................................................................................................. 604 5.2.3 Starting the Litronic® testing system........................................................................................................................................................ 611 5.3 Fuses.............................................................................................................................................................................................. 612 5.3.1 List of fuses................................................................................................................................................................................ 612 5.3.2 Checking fuses............................................................................................................................................................................... 612 5.3.3 Changing fuses............................................................................................................................................................................... 613 6 Operational planning..................................................................................................................................................................................... 617 6.1 Assembly site...................................................................................................................................................................................... 617 6.2 Tools required..................................................................................................................................................................................... 618 6.3 Restrictions due to wind........................................................................................................................................................................... 619 6.3.1 Park position................................................................................................................................................................................ 619 6.4 Traveling on the construction site................................................................................................................................................................. 620 6.4.1 Traveling with erected leader................................................................................................................................................................ 620 6.4.2 Traveling with leader put down and Kelly equipment attached.................................................................................................................................. 624 6.5 Rigging material and/or sling gear................................................................................................................................................................. 626 7 Assembly and dismantling................................................................................................................................................................................. 629 7.1 Work instructions for assembly/disassembly......................................................................................................................................................... 629 7.2 Locking elements - overview........................................................................................................................................................................ 632 7.2.1 Splint pin................................................................................................................................................................................... 632 7.2.2 Linchpin..................................................................................................................................................................................... 633 7.2.3 Spring cotter pin............................................................................................................................................................................ 634 7.2.4 Locking spring............................................................................................................................................................................... 635 7.2.5 Locking washers.............................................................................................................................................................................. 637 7.3 Assembling the basic machine....................................................................................................................................................................... 638 7.3.1 Explanations................................................................................................................................................................................. 638 7.3.2 Folding ladders into position on undercarriage............................................................................................................................................... 638 7.3.3 Installing the platforms and platform railings*.............................................................................................................................................. 639 7.3.4 Folding the ladder into operating position................................................................................................................................................... 644 7.3.5 Removing vandalism protection*............................................................................................................................................................... 646 7.3.6 Installing the outside mirror and antenna.................................................................................................................................................... 647 7.3.7 Bringing the rotating beacons* into operating position....................................................................................................................................... 647 7.3.8 Bringing the additional floodlights* into operating position................................................................................................................................. 648 7.3.9 Driving the machine off the low loader....................................................................................................................................................... 649 7.3.10 Removing the uppercarriage lock............................................................................................................................................................. 650 7.3.11 Assembling the carrier machine.............................................................................................................................................................. 650 7.3.12 Adjusting crawler side frames to working track.............................................................................................................................................. 666 7.3.13 Mounting the uppercarriage railing*......................................................................................................................................................... 674 7.3.14 Installing the drilling rig................................................................................................................................................................. 677 7.3.15 Preparing the drilling rig.................................................................................................................................................................. 688 7.3.16 Fitting the hoist limit switch.............................................................................................................................................................. 694 7.3.17 Installing the hoist limit switch (limit switch variant*)................................................................................................................................... 696 7.3.18 Unfolding the fall arrest*.................................................................................................................................................................. 700 7.3.19 Erecting the leader......................................................................................................................................................................... 700 7.3.20 Installing the counterweight................................................................................................................................................................ 703 7.3.21 Mounting the leader bottom plate*........................................................................................................................................................... 709 7.4 Installing and connecting rotary drive............................................................................................................................................................. 711 7.4.1 Installing rotary drive...................................................................................................................................................................... 711 7.4.2 Connecting the hydraulic system.............................................................................................................................................................. 715 7.4.3 Connecting the electrics..................................................................................................................................................................... 722 7.4.4 Installing the auger cleaner*................................................................................................................................................................ 