Liebherr Crane HS 8100 HD Operating Manual SN 184923 – PDF DOWNLOAD
FILE DETAILS:
Liebherr Crane HS 8100 HD Operating Manual SN 184923 – PDF DOWNLOAD
Language : English
Pages : 980
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Liebherr Crane HS 8100 HD Operating Manual SN 184923 – PDF DOWNLOAD
Foreword:
- The name Liebherr doesn’t just stand for products and services. It has become a byword for ideas
and innovations. For progress which has proved its worth in the marketplace. - We constantly strive to extend and improve our diverse range of products and serv- ices. This
requires ongoing cooperation and sharing of experience with our customers and business partners
throughout the world. We are therefore grateful for any ideas and suggestions for improvements. - Inform iebherr customer service if the machine is sold or bought by a previous
owner.
Using the documentation
The documentation supplied with the machine is designed to enable you to:
– operate the machine safely,
– use it in all permissible situations,
– carry out routine maintenance.
To do this, you will need to be able to find your way around the documentation,
which is in several parts.
The documentation consists of:
Operation manual
This contains information on starting, operating and maintaining the machine.
Spare parts catalog
This contains information on procuring spare parts.
Technical information
This contains information about the electrical and hydraulic systems of the
machine.
Load charts
This contains all the valid load charts for all machine setup options.
TABLE OF CONTENTS:
Liebherr Crane HS 8100 HD Operating Manual SN 184923 – PDF DOWNLOAD
Operating manual........................................................................................................................................................................................................ 1 Foreword............................................................................................................................................................................................................ 3 Notes regarding the documentation................................................................................................................................................................................... 5 Technical terms and abbreviations................................................................................................................................................................................... 11 Contents............................................................................................................................................................................................................ 13 1 Product description............................................................................................................................................................................................... 39 1.1 Type plate.................................................................................................................................................................................................. 39 1.2 Declaration of conformity................................................................................................................................................................................... 40 1.3 Appropriate use............................................................................................................................................................................................. 41 1.4 Inappropriate use........................................................................................................................................................................................... 43 1.5 Use of machine with load moment limitation and hoist limit switches......................................................................................................................................... 45 1.6 Service life classification................................................................................................................................................................................. 46 1.7 Load chart in dependence on working equipment............................................................................................................................................................... 47 1.7.1 Casing oscillator and grab (grab mode)................................................................................................................................................................ 48 1.7.2 Dynamic soil compaction............................................................................................................................................................................... 52 1.7.3 Dragline bucket....................................................................................................................................................................................... 53 1.7.4 Slurry wall grab...................................................................................................................................................................................... 55 1.8 Machine..................................................................................................................................................................................................... 60 1.8.1 Machine overview...................................................................................................................................................................................... 60 1.8.2 Technical data........................................................................................................................................................................................ 60 1.8.3 Safety devices........................................................................................................................................................................................ 65 1.8.4 Monitoring installations.............................................................................................................................................................................. 66 1.9 Basic machine............................................................................................................................................................................................... 67 1.9.1 Basic machine overview................................................................................................................................................................................ 67 1.9.2 A-frame1.............................................................................................................................................................................................. 71 1.9.3 Pendant straps on A-frame1............................................................................................................................................................................ 72 1.9.4 Uppercarriage......................................................................................................................................................................................... 73 1.9.5 Cabin................................................................................................................................................................................................. 75 1.9.6 Central power unit.................................................................................................................................................................................... 77 1.9.7 Undercarriage......................................................................................................................................................................................... 78 1.9.8 Crawler side frame.................................................................................................................................................................................... 79 1.9.9 Platforms on uppercarriage............................................................................................................................................................................ 80 1.9.10 Hydraulic platforms and electrohydraulic platforms* on uppercarriage................................................................................................................................. 81 1.9.11 Adapter for casing oscillator........................................................................................................................................................................ 87 1.9.12 Carbody counterweight................................................................................................................................................................................ 88 1.9.13 Rear counterweight................................................................................................................................................................................... 90 1.10 Information about boom designation......................................................................................................................................................................... 94 1.11 Main boom overview......................................................................................................................................................................................... 96 1.12 Short boom 1311.22......................................................................................................................................................................................... 97 1.12.1 Short boom 1311.22................................................................................................................................................................................... 97 1.12.2 Pendant ropes on short boom 1311.22.................................................................................................................................................................. 98 1.12.3 Pendant straps on short boom 1311.22................................................................................................................................................................. 99 1.13 Main boom 1311.24..........................................................................................................................................................................................100 1.13.1 Main boom base section 1311.24.......................................................................................................................................................................100 1.13.2 Main boom section 1311.24 3 m (10 ft)................................................................................................................................................................101 1.13.3 Main boom section 1311.24 6 m (20 ft)................................................................................................................................................................103 1.13.4 Main boom head 1311.24...............................................................................................................................................................................104 1.13.5 Hoist rope tagline...................................................................................................................................................................................106 1.13.6 Pendant ropes on main boom 1311.24...................................................................................................................................................................108 1.14 Auxiliary jib* (25 t (55,115 lb))..........................................................................................................................................................................110 1.15 Rope fixing point..........................................................................................................................................................................................112 1.15.1 Rope fixing point on main boom head..................................................................................................................................................................112 1.15.2 Rope lock............................................................................................................................................................................................113 1.15.3 Cross block..........................................................................................................................................................................................114 1.15.4 Link plate...........................................................................................................................................................................................115 1.15.5 Pin for rope fixing point............................................................................................................................................................................116 1.16 Pulley block/hook*.........................................................................................................................................................................................118 1.16.1 Pulley block 100 t (220,459 lb)......................................................................................................................................................................118 1.16.2 Pulley block 50 t (110,230 lb).......................................................................................................................................................................120 1.16.3 Pulley block 40 t (88,184 lb)........................................................................................................................................................................121 1.16.4 Hook 25 t (55,115 lb)................................................................................................................................................................................122 1.16.5 Hook 20 t (44,092 lb)................................................................................................................................................................................123 1.17 Safety barrier*............................................................................................................................................................................................125 1.18 Armrests* for operator's seat..............................................................................................................................................................................126 1.19 Catwalks*..................................................................................................................................................................................................127 1.19.1 Catwalks on main boom base section...................................................................................................................................................................127 1.19.2 Catwalks on main boom sections.......................................................................................................................................................................128 1.19.3 Catwalks on main boom head...........................................................................................................................................................................129 1.20 Tagline winch* 3 t (6,614 lb)..............................................................................................................................................................................130 1.21 Refueling pump*............................................................................................................................................................................................131 1.22 Uppercarriage railing......................................................................................................................................................................................132 1.23 Cab roof protection guard*.................................................................................................................................................................................133 1.24 Vandalism protection*......................................................................................................................................................................................134 1.24.1 Top cover............................................................................................................................................................................................135 1.24.2 Rear cover...........................................................................................................................................................................................136 1.24.3 Front cover..........................................................................................................................................................................................137 1.24.4 Right front cover....................................................................................................................................................................................138 1.24.5 Right rear cover.....................................................................................................................................................................................140 1.24.6 Left front cover.....................................................................................................................................................................................141 1.24.7 Left rear cover......................................................................................................................................................................................142 1.24.8 Brackets for front cover.............................................................................................................................................................................143 1.24.9 Barrier rod..........................................................................................................................................................................................143 1.25 Fire extinguishing system*.................................................................................................................................................................................145 1.26 External power supply*.....................................................................................................................................................................................146 1.26.1 External power supply obstacle warning light.........................................................................................................................................................146 1.26.2 External supply low temperature package..............................................................................................................................................................146 1.27 Radio remote control*......................................................................................................................................................................................147 1.28 GSM/GPRS/GPS modem.........................................................................................................................................................................................150 1.29 Virtual Private Network (VPN)*.............................................................................................................................................................................151 1.29.1 Cisco 3G VPN