Liebherr Crawler Crane LR 1280 OPERATING MANUAL 136084 - PDF DOWNLOAD

OPERATING MANUAL

TYPE

LR 1280 SERIAL NUMBER

136 084 VERSION

136 084 (tz) LWN - TD19/9/2006

003

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

SAFETY PRECAUTIONS ...................................3

CHAPTER SUMMARY

CONTROLS ........................................................4

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

ASSEMBLY AND DISMANTLING ......................6

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

136 084 (tz) LWN - TD19/9/2006

OPTIONS ............................................................8

INDEX

INDEX 1.

INTRODUCTION 1.1

Foreword

1-1

1.2

Using the documentation

1-2

1.2.1

How is the operating manual in Volume 1 organised?

1-3

1.2.2

System requirements for use of the CD-ROM

1-3

1.2.3

Keeping of documentation

1-3

1.2.4

Current status of the documentation

1-4

1.3

Publisher's imprint

1-4

1.4

Machine license

1-5

1.5

Conversion tables

1-9

1.6

2.

1.5.1

Length

1-9

1.5.2

Area

1-9

1.5.3

Weight (mass)

1 - 10

1.5.4

Volume

1 - 10

1.5.5

Pressure

1 - 10

1.5.6

Temperature

1 - 11

1.5.7

Speed

1 - 11

1.5.8

Force

1 - 11

1.5.9

Torque

1 - 11

1.5.10

Power

1 - 12

Conformity declaration

1 - 13

PRODUCT DESCRIPTION

2-1

2.1

General 2.1.1

2.2

136 084 (tz) LWN - TD19/9/2006

1-1

2-1 What should you be aware of when reading the operating manual?

Ranges of use for the machine

2-1 2-2

2.2.1

Equipment rating

2-3

2.2.2

Explanatory notes on the equipment rating

2-4

2.3

Machine overview

2-5

2.4

Boom

2-6

2.5

2.4.1

Information on boom designations

2-6

2.4.2

Main boom with 2220-boom head.

2-8

2.4.3

Tip boom*

2 - 24

2.4.4

Main boom with 2220/1916 reducing piece and 1916 boom head

2 - 28

2.4.5

Fixed jib on 2220-boom head

2 - 37

2.4.6

1916- luffing jib on 2220-boom head

2 - 47

2.4.7

Tip boom * for jib head with system no. 1916.21

2 - 60

Basic machine

2 - 62

2.5.1

Upper carriage

2 - 63

2.5.2

Central power unit

2 - 66

2.5.3

Lower carriage

2 - 67

0-1

INDEX

2.6

3.