722 7.4.5 Install lower pile guide*.................................................................................................................................................................... 724 7.5 Mounting the Kelly equipment....................................................................................................................................................................... 725 7.5.1 Mounting Kelly bar........................................................................................................................................................................... 726 7.5.2 Mounting the drilling equipment.............................................................................................................................................................. 739 7.6 Installing CFA/full displacement drilling equipment*............................................................................................................................................... 746 7.6.1 Installing and deinstalling the pulling system*.............................................................................................................................................. 747 7.6.2 Mounting the Kelly equipment*................................................................................................................................................................ 761 7.6.3 Mounting the Kelly extension*................................................................................................................................................................ 766 7.6.4 Installing CFA/full displacement drilling tool............................................................................................................................................... 772 7.6.5 Attaching the concrete pump.................................................................................................................................................................. 784 7.7 Putting down the leader............................................................................................................................................................................ 786 7.7.1 Brief summary................................................................................................................................................................................ 786 7.8 Moving the top part of leader into transport position*............................................................................................................................................. 788 7.8.1 Fully extending the rope tensioning cylinder................................................................................................................................................. 788 7.8.2 Removing the feed rope....................................................................................................................................................................... 788 7.8.3 Securing the feed rope and the auxiliary rope................................................................................................................................................ 789 7.8.4 Extending pin connection cylinder............................................................................................................................................................ 789 7.8.5 Folding top part of leader................................................................................................................................................................... 790 7.8.6 Retracting pin connection cylinder........................................................................................................................................................... 792 7.8.7 Installing the feed rope..................................................................................................................................................................... 792 7.8.8 Retracting the rope tensioning cylinders..................................................................................................................................................... 793 7.8.9 Terminating the process...................................................................................................................................................................... 793 7.9 Deinstalling the top part of leader*............................................................................................................................................................... 794 7.9.1 Extending ropes.............................................................................................................................................................................. 794 7.9.2 Installing the link (2x) between leader top and top part of leader........................................................................................................................... 796 7.9.3 Installing the frame......................................................................................................................................................................... 797 7.9.4 Rigging the top part of leader............................................................................................................................................................... 798 7.9.5 Detaching the top part of leader............................................................................................................................................................. 799 7.9.6 Removing the top part of leader.............................................................................................................................................................. 799 7.10 Disassembling the machine......................................................................................................................................................................... 800 7.10.1 Brief summary............................................................................................................................................................................... 800 8 Transport................................................................................................................................................................................................ 807 8.1 Rigging and lifting the machine.................................................................................................................................................................... 807 8.1.1 Mounting the leader claws.................................................................................................................................................................... 808 8.1.2 Installing the transport shackles............................................................................................................................................................ 809 8.1.3 Center of gravity position................................................................................................................................................................... 810 8.1.4 Rigging the machine.......................................................................................................................................................................... 811 8.1.5 Lifting the machine.......................................................................................................................................................................... 811 8.2 Loading the machine onto low loader................................................................................................................................................................ 813 8.3 Transporting the machine with a low loader......................................................................................................................................................... 814 8.3.1 Transport weights............................................................................................................................................................................ 814 8.3.2 Transport dimensions......................................................................................................................................................................... 816 8.3.3 Transporting the basic machine without crawler side frame and counterweight using a low loader............................................................................................... 819 8.3.4 Transporting the basic machine with crawler side frame and counterweight using a low loader.................................................................................................. 821 8.3.5 Transporting the basic machine with crawler side frame and without counterweight using a low loader.......................................................................................... 826 8.3.6 Basic machine rests on crawler chains........................................................................................................................................................ 828 8.3.7 Transporting the top part of leader (1300 mm (4‘ 3“ ft-in) leader top*)..................................................................................................................... 830 8.3.8 Transporting the top part of leader (1700 mm (5‘ 7“ ft-in) leader top*)..................................................................................................................... 831 8.4 Transporting the Kelly bar*........................................................................................................................................................................ 