router..................................................................................................................................................................................151 1.29.2 SIM card.............................................................................................................................................................................................152 1.29.3 Power unit...........................................................................................................................................................................................152 1.29.4 Cisco 3G antenna.....................................................................................................................................................................................152 1.30 Hook fixing point *........................................................................................................................................................................................154 1.31 Ventilation, heating and air-conditioning..................................................................................................................................................................156 1.31.1 Cooling circuit......................................................................................................................................................................................157 1.31.2 Heating circuit......................................................................................................................................................................................162 1.31.3 Auxiliary air heating*...............................................................................................................................................................................165 1.31.4 Electric components..................................................................................................................................................................................167 1.31.5 Mechanic components..................................................................................................................................................................................171 1.32 Obstacle warning light*....................................................................................................................................................................................172 1.33 Auxiliary winch *..........................................................................................................................................................................................173 1.34 Cable remote control.......................................................................................................................................................................................174 1.35 Leak oil return*...........................................................................................................................................................................................176 1.36 Ladder* for uppercarriage..................................................................................................................................................................................177 1.37 Reading light* for cabin...................................................................................................................................................................................179 1.38 Litronic control system....................................................................................................................................................................................180 1.39 Emergency operation control*...............................................................................................................................................................................181 1.40 Visual motion warning device*..............................................................................................................................................................................182 1.41 Process data recording (PDE)*..............................................................................................................................................................................184 1.42 Process data report (PDR)*.................................................................................................................................................................................185 1.43 Rope reeving winch* 17.5 kN (3,930 lbf)....................................................................................................................................................................186 1.44 Falling object protection* for cab.........................................................................................................................................................................188 1.45 Foldable falling object protection* for cabin..............................................................................................................................................................190 1.46 Video surveillance system*.................................................................................................................................................................................192 1.46.1 Angle of view rear camera and right camera...........................................................................................................................................................192 1.46.2 Quad monitor.........................................................................................................................................................................................193 1.46.3 Camera...............................................................................................................................................................................................195 1.47 Central lubrication system.................................................................................................................................................................................197 1.48 Auxiliary floodlights*.....................................................................................................................................................................................198 1.48.1 Floodlights on uppercarriage.........................................................................................................................................................................198 1.48.2 Floodlights on cabin.................................................................................................................................................................................200 1.48.3 Adjustable floodlights on main boom base section.....................................................................................................................................................201 2 Safety instructions...............................................................................................................................................................................................205 2.1 Technical condition of the machine..........................................................................................................................................................................205 2.2 Areas of responsibility.....................................................................................................................................................................................205 2.2.1 Manufacturer..........................................................................................................................................................................................205 2.2.2 Owner.................................................................................................................................................................................................205 2.2.3 Machine operator......................................................................................................................................................................................206 2.2.4 Rigger................................................................................................................................................................................................206 2.2.5 Banksman..............................................................................................................................................................................................206 2.2.6 Maintenance and service personnel.....................................................................................................................................................................207 2.3 Requirements to personnel...................................................................................................................................................................................207 2.3.1 Machine operator......................................................................................................................................................................................207 2.3.2 Rigger................................................................................................................................................................................................207 2.3.3 Banksman..............................................................................................................................................................................................208 2.3.4 Maintenance personnel.................................................................................................................................................................................208 2.4 Personal protective equipment...............................................................................................................................................................................208 2.5 Work area...................................................................................................................................................................................................209 2.6 Danger zone.................................................................................................................................................................................................210 2.8 Safety signs on the machine.................................................................................................................................................................................211 2.9 Meaning of the safety signs.................................................................................................................................................................................215 2.9.1 Mandatory signs.......................................................................................................................................................................................215 2.9.2 Prohibition signs.....................................................................................................................................................................................216 2.9.3 Warning signs.........................................................................................................................................................................................218 2.9.4 Rescue signs..........................................................................................................................................................................................219 2.9.5 Fire protection signs.................................................................................................................................................................................220 2.10 Meaning of machine-specific signs..........................................................................................................................................................................220 2.10.1 Safety signs.........................................................................................................................................................................................220 2.10.2 Notice signs.........................................................................................................................................................................................221 2.11 Hazards....................................................................................................................................................................................................225 2.11.1 Mechanical action....................................................................................................................................................................................225 2.11.2 Electrical energy....................................................................................................................................................................................225 2.11.3 Hydraulic energy.....................................................................................................................................................................................226 2.11.4 Burns................................................................................................................................................................................................227 2.11.5 Chemical burns.......................................................................................................................................................................................228 2.11.6 Fire and explosion...................................................................................................................................................................................228 2.11.7 Poisoning and suffocation............................................................................................................................................................................229 2.11.8 Electromagnetic influence............................................................................................................................................................................230 2.11.9 Exposure to wind.....................................................................................................................................................................................230 2.11.10 Advertising banner on main boom.....................................................................................................................................................................237 2.11.11 Snow load and ice load..............................................................................................................................................................................238 2.11.12 Ground bearing strength.............................................................................................................................................................................239 2.11.13 Lightning strike....................................................................................................................................................................................240 2.11.14 Overhead power lines................................................................................................................................................................................241 2.11.15 Environment.........................................................................................................................................................................................243 2.12 What to do in dangerous situations.........................................................................................................................................................................244 2.12.1 Procedure in event of current transfer...............................................................................................................................................................244 2.12.2 How to respond in the event of a fire................................................................................................................................................................245 2.12.3 Firefighting.........................................................................................................................................................................................246 2.13 Working at heights.........................................................................................................................................................................................248 2.14 Application on floating devices............................................................................................................................................................................248 2.14.1 Operation of the machine on floating devices.........................................................................................................................................................249 2.14.2 Transport of the machine on floating devices.........................................................................................................................................................249 2.14.3 Higher risk of machine corrosion on floating devices.................................................................................................................................................250 2.15 Use at low temperatures....................................................................................................................................................................................250 2.15.1 Operation of the machine down to -20 °C (-4 °F) (standard)...........................................................................................................................................251 2.15.2 Operation of the machine down to -25 °C (-13 °F)*....................................................................................................................................................251 2.15.3 Operation of the machine down to -40 °C (-40 °F)*....................................................................................................................................................252 2.16 Hand signals...............................................................................................................................................................................................252 2.16.1 General hand signals in accordance with BGV A8.......................................................................................................................................................253 2.16.2 Special hand signals for sling gear application......................................................................................................................................................255 2.16.3 Hand signals for lifting gear application in accordance with ASME/ANSI B30.5.........................................................................................................................258 3 Control and operating elements....................................................................................................................................................................................265 3.1 Operating elements on the undercarriage.....................................................................................................................................................................265 3.2 Operating elements on the uppercarriage.....................................................................................................................................................................267 3.3 