2.5.4

Hydraulic chain tensioner

2 - 69

2.5.5

Ballast

2 - 70

2.5.6

Overview of the hydraulic cylinders

2 - 73

Technical data

2 - 74

2.6.1

Dimensions and weights

2 - 74

2.6.2

Operating conditions

2 - 79

2.6.3

Emissions

2 - 79

2.6.4

Engine

2 - 80

2.6.5

Hydraulic system

2 - 81

2.6.6

Winches

2 - 81

2.6.7

Slewing gear

2 - 83

2.6.8

Travel gear

2 - 83

2.6.9

Control

2 - 87

SAFETY PRECAUTIONS

3-1

3.1

General 3.1.1

Appropriate use

3-2

3.1.2

Examples of inappropriate use

3-3

3.1.3

Danger symbols

3-4

3.1.4

Areas of responsibility

3-5

3.2

Personal attributes required of the machine operator

3-6

3.3

Personal protective wear

3-7

3.4

Work area

3-8

3.5

Safety and monitoring devices

3-9

3.6

3.5.1

Safety devices

3-9

3.5.2

Monitoring devices

3 - 11

Set of name plates on the machine 3.6.1

3.7

3.8

0-2

3-1

Meaning of the safety signs

Machine-specific dangers

3 - 12 3 - 17 3 - 20

3.7.1

Injuries resulting from operating machinery

3 - 20

3.7.2

Injuries due to hydraulic energy

3 - 22

3.7.3

Risk of burns

3 - 23

3.7.4

Risk of chemical burns

3 - 24

3.7.5

Fire and explosion hazards

3 - 25

3.7.6

Risk of poisoning and asphyxiation

3 - 28

3.7.7

Safety Precaution for using refrigerants

3 - 29

3.7.8

Electromagnetic influences

3 - 31

3.7.9

Endangering the environment

3 - 32

Additional dangers

3 - 33

3.8.1

Effect of winds and storms

3 - 33

3.8.2

Ground conditions on the site

3 - 38

3.8.3

Snow and ice loads

3 - 39

3.8.4

Lightning strikes

3 - 40

3.8.5

Overhead power lines

3 - 41

3.8.6

Underground pipes and cables

3 - 50

INDEX

4.

3.9

Safety precautions for the machine operator

3 - 55

3.10

Safety precautions for maintenance and repair personnel

3 - 55

3.11

Safety precautions for construction site personnel

3 - 56

3.11.1

Signalman

3 - 56

3.11.2

Rigger

3 - 58

3.11.3

Hand signals

3 - 58

CONTROLS 4.1

General

4-1

4.2

Control elements on the lower carriage

4-2

4.3

Cab

4-3

4.3.1

Cab overview

4-3

4.3.2

Control stand overview

4-5

4.3.3

Overhead view of control stand

4-7

4.3.4

Joysticks and pedals

4 - 10

4.4

Left-hand control panel (X11)

4 - 11

4.5

Left-hand control panel (X12)

4 - 14

4.6

Right-hand control panel (X23)

4 - 16

4.7

Litronic service panel

4 - 19

4.7.1 4.8

4.9

Emergency shut-down switch

Overview of screens

4 - 21 4 - 22

4.8.1

Main areas of the screen

4 - 22

4.8.2

Description of the main areas of the screen

4 - 23

4.8.3

Description of the LCD display:

4 - 24

4.8.4

Overview of mode screens

4 - 25

4.8.5

Function symbols and display fields

4 - 27

Set-up screens

4 - 29

4.9.1

Explanations of set-up screens

4 - 29

4.9.2

Main boom

4 - 30

4.9.3

Main boom with reducing piece

4 - 32

4.9.4

Main boom with fixed fly jib

4 - 34

4.9.5

Main boom with adjustable fly jib

4 - 36

4.9.6

Main boom with adjustable fly jib head and Midfall

4 - 37

4.10

Power operation

4 - 39

4.11

Power unit monitoring

4 - 46

4.12

Fault displays

4 - 49

4.13

Load capacity chart

4 - 51

136 084 (tz) LWN - TD19/9/2006

5.

4-1

4.13.1

Enter load capacity calculation in set-up modes 4 and 5.

4 - 52

4.13.2

Load capacity chart

4 - 52

4.13.3

Load capacity chart

4 - 52

4.13.4

Load capacity chart

4 - 53

4.13.5

Load capacity chart

4 - 53

OPERATION 5.1

Safe working with the machine

5-1 5-1

0-3

INDEX

5.2

5.3

5.4

5.5

5.1.1

Use of emergency shut-down switch

5-2

5.1.2

Hooter

5-2

5.1.3

Actuate safety lever (access lever)