832 9 Maintenance.............................................................................................................................................................................................. 835 9.1 Maintenance and inspection schedule................................................................................................................................................................ 835 9.2 Lubricants and consumables......................................................................................................................................................................... 847 9.2.1 Lubrication diagram.......................................................................................................................................................................... 848 9.2.2 Filling capacity table....................................................................................................................................................................... 850 9.2.3 Lubrication chart............................................................................................................................................................................ 851 9.2.4 Diesel engine lubricating oil................................................................................................................................................................ 854 9.2.5 Fuel......................................................................................................................................................................................... 855 9.2.6 Urea solution................................................................................................................................................................................ 855 9.2.7 Diesel engine coolant........................................................................................................................................................................ 855 9.2.8 Hydraulic oil................................................................................................................................................................................ 855 9.2.9 Preservation medium (anti-corrosion coating)................................................................................................................................................. 856 9.2.10 Liebherr oil diagnosis system............................................................................................................................................................... 858 9.3 Work instructions for preventive maintenance....................................................................................................................................................... 861 9.4 Fuel tank (see operating manual of the engine manufacturer on CD).................................................................................................................................. 863 9.4.1 Draining water and bottom sediments.......................................................................................................................................................... 863 9.5 Fuelling system* pressure filter................................................................................................................................................................... 864 9.5.1 Exchanging the fuelling system pressure filter............................................................................................................................................... 864 9.6 Air filter system.................................................................................................................................................................................. 865 9.6.1 Checking the function of the negative pressure indicator..................................................................................................................................... 865 9.6.2 Cleaning the air filter dust ejector......................................................................................................................................................... 865 9.6.3 Exchanging the dry air filter main element and dry air filter safety element................................................................................................................. 866 9.7 Distribution gearbox............................................................................................................................................................................... 868 9.7.1 Checking the gearbox oil level............................................................................................................................................................... 868 9.7.2 Topping up gearbox oil....................................................................................................................................................................... 868 9.7.3 Checking the venting valve................................................................................................................................................................... 869 9.8 Swing.............................................................................................................................................................................................. 871 9.8.1 Checking the gearbox oil level............................................................................................................................................................... 871 9.8.2 Topping up the gearbox oil................................................................................................................................................................... 871 9.9 Rotary joint....................................................................................................................................................................................... 873 9.9.1 Lubricating external teeth................................................................................................................................................................... 873 9.9.2 Lubricating the bearing races via the central lubrication point.............................................................................................................................. 873 9.10 Feed winch........................................................................................................................................................................................ 875 9.10.1 Checking the gearbox oil level.............................................................................................................................................................. 875 9.10.2 Topping up gearbox oil...................................................................................................................................................................... 876 9.10.3 Lubricating counter bearings................................................................................................................................................................ 876 9.10.4 Checking the rope end fastening for tight fit............................................................................................................................................... 877 9.11 Auxiliary winch................................................................................................................................................................................... 878 9.11.1 Checking the gearbox oil level.............................................................................................................................................................. 878 9.11.2 Topping up gearbox oil...................................................................................................................................................................... 879 9.11.3 Lubricating counter bearings................................................................................................................................................................ 879 9.11.4 Checking the rope end fastening for tight fit............................................................................................................................................... 880 9.12 Kelly winch....................................................................................................................................................................................... 881 9.12.1 Checking the gearbox oil level.............................................................................................................................................................. 881 9.12.2 Topping up gearbox oil...................................................................................................................................................................... 882 9.12.3 Lubricating counter bearings................................................................................................................................................................ 882 9.12.4 Checking the rope end fastening for tight fit............................................................................................................................................... 883 9.13 Additional winch*................................................................................................................................................................................. 884 9.13.1 Checking the gearbox oil level.............................................................................................................................................................. 