Liebherr Crawler Crane HS 885 HD OPERATING MANUAL SN 187406 – PDF DOWNLOAD

OPERATING MANUAL

TYPE

HS 885 HD SERIAL NUMBER

187 406 VERSION

187 406 (js) LWN - TD18/8/2008

001

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

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

CHAPTER SUMMARY

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

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

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

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

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

187 406 (js) LWN - TD18/8/2008

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

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

INDEX

INDEX 1.

INTRODUCTION 1.1

Foreword

1-1

1.2

Using the documentation

1-2

187 406 (js) LWN - TD18/8/2008

1.2.1

How is the operating manual in Volume 1 organized?

1-3

1.2.2

System requirements for use of the CD-ROM

1-3

1.2.3

Current status of the documentation

1-3

1.2.4

Keeping of documentation

1-4

1.3

Machine license

1-5

1.4

Publisher's imprint

1-8

1.5

Conversion tables

1-9

1.6

2.

1-1

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 output

1 - 12

Conformity declaration

1 - 13

PRODUCT DESCRIPTION

2-1

2.1

General

2-1

2.2

Intended use

2-3

2.2.1

Equipment rating

2-4

2.2.2

Appropriate use

2-5

2.2.3

Inappropriate use

2-6

2.3

Machine overview

2-7

2.4

Boom

2-8

2.4.1

Boom designations

2-8

2.4.2

Main boom

2-9

2.5

Superstructure

2 - 20

2.6

Central power unit

2 - 22

2.7

Undercarriage

2 - 25

2.8

Ballast

2 - 27

2.8.1 2.9

Rear counterweight

2 - 27

Technical data

2 - 28

2.9.1

Dimensions and weights

2 - 28

2.9.2

Operating conditions

2 - 35

2.9.3

Emissions

2 - 36

0-5

INDEX

3.

2.9.4

Engine aggregate

2 - 36

2.9.5

Hydraulic system

2 - 37

2.9.6

Winches

2 - 38

2.9.7

Slewing gear

2 - 39

2.9.8

Travel gear

2 - 39

2.9.9

Control

2 - 40

SAFETY PRECAUTIONS

3-1

3.1

General 3.1.1

Danger symbols

3-2

3.1.2

Appropriate use

3-3

3.2

Areas of responsibility

3-3

3.3

Personal attributes required of the machine operator

3-4

3.4

Personal protective gear

3-5

3.5

Work area

3-6

3.6

Safety and monitoring devices

3-7

3.7

3.6.1

Safety devices

3-7

3.6.2

Monitoring devices

3-9

Safety signs on the machine 3.7.1

3.8

3.9

4.

0-6

3-1

Meaning of the safety signs

Machine-specific dangers

3 - 10 3 - 13 3 - 16

3.8.1

Injuries resulting from operating machinery

3 - 16

3.8.2

Injuries due to hydraulic energy

3 - 18

3.8.3

Risk of burns

3 - 19

3.8.4

Risk of chemical burns

3 - 20

3.8.5

Fire and explosion hazards

3 - 21

3.8.6

Risk of poisoning and asphyxiation

3 - 24

3.8.7

Safety Precaution for using refrigerants

3 - 25

3.8.8

Electromagnetic influences

3 - 27

3.8.9

Endangering the environment

3 - 28

Additional dangers

3 - 29

3.9.1

Influence of winds and storms

3 - 29

3.9.2

Ground conditions on the site

3 - 34

3.9.3

Snow and ice loads

3 - 35

3.9.4

Lightning strikes

3 - 36

3.9.5

Overhead power lines

3 - 37

3.9.6

Underground pipes and cables

3 - 46

3.10

Safety precautions for the machine operator

3 - 51

3.11

Safety precautions for maintenance and repair personnel

3 - 51

3.12

Safety precautions for construction site personnel

3 - 52

3.12.1

Signalman

3 - 52

3.12.2

Rigger

3 - 54

3.12.3

Hand signals

3 - 54

CONTROL AND OPERATING ELEMENTS

4-1

INDEX 4.1

General

4-1

4.2

Operational controls on the undercarriage

4-2

4.3

Operational controls on the superstructure

4-3

4.4

Cab

4-4

4.4.1

Cab overview

4-4

4.4.2

Overview of the control stand

4-6

4.4.3

Overhead view of control stand

4-8

4.4.4

Joysticks, pedals, handwheels

4 - 11

4.5

Left-hand control panel (X11)

