Liebherr LR 1600-2 Crawler Crane With Lattice Mast Operating Instruction Manual 1600-2-002 – PDF DOWNLOAD
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Liebherr LR 1600-2 Crawler Crane With Lattice Mast Operating Instruction Manual 1600-2-002 – PDF DOWNLOAD
Language : English
Pages : 1807
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Liebherr LR 1600-2 Crawler Crane With Lattice Mast Operating Instruction Manual 1600-2-002 – PDF DOWNLOAD
Foreword:
General:
This crane was built according to the state of technology and recognized safety technical regulations.
Despite that, dangers to body and life for the user and / or third persons or damage to the crane and /
or other material assets can occur.
This crane may only be used:
– in impeccable technical condition.
– for destined use.
– by trained personnel, which acts in a safety and danger conscious way.
– when no safety relevant problems are present.
– when no modifications were made on the crane.
Any problems, which could affect safety must be fixed immediately.
Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen GmbH.
Data recording device:
This crane is equipped with a data recording device. Among others, the following data is recorded:
– Date and time of day
– Entered configuration of the crane
– Actual load
– Percentage of utilization of the crane
– Working radius
– Main boom angle, luffing jib angle
– Total telescopic boom length, length of each telescopic section
– Every actuation of bypass devices
The recorded data can be read with a respective software.
Safety and warning notes:
Safety and warning notes are directed to all persons who work with the crane.
The terms DANGER, WARNING, CAUTION and ATTENTION used in the crane documentation are
intended to point out certain rules of conduct to all persons working with the crane.
TABLE OF CONTENTS:
Liebherr LR 1600-2 Crawler Crane With Lattice Mast Operating Instruction Manual 1600-2-002 – PDF DOWNLOAD
1.00 Description of crane 23
1.01 Terminology 24
1 Component overview 25
2 Boom systems 29
1.02 Product description 41
1 Crawler travel gear 43
2 Crane superstructure 43
1.03 Technical data 45
1 Dimensions and weights 47
2 Lifting equipment 75
3 Ground pressure 75
4 Workplace-related emission value 75
5 Vibrations 75
6 Crane speeds 75
7 Ropes 76
2.00 Safety 79
2.03 Job planning 80
1 Crane operation planning 81
2.04 General safety technical guidelines 82
1 General 83
2 Emergency exit 91
3 Checking the rigging and fastening points 95
4 Personal protective equipment 97
5 Use of single-stranded height safety equipment, illustration 1 103
6 Use of double-stranded height safety equipment, illustration 2 103
7 Securing the assembly personnel against falling 103
8 Rescuing the assembly personnel 105
9 Documentation 105
10 Identification 105
IIEBHEIIII 11
Contents
11 Requirements for the crane operator 105
12 Selecting the location, illustrations 1 to 3 111
13 Slopes and excavations, illustrations 4 and 5 114
14 Permissible ground pressures 114
15 Supporting 119
16 Checking the safety measures 120
17 Endangering air traffic 120
18 Grounding 120
19 Consideration of wind conditions 121
20 Working in the vicinity of transmitters 131
21 Dangers when working together with several cranes 133
22 Hand signals for guidance 134
23 Crane operation with a load 141
24 Lifting of personnel 144
25 Crane operation in case of thunderstorms 145
26 Safety notes for external power feed ( 100 V AC to 400 V AC) 145
27 Welding work on the load 146
28 Interruption of crane operation. 147
29 Resumption of crane operation 148
30 Ending crane operation 148
31 Turning/ driving in reverse 149
32 Parking the vehicle 149
33 Safety guidelines for ladders 153
2.05 Signs on the crane 160
1 Warning signs 161
2 Command and prohibition signs 165
3 Notice signs 169
2.06 Antifall guards on the crane 172
1 Personal protective equipment 173
2 Fall arrest equipment on the crane chassis 175
3 Installing the fall arrest equipment on the crane operator’s cab 179
4 Fall arrest equipment on the crane superstructure 181