5-3

Checks before daily operation 5.2.1

Tour of inspection

5-4

5.2.2

Checks

5-4

Daily start up

0-4

5-6

5.3.1

Switching on the ignition

5-6

5.3.2

Confirming the existing set-up

5-6

5.3.3

Checking the fuel level

5-7

5.3.4

Refueling the machine with a tanker

5-7

5.3.5

Refueling the machine from a refueling pump

5-8

5.3.6

Select operating modes

5 - 11

5.3.7

Starting the diesel engine

5 - 11

5.3.8

Adjusting the engine speed

5 - 12

Machine operation - main functions

5 - 14

5.4.1

Checks/activities on start-up

5 - 15

5.4.2

Moving the machine

5 - 16

5.4.3

Travel gear overdrive

5 - 19

5.4.4

Slewing the superstructure

5 - 20

5.4.5

Adjusting the main boom

5 - 23

5.4.6

Adjusting the main boom or the adjustable fly jib

5 - 24

5.4.7

Operating the hoisting winches

5 - 26

5.4.8

Hoisting limit switch

5 - 29

5.4.9

Hydraulic cab inclination

5 - 30

5.4.10

Electronic load moment limiter (LML),

5 - 31

Power operation 5.5.1

5.6

5-4

Load pick-up equipment

load moment limiter (LML),

5 - 34 5 - 34 5 - 35

5.6.1

General information regarding boom head, load position and load capacity chart

5 - 35

5.6.2

Programming LML

5 - 37

5.6.3

Load on tip jib* (set-up 1 with head 2)

5 - 42

5.6.4

Load on the main boom with the tip boom* fitted (Set-up 1 with head 2)

5 - 43

5.6.5

Load on the main boom head with fixed fly jib fitted (Set-up 3 with load position 2)

5 - 45

5.6.6

Load on the main boom head with adjustable fly jib fitted (Set-up 4 with load position 5 - 46 2)

5.6.7

Load on tip boom* attached to fly jib head (set-up 4)

5 - 47

5.6.8

Load on fly jib head with tip boom* attached (set-up 4)

5 - 48

5.6.9

Load on midfall (set-up 5, load position 3)

5 - 49

5.6.10

Load on fly jib head with midfall attached (set-up 5, load position 1)

5 - 50

5.6.11

Twin hook operation

5 - 51

5.6.12

Combined twin hook operation with main boom head and fly jib head

5 - 57

5.6.13

Free-fall operation*

5 - 60

5.6.14

Winch synchronization*

5 - 66

5.6.15

Grapple control*

5 - 67

INDEX 5.7

5.7.1

General

5 - 69

5.7.2

Displays in the power operation screen

5 - 69

5.7.3

Programming rope length

5 - 69

Ground pressure gauge*

5 - 71

5.9

Outreach limitation*

5 - 72

5.11

5.12

5.13

136 084 (tz) LWN - TD19/9/2006

5 - 69

5.8

5.10

6.

Rope length metering*

5.9.1

Adjusting the outreach limitation*

5 - 73

5.9.2

Check outreach limitation*

5 - 73

Slewing gear limitation*

5 - 74

5.10.1

Setting slewing gear limitation*

5 - 75

5.10.2

Check slewing gear limitation*

5 - 77

5.10.3

Cancel slewing gear limitation*

5 - 78

Blocked crawlers*

5 - 79

5.11.1

Leveling out the crawler position

5 - 80

5.11.2

Support plates required

5 - 80

5.11.3

Positioning of the support plates

5 - 81

5.11.4

Driving onto the support plates

5 - 81

5.11.5

Selecting "Blocked Crawlers*" mode

5 - 82

5.11.6

Working in "Blocked Crawlers*" mode

5 - 82

5.11.7

Resetting the load capacity display to zero (taring)