4 - 12

4.6

Left-hand control panel (X12)

4 - 14

4.7

Right-hand control panel (X23)

4 - 16

4.8

Litronic service panel

4 - 22

4.8.1

Emergency shut-down switch

4 - 24

4.9

Operating elements in switch cabinet (X1)

4 - 25

4.10

LCD screen

4 - 26

4.11

Overview of the LCD screen

4 - 28

4.12

5.

4.11.1

Main areas of the screen

4 - 28

4.11.2

Description of the screen's main areas

4 - 28

4.11.3

Screen sequence

4 - 30

Set-up screens

4 - 32

4.12.1

Main boom set-up screen

4 - 33

4.12.2

Set-up screen 3 for main boom with fixed fly jib

4 - 37

4.13

"Mode screen" screen

4 - 39

4.14

"Operating modes" screen

4 - 47

4.15

"Power unit monitoring" page

4 - 49

4.16

"Fault monitor" page

4 - 53

4.17

"Load capacity chart " page

4 - 55

OPERATION 5.1

General 5.1.1

5.2

187 406 (js) LWN - TD18/8/2008

5.3

5.4

5-1 5-1 Safe working with the machine

Checks before daily operation

5-1 5-2

5.2.1

Tour of inspection

5-2

5.2.2

Checks

5-2

Daily start up

5-4

5.3.1

Battery main switch

5-4

5.3.2

Switching on the ignition

5-4

5.3.3

Confirming the existing set-up

5-4

5.3.4

Checking the fuel level

5-7

5.3.5

Refueling the machine

5-7

5.3.6

Select operating mode

5-8

5.3.7

Select operating mode on the left hand control desk (X12)

5-9

5.3.8

Select an operating mode in the "Operating modes" screen.

5 - 13

Starting the diesel engine 5.4.1

Prerequisites

5 - 17 5 - 17

0-7

INDEX 5.4.2 5.5

Machine operation - main functions

5 - 19 5 - 21

5.5.1

Checks/activities on start-up

5 - 21

5.5.2

Adjusting the main boom

5 - 23

5.5.3

Using the electronic load moment limiter (LML)

5 - 25

5.5.4

Load pick-up equipment

5 - 27

5.5.5

Resetting the load capacity display to zero (taring)

5 - 27

5.6

Operating the hoisting winches

5 - 29

5.7

Fast winches

5 - 33

5.8

5.9

0-8

Adjusting the engine speed

5.7.1

General

5 - 33

5.7.2

Preselection

5 - 33

5.7.3

Activating the slewing gear

5 - 35

5.7.4

Slewing gear free-wheel

5 - 38

5.7.5

Travelling with the machine

5 - 40

5.7.6

Travel gear overdrive

5 - 43

5.7.7

Free-fall operation

5 - 45

5.7.8

Working in free-fall operation

5 - 51

5.7.9

Shutting down free-fall operation

5 - 52

5.7.10

Winch standstill monitoring

5 - 52

5.7.11

Lowering control (SWG control unit)

5 - 53

5.7.12

Interlock control

5 - 55

5.7.13

Winch synchronization (optional)

5 - 57

5.7.14

Ramming control/chisel control

5 - 58

5.7.15

Casing oscillator

5 - 65

Litronic

5 - 69

5.8.1

Properties

5 - 69

5.8.2

General

5 - 69

5.8.3

Starting the Litronic

5 - 70

5.8.4

The menus

5 - 71

5.8.5

Main menu

5 - 71

5.8.6

INPUT/OUTPUT menu

5 - 72

5.8.7

MEMORY menu

5 - 72

5.8.8

SELECT menu

5 - 73

5.8.9

CORRECTION menu

5 - 76

5.8.10

MESSAGES menu

5 - 77

5.8.11

SPECIAL FUNCTIONS menu

5 - 78

Operating the machine - auxiliary functions

5 - 83

5.9.1

Adjusting the driver's seat

5 - 83

5.9.2

LCD screen adjustments

5 - 83

5.9.3

Windshield wiper

5 - 84

5.9.4

Lighting

5 - 85

5.9.5

Radio

5 - 86

5.9.6

Hooter

5 - 86

5.9.7

Ashtray

5 - 87

5.9.8

Cigarette lighter and socket in the cab

5 - 87

INDEX 5.10

5.11

6.

