Liebherr Crawler Crane LR 1200 OPERATING MANUAL SN 135033 – PDF DOWNLOAD

OPERATING MANUAL

TYPE

LR 1200 SERIAL NUMBER

135 033 VERSION

135 033 (gl) LWN - TD10/11/2006

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

135 033 (gl) LWN - TD10/11/2006

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 organized?

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

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

2.5 135 033 (gl) LWN - TD10/11/2006

1-1

2.6

2.4.1

Information on boom designations

2-6

2.4.2

A-frame 1

2-7

Main boom with 2320 boom head

2-8

2.5.1

2320 pivot piece, system length: 10 m [33 ft]

2 - 10

2.5.2

2320 intermediate piece, system length: 3 m [10 ft]

2 - 12

2.5.3

2320 intermediate piece, system length: 6 m [20 ft]

2 - 14

2.5.4

2320 intermediate piece, system length: 12 m [40 ft]

2 - 17

2.5.5

2320-1 boom head, system length: 7 m [22 ft]

2 - 20

2320-2 tip boom* on the 2320 boom head

2 - 22

2.6.1

Modification kit* for tip boom*

2 - 24

2.6.2

Rope guide *

2 - 25

0-1

INDEX 2.7

Main boom with 2320/1916 reducing piece and 1916 fly jib head 2.7.1 2.7.2

2.8

1916-2 fly jib head, system length: 8 m [26 ft]

Fixed 1008 fly jib on 2320 boom head

2 - 30 2 - 32

2.8.1

1008 fly jib pivot piece, system length: 5.5 m [18 ft]

2 - 36

2.8.2

1008 fly jib intermediate piece, system length: 3 m [10 ft]

2 - 39

2.8.3

1008 fly jib intermediate piece, system length: 6 m [20 ft]

2 - 41

2.8.4

1008-1 fly jib head, system length: 5.5 m [18 ft]

2 - 43

1008-2 fly jib head*, system length: 1.5 m [5 ft]

2 - 45

2.10

Adjustable 1916 fly jib on 2320 boom head

2 - 46

2.12

2.10.1

1916 fly jib pivot piece, system length: 7 m [23 ft]

2 - 48

2.10.2

1916 fly jib pivot piece with A-frames 2 and 3 on 2320 boom head

2 - 49

2.10.3

1916 fly jib intermediate piece, system length: 3 m [10 ft]

2 - 52

2.10.4

1916 fly jib intermediate piece, system length: 6 m [20 ft]

2 - 54

2.10.5

1916 fly jib intermediate piece, system length: 12 m [40 ft]

2 - 56

2.10.6

1916-1 fly jib head, system length: 7 m [23 ft]

2 - 58

2.10.7

Tip boom* for jib head

2 - 60

2.10.8

1916 Midfall* intermediate piece

2 - 62

Basic machine

2 - 64

2.11.1

Superstructure

2 - 65

2.11.2

Central power unit

2 - 68

2.11.3

Undercarriage

2 - 70

2.11.4

Hydraulic chain tensioner

2 - 72

2.11.5

Ballast

2 - 73

2.11.6

Platforms on the undercarriage

2 - 77

2.11.7

Overview of the hydraulic cylinders

2 - 78

Technical data

2 - 79

2.12.1

Dimensions and weights

2 - 79

2.12.2

Operating conditions

2 - 85

2.12.3

Emissions

2 - 85

2.12.4

Engine

2 - 86

2.12.5

Hydraulic system

2 - 87

2.12.6

Winches

2 - 88

2.12.7

Slewing gear

2 - 90

2.12.8

Travel gear

2 - 91

2.12.9

Control

2 - 95

SAFETY PRECAUTIONS

3-1

3.1

0-2

2 - 28

2.9

2.11

3.

2 - 26

General

3-1

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

INDEX 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

Signs on the machine 3.6.1

3.7

3.8

135 033 (gl) LWN - TD10/11/2006

4.

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

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

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

Control stand overview

4-6

4.4.3

Overhead view of control stand

4-8

4.4.4

Joysticks and pedals

4 - 11

4.5

Left-hand control panel (X11)

4 - 12

4.6

Left-hand control panel (X12)

4 - 15

4.7

Right-hand control panel (X23)

4 - 17

4.8

Litronic service panel

4 - 20

4.8.1 4.9

Emergency shut-down switch

Overview of screens

4 - 22 4 - 23

0-3

INDEX

4.10

5.