5 - 83

Operating the machine - auxiliary functions

5 - 84

5.12.1

Driver's seat

5 - 84

5.12.2

LCD screen adjustments

5 - 85

5.12.3

Windshield wiper

5 - 86

5.12.4

Heating and air-conditioning system*

5 - 88

5.12.5

Lighting

5 - 90

5.12.6

Radio

5 - 91

5.12.7

Ashtray

5 - 92

5.12.8

Cigarette lighter and socket in the cab

5 - 92

Shutting the machine down

5 - 93

5.13.1

Boom park position

5 - 93

5.13.2

Setting down the boom

5 - 94

5.13.3

Shutting down the diesel engine

5 - 95

5.13.4

Park position of the ignition starter switch

5 - 96

5.13.5

Checks before leaving the machine

5 - 97

ASSEMBLY AND DISMANTLING

6-1

6.1

General

6-1

6.2

Operational planning

6-2

6.3

6.2.1

Defining the set-up

6-3

6.2.2

Assemble and prepare the transport equipment

6-3

6.2.3

Required hoisting rope length

6-4

Safety precautions for assembly, dismantling and conversion

6-5

6.3.1

Requirements for the erecting team

6-5

6.3.2

Requirements for the site

6-5

0-5

INDEX 6.3.3 6.4

Information on set-up mode 6.4.1

6.5

6.6

6.7

6.8

0-6

Rules for executing the work

Operation in set-up mode

Unloading and erecting the basic machine

6-6 6-7 6-7 6 - 10

6.5.1

Requirements

6 - 10

6.5.2

Summary of assembly stages

6 - 10

6.5.3

Preparing for set-up mode

6 - 14

6.5.4

Swivelling the cab to the working position

6 - 15

6.5.5

Starting set-up mode

6 - 17

6.5.6

Lowering A-frame 1 to the unloading position

6 - 19

6.5.7

Unloading the basic machine

6 - 20

6.5.8

Preparing the basic machine as a mounting crane

6 - 29

6.5.9

Attaching the crawler carrier

6 - 31

6.5.10

Attaching the central counterweight

6 - 45

6.5.11

Assembling the rear counterweight

6 - 50

6.5.12

Connecting the cable remote control for rear counterweight assembly

6 - 61

6.5.13

Mounting and bolting the rear counterweight

6 - 62

6.5.14

Bolting the rear counterweight

6 - 66

Assembly of main boom

6 - 69

6.6.1

Requirements

6 - 69

6.6.2

Overview of assembly stages

6 - 69

6.6.3

Unload and position the main boom head

6 - 70

6.6.4

Unload and position the main boom intermediate pieces

6 - 70

6.6.5

Assembly of the main boom

6 - 71

6.6.6

Assemble main boom anchoring rods

6 - 72

6.6.7

Intermediate tensioners on the main boom

6 - 76

6.6.8

Arrangement of rope guide*

6 - 80

6.6.9

Position the load hook

6 - 82

Attaching the main boom pivot piece

6 - 83

6.7.1

General

6 - 83

6.7.2

Attach main boom pivot piece to superstructure

6 - 84

6.7.3

Connecting the multicoupling on the superstructure

6 - 87

Attachment of main boom

6 - 88

6.8.1

General

6 - 88

6.8.2

Preparations for attachment

6 - 88

6.8.3

Attachment of main boom

6 - 91

6.8.4

Preparing connection of electrical plugs to the upper carriage

6 - 94

6.8.5

Connect the electrics to the upper carriage

6 - 95

6.8.6

Connect the electrics to the main boom head

6 - 96

6.8.7

Mounting and connecting the anemometer

6 - 97

6.8.8

Luffing the hoisting rope

6 - 98

6.8.9

Choosing the correct load hook

6 - 103

6.8.10

Rope reeving plans

6 - 106

6.8.11

Hoisting limit switch

6 - 117

6.8.12

Erecting the main boom

6 - 119

INDEX

6.9

6.10

136 084 (tz) LWN - TD19/9/2006

6.11

6.12

6.8.13

Erecting procedure

6 - 122

6.8.14

Erectability of the 2220 main boom

6 - 123

6.8.15

Canceling set-up mode

6 - 124

Attachment of tip boom* to the 2220-boom head

6 - 125

6.9.1

Requirements

6 - 125

6.9.2

Position the tip boom* in front of the 2220-boom head

6 - 126

6.9.3

Bolt the tip boom* to the 2220-boom head

6 - 126

6.9.4

Mount the hoisting limit switch on the tip boom*

6 - 130

Assembly of main boom with reducing piece

6 - 132

6.10.1

Requirements

6 - 132

6.10.2

Overview of assembly stages

6 - 132

6.10.3