Cabin.......................................................................................................................................................................................................268 3.4 Left multi-directional control lever........................................................................................................................................................................269 3.4.1 Function assignment of buttons on left multi-directional control lever................................................................................................................................269 3.5 Right double T-lever........................................................................................................................................................................................278 3.5.1 Function assignment of buttons on right double T-lever................................................................................................................................................278 3.6 Foot pedals and hand levers.................................................................................................................................................................................283 3.7 Circular bubble.............................................................................................................................................................................................285 3.8 Control panel X11...........................................................................................................................................................................................286 3.9 Control panel X12...........................................................................................................................................................................................288 3.10 Control panel X22..........................................................................................................................................................................................290 3.11 Control panel X23..........................................................................................................................................................................................292 3.12 Control panel X25..........................................................................................................................................................................................297 3.13 Monitor....................................................................................................................................................................................................301 3.13.1 Status bar...........................................................................................................................................................................................301 3.13.2 Display section......................................................................................................................................................................................307 3.13.3 Menu bar.............................................................................................................................................................................................307 3.13.4 Submenu bar..........................................................................................................................................................................................309 3.14 Screen Start...............................................................................................................................................................................................311 3.15 Mode screen................................................................................................................................................................................................312 3.15.1 Screen Mode - piling control.........................................................................................................................................................................319 3.15.2 Operation - vibrator screen..........................................................................................................................................................................320 3.15.3 Hammer mode screen...................................................................................................................................................................................322 3.15.4 Screen Mode - hydraulic grab.........................................................................................................................................................................324 3.15.5 Screen Mode - dragline bucket........................................................................................................................................................................326 3.16 Aggregate screen...........................................................................................................................................................................................329 3.17 Operating hours screen.....................................................................................................................................................................................336 3.18 Setup screen...............................................................................................................................................................................................339 3.18.1 Setup - boom configuration screen....................................................................................................................................................................341 3.18.2 Setup - boom configuration 1 screen..................................................................................................................................................................342 3.18.3 Screen Setup - load chart............................................................................................................................................................................344 3.19 Screen Working range limitation............................................................................................................................................................................346 3.19.1 Screen Working range limitation - working range limitation...........................................................................................................................................346 3.19.2 Screen Working range limitation - lifting height limitation..........................................................................................................................................351 3.20 Screen Access control......................................................................................................................................................................................354 3.20.1 Without retrofit kit access control (black ignition keys)............................................................................................................................................354 3.20.2 Without retrofit kit access control (blue ignition keys).............................................................................................................................................355 3.20.3 With retrofit kit access control (red and blue ignition keys)*.......................................................................................................................................356 3.21 Mode screen................................................................................................................................................................................................359 3.22 Settings screen............................................................................................................................................................................................362 3.22.1 Screen Settings - components.........................................................................................................................................................................362 3.22.2 Settings - units screen..............................................................................................................................................................................365 3.22.3 Settings - vibrator..................................................................................................................................................................................369 3.22.4 Settings - hammer mode...............................................................................................................................................................................370 3.22.5 Settings - hydraulic grab............................................................................................................................................................................371 3.22.6 Screen Settings - Litronic testing system............................................................................................................................................................372 3.23 Error messages screen......................................................................................................................................................................................376 3.24 Radio remote control*......................................................................................................................................................................................378 3.24.1 Operating elements...................................................................................................................................................................................378 3.24.2 Monitor..............................................................................................................................................................................................384 3.25 Cable remote control.......................................................................................................................................................................................390 3.25.1 Cable remote control on uppercarriage................................................................................................................................................................390 3.25.2 Cable remote control on undercarriage................................................................................................................................................................390 3.26 Emergency control system*..................................................................................................................................................................................392 3.27 Auxiliary heating*.........................................................................................................................................................................................394 3.28 Video monitoring system*...................................................................................................................................................................................395 3.28.1 Quad monitor.........................................................................................................................................................................................395 3.28.2 Control panel zoom camera............................................................................................................................................................................396 3.29 Central lubrication*.......................................................................................................................................................................................398 3.30 Additional floodlights*....................................................................................................................................................................................399 3.30.1 Cabin................................................................................................................................................................................................399 4 Operation.........................................................................................................................................................................................................403 4.1 Checks before start up......................................................................................................................................................................................403 4.1.1 Inspecting the machine................................................................................................................................................................................404 4.1.2 Checking position of main battery switch..............................................................................................................................................................404 4.2 Start-up....................................................................................................................................................................................................405 4.2.1 Adjusting the operator's seat.........................................................................................................................................................................405 4.2.2 Switching on the ignition.............................................................................................................................................................................405 4.2.3 Confirming the existing setup.........................................................................................................................................................................405 4.2.4 Checking the fuel fill level..........................................................................................................................................................................406 4.2.5 Checking the urea solution fill level.................................................................................................................................................................406 4.2.6 Checking the hydraulic oil tank gate valve............................................................................................................................................................406 4.2.7 Starting the diesel engine............................................................................................................................................................................407 4.2.8 Adjusting the RPM of the diesel engine................................................................................................................................................................408 4.2.9 Setting the constant engine RPM.......................................................................................................................................................................410 4.2.10 Releasing operating elements in the cabin............................................................................................................................................................412 4.2.11 Checking the tilting-back support cylinder...........................................................................................................................................................412 4.3 Control panels..............................................................................................................................................................................................413 4.3.1 Setting control panel X25* or control panel X26*......................................................................................................................................................413 4.4 Operator's seat.............................................................................................................................................................................................415 4.4.1 Adjusting the control stand horizontally..............................................................................................................................................................416 4.4.2 Adjusting the operator's seat.........................................................................................................................................................................416 4.4.3 Adjusting the dampening...............................................................................................................................................................................420 4.4.4 Adjusting the ergonomics*.............................................................................................................................................................................421 4.4.5 Safety belt*..........................................................................................................................................................................................423 4.5 Lighting....................................................................................................................................................................................................424 4.5.1 Operating the floodlights on the uppercarriage........................................................................................................................................................424 4.5.2 Operating the additional floodlights..................................................................................................................................................................424 4.5.3 Operating the cab lighting............................................................................................................................................................................425 4.5.4 Operating the engine compartment lighting.............................................................................................................................................................425 4.6 Windscreen wiper system.....................................................................................................................................................................................426 4.6.1 Operating the windscreen wipers.......................................................................................................................................................................426 4.6.2 Operating the windscreen washer system................................................................................................................................................................427 4.7 Ventilation, heating and air-conditioning...................................................................................................................................................................428 4.7.1 Setting the air vent..................................................................................................................................................................................430 4.7.2 Adjusting the lamella vents...........................................................................................................................................................................431 4.7.3 Setting recirculated air or fresh air.................................................................................................................................................................431 4.7.4 Operating the ventilation.............................................................................................................................................................................431 4.7.5 Using the heater......................................................................................................................................................................................432 