Liebherr Crane LR 1100 Litronic Operating Manual SN 133003 – PDF DOWNLOAD

OPERATING MANUAL

133 003 (rk) LWN - TD30/8/2002

Serial number: 133 003

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INTRODUCTION .................................................1 PRODUCT DESCRIPTION .................................2

SAFETY REGULATIONS ...................................3

CONTROL AND OPERATING ELEMENTS .......4

OPERATION .......................................................5

INDEX

ASSEMBLY AND DISASSEMBLY .....................6

MAINTENANCE ..................................................7

REPAIR ...............................................................8

133 003 (rk) LWN - TD30/8/2002

OPTIONS ............................................................9

APPENDIX ....................................................... 10

INDEX

INDEX 1.

INTRODUCTION 1.1

Foreword

1-1

1.2

Using the documentation

1-2

133 003 (rk) LWN - TD30/8/2002

1.2.1

How is the operating manual in book 1 compiled?

1-3

1.2.2

Computer system requirements to use the CD-ROMs

1-3

1.2.3

Current status of the documentation

1-3

1.2.4

Storing the documentation

1-4

1.3

Machine's passport

1-5

1.4

Documentation

1-7

1.5

Conversion charts

1-8

1.6

2.

1-1

1.5.1

Length

1-8

1.5.2

Area

1-8

1.5.3

Weight (mass)

1-9

1.5.4

Volume

1-9

1.5.5

Pressure

1-9

1.5.6

Temperature

1 - 10

1.5.7

Speed

1 - 10

1.5.8

Force

1 - 10

1.5.9

Torque

1 - 10

1.5.10

Output

1 - 11

Declaration of conformity

1 - 12

PRODUCT DESCRIPTION

2-1

2.1

General

2-1

2.2

Various configurations

2-1

2.2.1

Machine classifications

2-2

2.2.2

Explanations to machine classifications

2-3

2.3

Machine overview

2-4

2.4

Boom

2-6

2.5

2.6

2.4.1

Information on boom designations

2-6

2.4.2

Main boom

2-7

2.4.3

The optional mast nose for the Main boom head

2 - 18

2.4.4

Main boom with optional main boom-reduction piece, System-no./-length: 1311/1008.21 / 12m

2 - 20

2.4.5

Main boom with fixed fly-jib

2 - 24

2.4.6

Main boom with luffing fly-jib

2 - 32

Uppercarriage

2 - 42

2.5.1

Center unit

2 - 46

2.5.2

Pump fitting

2 - 50

Counterweights

2 - 52

2.6.1

2 - 52

Rear counterweight

0-1

INDEX 2.6.2 2.7

3.

