Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-04-02 – PDF DOWNLOAD
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Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-04-02 – PDF DOWNLOAD
Language : English
Pages : 1670
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-04-02 – 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 NOTICE used in the crane documentation are
intended to point out certain rules of conduct to all persons working with the crane.
TABLE OF CONTENTS:
Liebherr LTM 1200-5.1 Mobile Crane with Telescopic Boom Operating Instruction Manual 21001-04-02 – PDF DOWNLOAD
Operating instructions............................................................................. 1 1 Description of crane......................................................................... 25 1.01 Terminology........................................................................... 26 1 Crane components..................................................................... 27 2 Auxiliary boom....................................................................... 29 1.02 Product description................................................................... 30 1 Crane chassis........................................................................ 31 2 Crane superstructure................................................................. 32 3 Auxiliary equipment.................................................................. 33 1.03 Technical data........................................................................ 35 1 Dimensions........................................................................... 37 2 Support.............................................................................. 37 3 Tires................................................................................ 38 4 Weights.............................................................................. 38 5 Workplace-related emission value..................................................... 38 6 Vibrations........................................................................... 39 7 Speeds............................................................................... 39 8 Rope diameter........................................................................ 40 9 Lifting heights...................................................................... 40 2 Safety....................................................................................... 45 2.01 Traffic regulations................................................................... 46 1 Traffic regulations.................................................................. 47 2.01.10 General traffic regulations........................................................ 48 1 General traffic regulations.......................................................... 49 2.01.20 National traffic regulations....................................................... 51 1 National traffic regulations......................................................... 53 2.02 Break-in instructions................................................................. 54 1 Break-in instructions................................................................ 55 2.03 Job planning.......................................................................... 56 1 Planning crane operation............................................................. 57 2.04 General safety technical guidelines................................................... 58 1 General.............................................................................. 59 2 Emergency exit....................................................................... 67 3 Checking the rigging and fastening points............................................ 71 4 Personal protective equipment........................................................ 73 5 Use of single-stranded height safety equipment, illustration 1....................... 79 6 Use of double-stranded height safety equipment, illustration 2....................... 79 7 Securing the assembly personnel against falling...................................... 79 8 Rescuing the assembly personnel...................................................... 81 9 Documentation........................................................................ 81 10 Identification...................................................................... 81 11 Crane operator responsibilities..................................................... 81 12 Selecting the location, illustrations 1 to 3........................................ 87 13 Slopes and excavations, illustrations 4 and 5....................................... 90 14 Permissible ground pressures........................................................ 90 15 Support............................................................................. 93 16 Checking the safety measures........................................................ 95 17 Endangering air traffic............................................................. 95 18 Grounding........................................................................... 96 19 Consideration of wind conditions.................................................... 96 20 Working in the vicinity of transmitters............................................. 107 21 Dangers when working together with several cranes................................... 109 22 Hand signals for guidance........................................................... 110 23 Crane operation with a load......................................................... 118 24 Lifting of personnel................................................................ 121 25 Crane operation in case of thunderstorms............................................ 122 26 Safety notes for external power feed (100 V AC to 400 V AC)......................... 122 27 Welding work on the load............................................................ 123 28 Interruption of crane operation..................................................... 124 29 Resumption of crane operation....................................................... 125 30 Ending crane operation.............................................................. 125 31 Turning / driving in reverse........................................................ 126 32 Parking the vehicle................................................................. 126 33 Safety guidelines for ladders....................................................... 129 2.05 Signs on the crane.................................................................... 136 1 Signs................................................................................ 137 2.05.10 Labeling of load lifting equipment................................................. 167 1 Identifications on the hook block or load hooks...................................... 169 2 Identifications on single hook or double hook........................................ 170 3 Identifications on auxiliary weights................................................. 171 2.06 Antifall guards on the crane.......................................................... 173 1 Personal protective equipment........................................................ 175 2 Preparing the ladder................................................................. 177 3 Attachment and fastening points...................................................... 179 4 Railings on the crane superstructure................................................. 183 2.07 Access to the crane................................................................... 184 1 Components on the crane.............................................................. 185 2 Ascent and descent on the crane chassis.............................................. 189 3 Walking and stepping surfaces........................................................ 199 2.08 Working in low temperatures........................................................... 200 1 Working in low temperatures.......................................................... 201 2 Working in ambient temperatures up to -40 °C......................................... 201 3 Working in ambient temperatures below -40 °C......................................... 209 2.10 General safety technical notes for driving with dolly................................. 211 1 Travel operation with dolly.......................................................... 213 3 Crane chassis operation...................................................................... 223 3.01 Operating and control instruments on the crane chassis................................ 224 1 Operating and monitoring elements.................................................... 225 2 Camera - monitor*.................................................................... 