4.7.6 Turning the air conditioning system on or off.........................................................................................................................................................432 4.7.7 Operating the external air conditioning system*.......................................................................................................................................................433 4.7.8 Auxiliary heating*....................................................................................................................................................................................440 4.8 Additional cab equipment....................................................................................................................................................................................444 4.8.1 Using the horn........................................................................................................................................................................................444 4.8.2 Operating the safety lever............................................................................................................................................................................444 4.8.3 Operating the radio...................................................................................................................................................................................445 4.8.4 Using the ashtray.....................................................................................................................................................................................446 4.8.5 Using the cigarette lighter...........................................................................................................................................................................447 4.9 Cab tilting device*.........................................................................................................................................................................................448 4.9.1 Operating the cab tilting device......................................................................................................................................................................448 4.10 Central lubrication*.......................................................................................................................................................................................449 4.10.1 Set lubrication time.................................................................................................................................................................................449 4.10.2 Set pause time.......................................................................................................................................................................................449 4.10.3 Interim lubrication..................................................................................................................................................................................449 4.11 Mode.......................................................................................................................................................................................................450 4.11.1 Deactivating the assembly functions..................................................................................................................................................................450 4.11.2 Selecting the mode...................................................................................................................................................................................450 4.12 Programming the setup......................................................................................................................................................................................452 4.12.1 Calling up the setup screen..........................................................................................................................................................................452 4.12.2 Selecting and changing settings......................................................................................................................................................................452 4.12.3 Calculating the entered setup........................................................................................................................................................................453 4.12.4 Exiting the setup screen.............................................................................................................................................................................453 4.13 Load moment limiter (LML)..................................................................................................................................................................................454 4.13.1 General..............................................................................................................................................................................................454 4.13.2 Load moment limiter self-lock........................................................................................................................................................................456 4.13.3 Load moment limiter shut-down........................................................................................................................................................................458 4.14 Calculating load charts online.............................................................................................................................................................................460 4.14.1 Calculating load chart...............................................................................................................................................................................460 4.15 Set the load capacity display to zero (taring).............................................................................................................................................................461 4.15.1 Setting the load display of winch1 or winch2 to zero.................................................................................................................................................461 4.16 Crawler....................................................................................................................................................................................................462 4.16.1 Setting the crawler speed*...........................................................................................................................................................................462 4.16.2 Operating the crawler................................................................................................................................................................................462 4.16.3 Locking or unlocking the crawler.....................................................................................................................................................................466 4.17 Swing......................................................................................................................................................................................................468 4.17.1 Setting the swing speed..............................................................................................................................................................................468 4.17.2 Turning swing free-wheel on or off...................................................................................................................................................................468 4.17.3 Operating the swing..................................................................................................................................................................................470 4.17.4 Locking or unlocking the swing.......................................................................................................................................................................471 4.18 Main boom..................................................................................................................................................................................................472 4.18.1 Selecting the speed level of boom adjustment.........................................................................................................................................................472 4.18.2 Operating the main boom..............................................................................................................................................................................472 4.18.3 Locking or unlocking the boom adjustment.............................................................................................................................................................476 4.19 Winch1/winch2..............................................................................................................................................................................................477 4.19.1 Operating winch1.....................................................................................................................................................................................477 4.19.2 Operating winch2.....................................................................................................................................................................................479 4.19.3 Locking or unlocking winch1/winch2...................................................................................................................................................................481 4.20 Free-fall mode*............................................................................................................................................................................................482 4.20.1 Activating free-fall mode............................................................................................................................................................................482 4.20.2 Selecting free-fall mode.............................................................................................................................................................................483 4.20.3 Operating free-fall mode.............................................................................................................................................................................484 4.20.4 Deactivating free-fall mode..........................................................................................................................................................................488 4.21 Winch synchronization*.....................................................................................................................................................................................489 4.21.1 Activating winch synchronization.....................................................................................................................................................................489 4.21.2 Operating the winch synchronization..................................................................................................................................................................490 4.21.3 Deactivating winch synchronization...................................................................................................................................................................492 4.22 Grab mode*.................................................................................................................................................................................................493 4.22.1 Turning grab mode on or off..........................................................................................................................................................................493 4.22.2 Operating grab mode..................................................................................................................................................................................494 4.23 Hammer mode................................................................................................................................................................................................497 4.23.1 Selecting hammer mode................................................................................................................................................................................497 4.23.2 Saving hammer mode...................................................................................................................................................................................497 4.23.3 Adjusting the hammer.................................................................................................................................................................................498 4.23.4 Activating the hammer................................................................................................................................................................................499 4.23.5 Adjusting the delivery rate..........................................................................................................................................................................500 4.23.6 Deactivating the hammer..............................................................................................................................................................................500 4.24 Interlock control..........................................................................................................................................................................................501 4.24.1 Activating the interlock control.....................................................................................................................................................................501 4.24.2 Operating the interlock control......................................................................................................................................................................501 4.24.3 Deactivating the interlock control...................................................................................................................................................................502 4.25 Piling control*............................................................................................................................................................................................503 4.25.1 Selecting the piling control.........................................................................................................................................................................503 4.25.2 Saving the piling control............................................................................................................................................................................504 4.25.3 Selecting piling control winch.......................................................................................................................................................................504 4.25.4 Setting the piling control...........................................................................................................................................................................505 4.25.5 Activating the piling control........................................................................................................................................................................505 4.25.6 Deactivating the piling control......................................................................................................................................................................506 4.26 Vibrator mode*.............................................................................................................................................................................................508 4.26.1 Selecting vibrator mode..............................................................................................................................................................................508 4.26.2 Saving vibrator mode.................................................................................................................................................................................508 4.26.3 Setting the vibrator.................................................................................................................................................................................509 4.26.4 Closing the clamp....................................................................................................................................................................................510 4.26.5 Activating the vibrator..............................................................................................................................................................................511 4.26.6 Adjusting the delivery rate..........................................................................................................................................................................511 4.26.7 Adjusting the eccentric..............................................................................................................................................................................512 4.26.8 Deactivating the vibrator............................................................................................................................................................................512 4.26.9 Opening the clamp....................................................................................................................................................................................512 4.27 Lowering control...........................................................................................................................................................................................514 4.27.1 Activating the lowering control......................................................................................................................................................................514 4.27.2 Operating the lowering control.......................................................................................................................................................................514 4.27.3 Deactivating the lowering control....................................................................................................................................................................516 4.28 Casing oscillator*.........................................................................................................................................................................................517 4.28.1 Connecting the casing oscillator.....................................................................................................................................................................517 4.28.2 Activating and deactivating the casing oscillator - standard mode (without ecological control*)......................................................................................................518 4.28.3 Activating and deactivating the casing oscillator - standard mode (with ecological control*).........................................................................................................518 4.28.4 Activating and deactivating the casing oscillator - ecological mode (with ecological control*).......................................................................................................518 4.28.5 Adjusting the casing