2 - 54

Counterweight

2 - 55

2.7.1

Rear counterweight

2 - 55

2.7.2

Center counterweight

2 - 57

2.8

Overview of the hydraulic cylinder

2 - 58

2.9

Technical data

2 - 59

2.9.1

Dimension and weights

2 - 59

2.9.2

OPERATING CONDITIONS

2 - 63

2.9.3

Emissions

2 - 63

2.9.4

Engine

2 - 64

2.9.5

Hydraulic system

2 - 65

2.9.6

Winches

2 - 66

2.9.7

Slewing system

2 - 68

2.9.8

Tracks

2 - 69

2.9.9

Controls

2 - 73

SAFETY GUIDELINES 3.1

General 3.1.1

3.2

3-1 3-1

Danger symbols

Utilization as directed 3.2.1

3-2 3-3

Purpose

3-3

3.3

Areas of responsibility

3-4

3.4

Personal requirements of the crane operator

3-5

3.5

Personal protective gear

3-6

3.6

Work area

3-7

3.7

Safety and monitoring devices

3-8

3.8

3.7.1

Safety devices

3-8

3.7.2

Monitoring devices

3 - 10

Safety signs on the crawler crane

3 - 11

3.8.1 3.9

3.10

0-2

Center counterweight

Meaning of the safety signs

Machine specific dangers

3 - 16 3 - 18

3.9.1

Injuries caused by mechanical parts

3 - 18

3.9.2

Injuries due to hydraulic energy

3 - 19

3.9.3

Danger of burns

3 - 20

3.9.4

Chemical burns

3 - 20

3.9.5

Danger of fire and explosion

3 - 21

3.9.6

Danger of poisoning and asphyxiation

3 - 23

3.9.7

Environmental protection

3 - 24

3.9.8

Electromagnetic influences

3 - 24

Additional dangers

3 - 26

3.10.1

Influence of winds and storms

3 - 26

3.10.2

Ground composition at the site

3 - 30

3.10.3

Snow and ice loads

3 - 32

3.10.4

Lightning strokes

3 - 33

3.10.5

Overhead power lines

3 - 34

INDEX 3.10.6 3.11

3.12

4.

Ground cables

3 - 43

Notes on safety for the machine operator

3 - 48

3.11.1

An assistant

3 - 48

3.11.2

Slinger

3 - 50

Notes on safety for the maintenance and repair personnel on site 3.12.1

Assistant

3 - 51

3.12.2

Slinger

3 - 52

3.12.3

Hand signals

3 - 52

CONTROL AND OPERATING ELEMENTS General

4-1

4.2

Control elements on the undercarriage

4-2

4.3

Control elements on the uppercarriage

4-3

4.4

Operator's cab

4-4

4.4.1

Overview of operator's cab

4-4

4.4.2

Overview of the operator's seat

4-5

4.4.3

Gear levers and pedals

4-7

4.5

Left control panel (X11)

4-9

4.6

Left control panel (X12)

4 - 11

4.7

Control panel on the right (X23)

4 - 13

4.8

Litronic service panel

4 - 16

4.9

4.10

EMERGENCY- OFF switch

Overview of the LCD-screen

4 - 17 4 - 18

4.9.1

Main areas of the screen

4 - 18

4.9.2

Describing the screen's main areas

4 - 18

4.9.3

Order of display screen pages

4 - 20

Set-up stage screens

4 - 22

4.10.1

Set-up stage screen 1 for main boom

4 - 23

4.10.2

Set-up stage diagram 2 for main boom with reduction

4 - 27

4.10.3

Set-up stage diagram 3 for main boom with fixed fly -jib

4 - 29

4.10.4

Set-up stage diagram 4 for main boom with luffing fly-jib

4 - 31

4.11

Screen "Crane operation"

4 - 32

4.12

Screen " Monitoring of components"

4 - 38

4.13

Screen for "Error displays"

4 - 41

4.14

Screen "Load chart"

4 - 43

4.14.1 133 003 (rk) LWN - TD30/8/2002

4-1

4.1

4.8.1

5.

3 - 50

Display of a load table for a set-up stage of the operation type 4

OPERATION 5.1

5.2

5.3

5-1

General 5.1.1

4 - 44

5-1 Safe operations with the crawler crane

Checks before daily operations

5-1 5-2

5.2.1

Inspection tour

5-2

5.2.2

Checks

5-2

Daily start up 5.3.1

5-4 Switch ignition on

5-4

0-3

INDEX

5.4

5.5

5.6

5.7

6.

0-4

5.3.2

Confirm current set-up stage

5-4

5.3.3

Check fuel level

5-5

5.3.4

Refueling the crawler crane

5-5

5.3.5

Select operating mode

5-6

5.3.6

Start diesel engine

5-6

5.3.7

Throttling the engine

5-7

crawler crane operation - main functions

5-9

5.4.1

Start up checks

5-9

5.4.2

Activating the main boom

5 - 11

5.4.3

Adjusting the main boom or the luffing fly-jib

5 - 12

5.4.4

Using electronic load moment limiters (LML)