229 3 Trip recorder*....................................................................... 231 4 Keyboard............................................................................. 233 5 Display unit......................................................................... 237 3.02 Before starting to travel............................................................. 244 1 General checks before starting to travel............................................. 245 2 Work station - Driver's cab.......................................................... 253 3.03 Axle suspension system................................................................ 262 1 Crane vehicle axles suspended........................................................ 263 2 Crane vehicle axles blocked.......................................................... 267 3 Level regulation..................................................................... 271 3.04 Travel operation...................................................................... 282 1 Driving configurations of the crane.................................................. 283 2 Starting and stopping the engine..................................................... 287 3 Driving the crane vehicle............................................................ 293 4 Creeper gear (off-road gear / maneuvering or taxiing mode)........................... 331 5 Differential locks................................................................... 337 6 Steering............................................................................. 343 3.05 Crane at the job site................................................................. 350 1 General.............................................................................. 351 2 Bluetooth Terminal (BTT)............................................................ 359 3 Supporting from the crane operator's cab............................................. 395 4 Before leaving the jobsite........................................................... 415 3.07 Towing the crane...................................................................... 416 1 Towing............................................................................... 417 3.80 Transport of crane and crane components............................................... 418 1 Transporting the crane............................................................... 419 4 Operation of crane superstructure............................................................ 427 4.01 Operating and control instruments on the crane superstructure......................... 428 1 Operating and control instruments.................................................... 429 2 Operating elements on camera - monitor*.............................................. 433 3 Operating elements on control consoles............................................... 435 4 Operating elements on the operating and control unit (BKE)........................... 463 4.02 LICCON computer system................................................................ 470 1 General.............................................................................. 471 2 LICCON computer system boot up....................................................... 473 3 Operating elements of the LICCON computer system..................................... 475 4 “Set up” program..................................................................... 479 5 “Crane operation” program............................................................ 497 6 “Telescoping” program................................................................ 561 7 The “Working range limitation” program*.............................................. 565 8 The “Support force monitoring” program*.............................................. 567 9 The settings window “Speed reduction master switch”.................................. 575 10 Power-Save and Stand-by mode in the LICCON computer system.......................... 583 4.03 Crane start up and taking the crane out of service.................................... 588 1 Checks before start up............................................................... 589 2 Work station - Crane operator's cab.................................................. 595 3 Preheating the hydraulic oil with the Hydraulic oil preheating*...................... 613 4 Starting the engines from the crane operator's cab................................... 617 5 Engine regulation from the crane driver's cab........................................ 629 6 Detaching / attaching the hook block on the fastening point.......................... 633 7 LICCON computer system after engine start............................................ 645 4.04 Safety equipment...................................................................... 648 1 General.............................................................................. 649 2 Quick test Crane geometry............................................................ 649 3 Quick test Overload protection....................................................... 649 4 LICCON computer system............................................................... 650 5 Safety devices on the crane.......................................................... 655 4.05 Crane operation....................................................................... 666 1 General.............................................................................. 667 2 LICCON computer system............................................................... 673 3 Luffing.............................................................................. 675 4 Lifting / lowering................................................................... 681 5 Turning.............................................................................. 687 6 Telescoping.......................................................................... 699 4.06 Rope reeving.......................................................................... 726 1 Wire ropes and rope end connections.................................................. 727 2 Reeving the hoist rope with the auxiliary reeving rope............................... 729 3 Reeving the hook block in and out.................................................... 733 4 Securing and removing the load hook*................................................. 739 5 Attaching / removing the hoist limit switch weight................................... 743 6 Assembling / disassembling the wedge lock............................................ 747 7 Crane operation with auxiliary block* on the telescopic boom......................... 749 8 Rope reeving......................................................................... 749 4.07 Counterweight......................................................................... 750 1 General.............................................................................. 751 2 Assembly............................................................................. 761 3 Disassembly of the counterweight plates.............................................. 767 4.08 Working with a load................................................................... 774 1 Safety technical instructions for working with a load................................ 775 2 Checks before starting to work with the crane........................................ 776 3 Crane movement - Telescoping......................................................... 777 4 Taking on a load..................................................................... 779 5 Crane operation...................................................................... 785 4.15 Reeving plans......................................................................... 787 1 Reeving plans........................................................................ 789 4.20 Procedure for shut off of crane movements............................................. 806 1 General.............................................................................. 807 2 Instructions to resume the crane movement............................................ 823 5 Equipment.................................................................................... 863 5.01 Safety technical notes for assembly and disassembly................................... 864 1 Checking the retaining elements...................................................... 865 2 Rope pulleys......................................................................... 865 3 Checking the ropes................................................................... 865 4 Control measures..................................................................... 866 5 Dangerous conditions without shut off................................................ 868 6 Transporting components.............................................................. 