oscillator......................................................................................................................................................................519 4.29 Working range limitation...................................................................................................................................................................................520 4.29.1 Operating the edge limitation........................................................................................................................................................................520 4.29.2 Operating the sector limitation......................................................................................................................................................................522 4.29.3 Operating the radius limitation......................................................................................................................................................................524 4.29.4 Operating the slewing range limitation...............................................................................................................................................................527 4.29.5 Operating the lifting height limitation..............................................................................................................................................................528 4.29.6 Unlocking swing and booms after operating the crawler................................................................................................................................................530 4.29.7 Resetting the working range limitations..............................................................................................................................................................531 4.30 Rope reeving winch.........................................................................................................................................................................................532 4.30.1 Setting the rope reeving winch to free-wheel.........................................................................................................................................................532 4.30.2 Deactivating rope reeving winch free-fall............................................................................................................................................................533 4.30.3 Reeving the rope of the rope reeving winch...........................................................................................................................................................533 4.31 Tagline winch*.............................................................................................................................................................................................534 4.31.1 Putting the tagline winch into operation.............................................................................................................................................................534 4.31.2 Activating/deactivating the tagline winch............................................................................................................................................................535 4.31.3 Setting the constant pull of the tagline winch.......................................................................................................................................................536 4.31.4 Setting the pull force of the tagline winch..........................................................................................................................................................536 4.31.5 Activating/deactivating maximum pull force of tagline winch..........................................................................................................................................537 4.31.6 Activating/deactivating tagline winch free-wheel.....................................................................................................................................................538 4.31.7 Decommissioning the tagline winch....................................................................................................................................................................538 4.32 Radio remote control*......................................................................................................................................................................................539 4.32.1 rechargeable battery.................................................................................................................................................................................539 4.32.2 battery charger......................................................................................................................................................................................539 4.32.3 Starting the machine with the radio remote control...................................................................................................................................................541 4.33 Constant pull winch1 and winch2............................................................................................................................................................................547 4.33.1 Operating constant pull..............................................................................................................................................................................547 4.34 Filling machine with fuel..................................................................................................................................................................................549 4.34.1 Filling machine with fuel from a tank truck..........................................................................................................................................................549 4.34.2 Filling the machine with fuel from a refueling pump..................................................................................................................................................550 4.34.3 Filling up with urea solution*.......................................................................................................................................................................551 4.35 Inclination display........................................................................................................................................................................................552 4.35.1 Operating the inclinometer...........................................................................................................................................................................552 4.36 Rope measuring system*.....................................................................................................................................................................................553 4.36.1 Initializing the rope measuring system...............................................................................................................................................................553 4.36.2 Programming layer change.............................................................................................................................................................................553 4.37 Diesel engine automatic stop system*.......................................................................................................................................................................555 4.37.1 Switching the diesel engine automatic stop system on or off..........................................................................................................................................555 4.38 Sensitive hoisting*........................................................................................................................................................................................556 4.38.1 Turning the function sensitive lift on or off........................................................................................................................................................556 4.38.2 Operating sensitive hoisting.........................................................................................................................................................................556 4.39 Emergency stop.............................................................................................................................................................................................557 4.39.1 Using emergency stop.................................................................................................................................................................................557 4.40 Shutdown...................................................................................................................................................................................................558 4.40.1 Short work interruption..............................................................................................................................................................................558 4.40.2 Long work interruption...............................................................................................................................................................................559 4.40.3 Switching off battery main switch....................................................................................................................................................................560 4.41 Hydraulic emergency mode*..................................................................................................................................................................................561 4.41.1 Winch 2 emergency mode...............................................................................................................................................................................561 4.41.2 Main boom adjusting winch emergency mode.............................................................................................................................................................563 4.41.3 Swing emergency mode.................................................................................................................................................................................564 4.42 Emergency control system*..................................................................................................................................................................................567 4.42.1 Operating the emergency control system...............................................................................................................................................................567 5 Operational faults, diagnosis.....................................................................................................................................................................................571 5.1 Malfunctions................................................................................................................................................................................................571 5.1.1 Identifying faults....................................................................................................................................................................................571 5.1.2 Error displays on monitor.............................................................................................................................................................................571 5.1.3 Troubleshooting.......................................................................................................................................................................................574 5.2 Litronic testing system.....................................................................................................................................................................................576 5.2.1 Litronic testing system overview......................................................................................................................................................................576 5.2.2 Screen pages..........................................................................................................................................................................................577 5.2.3 Starting the Litronic testing system..................................................................................................................................................................584 5.3 Fuses.......................................................................................................................................................................................................585 5.3.1 List of fuses.........................................................................................................................................................................................585 5.3.2 Checking the fuses....................................................................................................................................................................................587 5.3.3 Replacing fuses.......................................................................................................................................................................................589 6 Operational planning..............................................................................................................................................................................................593 6.1 Tools required..............................................................................................................................................................................................593 6.1.1 Assembling the machine with the self-assembly system..................................................................................................................................................593 6.1.2 Assembling the machine without the self-assembly system...............................................................................................................................................594 6.2 Positioning the hook or pulley block........................................................................................................................................................................595 6.3 Restrictions due to wind....................................................................................................................................................................................596 6.3.1 Reducing the load.....................................................................................................................................................................................596 6.3.2 Laying down the boom..................................................................................................................................................................................596 6.4 Traveling on gradients......................................................................................................................................................................................597 6.4.1 Permitted gradient with main boom 1311.24 (+ auxiliary jib)...........................................................................................................................................599 6.5 Rigging equipment and/or sling gear.........................................................................................................................................................................601 7 Assembly and dismantling..........................................................................................................................................................................................605 7.1 Explanation of symbols used.................................................................................................................................................................................605 7.2 Implementation instructions for assembly and disassembly....................................................................................................................................................607 7.3 Locking elements - overview.................................................................................................................................................................................608 7.3.1 Split pin.............................................................................................................................................................................................608 7.3.2 Linchpin..............................................................................................................................................................................................609 7.3.3 Spring cotter pin.....................................................................................................................................................................................610 7.3.4 Safety pin............................................................................................................................................................................................611 7.3.5 Locking washers.......................................................................................................................................................................................613 7.4 Assembling the basic machine................................................................................................................................................................................614 7.4.1 Explanations..........................................................................................................................................................................................614 7.4.2 Moving cabin platforms* into working position.........................................................................................................................................................614 7.4.3 Moving the platforms into working position............................................................................................................................................................618 7.4.4 Moving left hydraulic platform* into working position.................................................................................................................................................623 7.4.5 Moving right hydraulic platform* into working position................................................................................................................................................634 7.4.6 Mounting the ladder on the uppercarriage..............................................................................................................................................................642 7.4.7 Mounting the uppercarriage railing....................................................................................................................................................................643 7.4.8 Putting the load moment limiter lamp and flashing light into working position.........................................................................................................................647 7.4.9 Fitting the exhaust pipe..............................................................................................................................................................................648 7.4.10 Checking the position of the bypass plug.............................................................................................................................................................651 7.4.11 Putting the machine into operation...................................................................................................................................................................652 