5 Fall arrest equipment o the pivot sections and lattice mast boom 185
2.15 General safety technical notes for operation with ballast trailer 190
12 IIEBHEIIII
Contents
1 Safety guidelines 191
2 Inspection of tires and disk wheels 192
3.00 Crane assembly 195
3.01 Crawler carrier assembly 196
1 Component overview crawler travel gear 197
2 Dimensions and weights 197
3 Installing the assembly supports 199
4 Assembly/ disassembly of the crawler carrier with the auxiliary crane 205
5 Assembly I disassembly of the crawler carrier with SA-frame 221
6 Disassembling the assembly support 239
3.02 Turntable assembly 242
1 Turntable with Quick Connection* 243
2 Installing the turntable 247
3 Removing the turntable 251
3.03 Central ballast 252
1 Components 253
2 Central ballast combinations 255
3 Permissible central ballast assemblies 255
4 Installing the central ballast 257
5 Removing the central ballast 269
3.04 Mechanical auxiliary support 278
1 Installing the mechanical auxiliary support 279
3.05 Assembly of SA bracket 282
1 Component overview SA-frame 283
2 Attachment points SA-frame 283
3 Assemble SA-frame 285
4 Disassemble SA-frame 293
3.06 Assembly conditions 300
1 Assembly conditions for operation on crawlers 301
3.07 Assembly hoist winches 302
1 Component overview 303
2 Dimensions and weights 303
3 Assembling winch 1 305
IIEBHEIIII 13
Contents
4 Removing winch 1 313
5 Assembly and disassembly of winch 1 317
4.00 Operation of crane superstructure 319
4.01 Operating and control instruments on the crane superstructure 320
1 Operating and control instruments 321
2 Equipment in the cab 321
3 Operating units in the cab 325
4.02 LICCON computer system 350
1 General 351
2 LICCON computer system boot up 355
3 Operating elements of the LICCON computer system on monitor 0 359
4 The set up program 363
5 The winch – pulley head assignment screen 387
6 The Crane operation program on monitor 0 407
7 Operating elements of the LICCON computer system on monitor 1 477
8 The Crane operation program on monitor 1 479
9 The Control parameter program 523
10 The Support program 531
11 The Working range limitation program* 545
12 The Engine monitoring program 549
13 LICCON computer system in stand-by mode 557
4.03 Crane start up and taking the crane out of service 560
1 Power supply for the crane* 561
2 Checks before start up 565
3 Work station – Crane operator’s cab 573
4 Starting and stopping the engine 583
5 LICCON computer system after engine start 589
6 Load weighing and load display 595
4.04 Safety equipment 600
1 Prerequisites for crane operation 601
2 Overload protection of LICCON computer system 601
3 Wind warning device 605
4 Hoist limit switch “Hoist top” 605
14 IIEBHEIIII
Contents
5 Limit switch “Winch spooled out” 607
6 EMERGENCY OFF switch 609
7 Control release 609
8 Hydraulic safety valves 609
9 Limit switch 611
10 Angle sensors 613
11 Test brackets (KMD = force test box) 613
12 Acoustical / optical warning 615
13 Bypassing the safety devices 619
4.05 Crane operation 624
1 LICCON computer system 625
2 Winch and master switch assignment to operating modes 625
3 Carrying out crane movements 627
4.06 Rope reeving 654
1 Wire ropes and rope end connections 655
2 Reeving the hook block in and out 657
3 Securing and removing the load hook* 665
4 Attaching / removing the hoist limit switch weight 669
5 Assembling / disassembling the wedge lock 673
6 Rope reeving 673
4.07 Counterweight 674
1 Counterweight combinations 675
2 Assembling the counterweight 679
3 Removing the counterweight 691
4.08 Working with a load 702
1 Safety technical instructions for working with a load 703
2 Checks before starting to work with the crane 704
3 Crane movement – Telescoping 705
4 Taking on a load 707
5 Crane operation 713
4.10 Driving from the crane operator’s cab 715
1 Prerequisites for crawler operation 717
2 Driving the crawler crane 731
4.12 Two hook operation 746
1 General 747
4.15 Reeving plans 752
1 Reeving plans 753
5.00 Equipment 755
5.01 Safety technical guidelines for assembly and disassembly 756