Main areas of the screen

4 - 23

4.9.2

Description of the main areas of the screen

4 - 24

4.9.3

Description of the LCD display:

4 - 25

4.9.4

Overview of mode screens

4 - 26

4.9.5

Function symbols and display fields

4 - 28

Set-up screens

4 - 30

4.10.1

Explanations of set-up screens

4 - 30

4.10.2

Main boom

4 - 31

4.10.3

Main boom with reducing piece

4 - 33

4.10.4

Main boom with fixed fly jib

4 - 35

4.10.5

Main boom with adjustable fly jib

4 - 37

4.10.6

Main boom with adjustable fly jib head and Midfall

4 - 38

4.11

Power operation

4 - 40

4.12

Power unit monitoring

4 - 47

4.13

Fault displays

4 - 50

4.14

Load capacity chart

4 - 52

4.14.1

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

4 - 53

4.14.2

Load capacity chart

4 - 53

4.14.3

Load capacity chart

4 - 53

4.14.4

Load capacity chart

4 - 54

4.14.5

Load capacity chart

4 - 54

OPERATION 5.1

5.2

5.3

5.4

0-4

4.9.1

5-1

Safe working with the machine

5-1

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

5-4

5.2.1

Tour of inspection

5-4

5.2.2

Checks

5-4

Daily start up

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

Adjusting the cylinders

5 - 19

5.4.5

Slewing the superstructure

5 - 20

INDEX

5.5

5.4.6

Adjusting the main boom

5 - 23

5.4.7

Adjusting the main boom or the adjustable fly jib

5 - 24

5.4.8

Operating the hoisting winches

5 - 26

5.4.9

Hoisting limit switch

5 - 29

5.4.10

Hydraulic cab inclination

5 - 30

5.4.11

Electronic load moment limiter (LML),

5 - 31

Power operation 5.5.1

5.6

5.7

load moment limiter (LML),

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

Rope length metering*

5 - 69

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

5.8

Ground pressure gauge*

5 - 71

5.9

Outreach limitation*

5 - 72

5.10

135 033 (gl) LWN - TD10/11/2006

Load pick-up equipment

5 - 34

5.11

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

0-5

INDEX 5.12

5.13

6.

Operating the machine - auxiliary functions 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 down the machine

5 - 93

5.13.1

Boom park position

5 - 93

5.13.2

Laying down the boom

5 - 94

5.13.3

Shutting down the diesel engine

5 - 96

5.13.4

Park position of the ignition starter switch

5 - 97

5.13.5

Checks before leaving the machine

5 - 98

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

6-3

6.2.3

Assembling and preparing the transport equipment

6-3

6.2.4

Required hoisting rope length

6-4

Safety precautions for assembly, dismantling and reconfiguring

6.5

6-5

6.3.1

Requirements for the erecting team

6-5

6.3.2

Requirements for the site

6-5

6.3.3

Rules for executing the work

6-6

Information on set-up mode 6.4.1

0-6

5 - 84

Operation in set-up mode

Unloading and erecting the basic machine

6-7 6-7 6 - 10

6.5.1

Prerequisites

6 - 10

6.5.2

Overview of assembly stages

6 - 10

6.5.3

Slinging equipment

6 - 14

6.5.4

Swivelling the cab to the working position

6 - 16

6.5.5

Removing uppercarriage locking

6 - 18

6.5.6

Starting set-up mode

6 - 21

6.5.7

Lowering A-frame 1 to the unloading position

6 - 23

6.5.8

Unloading the basic machine

6 - 25

6.5.9

Unloading and attaching the pivot piece

6 - 34

6.5.10

Unloading the pivot piece.

6 - 36

6.5.11

Cable remote control for pivot piece

6 - 38

6.5.12

Connecting the cable remote control

6 - 38

6.5.13

Operating the cable remote control

6 - 39

6.5.14

Guide the pivot piece towards the bolting points on the superstructure

6 - 40

6.5.15

Connecting the multicoupling on the superstructure

6 - 42

INDEX

6.6

135 033 (gl) LWN - TD10/11/2006

6.7

6.8

6.5.16

Connect the electrics to the superstructure

6 - 43

6.5.17

Connect the pivot piece to the basic cable

6 - 44

6.5.18

Extending the tilting-back support cylinders

6 - 45

6.5.19

Extending the mounting cylinder

6 - 46

6.5.20

Attaching the crawler carrier

6 - 48

6.5.21

Putting the travel gear into operation

6 - 59

6.5.22

Attaching the steps

6 - 60

6.5.23

Attaching the central counterweight

6 - 61

6.5.24

Attaching platforms to the undercarriage

6 - 68

6.5.25

Assembling the rear counterweight

6 - 70

6.5.26

Connecting the cable remote control for rear counterweight assembly

6 - 81

6.5.27

Mounting the rear counterweight

6 - 82

6.5.28

Bolting the rear counterweight

6 - 86

Assembly of 2320 main boom

6 - 88

6.6.1

Prerequisites

6 - 88

6.6.2

Overview of assembly stages

6 - 88

6.6.3

Unload and position the main boom head

6 - 89

6.6.4

Unload and position the main boom intermediate pieces

6 - 89

6.6.5

Assembling the main boom

6 - 89

6.6.6

Assemble the main boom anchoring rods

6 - 91

6.6.7

Possible main boom lengths

6 - 93

6.6.8

Intermediate tensioners on the main boom

6 - 94

6.6.9

Installation position of intermediate tensioners on main boom with 2320 boom head 6 - 95

6.6.10

Arrangement of rope guide*

6 - 98

6.6.11

Position the pulley block (or load hook)