Shutting down the machine

5 - 88

5.10.1

Laying down the boom

5 - 89

5.10.2

Shutting down the diesel engine

5 - 90

5.10.3

Park position of the ignition starter switch

5 - 90

5.10.4

Checks before leaving the machine

5 - 91

Emergency control system

5 - 92

5.11.1

General

5 - 92

5.11.2

Safety instructions

5 - 92

5.11.3

Functions of the control desk

5 - 93

5.11.4

Connecting the control desk to the emergency control system

5 - 94

5.11.5

Instructions for emergency operation

5 - 94

ASSEMBLY AND DISMANTLING

6-1

6.1

General

6-1

6.2

Operational planning

6-2

6.3

6.4

6.2.1

Defining the working range

6-2

6.2.2

Defining the set-up

6 - 12

6.2.3

Assembling and preparing the transport equipment

6 - 12

6.2.4

Required hoisting rope length

6 - 13

Safety precautions for assembly, dismantling and reconfiguring 6.3.1

Requirements for the erecting team

6 - 15

6.3.2

Requirements for the site

6 - 15

6.3.3

Rules for executing the work

6 - 16

Information on set-up mode 6.4.1

6.5

Operation in set-up mode

Unloading the basic machine

187 406 (js) LWN - TD18/8/2008

6 - 17 6 - 17 6 - 18

6.5.1

Prerequisites

6 - 18

6.5.2

Overview

6 - 19

6.5.3

Preparing for assembly mode

6 - 21

6.5.4

Platform on the cab

6 - 22

6.5.5

Starting assembly mode

6 - 23

6.5.6

Erecting the A-frame

6 - 26

6.5.7

Drive the machine off the low-loader

6 - 29

6.5.8

Removing the superstructure locking

6 - 31

6.5.9

Adjust crawler carrier on work track

6 - 33

6.5.10

Attaching steps and ladders

6 - 37

6.5.11

6.6

6 - 15

6 - 37

6.5.12

Unloading the rear counterweight

6 - 38

6.5.13

Location of the rope pulleys on the rear counterweight

6 - 39

6.5.14

General

6 - 40

6.5.15

Mounting the rear counterweight (Figure 32).

6 - 41

6.5.16

Additional counterweight

6 - 44

6.5.17

General

6 - 44

6.5.18

Mounting the additional counterweight

6 - 45

Assembling the main boom

6 - 46

0-9

INDEX

6.7

6.8

6.9

6.10

0 - 10

6.6.1

Prerequisites

6 - 46

6.6.2

Overview of assembly stages

6 - 46

6.6.3

Unloading and positioning the boom head

6 - 47

6.6.4

Assembling the main boom

6 - 47

6.6.5

Assembling the main boom

6 - 48

6.6.6

Attaching the main boom to the pivot piece

6 - 53

6.6.7

Luffing the hoisting rope

6 - 57

6.6.8

Rope reeving plans

6 - 58

6.6.9

Connecting the electrics

6 - 60

Hoisting limit switch

6 - 63

6.7.1

Snap hook on hoisting limit switch weight (wedge)