Unloading and positioning the main boom with reducing piece

6 - 132

6.10.4

Assemble main boom with reduction

6 - 135

6.10.5

Assembling the anchoring rods

6 - 137

6.10.6

Intermediate tensioners on main boom with 2220/1916 reduction

6 - 141

6.10.7

Further procedure

6 - 144

6.10.8

Rope reeving plans

6 - 144

6.10.9

Erectability of main boom with 2220/1916 reducing piece

6 - 147

6.10.10

Ending set-up mode

6 - 148

Assembling the main boom with fixed jib

6 - 149

6.11.1

Requirements

6 - 149

6.11.2

Overview of assembly stages

6 - 151

6.11.3

Unload and position the main boom head

6 - 152

6.11.4

Attach the jib pivot piece

6 - 153

6.11.5

Assemble the jib

6 - 154

6.11.6

Assembling the jib anchoring rods

6 - 156

6.11.7

Assembly of the main boom

6 - 157

6.11.8

Completing assembly of the boom

6 - 157

6.11.9

Attaching coupling links to the main boom

6 - 158

6.11.10

Attach the tensioning rods to the coupling links

6 - 159

6.11.11

Erecting A-frame 2

6 - 160

6.11.12

Attaching the tensioning rods to the crossbar

6 - 161

6.11.13

Position the jib pivot piece

6 - 162

6.11.14

Connecting the electrics

6 - 163

6.11.15

Reeving the load hook

6 - 165

6.11.16

Mount the hoisting limit switch weight

6 - 167

6.11.17

Erecting the main boom with fixed jib

6 - 169

6.11.18

Erecting procedure

6 - 169

6.11.19

Erectability with fixed fly jib

6 - 173

Assembly of main boom with adjustable jib

6 - 174

6.12.1

Requirements

6 - 174

6.12.2

Mounting instructions

6 - 174

6.12.3

Overview of assembly stages

6 - 175

6.12.4

Unload and position the 2220-boom head

6 - 177

6.12.5

Attaching the jib pivot piece

6 - 178

0-7

INDEX

0-8

6.12.6

Assembling the jib

6 - 180

6.12.7

Assembling the jib anchoring rods

6 - 181

6.12.8

Intermediate tensioners on the jib

6 - 182

6.12.9

Attaching the jib head

6 - 185

6.12.10

Attach the tip boom* to the jib head

6 - 186

6.12.11

Assembling the main boom

6 - 187

6.12.12

Mount the main boom anchoring rods and jib tensioning rods of the main boom

6 - 188

6.12.13

Completing preparations on the boom

6 - 189

6.12.14

Attach the main boom pivot piece to the basic machine

6 - 189

6.12.15

Attaching the main boom to the main boom pivot piece

6 - 190

6.12.16

Preparing the hoisting rope as a mounting aid

6 - 192

6.12.17

Reeving the jib luffing rope

6 - 193

6.12.18

Erecting A-frames 2 and 3

6 - 196

6.12.19

Connecting the jib pivot piece to A-frame 3

6 - 198

6.12.20

Bolting the jib tensioning rods to the basic rope of A-frame 2

6 - 200

6.12.21

Attaching the jib to the jib pivot piece

6 - 202

6.12.22

Bolting the jib anchoring rods of the jib and A-frame 3 together

6 - 204

6.12.23

Luffing the hoisting rope(s) on the jib

6 - 206

6.12.24

Reeving the load hook on the 2220-boom head

6 - 206

6.12.25

Connecting the electrics

6 - 207

6.12.26

Mounting the hoisting limit switch on the 2220-boom head

6 - 208

6.12.27

Raising the main boom with adjustable jib

6 - 209

6.12.28

Reeving the load hook on the jib head and tip boom*

6 - 213

6.12.29

Mounting the hoisting limit switch on the jib head and tip boom*

6 - 216

6.12.30

Erecting the main boom and jib

6 - 217

6.12.31

Erectability with adjustable fly jib

6 - 219

6.13

Time-saving conversion of the main boom

6 - 220

6.14

Dismantling the main boom with adjustable jib

6 - 225

6.14.1

Requirements

6 - 225

6.14.2

Overview of dismantling stages

6 - 226

6.14.3

Preparations for dismantling in crane mode

6 - 226

6.14.4

Activate set-up mode

6 - 226

6.14.5

Setting down the load hook

6 - 227

6.14.6

Lowering the jib

6 - 227

6.14.7

Unreeving the hoisting rope on the jib head

6 - 229

6.14.8

Lowering the jib and main boom

6 - 230

6.14.9

Retracting the hoisting rope(s)