1 Checking the retaining elements 757
2 Rope pulleys 757
3 Checking the ropes 757
4 Control measures 758
5 Dangerous conditions without shut off 760
6 Transporting components 761
7 Pneumatic springs for assembly support of components 761
8 Manual rope winches for assembly support of components 761
9 Weights 762
10 Guy rods 762
11 Auxiliary guying 763
12 Bypassing the overload protection 763
13 Bypassing the hoist top shut off 765
14 Assembly/ disassembly 767
15 Erection / take down 798
5.02 SA-frame 800
1 SA-frame 801
5.03 Boom systems 812
1 Equipment for boom combinations 813
5.05 D-boom 814
1 Components and attachment points 815
2 Assembly D-boom 817
3 Disassembly 845
5.07 SW/SOW boom combination 860
1 Component overview W-boom system 861
2 Fastening points W-transport units 861
3 Assembling the W-boom system 863
4 Operating the crane 895
16 IIEBHEIIII
Contents
5 Disassembling the W-boom system 897
5.08 WV-lattice jib 916
1 Overview WV-lattice jib 917
2 Assembling the WV-boom system 919
3 Operating the crane 931
4 Disassembling the WV-boom system 933
5.10 Boom nose 942
1 Overview of boom nose components 943
2 Assembling the 36 t boom nose on the SW-end section 945
3 Erecting / taking down the boom 951
4 Crane operation 953
5 Disassembling the 36 t boom nose 955
5.13 SLF-Boom combination 958
1 Component overview 959
2 Assembling the auxiliary jib 961
3 Operating the crane 987
4 Disassembling the auxiliary jib 989
5.14 Pulley set 1002
1 Combinations of boom heads with pulley sets 1003
2 Overview components pulley set 1005
3 Assembling / disassembling the pulley set 1007
5.17 SWF-boom combination 1010
1 Component overview 1011
2 Assembling SWF-boom 1013
3 Operating the crane 1029
4 Disassembling the SWF-booms 1031
5.19 Hook blocks 1040
1 Minimum required hook block weight 1041
2 Procedure in case of slack rope 1044
3 Hook block overview 1047
4 Installing a double hook block for single operation 1049
5 Installing a double hook block for parallel operation 1059
6 Single hook blocks 1071
5.30 Pin pulling device 1078
IIEBHEIIII 17
Contents
1 Operating the pin pulling device 1079
5.35 Derrick ballast – Ballast trailer 1088
1 Component description and general notes 1089
2 Assembling the ballast trailer 1095
3 Setting the ballast trailer radii 1121
4 Steering programs 1123
5 Driving with the ballast trailer 1143
6 Crane operation with derrick ballast 1157
7 Disassembling the ballast trailer 1177
8 Emergency operation with a defective CPU 1195
9 Maintenance intervals for the ballast trailer 1203
10 Maintenance 1205
11 Fill quantities 1217
12 Lubrication schedule 1219
5.36 Derrick ballast – Suspended ballast 1220
1 Suspended ballast 1221
2 Derrick radii 1225
3 Assembly 1227
4 Crane operation with derrick ballast 1245
5 Crawler operation with derrick ballast 1265
6 Disassembly 1267
5.38 S/SL-boom 1278
1 Component overview S-pivot section 1279
2 Attachment points 1279
3 Assembling the S/SL boom 1281
4 Operating the crane 1317
5 Disassembling the S/SL boom 1319
5.39 LD/SLD/SD-boom combination 1330
1 Component overview S-pivot section 1331
2 Attachment points 1331
3 Assembling the SLD/SD-boom 1333
4 Operating the crane 1373
5 Disassembling the SLD/SD-boom 1375
5.42 HS auxiliary jib 1392
18 IIEBHEIIII
Contents
1 Auxiliary jib “HS” 1393
2 Installing the auxiliary jib “HS” on the SL-boom 1395
3 Erecting the SL-boom 1405
4 Operating the crane 1411
5 Removing the auxiliary jib “HS” 1413
5.61 Pulley cart 1420
1 Overview components pulley cart 1421
2 Installing/ removing the pulley cart 1423
6.00 Additional equipment 1425
6.01 Heater/ engine pre-heating 1426
1 Heating the crane cab 1427
2 The “Air conditioning settings” menu 1427
6.05 Emergency take-down 1460
1 Emergency operation 1461
2 Emergency operation with assembly plate Variation 1 (V1) 1467
3 Emergency operation of slewing gear(s) with assembly plate Variation 1 (V1) 1473
4 Emergency operation with assembly plate(s) Variation 2 (V2) 1477
5 Emergency operation slewing gear(s) with assembly plate(s) Variation 2 (V2) 1487