7.4.12 Switching on assembly mode functions.................................................................................................................................................................652 7.4.13 Switching on cylinder adjustment functions...........................................................................................................................................................653 7.4.14 Extend the tilting back support cylinders............................................................................................................................................................653 7.4.15 Remove round sling between boom base section and A-frame 1...........................................................................................................................................653 7.4.16 Erecting A-frame 1...................................................................................................................................................................................653 7.4.17 Driving the machine off the transport vehicle........................................................................................................................................................655 7.4.18 Removing the uppercarriage lock......................................................................................................................................................................655 7.4.19 Adjusting crawler side frames to working track.......................................................................................................................................................656 7.4.20 Using the machine as assembly crane..................................................................................................................................................................664 7.4.21 Attach the carbody counterweight.....................................................................................................................................................................667 7.4.22 Fitting the rear counterweight.......................................................................................................................................................................671 7.5 Main boom 1311.24...........................................................................................................................................................................................681 7.5.1 Configuration of main boom............................................................................................................................................................................681 7.5.2 Overview of main boom 1311.24 pendant ropes...........................................................................................................................................................682 7.5.3 Reeving diagram lifting gear utilization..............................................................................................................................................................683 7.5.4 Reeving diagram grab mode.............................................................................................................................................................................686 7.6 Short boom 1311.22..........................................................................................................................................................................................688 7.6.1 Configuration of short boom...........................................................................................................................................................................688 7.6.2 Overview of short boom 1311.22........................................................................................................................................................................689 7.6.3 Overview of short boom pendant straps 1311.22.........................................................................................................................................................691 7.6.4 Reeving diagram lifting gear utilization..............................................................................................................................................................692 7.6.5 Reeving diagram grab mode.............................................................................................................................................................................694 7.7 Assembling the main boom....................................................................................................................................................................................696 7.7.1 Explanations..........................................................................................................................................................................................696 7.7.2 Programming the setup.................................................................................................................................................................................696 7.7.3 Unloading and positioning the main boom components....................................................................................................................................................696 7.7.4 Pinning the main boom head to the main boom sections..................................................................................................................................................697 7.7.5 Installing the hoist rope tagline.....................................................................................................................................................................699 7.7.6 Pinning the pendant ropes.............................................................................................................................................................................701 7.7.7 Pinning the main boom base section to the main boom...................................................................................................................................................701 7.7.8 Pinning the main boom base section to short boom......................................................................................................................................................702 7.7.9 Pinning the equalizer on A-frame1 to the main boom pendant ropes......................................................................................................................................703 7.7.10 Pinning the equalizer on A-frame1 to the short boom pendant ropes....................................................................................................................................704 7.7.11 Installing the auxiliary jib (25 t (55,115 lb)) on the main boom head................................................................................................................................706 7.7.12 Connect the electric cables..........................................................................................................................................................................710 7.7.13 Installing the obstacle warning light................................................................................................................................................................710 7.7.14 Fitting the anemometer...............................................................................................................................................................................712 7.7.15 Rope reeving.........................................................................................................................................................................................714 7.7.16 Installing the rope fixing point.....................................................................................................................................................................714 7.7.17 Installing the hoist limit switch....................................................................................................................................................................716 7.7.18 Bypassing unused hoist limit switches................................................................................................................................................................719 7.7.19 Erecting the main boom...............................................................................................................................................................................720 7.7.20 Switching off assembly mode functions................................................................................................................................................................722 7.7.21 Checking the main boom limit switch plate for proper adjustment......................................................................................................................................723 7.8 Adjusting the track.........................................................................................................................................................................................725 7.8.1 Changing from wide track to narrow track..............................................................................................................................................................725 7.8.2 Changing from narrow track to wide track..............................................................................................................................................................730 7.9 Vandalism protection*.......................................................................................................................................................................................731 7.9.1 Installing the vandalism protection...................................................................................................................................................................731 7.10 Assembling the machine without a self-assembly system......................................................................................................................................................733 7.10.1 Specific procedure when no jacks are available.......................................................................................................................................................733 7.10.2 Specific procedure with no counterweight hoisting cylinder...........................................................................................................................................733 7.10.3 Specific procedure with no assembly cylinder.........................................................................................................................................................735 7.11 Disassembling the main boom................................................................................................................................................................................736 7.11.1 Brief summary........................................................................................................................................................................................736 7.12 Disassembling the basic machine............................................................................................................................................................................739 7.12.1 Brief summary........................................................................................................................................................................................739 8 Transport.........................................................................................................................................................................................................743 8.1 Loading the basic machine with an assist crane..............................................................................................................................................................743 8.1.1 Loading the basic machine with crawler side frame, carbody counterweight and rear counterweight 17.3 t (38,139 lb)....................................................................................744 8.1.2 Loading the basic machine with crawler side frame, without carbody counterweight and rear counterweight...............................................................................................746 8.1.3 Loading the basic machine without crawler side frame, carbody counterweight and rear counterweight....................................................................................................748 8.2 Transporting the basic machine with crawler side frame with a transport vehicle.............................................................................................................................751 8.3 Transporting the basic machine with crawler side frame with a transport vehicle.............................................................................................................................754 8.4 Transporting the basic machine without crawler side frame with a transport vehicle..........................................................................................................................757 9 Maintenance.......................................................................................................................................................................................................763 9.1 Maintenance and inspection schedule.........................................................................................................................................................................763 9.2 Lubricants and consumables..................................................................................................................................................................................777 9.2.1 Lubrication chart.....................................................................................................................................................................................778 9.2.2 Filling capacity table................................................................................................................................................................................780 9.2.3 Lubrication chart.....................................................................................................................................................................................781 9.2.4 Diesel engine lubricating oil.........................................................................................................................................................................785 9.2.5 Fuel..................................................................................................................................................................................................785 9.2.6 Urea solution.........................................................................................................................................................................................785 9.2.7 Diesel engine coolant.................................................................................................................................................................................785 9.2.8 Hydraulic oil.........................................................................................................................................................................................785 9.2.9 Preservation medium (anti-corrosion coating)..........................................................................................................................................................786 9.2.10 Liebherr oil diagnosis system........................................................................................................................................................................788 9.3 Implementation instructions for the maintenance.............................................................................................................................................................791 9.4 Fuel tank...................................................................................................................................................................................................792 9.4.1 Draining water and sediments..........................................................................................................................................................................792 9.5 Air filter system...........................................................................................................................................................................................793 9.5.1 Checking the negative pressure indicator..............................................................................................................................................................793 9.5.2 Cleaning the air filter dust ejector..................................................................................................................................................................794 9.5.3 Replacing the dry air filter main element and dry air filter safety element...........................................................................................................................794 9.6 Distribution gearbox........................................................................................................................................................................................796 9.6.1 Checking the gearbox oil level........................................................................................................................................................................796 9.6.2 Topping up gearbox oil................................................................................................................................................................................797 9.6.3 Checking the venting valve............................................................................................................................................................................798 9.7 Swing.......................................................................................................................................................................................................799 9.7.1 Checking the gearbox oil level........................................................................................................................................................................799 9.7.2 Topping up the gearbox oil............................................................................................................................................................................799 9.8 Rotary joint................................................................................................................................................................................................801 9.8.1 Lubricating external teeth............................................................................................................................................................................801 9.8.2 Lubricating the bearing races via the central lubrication point.......................................................................................................................................801 9.9 Winch1/winch2...............................................................................................................................................................................................803 9.9.1 Checking the gearbox oil level........................................................................................................................................................................803 9.9.2 Topping up gearbox