6 - 231

6.14.10

Disconnecting the electrics

6 - 232

6.14.11

Connect jib pivot piece to A-frame 3

6 - 234

6.14.12

Detaching the boom pivot piece from the jib

6 - 235

6.14.13

Move A-frames 2 and 3 towards the rear

6 - 236

6.14.14

Lower A-frames 2 and 3

6 - 237

6.14.15

Pulling out the jib luffing rope

6 - 240

6.14.16

Retracting the tilting-back cylinders

6 - 240

6.14.17

Separating the main boom anchoring rods from the basic rope on A-frame 1

6 - 241

INDEX

136 084 (tz) LWN - TD19/9/2006

6.15

6.14.18

Detaching the mounting cylinder from the basic rope on A-frame 1

6 - 241

6.14.19

Unbolt the main boom pivot piece from the main boom

6 - 241

6.14.20

Detaching the main boom pivot piece from the upper carriage

6 - 242

6.14.21

Preparing the mounting crane

6 - 242

6.14.22

Dismantling the jib pivot piece

6 - 242

6.14.23

Detaching the tip boom* from the jib head

6 - 243

6.14.24

Dismembering the main boom and jib

6 - 244

6.14.25

Loading up the equipment

6 - 245

Dismantling the main boom with fixed jib

6 - 246

6.15.1

Requirements

6 - 246

6.15.2

Overview of dismantling stages

6 - 247

6.15.3

Preparations for crane operation

6 - 248

6.15.4

Activate set-up mode

6 - 248

6.15.5

Setting down the main boom with fixed jib

6 - 249

6.15.6

Lowering the main boom with fixed jib attached

6 - 251

6.15.7

Detaching the anemometer

6 - 253

6.15.8

Disconnecting the electrics

6 - 254

6.15.9

Dismantling the jib pivot piece

6 - 256

6.15.10

Dismantling the main boom and the main boom pivot piece

6 - 258

6.15.11

Dismembering the jib

6 - 258

6.15.12

Dismantling the jib pivot piece

6 - 258

6.16

Dismantling the main boom with reduction

6 - 260

6.17

Dismantling the tip boom* on the main boom head

6 - 260

6.18

Dismantling the main boom

6 - 260

6.19

6.20

6.18.1

Requirements

6 - 260

6.18.2

Overview of dismantling stages

6 - 261

6.18.3

Preparations for crane operation

6 - 262

6.18.4

Activate set-up mode

6 - 263

6.18.5

Laying down the main boom

6 - 263

6.18.6

Laying down procedure

6 - 265

6.18.7

Laying down procedure with tip boom*

6 - 266

6.18.8

Dismantling the tip boom*

6 - 267

6.18.9

Pulling out the hoisting rope(s)

6 - 268

6.18.10

Disconnecting the electrics of the main boom head

6 - 270

6.18.11

Disconnecting the electrics from the upper carriage

6 - 272

6.18.12

Detaching the mounting cylinder from the basic rope

6 - 274

6.18.13

Detaching the main boom pivot piece from the main boom

6 - 275

Dismantling the main boom pivot piece

6 - 278

6.19.1

General

6 - 278

6.19.2

Detaching the multicoupling on the superstructure

6 - 279

Dismembering the main boom

6 - 286

6.20.1

Unbolting the rear counterweight from the superstructure and setting it down

6 - 287

6.20.2

Dismantling and loading up the rear counterweight

6 - 291

6.20.3

Dismantling the central counterweight

6 - 297

6.20.4

Preparing to dismantle the crawler carriers

6 - 300

0-9

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