869 7 Pneumatic springs for assembly support of components................................. 869 8 Manual rope winches for assembly support of components............................... 869 9 Weights.............................................................................. 870 10 Guy rods............................................................................ 870 11 Auxiliary guying.................................................................... 871 12 Bypassing the overload protection................................................... 871 13 Bypassing the hoist top shut off.................................................... 873 14 Assembly / disassembly.............................................................. 875 15 Erection / take down................................................................ 912 5.02 Folding jib - TK...................................................................... 914 1 General.............................................................................. 915 2 Assembling the folding jib........................................................... 929 3 Reeving in the hoist rope............................................................ 959 4 Changing over mechanical folding jib from 0° to 22.5° or 45°......................... 961 5 Hydraulic connections................................................................ 973 6 Electrical connections............................................................... 981 7 Erection............................................................................. 989 8 Adjusting the folding jib angle hydraulically*....................................... 991 9 Changing over mechanical folding jib from 22.5° or 45° to 0°......................... 993 10 Unreeving the hoist rope............................................................1001 11 Removing the folding jib............................................................1003 5.09 Winch 2...............................................................................1026 1 General..............................................................................1027 2 Assembly.............................................................................1031 3 Disassembly..........................................................................1033 5.10 Boom nose.............................................................................1034 1 General..............................................................................1035 2 Assembly.............................................................................1037 3 Disassembly..........................................................................1043 5.12 Auxiliary boom........................................................................1048 1 General..............................................................................1049 2 Assembling the auxiliary boom........................................................1053 3 Reeving in the hoist rope............................................................1077 4 Changing the mechanical auxiliary boom from 0° to 22.5° or 45°.......................1079 5 Hydraulic connections................................................................1085 6 Electrical connections...............................................................1087 7 Erection.............................................................................1091 8 Adjusting the auxiliary boom angle hydraulically*....................................1093 9 Changing the mechanical auxiliary boom from 22.5° or 45° to 0°.......................1095 10 Unreeving the hoist rope............................................................1099 11 Disassembling the auxiliary boom....................................................1101 5.14 Telescopic boom disassembly/assembly, luffing cylinder on the crane superstructure....1122 1 General..............................................................................1123 2 Removal of telescopic boom...........................................................1123 3 Installation of telescopic boom......................................................1135 5.17 Sliding beam disassembly / assembly...................................................1146 1 General..............................................................................1147 2 Remove sliding beams with auxiliary crane*...........................................1149 3 Removing the rear sliding beams with own crane*......................................1151 4 Installing the sliding beams with the auxiliary crane*...............................1159 5 Installing the rear sliding beams with own crane*....................................1161 5.19 Hook blocks...........................................................................1167 1 Minimum required hook block weight...................................................1169 2 Procedure in case of slack rope......................................................1172 3 Hook block overview..................................................................1175 4 Transporting the hook block / load hook..............................................1177 5 Installing the single blocks.........................................................1179 6 Removing the single blocks...........................................................1183 5.25 Telescopic boom extension.............................................................1186 1 General..............................................................................1187 2 Assembly.............................................................................1189 3 Establishing the electrical / hydraulic connections..................................1191 4 Erection.............................................................................1191 5 Disassembly..........................................................................1193 5.31 Bluetooth Terminal (BTT).............................................................1196 1 Display / operating element Bluetooth Terminal......................................1197 2 The Bluetooth Terminal (BTT) is plugged into the instrument console.................1211 3 The Bluetooth Terminal (BTT) removed from its charging cradle.......................1217 4 Operation of the Bluetooth Terminal (BTT)...........................................1251 6 Additional equipment.........................................................................1257 6.01 Heater / engine preheating / Air conditioning system Drivers cab.....................1258 1 Heating the driver's cab.............................................................1259 2 Maintaining the engine independent heater............................................1281 6.02 Heater / engine preheating / Air conditioning system Crane operators cab.............1283 1 Heating the crane operator's cab.....................................................1285 2 Menu “Climate control settings”......................................................1285 3 Maintaining the engine independent heater............................................1319 6.04 Support beam monitoring / sliding beam monitoring.....................................1321 1 General..............................................................................1323 2 Support bases........................................................................1323 3 Working with sliding beam monitoring*................................................1325 6.05 Emergency take-down...................................................................1326 1 Emergency procedure..................................................................1327 6.07 Emergency operation of support........................................................1330 1 Emergency operation of support.......................................................1331 7 Service and maintenance......................................................................1335 7.01 Maintenance and service - General.....................................................1336 1 Liebherr Service.....................................................................1337 2 Warranty.............................................................................1337 3 Technical safety instructions........................................................1338 4 Work interruption and transport......................................................1340 5 Maintenance and inspection guidelines................................................1340 6 Maintenance and repair work..........................................................1341 7 Cleaning and care of the crane.......................................................1343 7.02 Maintenance intervals - Crane chassis.................................................1345 1 Crane chassis maintenance and inspection schedule....................................1347 