5 - 14

5.4.5

Hoisting

5 - 16

5.4.6

Resetting the load screen to zero (incl. weight of the load hook)

5 - 16

Crane operation

5 - 18

5.5.1

Activate hoisting winch

5 - 18

5.5.2

Lifting loads with the main boom mounted optional mast nose

5 - 21

5.5.3

Lifting loads only with the main boom head and the added optional mast nose

5 - 22

5.5.4

Lifting loads with the main boom head with built-in fixed or adjustable fly-jib

5 - 23

5.5.5

Twin hook operation

5 - 25

5.5.6

Free fall operation

5 - 34

5.5.7

Activating the uppercarriage swing

5 - 39

5.5.8

Crane procedure

5 - 43

5.5.9

Adjusting the cylinders

5 - 46

Operating the crawler crane - auxiliary functions

5 - 47

5.6.1

Adjusting the operator' seat

5 - 47

5.6.2

LCD-screen adjustments

5 - 47

5.6.3

Wiper

5 - 48

5.6.4

Heating and optional air-conditioning

5 - 49

5.6.5

Lighting

5 - 51

5.6.6

The radio

5 - 52

5.6.7

The horn

5 - 52

5.6.8

Ash tray

5 - 53

5.6.9

Cigarette lighter and socket in the cabin

5 - 53

Shutting down the crawler crane

5 - 54

5.7.1

Park position

5 - 54

5.7.2

Setting down the boom

5 - 55

5.7.3

Shutting down the diesel engine

5 - 56

5.7.4

Park position of the ignition switch

5 - 56

5.7.5

Checks for leaving the crawler crane

5 - 57

ASSEMBLY AND DISASSEMBLY

6-1

6.1

General

6-1

6.2

Application planning

6-2

6.2.1

Determining the working area

6-2

6.2.2

Determine set-up stage

6 - 13

INDEX 6.2.3 6.3

6.4

6.5

Application planning

133 003 (rk) LWN - TD30/8/2002

6.7

6.8

6 - 13 6 - 14

6.3.1

Determining the working area

6 - 14

6.3.2

Determine set-up stage

6 - 25

6.3.3

Arrange and prepare the equipment for transport

6 - 25

Safety guidelines for assembly, disassembly and reconfiguration.