6 Emergency operation of winch 4 (W IV) on the LR1600/2 and LR1600/2-W 1491
7 Ending emergency operation 1495
7.00 Service and maintenance 1497
7.01 Maintenance and service – General 1498
1 Liebherr Service 1499
2 General specifications 1499
3 Cleaning and care of the crane 1500
4 Measures for work interruption or transport 1501
5 Maintenance work on gear components 1501
6 Maintenance work on the crane superstructure or boom 1502
7 Maintenance and inspection guidelines 1503
7.02 Maintenance intervals Crawler chassis, ballast trailer 1507
1 Crane chassis maintenance and inspection schedule 1509
2 Ballast trailer maintenance and inspection schedule 1513
7.03 Maintanance intervals – Crane superstructure 1515
1 Crane superstructure maintenance and inspection schedule 1517
7.04 Maintenance guidelines – Crane chassis 1526
1 Servicing the travel gear 1527
2 Servicing the central lubrication system of the crawler carrier 1535
3 Servicing the track chain 1543
7.05 Maintenance guidelines – Crane superstructure 1554
1 Crane engine 1555
2 Pump distributor gear 1561
3 Hydraulic system 1563
4 Slewing ring connection 1569
5 Central lubrication system 1571
6 Hoist gear 1 to 6, illustration 1 1581
7 Assembly winch, illustration 2 1583
8 Slewing gear 1585
9 Air dryer of the compressed air system of the crane superstructure 1587
10 Electrical system – Lighting 1587
7.06 Fill quantities, lubrication schedule 1590
1 Fill quantities 1591
2 Lubrication schedule 1595
7.07 Service fluids and lubricants 1604
1 Specified service items and lubricants for Liebherr cranes 1605
7.15 Procedure in case of problems 1613
1 Procedure to follow in case of a problem 1615
2 Measures in clear problem cases 1619
3 Carry out error diagnostics 1629
4 Measures for defective components 1631
8.00 Inspections of cranes 1635
8.01 Periodic crane inspections 1636
1 General 1637
2 Inspection of carrying crane structures, especially steel structures 1638
3 Inspection of tires and disk wheels 1711
4 Inspecting the hoist and retracting winches 1713
5 Inspecting load hooks 1725
6 Inspection of the rope feed mechanism in the telescopic boom
7 Inspection of locking system of telescopic boom
8 Inspection of retaining ropes and anchor points
9 Inspection of membrane accumulator
10 Inspection of relapse cylinders
11 Inspection of the safety controls on the relapse cylinders
12 Inspection of rope pulleys
13 Inspecting the function of the overload protection
14 Inspecting the roller slewing ring connection
15 Inspection of the mounting of the load bearing equipment
16 Inspection of the tele extension with eccentric, illustration 1
17 Inspection of change over pulleys, illustration 2
18 Inspection of the oil and fuel reservoirs
19 Inspection of the auxiliary reeving winch, recovery winch and spare gear
winch
20 Appendix
8.04 Inspection of crane wire ropes
1 Introduction
2 Wire rope
3 Operating behavior of steel ropes
4 Condition of equipment that is functionally associated with the rope
5 Rope inspection log
6 Rope storage and marking
7 Wire ropes and rope end connections
8 Twisting caused by stretching in rotation-resistant ropes and its remedy
9 Appendix 1
10 Appendix 2
11 Appendix 3
12 Appendix 4
8.12 Inspection of safety switching on the relapse supports
1 S-boom relapse retainer
2 Derrick relapse retainer
3 W-lattice jib
8.14 Inspection of accumulator pressure in relapse cylinder
Contents
1 Checking jib stop cylinder pressure 1783
8.15 Inspection and maintenance of guy rods 1784
1 General 1785
2 Repeat inspection of guy rods 1785
9.00 General notes 1787
9.02 Supplementary service work 1788
1 Checks before start up 1789
2 Repair and maintenance tasks 1789
3 Important servicing 1789
4 Maintenance notes for replacement parts 1790
5 Recommendations for travel operation 1790
6 Disposal of fuels and greases 1790
90.00 Appendix 1791
90.01 Foreword to appendix 1792
1 Preface 1793
90.05 Update confirmation 1794
1 Update confirmation 1795
2 Customer information 1795
Index 1797
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