7.03 Maintanance intervals - Crane superstructure..........................................1356 1 Crane superstructure maintenance and inspection schedule.............................1357 7.03.50 Maintenance intervals - Crane boom.................................................1364 1 Crane boom maintenance and inspection schedule.......................................1365 7.04 Maintenance guidelines - Crane chassis................................................1369 1 Diesel engine........................................................................1371 2 Coolant system.......................................................................1375 3 Air filter system....................................................................1379 4 Fuel system..........................................................................1381 5 Urea system*.........................................................................1385 6 Exhaust system.......................................................................1387 7 Automatic transmission...............................................................1389 8 Distributor gear.....................................................................1393 9 Axles................................................................................1395 10 Steering............................................................................1399 11 Tires...............................................................................1401 12 Driver's cab........................................................................1413 13 Auxiliary heater*...................................................................1417 14 Hydraulic system....................................................................1419 15 Hydraulic hose lines................................................................1423 16 Compressed air and brake system.....................................................1425 17 Electrical system...................................................................1425 7.05 Maintenance guidelines - Crane superstructure.........................................1430 1 Diesel engine........................................................................1431 2 Coolant system.......................................................................1435 3 Air filter system....................................................................1439 4 Fuel system..........................................................................1441 5 Urea system*.........................................................................1445 6 Exhaust system.......................................................................1449 7 Pump distributor gear................................................................1451 8 Central lubrication system...........................................................1453 9 Slewing ring connection..............................................................1463 10 Slewing gear(s).....................................................................1465 11 Hoist gear(s).......................................................................1467 12 Auxiliary heater*...................................................................1473 13 Hydraulic system....................................................................1479 14 Hydraulic hose lines................................................................1482 15 Electrical system...................................................................1482 7.05.50 Maintenance guidelines - Crane boom................................................1483 1 Telescopic boom......................................................................1485 7.06 Fill quantities, lubrication schedule.................................................1488 1 Fill quantities......................................................................1489 2 Lubrication schedule.................................................................1490 3 Disposal.............................................................................1490 7.06 Fill quantities, lubrication schedule.................................................1491 1 Fill quantities......................................................................1493 2 Lubrication schedule.................................................................1497 7.07 Service fluids and lubricants.........................................................1502 1 Specified service items and lubricants for Liebherr cranes...........................1503 8 Inspections of cranes........................................................................1511 8.01 Periodic crane inspections............................................................1512 1 General..............................................................................1513 2 Inspection of carrying crane structures, especially steel structures.................1514 3 Inspecting the hoist and retracting winches..........................................1588 4 Inspecting the load hooks............................................................1599 5 Inspection of the rope feed mechanism in the telescopic boom.........................1601 6 Inspection of locking system of telescopic boom......................................1603 7 Inspection of safety ropes and anchor points.........................................1605 8 Inspection of membrane accumulator...................................................1607 9 Inspection of relapse cylinders......................................................1607 10 Inspection of the safety controls on the relapse cylinders..........................1608 11 Inspection of rope pulleys..........................................................1608 12 Inspecting the function of the overload protection..................................1608 13 Inspecting the roller slewing ring connection.......................................1608 14 Inspection of the mounting of the load bearing equipment............................1609 15 Inspection of the tele extension with eccentric, illustration 1.....................1611 16 Inspection of change over pulleys, illustration 2...................................1611 17 Inspection of the oil and fuel reservoirs...........................................1611 18 Inspection of the auxiliary reeving winch, recovery winch and spare gear winch......1611 19 Appendix............................................................................1612 8.04 Inspection of crane wire ropes........................................................1622 1 Introduction.........................................................................1623 2 Wire rope............................................................................1623 3 Operating behavior of steel ropes....................................................1629 4 Condition of equipment that is functionally associated with the rope.................1630 5 Rope inspection log..................................................................1630 6 Rope storage and marking.............................................................1630 7 Wire ropes and rope end connections..................................................1630 8 Twisting caused by stretching in rotation-resistant ropes and its remedy.............1635 9 Appendix 1...........................................................................1639 10 Appendix 2..........................................................................1641 11 Appendix 3..........................................................................1643 12 Appendix 4..........................................................................1643 8.07 Inspection of pneumatic brake system for disk brakes..................................1646 1 General..............................................................................1647 2 Visual inspection....................................................................1647 3 Function and performance test........................................................1647 4 Internal inspection of the wheel brake...............................................1649 90 Appendix....................................................................................1653 90.01 Foreword to appendix.................................................................1654 1 Preface..............................................................................1655 90.05 Update confirmation..................................................................1656 1 Update confirmation..................................................................1657 2 Customer information.................................................................1657 Index..........................................................................................1659
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