6 - 30

6.4.1

Requirements of the assembly team

6 - 30

6.4.2

Requirements of the set-up site

6 - 30

6.4.3

Performance guidelines

6 - 31

Notes for assembly operation 6.5.1

6.6

Arrange and prepare the equipment for transport

Operation in assembly operation

Unloading the basic machine

6 - 32 6 - 32 6 - 34

6.6.1

Prerequisites

6 - 34

6.6.2

Summary of unloading with the self-unloading system

6 - 34

6.6.3

Checks before unloading

6 - 36

6.6.4

Start assembly operation for unloading

6 - 38

6.6.5

Prepare basic machine for assembly

6 - 41

6.6.6

Support and unload the basic machine

6 - 44

6.6.7

Mounting the crawler

6 - 51

6.6.8

Mounting center counterweight

6 - 66

6.6.9

Assemble rear counterweight

6 - 69

6.6.10

Fit rear counterweight

6 - 74

6.6.11

Bolt rear counterweight

6 - 80

Assembly of main boom

6 - 82

6.7.1

Prerequisites

6 - 82

6.7.2

Summary of assembly stages

6 - 82

6.7.3

Unload and position main boom-head

6 - 83

6.7.4

Unload and position mast stub *

6 - 83

6.7.5

Assemble main boom

6 - 84

6.7.6

Assemble main boom retaining rods

6 - 86

6.7.7

Intermediate guying on the main boom

6 - 93

6.7.8

Arrangement of cable guide

6 - 96

6.7.9

Completing main boom assembly

6 - 97

6.7.10

Mount main boom onto main boom-pivot piece

6 - 99

6.7.11

Luffing hoisting cable

6 - 103

6.7.12

Cable reeving diagrams

6 - 107

6.7.13

Connecting the electrical system

6 - 110

6.7.14

Hoist end switches

6 - 112

6.7.15

Erecting the main boom

6 - 114

6.7.16

Procedures of the set up stage

6 - 116

6.7.17

Switching off set-up stage

6 - 117

6.7.18

Erectable main boom

6 - 118

6.7.19

Erectable main boom

6 - 122

Mounting optional mast nose on the main boom head 6.8.1

Prerequisite

6 - 126 6 - 126

0-5

INDEX

6.9

6.10

6.11

0-6

6.8.2

Position optional mast nose before the main boom head

6 - 127

6.8.3

Bolt optional mast nose to main boom head

6 - 127

6.8.4

Mounting hoist end switches to optional mast noses

6 - 130

Mounting the main boom with Reduction pieces (optional)