6 - 65

6.7.2

Erecting the main boom

6 - 67

6.7.3

Erecting procedure

6 - 69

6.7.4

Cancelling mounting mode

6 - 70

Dismantling the main boom

6 - 71

6.8.1

Prerequisites

6 - 71

6.8.2

Overview of dismantling stages

6 - 71

6.8.3

Preparations in lifting operation

6 - 72

6.8.4

Select assembly mode

6 - 72

6.8.5

Lay down the main boom

6 - 73

6.8.6

Laying down procedure

6 - 75

6.8.7

Disconnecting the electrics

6 - 76

6.8.8

Pulling out the hoisting ropes

6 - 78

6.8.9

Detaching the main boom from the pivot piece

6 - 79

6.8.10

Dismantling the main boom

6 - 83

Dismantling and loading the basic machine

6 - 84

6.9.1

Prerequisites

6 - 84

6.9.2

Overview

6 - 85

6.9.3

Additional counterweight

6 - 86

6.9.4

General

6 - 86

6.9.5

Dismantling the additional counterweight

6 - 87

6.9.6

Setting down the rear counterweight

6 - 88

6.9.7

Loading the rear counterweight

6 - 91

6.9.8

Fitting the superstructure locking

6 - 92

6.9.9

Platforms on the superstructure

6 - 93

6.9.10

Remove steps and ladders

6 - 93

6.9.11

Adjusting crawler carrier on transport track

6 - 95

6.9.12

Drive the machine onto the low-loader

6 - 99

6.9.13

Setting down the A-frame

6 - 100

6.9.14

Taking the basic machine out of operation

6 - 101

Transport

6 - 102

6.10.1

Safety precautions for loading and unloading

6 - 102

6.10.2

Transporting the basic machine with a low-loader

6 - 103

6.10.3

Transporting fittings

6 - 105

6.10.4

Loading the basic machine with an auxiliary crane

6 - 107

INDEX 6.10.5

7.

Transporting overseas

MAINTENANCE 7.1

7.2

7.5

7.6

7.7

7.8

187 406 (js) LWN - TD18/8/2008

7.9

7.10

7-1

7.1.1

Lubricants

7-2

7.1.2

Welding work

7-2

7.1.3

Cylinder

7-2

Maintenance chart Work to be carried out

Diesel engine 7.3.1

7.4

7-1

General

7.2.1 7.3

6 - 109

7-3 7-3 7 - 17

Engine; check oil level and oil pressure

Fuel system

7 - 17 7 - 18

7.4.1

Draining condensation from the fuel prefilter

7 - 18

7.4.2

Draining condensation and sediments from the fuel tank

7 - 18

7.4.3

Draining the fuel tank

7 - 18

7.4.4

Cleaning the fuel tank

7 - 19

7.4.5

Refuelling

7 - 19

7.4.6

Bleeding the fuel system

7 - 21

Cooling system

7 - 22

7.5.1

7 - 22

Check coolant level, top up if necessary

The dry air filter

7 - 23

7.6.1

Arrangement on the central power unit

7 - 23

7.6.2

Emptying the dust collection container

7 - 23

Power divider

7 - 24

7.7.1

General

7 - 24

7.7.2

Checking the gearbox oil level

7 - 24

7.7.3

Draining the gearbox oil

7 - 25

7.7.4

Refilling the gearbox oil

7 - 25

7.7.5

Recommendation for servicing

7 - 25

7.7.6

Gearbox oil cooler

7 - 25

Travel gear

7 - 26

7.8.1

Cleaning the travel gear

7 - 26

7.8.2

Check the chain tension, retighten if necessary

7 - 26

7.8.3

Slackening the chain

7 - 27

7.8.4

Floor plates

7 - 27

Hydraulic system

7 - 28

7.9.1

General

7 - 29

7.9.2

Checking the oil level

7 - 29

7.9.3

Filling with hydraulic oil

7 - 29

7.9.4

Cleaning the magnet plug

7 - 30

7.9.5

Suction pipe shut-off valve on hydraulic tank

7 - 31

7.9.6

Checking the hydraulic system

7 - 33

7.9.7

Special maintenance activities

7 - 33

Slewing gear transmission/Rotary connection

7 - 34

7.10.1

Slewing gear transmission, checking the oil level

7 - 34

0 - 11

INDEX

7.11

7.12

7.13

7.14

7.15

0 - 12

7.10.2

Lubricating the crown gear/pinion

7 - 34

7.10.3

Lubricating the slew ring bearing races

7 - 34

Winches

7 - 35

7.11.1

Checking oil level of winches 1 and 2 and main boom adjusting winches;