oil................................................................................................................................................................................804 9.9.3 Lubricating counter bearings..........................................................................................................................................................................804 9.9.4 Checking the rope end fastening for tight fit.........................................................................................................................................................805 9.10 Boom luffing winches.......................................................................................................................................................................................806 9.10.1 Checking the gearbox oil level.......................................................................................................................................................................806 9.10.2 Topping up the gearbox oil...........................................................................................................................................................................807 9.10.3 Lubricating the counter bearing......................................................................................................................................................................807 9.10.4 Checking the rope end fastening for tight fit........................................................................................................................................................808 9.11 Rope reeving winch.........................................................................................................................................................................................809 9.11.1 Lubricating the counter bearing......................................................................................................................................................................809 9.11.2 Checking rope end attachment for tight fit when starting up rope reeving winch.......................................................................................................................809 9.12 Tagline winch..............................................................................................................................................................................................810 9.12.1 Checking the gearbox oil level.......................................................................................................................................................................810 9.12.2 Topping up the gearbox oil...........................................................................................................................................................................811 9.12.3 Lubricating the rope bracket on the boom base section and checking pulleys for damage................................................................................................................811 9.12.4 Checking the rope end fastening for tight fit........................................................................................................................................................812 9.13 Crawler....................................................................................................................................................................................................813 9.13.1 Checking the gearbox oil level.......................................................................................................................................................................813 9.13.2 Check gearbox and hydraulic screw connections for leaks..............................................................................................................................................814 9.13.3 Cleaning the crawler.................................................................................................................................................................................814 9.13.4 Checking locking screws of struts on crawler side frames for tight fit on extendable undercarriages..................................................................................................814 9.13.5 Checking the chain tension, earlier if necessary.....................................................................................................................................................816 9.13.6 Tightening the base plate screws.....................................................................................................................................................................819 9.13.7 Checking locking screws of the track pads axes.......................................................................................................................................................821 9.14 Lifting device.............................................................................................................................................................................................822 9.14.1 Check transport lashing and round slings for wear (according to EN 1492-2)...........................................................................................................................822 9.14.2 Check the round steel chains for wear and damage.....................................................................................................................................................822 9.15 Hook/pulley block..........................................................................................................................................................................................823 9.15.1 Checking all hooks/pulley blocks for damage, wear, corrosion and widening of the hook aperture.......................................................................................................823 9.15.2 Lubricating bearings and axels.......................................................................................................................................................................823 9.15.3 Check that the safety catch is present and working properly..........................................................................................................................................824 9.16 Hydraulic system...........................................................................................................................................................................................825 9.16.1 Check the hydraulic system for leaks.................................................................................................................................................................825 9.16.2 Checking the oil cooler for contamination............................................................................................................................................................825 9.16.3 Changing the compressed air filter...................................................................................................................................................................826 9.17 Hydraulic oil tank.........................................................................................................................................................................................828 9.17.1 Carrying out a hydraulic oil analysis................................................................................................................................................................828 9.17.2 Filling with hydraulic oil...........................................................................................................................................................................828 9.17.3 Draining the hydraulic oil...........................................................................................................................................................................829 9.17.4 Cleaning the magnetic rod in the return filter.......................................................................................................................................................829 9.17.5 Exchanging return filter.............................................................................................................................................................................832 9.18 Hydraulic cylinders........................................................................................................................................................................................834 9.18.1 Check that the hydraulic cylinder fits properly and does not leak....................................................................................................................................834 9.18.2 Protecting the piston rods of the hydraulic cylinders from corrosion.................................................................................................................................834 9.18.3 Preserving the piston rods of the hydraulic cylinders in case of longer periods of non-use...........................................................................................................834 9.19 Hydraulic hoses............................................................................................................................................................................................835 9.19.1 Checking the hydraulic hoses.........................................................................................................................................................................835 9.20 Bypass filter system.......................................................................................................................................................................................836 9.20.1 Checking the bypass filter system....................................................................................................................................................................836 9.20.2 Changing the filter elements.........................................................................................................................................................................836 9.21 Electrical system..........................................................................................................................................................................................839 9.21.1 Checking cable ducts and cable connections for chafing...............................................................................................................................................839 9.22 Batteries..................................................................................................................................................................................................840 9.22.1 Checking the fluid level in the cells................................................................................................................................................................840 9.22.2 Checking the battery fluid...........................................................................................................................................................................840 9.22.3 Exchanging the fuses on the battery..................................................................................................................................................................841 9.23 Lighting...................................................................................................................................................................................................842 9.23.1 Checking that the cabin lighting, floodlights and auxiliary floodlights are working properly.........................................................................................................842 9.23.2 Changing the cab lamp light bulb.....................................................................................................................................................................842 9.23.3 Changing the bulbs of floodlights on the cabin and on the uppercarriage..............................................................................................................................842 9.23.4 Changing the bulbs of floodlights on main boom base section..........................................................................................................................................845 9.24 Rope measuring system......................................................................................................................................................................................849 9.24.1 Checking the rope measuring system and height adjustment of all winches (if available) for correct function..........................................................................................849 9.24.2 Readjusting layer change when changing ropes.........................................................................................................................................................849 9.25 Limit switches.............................................................................................................................................................................................850 9.25.1 Checking hoist limit switches, boom limit switches and, if necessary, limit switches of the piling and drilling rig to ensure they are working correctly.............................................850 9.26 Mechanical inclinometer....................................................................................................................................................................................851 9.26.1 Checking that the mechanical inclinometer is working properly........................................................................................................................................851 9.27 Emergency stop.............................................................................................................................................................................................852 9.27.1 Checking the emergency stop..........................................................................................................................................................................852 9.28 Obstacle warning light*....................................................................................................................................................................................853 9.28.1 Check obstacle warning light for function and damage, check mains cable and plug (if available) for damage...........................................................................................853 9.29 Fire extinguishers.........................................................................................................................................................................................854 9.29.1 Checking the seals and inspection dates on the fire extinguishers....................................................................................................................................854 9.30 Personal protective equipment..............................................................................................................................................................................855 9.30.1 Checking personal protective gear....................................................................................................................................................................855 9.31 Safety signs...............................................................................................................................................................................................856 9.31.1 Checking that all required safety labels are mounted on the machine and are legible..................................................................................................................856 9.32 Access systems and railings................................................................................................................................................................................857 9.32.1 Checking ladders, steps, platforms, and ascents for wear, damage and anti-slip surfaces..............................................................................................................857 9.32.2 Checking latches and hand rails for wear and damage..................................................................................................................................................857 9.32.3 Checking the spring tension of railing doors.........................................................................................................................................................857 9.32.4 Setting the spring tension of railing doors..........................................................................................................................................................858 9.32.5 Checking the function of the railing stabilization...................................................................................................................................................860 9.33 Steel structure............................................................................................................................................................................................862 9.33.1 Checking the machine steel structure for damage, cracks..............................................................................................................................................862 9.33.2 Repairs on the steel structure.......................................................................................................................................................................863 9.34 Main boom..................................................................................................................................................................................................865 9.34.1 Check main boom base section, main boom head and main boom sections for damage and wear (cracks, notches, corrosion, plastic deformation, wear)......................................................865 9.34.2 Boom base section: checking that the knuckle pins and locking elements fit tightly...................................................................................................................866 9.34.3 Boom base section: lubricating knuckle pins..........................................................................................................................................................866 9.34.4 Boom base section or A-frame 1: checking the operation of the mechanical boom angle indicator........................................................................................................868 9.34.5 Checking the main boom head for function and damage..................................................................................................................................................869 9.34.6 Checking the anemometer for tight fit and function...................................................................................................................................................869 9.34.7 Checking the auxiliary jib for function and damage...................................................................................................................................................870 9.35 A-frame1...................................................................................................................................................................................................871 9.35.1 Checking A-frame 1...................................................................................................................................................................................871 9.35.2 Lubricating the bearings on A-frame 1................................................................................................................................................................871 9.36 Steel pendant straps.......................................................................................................................................................................................873 9.36.1 Checking steel pendant straps and pins for damage and wear and check that locking springs and split pins are present.................................................................................873 9.36.2 Checking the ease of movement of pin connections in the entire pendant strap strand..................................................................................................................874 9.36.3 Protecting steel pendant straps, connecting links and pins from corrosion............................................................................................................................874 9.36.4 Checking connecting links for damage and wear........................................................................................................................................................874 9.36.5 Checking tension load cells for damage and wear, checking electricity connections for tight fit......................................................................................................874 9.37 Pendant ropes..............................................................................................................................................................................................876 9.37.1 Check pendant ropes and pins for damage and wear and check that locking springs and cotter pins are present (cracks, notches, corrosion, plastic deformation, wear, lubrication, etc.)