6 - 132

6.9.1

Prerequisites

6 - 132

6.9.2

Summary of the assembly steps

6 - 132

6.9.3

Unloading and positioning the main boom head

6 - 133

6.9.4

Assembling the main boom

6 - 134

6.9.5

Assembling the retaining rods

6 - 137

6.9.6

Intermediate tensioning main boom with reduction piece *

6 - 147

6.9.7

Connecting the electrics

6 - 154

6.9.8

Cable reeving diagrams

6 - 156

6.9.9

Mounting main boom with reduction piece *

6 - 157

6.9.10

Procedure when raising

6 - 159

6.9.11

Deselection of assembly operation

6 - 159

6.9.12

Mounting capability of main boom with reduction piece *

6 - 161

Assembly of fixed fly-jib

6 - 162

6.10.1

Prerequisites

6 - 162

6.10.2

Summary of assembly stages

6 - 163

6.10.3

Unload and position main boom-head

6 - 163

6.10.4

Mount fly-jib-pivot piece

6 - 164

6.10.5

Assemble fly-jib

6 - 165

6.10.6

Assemble fly-jib boom retaining rods

6 - 167

6.10.7

Assemble main boom

6 - 172

6.10.8

Assembling main boom-retaining rods

6 - 173

6.10.9

Completing assembly of the boom

6 - 173

6.10.10

Mount main boom to the main boom foot

6 - 174

6.10.11

Install shackles

6 - 177

6.10.12

Mount the tensioning rods to the shackles

6 - 178

6.10.13

Retract A-cylinder on the fly-jib-pivot piece

6 - 179

6.10.14

Mounting the tensioning rods to the girder

6 - 180

6.10.15

Reeve load hooks

6 - 181

6.10.16

Mounting hoist end switches

6 - 183

6.10.17

Connecting the electrical system

6 - 185

6.10.18

Erect main boom with fixed fly-jib

6 - 187

6.10.19

Procedure

6 - 187

6.10.20

Erectable with fixed fly-jib

6 - 191

Assembly of luffing fly-jib

6 - 194

6.11.1

Prerequisites

6 - 194

6.11.2

Summary of assembly stages

6 - 195

6.11.3

Unload and position main boom head

6 - 196

6.11.4

Mount fly-jib foot

6 - 196

6.11.5

Assemble fly-jib

6 - 198

6.11.6

Assemble fly-jib retaining rods

6 - 200

6.11.7

Mount fly-jib head

6 - 203

INDEX

6.12

133 003 (rk) LWN - TD30/8/2002

6.13

6.11.8

Intermediate tensionings on the fly-jib

6 - 205

6.11.9

Assemble main boom

6 - 210

6.11.10

Mounting retaining and tensioning rods of the main boom

6 - 211

6.11.11

Completing preparation work on the boom

6 - 212

6.11.12

Mount main boom on foot

6 - 213

6.11.13

Secure hoist cable as assembly aid

6 - 217

6.11.14

Reeve fly-jib hoist cable

6 - 218

6.11.15

Mounting A-frame 2 and 3

6 - 220

6.11.16

Connecting fly-jib foot with A-frame 3

6 - 221

6.11.17

Assembling fly-jib tensioning rods

6 - 222

6.11.18

Mounting the fly-jib

6 - 225

6.11.19

Assembling fly-jib retaining rods

6 - 226

6.11.20

Luff hoist cable via fly-jib

6 - 228

6.11.21

Reeving load hook on main boom head

6 - 228

6.11.22

Connecting the electrics

6 - 229

6.11.23

End of stroke switch

6 - 233

6.11.24

Mounting main boom with luffing fly-jib

6 - 236

6.11.25

Lifting and mounting main boom

6 - 239

6.11.26

Reeve load hook on fly-jib head

6 - 241

6.11.27

Possible main boom lengths using single pulley hooks

6 - 241

6.11.28

Mounting hoist limit switch on fly-jib head

6 - 244

6.11.29

Mount main boom and fly-jib

6 - 245

6.11.30

End assembly operation

6 - 247

6.11.31

Mounting capability luffing fly-jib

6 - 248

Modifications

6 - 252

6.12.1

Modification from wide to narrow track *

6 - 252

6.12.2

Conversion from narrow* to wide track

6 - 260

6.12.3

Time-saving conversion of the main boom

6 - 266

Disassembly of the Main boom with luffing fly-jib

6 - 269

6.13.1

Prerequisites

6 - 269

6.13.2

Summary of disassembly stages

6 - 270

6.13.3

Preparations for crane operation

6 - 270

6.13.4

Switching to assembly operation

6 - 270

6.13.5

Lay down main boom with luffing fly-jib

6 - 271

6.13.6

Lower fly-jib

6 - 273

6.13.7

Disconnecting the electrical system

6 - 276

6.13.8

Connect fly-jib-pivot piece with A-cylinder 3

6 - 279

6.13.9

Disassembling the fly-jib

6 - 280

6.13.10

Adjusting the A-frames 2 and 3 backwards

6 - 281

6.13.11

Separate fly-jib tensioning rods

6 - 282

6.13.12

Set down A-frame 2 and 3

6 - 282

6.13.13

Pull out fly-jib retraction cable

6 - 284

6.13.14

Remove main boom from the pivot piece

6 - 285

6.13.15

Disassembling the fly-jib pivot piece

6 - 289

6.13.16

Disassemble main boom and fly-jib

6 - 290

0-7

INDEX 6.14

6.15

6 - 291

6.14.1

Prerequisites

6 - 291

6.14.2

Summary of disassembly steps

6 - 292

6.14.3

Preparation for crane operation

6 - 292

6.14.4

Switch to assembly operation

6 - 292

6.14.5

Setting down main boom with fixed fly-jib

6 - 293

6.14.6

Lowering main boom with mounted fixed fly-jib

6 - 295

6.14.7

Disconnect electrical connections

6 - 296

6.14.8

Disassembling the fly-jib

6 - 297

6.14.9

Disassembling the main boom from the pivot piece

6 - 299

6.14.10

Disassembling the fly-jib pivot piece

6 - 302

6.14.11

Disassembling main boom and fly-jib

6 - 302

Disassembling the main boom

6 - 304

6.15.1

Prerequisites

6 - 304

6.15.2

Summary of the stages of disassembly

6 - 304

6.15.3

Preparations for crane operation

6 - 305

6.15.4

Switching to assembly operation

6 - 305

6.15.5

Lay down main boom

6 - 306

6.15.6

Procedures in laying down

6 - 307

6.15.7

Procedure in laying down with mast nose (optional)

6 - 308

6.15.8

Disassemble the mast nose (optional)

6 - 309

6.15.9

Disconnecting the electrical system

6 - 310

6.15.10

Pull out hoisting cable(s)