7 - 35

7.11.2

Lubrication points on the main boom adjusting winch

7 - 36

7.11.3

Needle bearing

7 - 36

7.11.4

Counter bearing

7 - 36

7.11.5

Torque support

7 - 36

7.11.6

Balancing rocker

7 - 36

7.11.7

Main boom adjusting winch and A-frame;

7 - 36

Ropes and pulleys

7 - 37

7.12.1

Checking the rope against end of service life criteria

7 - 37

7.12.2

Check the rope for diameter shrinkage

7 - 38

7.12.3

Check for rope deformations

7 - 39

7.12.4

Check ropes for corrosion

7 - 40

7.12.5

Check ropes for abrasion

7 - 41

7.12.6

Check ropes for the effects of heat

7 - 41

7.12.7

Check the rope for number of permitted wire breaks

7 - 43

7.12.8

Selecting a rope

7 - 44

7.12.9

Storing ropes

7 - 48

7.12.10

Transporting ropes

7 - 49

7.12.11

Checking the rope drive

7 - 49

7.12.12

Winding ropes

7 - 53

7.12.13

Luffing ropes

7 - 55

7.12.14

Lubricating ropes

7 - 57

7.12.15

Check rope suspensions and fastenings

7 - 57

7.12.16

Checking the pocket locks

7 - 58

7.12.17

Check the rope fixation and rope thimble

7 - 59

Load hook

7 - 61

7.13.1

Load hooks with one or more pulleys

7 - 61

7.13.2

Single hook

7 - 61

Maintaining the anchoring rods

7 - 63

7.14.1

Arrangement of anchoring rods

7 - 64

7.14.2

Checking the anchoring rods

7 - 64

7.14.3

Checks

7 - 64

7.14.4

Wear to the protective sheath

7 - 65

7.14.5

Checking the anchoring rod bushes

7 - 65

7.14.6

Parallel flanges

7 - 65

7.14.7

Checking the connecting bolts

7 - 66

7.14.8

Inspecting the coupling links

7 - 66

7.14.9

Replacing the anchoring rods

7 - 66

7.14.10

Transporting the anchoring rods

7 - 66

Boom maintenance

7 - 68

7.15.1

Boom pivot piece

7 - 68

7.15.2

Boom intermediate pieces

7 - 68

INDEX

7.16

7.17

7.15.3

Main boom head

7 - 68

7.15.4

Checking the boom bolting and the guy rope connections

7 - 69

Electrical system

7 - 71

7.16.1

Checking displays, lighting etc.

7 - 71

7.16.2

Boom limit switch

7 - 72

7.16.3

Hoisting limit switch

7 - 72

7.16.4

Slip ring carrier *

7 - 73

7.16.5

Battery main switch

7 - 73

Cab 7.17.1

Windshields

7 - 75

7.17.2

Cab door and door lock

7 - 75

7.17.3

Inside and outside mirrors

7 - 75

7.17.4

Hydraulic height adjustment of the cab (optional)

7 - 76

7.17.5

Hydraulic cab adjustment

7 - 76

7.18

Personal protective gear

7 - 77

7.19

Lubricant requirements

7 - 78

7.19.1

7 - 80

7.21

Diesel fuels

7 - 80

7.22

Diesel engine lubricating oils

7 - 81

7.23

Coolant

7 - 83 Fresh water guidelines:

7 - 83

7.24

Capacities

7 - 84

7.25

Lubrication chart

7 - 85

REPAIR

8-1

8.1

General

8-1

8.2

Repair-welding

8-2

8.3

Fire extinguishers

8-3

8.4

8.5

General

Conservation regulations 8.5.1

8.6

General

Personal protective gear 8.4.1

General

Resale - Decommissioning 8.6.1

187 406 (js) LWN - TD18/8/2008

7 - 79

Hydraulic oil (initial filling)

8.3.1

9.

Rapidly biodegradable hydraulic oils

7.20

7.23.1

8.