884 9.13.2 Topping up gearbox oil...................................................................................................................................................................... 884 9.13.3 Checking the rope end fastening for tight fit............................................................................................................................................... 886 9.14 Crawler........................................................................................................................................................................................... 887 9.14.1 Checking the gearbox oil level.............................................................................................................................................................. 887 9.14.2 Check gearbox and hydraulic screw connections for leaks..................................................................................................................................... 887 9.14.3 Cleaning the crawler........................................................................................................................................................................ 888 9.14.4 Check locking screws of the struts on crawler side frames for tight fit on extendable undercarriages........................................................................................ 888 9.14.5 Checking the chain tension.................................................................................................................................................................. 890 9.14.6 Adjusting chain tension..................................................................................................................................................................... 891 9.14.7 Retightening chain.......................................................................................................................................................................... 891 9.14.8 Relaxing the chain.......................................................................................................................................................................... 892 9.14.9 Tightening the base plate screws............................................................................................................................................................ 893 9.15 Lifting device.................................................................................................................................................................................... 896 9.15.1 Check transport lashing and round slings for wear (according to EN 1492-2).................................................................................................................. 896 9.15.2 Check the round steel chains for wear and damage............................................................................................................................................ 896 9.16 Hook.............................................................................................................................................................................................. 897 9.16.1 Checking all hooks for damage, wear, corrosion and widening of the hook aperture............................................................................................................ 897 9.16.2 Hook (10t): lubricate the swivel............................................................................................................................................................ 897 9.16.3 Check that the safety catch is present and working properly................................................................................................................................. 898 9.17 Hydraulic system.................................................................................................................................................................................. 899 9.17.1 Check the hydraulic system for leaks........................................................................................................................................................ 899 9.17.2 Checking the oil cooler for contamination................................................................................................................................................... 899 9.17.3 Changing the compressed air filter.......................................................................................................................................................... 900 9.18 Hydraulic oil tank................................................................................................................................................................................ 902 9.18.1 Carrying out a hydraulic oil analysis....................................................................................................................................................... 902 9.18.2 Filling with hydraulic oil.................................................................................................................................................................. 902 9.18.3 Draining the hydraulic oil.................................................................................................................................................................. 904 9.18.4 Cleaning the magnetic rod in the return filter.............................................................................................................................................. 904 9.18.5 Exchanging return filter.................................................................................................................................................................... 906 9.19 Hydraulic cylinders............................................................................................................................................................................... 909 9.19.1 Check that the hydraulic cylinder fits properly and does not leak........................................................................................................................... 909 9.19.2 Protecting the piston rods of the hydraulic cylinders from corrosion........................................................................................................................ 909 9.19.3 Preserving the piston rods of the hydraulic cylinders in case of longer periods of non-use.................................................................................................. 909 9.20 Hydraulic leads................................................................................................................................................................................... 910 9.20.1 Visual inspection of hydraulic leads (hydraulic hoses, hydraulic pipes)..................................................................................................................... 910 9.21 Bypass filter system.............................................................................................................................................................................. 911 9.21.1 Checking the bypass filter system........................................................................................................................................................... 911 9.21.2 Changing the filter elements................................................................................................................................................................ 911 9.22 Batteries......................................................................................................................................................................................... 914 9.22.1 Checking the fluid level in the cells....................................................................................................................................................... 914 9.22.2 Checking the battery fluid.................................................................................................................................................................. 914 9.22.3 Exchanging the fuses on the battery......................................................................................................................................................... 915 9.23 Lighting.......................................................................................................................................................................................... 916 9.23.1 Checking that the cabin lighting, floodlights and additional floodlights are working properly............................................................................................... 916 9.23.2 Changing the cabin illuminant............................................................................................................................................................... 916 9.23.3 Changing the floodlights illuminants........................................................................................................................................................ 917 9.23.4 LED floodlight.............................................................................................................................................................................. 919 9.24 Rope measuring system............................................................................................................................................................................. 920 9.24.1 Checking the rope measuring system and height adjustment of all winches (if available) for correct function................................................................................. 920 9.24.2 Readjusting layer change when changing ropes................................................................................................................................................ 