6 - 312

6.15.11

Remove main boom from the pivot piece

6 - 313

6.15.12

Dissemble the main boom

6 - 317

6.16

Disassembling the main booms with reduction piece *

6 - 318

6.17

Disassembling the base machine

6 - 319

6.18

0-8

Disassembling the main boom with fixed fly-jib

6.17.1

Prerequisites

6 - 319

6.17.2

Summary of stages of disassembly

6 - 320

6.17.3

Set down rear counterweight

6 - 322

6.17.4

Lay down and load rear counterweight

6 - 324

6.17.5

Disassembling center counterweight

6 - 327

6.17.6

Prepare disassembly of crawler

6 - 328

6.17.7

Base machine support

6 - 329

6.17.8

Lift and load crawler from undercarriage

6 - 334

6.17.9

Load base machine

6 - 341

6.17.10

Disassembling the assembly crane

6 - 343

6.17.11

Switching off base machine

6 - 344

Transport

6 - 345

6.18.1

Safety instructions for the loading and unloading

6 - 345

6.18.2

Transporting base machine with a flat-bed trailer

6 - 346

6.18.3

Transporting the attachments

6 - 348

6.18.4

Load base machine with auxiliary crane

6 - 349

6.18.5

Transporting overseas

6 - 352

INDEX

7.

MAINTENANCE

7-1

7.1

General

7-1

7.2

Table of maintenance intervals

7-2

7.2.1 7.3

Diesel engine 7.3.1

7.4

7.5

7.6

7.7

7.8

7.9

133 003 (rk) LWN - TD30/8/2002

7.10

7.11

Work to be carried out

7-2 7 - 13

Engine; check oil level and oil pressure

Fuel system

7 - 13 7 - 14

7.4.1

Layout of the components

7 - 14

7.4.2

Drain condensed water out of prime fuel filter

7 - 15

7.4.3

Draining off condensed water and sediments

7 - 15

7.4.4

Draining the fuel tank

7 - 15

7.4.5

Cleaning the fuel tank

7 - 16

7.4.6

Refueling

7 - 16

7.4.7

Changing the fuel intake filter

7 - 16

7.4.8

Venting the fuel system

7 - 17

Fuel system

7 - 18

7.5.1

Drain condensed water at the water separator

7 - 18

7.5.2

Venting the fuel system

7 - 18

The dry gas filter

7 - 19

7.6.1

Layout of the center components

7 - 19

7.6.2

Emptying the dust container

7 - 19

Crawler tracks

7 - 20

7.7.1

Cleaning the crawler tracks

7 - 20

7.7.2

Check and if required, put new tension in the crawler tracks.

7 - 20

7.7.3

Releasing the crawler tracks

7 - 20

7.7.4

Set screw on the crawler track support beam

7 - 21

7.7.5

Locking lid of the crawler support beam

7 - 21

Rotation gear / revolving joints

7 - 22

7.8.1

Check oil level of rotation gear To check the oil level the crane must be level

7 - 22

7.8.2

Lubricating the crown gears / pinions

7 - 22

7.8.3

Lubricating pinions, tracks

7 - 22

Winches

7 - 23

7.9.1

Check oil level of winches 1 and 2 and main-boom adjustable winches;

7 - 23

7.9.2

Main boom-adjustment winch and A-frame;

7 - 23

7.9.3

Check oil level of fly-jib adjustment winch

7 - 23

Cables

7 - 24

7.10.1

Cable guides and cable windings

7 - 24

7.10.2

Cable deflectors on winches "1" and "2"

7 - 24

7.10.3

Check wire rope clamp for tears

7 - 24

7.10.4

Inspect pocket lock

7 - 24

7.10.5

Inspect the wire clamp

7 - 25

7.10.6

Cable clips

7 - 25

7.10.7

Check cables

7 - 25

7.10.8

Pulleys and balancers

7 - 31

Load hooks

7 - 32

0-9

CLICK HERE TO

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• Thank you very much for reading the preview of the manual.

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