...............876 9.37.2 Protecting pendant ropes, connecting links and pins from corrosion...................................................................................................................................876 9.37.3 Checking connecting links for damage and wear........................................................................................................................................................877 9.37.4 Checking tension load cells for damage and wear, checking electricity connections for tight fit......................................................................................................877 9.38 Counterweight..............................................................................................................................................................................................878 9.38.1 Checking tension rod screw lock for correct position / color coding..................................................................................................................................878 9.38.2 Checking the screws of the rear counterweight tie-down for tight fit.................................................................................................................................878 9.38.3 Checking the rear counterweight, fixing lugs and round steel chains for damage, wear and secure fit..................................................................................................878 9.38.4 Checking locking elements for availability, damage, wear and tight fit...............................................................................................................................878 9.38.5 Checking the function of the pin connection cylinder and limit switch (if available).................................................................................................................878 9.38.6 Checking counterweight supports (pins, link plates) for damage and wear..............................................................................................................................878 9.39 Lubrication system.........................................................................................................................................................................................879 9.39.1 Checking the operation of the central lubrication for the swing ring tooth flanks....................................................................................................................879 9.39.2 Checking the operation of the central lubrication for the swing ring bearing.........................................................................................................................880 9.39.3 Checking the fill level of the lubrication pumps.....................................................................................................................................................880 9.39.4 Checking the time intervals of the lubrication pumps.................................................................................................................................................881 9.39.5 Checking the lubrication points......................................................................................................................................................................881 9.40 Ropes......................................................................................................................................................................................................882 9.40.1 Assembly of a rope...................................................................................................................................................................................882 9.40.2 Visual inspection of the ropes for deterioration or mechanical damage................................................................................................................................882 9.40.3 Checking ropes for lubrication.......................................................................................................................................................................882 9.40.4 Rope lubrication.....................................................................................................................................................................................883 9.40.5 Checking ropes for end of service life...............................................................................................................................................................883 9.40.6 Storing ropes........................................................................................................................................................................................895 9.40.7 Transporting the ropes...............................................................................................................................................................................896 9.40.8 Selecting a rope.....................................................................................................................................................................................896 9.40.9 Unwind rope from rope reel...........................................................................................................................................................................898 9.40.10 Laying on the rope..................................................................................................................................................................................900 9.41 Drum.......................................................................................................................................................................................................908 9.41.1 Checking rope tensioning pulleys* of drum for wear...................................................................................................................................................908 9.41.2 Checking the groove diameter of the drum.............................................................................................................................................................908 9.41.3 Checking drum for loose rope layers..................................................................................................................................................................909 9.42 Rope pulleys...............................................................................................................................................................................................910 9.42.1 Assembly of a pulley.................................................................................................................................................................................910 9.42.2 Checking the groove diameter of the pulley...........................................................................................................................................................910 9.42.3 Checking the bottom of groove diameter of the pulley.................................................................................................................................................911 9.42.4 Checking the gap width of the pulley.................................................................................................................................................................912 9.42.5 Checking bottom of pulley groove for sharp edges.....................................................................................................................................................913 9.42.6 Checking pulleys for damage..........................................................................................................................................................................913 9.42.7 Checking the pulley bearings.........................................................................................................................................................................914 9.42.8 Lubricating the pulley bearings......................................................................................................................................................................914 9.42.9 Checking the position of bearing and locking ring....................................................................................................................................................914 9.42.10 Cleaning plastic pulleys............................................................................................................................................................................915 9.43 Rope suspension and rope fixation..........................................................................................................................................................................916 9.43.1 Checking rope suspensions (rope clamps, rope thimbles) for wire breaks, absence of corrosion and tight fit of screw fittings.........................................................................916 9.43.2 Checking the pocket locks............................................................................................................................................................................917 9.43.3 Checking the rope end fittings for cracks............................................................................................................................................................918 9.43.4 Checking the rope fixing point.......................................................................................................................................................................919 9.44 Cab........................................................................................................................................................................................................920 9.44.1 Removing the cabin roof protection guard or fixed falling object protection*.........................................................................................................................920 9.44.2 Opening foldable falling object protection*..........................................................................................................................................................921 9.44.3 Check the windows of the cab for damage..............................................................................................................................................................921 9.44.4 Checking that the cab door and the door lock work properly...........................................................................................................................................922 9.44.5 Checking cabin roof protection guard or falling object protection* for damage and locking in case of foldable falling object protection..............................................................922 9.44.6 Lubricating the falling object protection*...........................................................................................................................................................923 9.44.7 Replacing the windscreen wiper.......................................................................................................................................................................923 9.44.8 Filling the windscreen cleaning system...............................................................................................................................................................924 9.44.9 Checking outside mirrors and inside mirrors for damage...............................................................................................................................................925 9.44.10 Checking the operation of the hydraulic cab tilting device and for damage...........................................................................................................................925 9.44.11 Checking hydraulic cabin elevation for function and damage..........................................................................................................................................926 9.44.12 Cleaning or replacing the filter insert in the cabin................................................................................................................................................927 9.45 Ventilation, heating and air-conditioning..................................................................................................................................................................929 9.45.1 Checking the recirculated air filter for contamination...............................................................................................................................................929 9.45.2 Replacing the recirculated air filter................................................................................................................................................................933 9.45.3 Checking the fresh air filter for contamination......................................................................................................................................................938 9.45.4 Replacing the fresh air filter.......................................................................................................................................................................939 9.45.5 Checking the coolant level in the inspection glass...................................................................................................................................................943 9.45.6 Checking the condenser for contamination.............................................................................................................................................................944 9.45.7 Checking the condenser for loose leads, loos screws and corrosion....................................................................................................................................945 9.45.8 Checking the fan on condenser for function, tight fit and damage.....................................................................................................................................945 9.45.9 Checking the climate box for contamination...........................................................................................................................................................946 9.45.10 Checking the dryer for damage and corrosion.........................................................................................................................................................947 9.45.11 Starting the ventilation, heating, air conditioning, external air conditioning system* and auxiliary heating system* and ensuring that sufficient antifreeze has been added to the water circuit....947 9.45.12 Replacing the fuel filter of auxiliary water heating................................................................................................................................................950 9.46 Hoses, cables..............................................................................................................................................................................................952 9.46.1 Check hose winches, collecting trays, cable winches, hose guides, cable ducts, rope pulley cables, and hose rolls with scraper for damage and correct attachment.....................................952 9.46.2 Check cable drum and hose drums on boom head for ease of movement....................................................................................................................................952 9.46.3 Grease hose winch bearing at the central lubrication point...........................................................................................................................................952 9.46.4 Hose winch drive: Check oil level....................................................................................................................................................................952 9.47 Gab rope guide.............................................................................................................................................................................................953 9.47.1 Lubricate grab rope guide............................................................................................................................................................................953 9.47.2 Check grab rope guide for wear and damage............................................................................................................................................................953 9.48 Vibrator cooling...........................................................................................................................................................................................954 9.48.1 Checking vibrator cooling for correct function.......................................................................................................................................................954 9.49 Compressor*................................................................................................................................................................................................955 9.49.1 Checking the oil level and draining condensate from the air container................................................................................................................................955 9.50 Machine care...............................................................................................................................................................................................956 9.50.1 Cleaning the machine.................................................................................................................................................................................956 9.50.2 Preserving the machine...............................................................................................................................................................................957 Index...............................................................................................................................................................................................................969
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