920 9.25 Limit switches.................................................................................................................................................................................... 921 9.25.1 Checking the function of the drilling equipment's hoist limit switches and limit switches................................................................................................... 921 9.25.2 Checking the hoist limit switches for tight fit and function................................................................................................................................ 921 9.25.3 Checking the limit switch of the drilling rig for attachment and function................................................................................................................... 921 9.26 Emergency stop.................................................................................................................................................................................... 924 9.26.1 Checking the emergency stop................................................................................................................................................................. 924 9.27 Obstacle warning light*........................................................................................................................................................................... 925 9.27.1 Check obstacle warning light for function and damage, check mains cable and plug (if available) for damage.................................................................................. 925 9.28 Fire extinguishers................................................................................................................................................................................ 926 9.28.1 Checking the seals and inspection dates on the fire extinguishers........................................................................................................................... 926 9.29 Personal protective equipment..................................................................................................................................................................... 927 9.29.1 Checking personal protective gear........................................................................................................................................................... 927 9.30 Safety harness, fall arrest slider (see respective documentation on CD)........................................................................................................................... 928 9.30.1 Checking the safety harness and fall arrest slider.......................................................................................................................................... 928 9.31 Safety signs...................................................................................................................................................................................... 929 9.31.1 Checking that all required safety labels are mounted on the machine and are legible......................................................................................................... 929 9.32 Steel structure................................................................................................................................................................................... 930 9.32.1 Checking the machine steel structure for damage, cracks..................................................................................................................................... 930 9.33 Repair welding.................................................................................................................................................................................... 931 9.33.1 Welding requirements........................................................................................................................................................................ 931 9.34 Drilling rig...................................................................................................................................................................................... 932 9.34.1 Checking leader joints...................................................................................................................................................................... 932 9.34.2 Checking the screws of the leader joints for tight fit...................................................................................................................................... 932 9.34.3 Lubricating the drilling rig................................................................................................................................................................ 932 9.34.4 Checking the slider tracks of the universal carriage for wear............................................................................................................................... 933 9.34.5 Checking the drilling rig for damage and wear............................................................................................................................................... 933 9.35 Lubrication system*............................................................................................................................................................................... 935 9.35.1 Checking the central lubrication swing ring tooth flanks, bearing and kinematics for functioning............................................................................................ 936 9.35.2 Setting the lubrication time................................................................................................................................................................ 937 9.35.3 Setting the break time...................................................................................................................................................................... 937 9.35.4 Checking the function of the leader carriage and leader track central lubrication system and the rotary drive central lubrication system (if available)..................................... 937 9.35.5 Checking the fill level of the lubrication pumps............................................................................................................................................ 938 9.35.6 Checking the time intervals of the lubrication pumps........................................................................................................................................ 938 9.35.7 Checking lubrication points................................................................................................................................................................. 938 9.36 Ropes............................................................................................................................................................................................. 939 9.36.1 Assembly of a rope.......................................................................................................................................................................... 939 9.36.2 Visual inspection of the ropes for deterioration or mechanical damage....................................................................................................................... 939 9.36.3 Checking ropes for lubrication.............................................................................................................................................................. 939 9.36.4 Rope lubrication............................................................................................................................................................................ 940 9.36.5 Checking ropes for end of service life...................................................................................................................................................... 940 9.36.6 Storing ropes............................................................................................................................................................................... 953 9.36.7 Transporting the ropes...................................................................................................................................................................... 953 9.36.8 Selecting a rope............................................................................................................................................................................ 954 9.36.9 Unwind rope from rope reel.................................................................................................................................................................. 956 9.36.10 Luffing ropes.............................................................................................................................................................................. 957 9.37 Drum.............................................................................................................................................................................................. 959 9.37.1 Checking rope tensioning pulleys* of drum for wear.......................................................................................................................................... 959 9.37.2 Checking the groove diameter of the drum.................................................................................................................................................... 959 9.37.3 Checking drum for loose rope layers......................................................................................................................................................... 960 9.38 Rope pulleys...................................................................................................................................................................................... 