7 - 75

General

8-3 8-3 8-3 8-3 8-3 8-3 8-3

OPTIONS

9-1

9.1

General

9-1

9.2

Boom walkways

9-2

9.3

Diagonal protection set

9-3

9.3.1

General

9-3

9.4

Rope brackets

9-4

9.5

Heating and air conditioning system

9-5

9.5.1

General

9-5

0 - 13

INDEX 9.5.2

Air conditioning system units

9-5

9.5.3

Operation

9-6

9.5.4

Information on the use of the heating and air conditioning system

9-7

9.6

Rope pull limitation, hoisting winch 1 + 2

9-9

9.7

GSM Service Modem

9 - 11

9.8

3-windings limit switch

9 - 12

9.9

9.10

9.11

9.12

9.13

9.14

9.15

9.16

9.8.1

General

9 - 12

9.8.2

Setting the 3-windings limit switch

9 - 12

Central lubrication of the slewing ring bearings

9 - 13

9.9.1

General

9 - 13

9.9.2

Filling the grease container

9 - 14

9.9.3

Time interval programming

9 - 14

9.9.4

Function

9 - 15

9.9.5

Maintenance of the central lubricating system

9 - 15

Central lubrication of the tooth flanks of the slewing ring 9.10.1

General

9 - 16

9.10.2

Filling the grease container

9 - 17

9.10.3

Time interval programming

9 - 17

9.10.4

Function

9 - 18

9.10.5

Maintenance of the central lubricating system

9 - 18

Refuelling pump

9 - 19

9.11.1

General

9 - 20

9.11.2

Refuelling

9 - 20

Pay out metering

0 - 14

9 - 23

9.12.1

General

9 - 23

9.12.2

Displays in the mode screen

9 - 23

9.12.3

Programming rope length

9 - 23

Winch synchronization

9 - 25

9.13.1

General

9 - 25

9.13.2

Switching on winch synchronization

9 - 25

9.13.3

Switching off winch synchronization

9 - 25

Additional floodlight at the uppercarriage

9 - 27

9.14.1

Arrangement

9 - 27

9.14.2

Operating Elements

9 - 27

Additional winch

9 - 29

9.15.1

Preselecting the additional winch

9 - 30

9.15.2

Deselecting the additional winch

9 - 31

9.15.3

Transporting personnel

9 - 32

9.15.4

Instructions for using the additional winch for carrying personnel

9 - 32

9.15.5

Additional winch emergency lowering

9 - 32

Names of measuring points 9.16.1

9.17

9 - 16

9 - 35

General

9 - 35

Pump wear indication

9 - 37

9.17.1

General

9 - 37

9.17.2

Checking the contamination monitor

9 - 38

INDEX 9.18

Orthopedic driver's seat 9.18.1

9.19

9.20

9.21

9.22

9 - 39

Auxiliary winch

9 - 41

9.19.1

General

9 - 41

9.19.2

Technical data

9 - 41

Rope run

9 - 42

9.20.1

Checks before start up

9 - 43

9.20.2

Operating the auxiliary winch

9 - 43

9.20.3

Maintenance of the auxiliary winch

9 - 45

Cold weather kit

9 - 47

9.21.1

General

9 - 47

9.21.2

Off-duty heating

9 - 48

9.21.3

Heating the hydraulic oil

9 - 49

Milling operation

9 - 51

9.22.1

General

9 - 51

9.22.2

Pre-select milling operation

9 - 52

9.22.3

Operating the milling wheels

9 - 55

9.22.4

Feeder winch

9 - 56

9.22.5

Automatic feeder operation

9 - 56

9.22.6

Manual adjustment of the feeder winch

9 - 56

9.22.7

Fast hoist

9 - 56

9.22.8

Bentonite pump

9 - 57

9.22.9

Operation of the hose winches

9 - 57

9.22.10

Operation of small loads

9 - 57

9.22.11

Hydraulic connections and interfaces

9 - 58

APPENDIX

10 - 1

10.1

10 - 1

General

187 406 (js) LWN - TD18/8/2008

10.

General

9 - 39

0 - 15

INDEX

NOTES:

0 - 16

187 406 (js) LWN - TD18/8/2008

INDEX

0 - 17

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