961 9.38.1 Assembly of a pulley........................................................................................................................................................................ 961 9.38.2 Checking the groove diameter of the pulley.................................................................................................................................................. 961 9.38.3 Checking the bottom of groove diameter of the pulley........................................................................................................................................ 962 9.38.4 Checking the gap width of the pulley........................................................................................................................................................ 963 9.38.5 Checking bottom of pulley groove for sharp edges............................................................................................................................................ 964 9.38.6 Checking pulleys for damage................................................................................................................................................................. 964 9.38.7 Checking the pulley bearings................................................................................................................................................................ 965 9.38.8 Lubricating the pulley bearings............................................................................................................................................................. 965 9.38.9 Checking the position of bearing and locking ring........................................................................................................................................... 965 9.38.10 Cleaning plastic pulleys................................................................................................................................................................... 966 9.39 Rope suspension and rope fixation................................................................................................................................................................. 967 9.39.1 Checking rope suspensions (rope clamps, rope thimbles) for wire breaks, absence of corrosion and tight fit of screw fittings................................................................ 967 9.39.2 Lubricating the swivel...................................................................................................................................................................... 969 9.39.3 Checking the rope end fittings for cracks................................................................................................................................................... 969 9.39.4 Checking the rope fixing point.............................................................................................................................................................. 970 9.40 Cabin............................................................................................................................................................................................. 971 9.40.1 Checking the windows of the cabin for damage................................................................................................................................................ 971 9.40.2 Cleaning the cabin windows.................................................................................................................................................................. 971 9.40.3 Checking the function of the cabin door and door lock....................................................................................................................................... 971 9.40.4 Check cabin roof protection guard for damage, locking (in case of foldable design).......................................................................................................... 972 9.40.5 Changing the windscreen wipers.............................................................................................................................................................. 972 9.40.6 Filling the windscreen wiper system......................................................................................................................................................... 973 9.40.7 Checking outside mirrors and inside mirrors for damage...................................................................................................................................... 973 9.41 Ventilation, heating and air-conditioning......................................................................................................................................................... 974 9.41.1 Checking the recirculated air filter for contamination...................................................................................................................................... 974 9.41.2 Replacing the recirculated air filter....................................................................................................................................................... 978 9.41.3 Checking fresh air filter for contamination................................................................................................................................................. 983 9.41.4 Replacing the fresh air filter.............................................................................................................................................................. 984 9.41.5 Checking the coolant level in the sight glass............................................................................................................................................... 988 9.41.6 Checking the condenser for contamination.................................................................................................................................................... 989 9.41.7 Checking the condenser for loose leads, loos screws and corrosion........................................................................................................................... 990 9.41.8 Checking the fan on condenser for function, tight fit and damage............................................................................................................................ 990 9.41.9 Checking the climate box for contamination.................................................................................................................................................. 991 9.41.10 Checking the dryer for damage and corrosion................................................................................................................................................ 992 9.41.11 Starting the ventilation, heating, air conditioner, external air conditioner* and auxiliary heating system* and ensuring that sufficient antifreeze has been added to the water circuit.... 992 9.41.12 Replacing the fuel filter of auxiliary water heating*...................................................................................................................................... 995 9.42 Access systems.................................................................................................................................................................................... 997 9.42.1 Checking ladders, steps, platforms, and ascents for wear, damage and anti-slip surfaces..................................................................................................... 997 9.42.2 Checking latches and hand rails for wear and damage......................................................................................................................................... 997 9.43 Vibrator cooling*................................................................................................................................................................................. 998 9.43.1 Checking vibrator cooling for correct function.............................................................................................................................................. 998 9.44 Tremie head*...................................................................................................................................................................................... 999 9.44.1 Lubricating the tremie head................................................................................................................................................................. 999 9.45 Compressor*.......................................................................................................................................................................................1000 9.45.1 Checking the oil level and draining condensate from the air container.......................................................................................................................1000 9.46 Machine care......................................................................................................................................................................................1001 9.46.1 Cleaning the machine........................................................................................................................................................................1001 9.46.2 Preserving the machine......................................................................................................................................................................1002 Index......................................................................................................................................................................................................1011
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