6 - 102

6.6.12

Selecting the correct pulley block

6 - 102

Attaching the main boom

6 - 106

6.7.1

General

6 - 106

6.7.2

Preparations for attachment

6 - 106

6.7.3

Attaching the main boom

6 - 108

6.7.4

Supplying electricity to the 2320 boom head

6 - 110

6.7.5

Mounting and connecting the anemometer

6 - 111

6.7.6

Luffing the hoisting rope

6 - 111

6.7.7

Rope reeving plans

6 - 116

6.7.8

Hoisting limit switch

6 - 127

6.7.9

Erect the main boom

6 - 129

6.7.10

Erecting procedure

6 - 132

6.7.11

Erectability of the main boom

6 - 133

6.7.12

Canceling set-up mode

6 - 134

Attachment of tip boom* to the 2320 boom head

6 - 135

6.8.1

Prerequisites

6 - 135

6.8.2

Position the tip boom* in front of the 2320 boom head

6 - 136

6.8.3

Bolt the tip boom* to the 2320 boom head

6 - 136

6.8.4

Fit the hoisting limit switch to the tip boom*

6 - 139

6.8.5

Erectability of the main boom with tip boom attached

6 - 141

0-7

INDEX 6.8.6 6.9

6.10

6.11

6.12

0-8

Canceling set-up mode

Assembling the main boom with 2320/1916 reducing piece and 1916-2 fly jib head

6 - 142 6 - 143

6.9.1

Prerequisites

6 - 143

6.9.2

Overview of assembly stages

6 - 143

6.9.3

Unloading and positioning the main boom with reducing piece

6 - 143

6.9.4

Assemble main boom with reduction

6 - 144

6.9.5

Assembling the anchoring rods

6 - 147

6.9.6

Number of boom components for reduction variant 1.

6 - 149

6.9.7

Number of boom components for reduction variant 2.

6 - 150

6.9.8

Intermediate tensioners on main boom with 2320/1916 reduction and 1916-2 fly jib 6 - 151 head

6.9.9

Arrangement of rope guide*

6 - 157

6.9.10

Further procedure

6 - 158

6.9.11

Rope reeving plans

6 - 158

6.9.12

Erectability of main boom with reducing piece

6 - 161

6.9.13

Ending set-up mode

6 - 162

Assembling the main boom with fixed 1008 fly jib

6 - 163

6.10.1

Prerequisites

6 - 163

6.10.2

Overview of assembly stages

6 - 163

6.10.3

Unload and position the main boom head

6 - 166

6.10.4

Attach the fly jib pivot piece

6 - 166

6.10.5

Assembling the fly jib

6 - 167

6.10.6

Assembling the fly jib anchoring rods

6 - 169

6.10.7

Assembling the main boom

6 - 170

6.10.8

Completing assembly of the boom

6 - 171

6.10.9

Attaching coupling links to the main boom

6 - 172

6.10.10

Attach the tensioning rods to the coupling links

6 - 173

6.10.11

Erecting the A-frame

6 - 174

6.10.12

Attaching the tensioning rods to the crossbar

6 - 175

6.10.13

Reeve the pulley block (or load hook) on the 2320 boom head

6 - 176

6.10.14

Rope reeving plans main boom

6 - 177

6.10.15

Connecting the electrical system

6 - 187

6.10.16

Luffing the hoisting rope

6 - 189

6.10.17

Reeve the load hook

6 - 190

6.10.18

Fitting the hoisting limit switch weight

6 - 191

6.10.19

Erecting the main boom with fixed fly jib

6 - 193

6.10.20

Erecting procedure

6 - 194

6.10.21

Erectability with fixed jib

6 - 197

6.10.22

Ending set-up mode

6 - 198

Assembling the main boom with fixed 1008-2 fly jib head

6 - 199

6.11.1

Rope reeving plans for 1008-2 boom head

6 - 200

6.11.2

Reeve the load hook

6 - 200

6.11.3

Erectability with fixed jib

6 - 202

6.11.4

Ending set-up mode

6 - 203

Assembly of main boom with adjustable jib

6 - 204

INDEX

6.13

6.12.1

Prerequisites

6 - 204

6.12.2

Mounting instructions

6 - 204

6.12.3

Overview of assembly stages

6 - 205

6.12.4

Unloading and positioning the 2320 boom head

6 - 206

6.12.5

Attaching the fly jib pivot piece

6 - 207

6.12.6

Assembling the fly jib

6 - 209

6.12.7

Assembling the fly jib anchoring rods

6 - 211

6.12.8

Intermediate tensioners on the 1916 fly jib

6 - 212

6.12.9

Attaching the 1916 fly jib head

6 - 216

6.12.10

Attaching the tip boom* to the 1916 fly jib head

6 - 216

6.12.11

Assemble the main boom

6 - 217

6.12.12

Mount the main boom anchoring rods and fly jib tensioning rods of the main boom 6 - 218

6.12.13

Completing preparations on the boom

6 - 219

6.12.14

Attaching the main boom to the main boom pivot piece

6 - 220

6.12.15

Preparing the hoisting rope as a mounting aid

6 - 221

6.12.16

Reeving the fly jib luffing rope

6 - 222

6.12.17

Erecting A-frames 2 and 3

6 - 225

6.12.18

Connecting the fly jib pivot piece to A-frame 3

6 - 227

6.12.19

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

6 - 229

6.12.20

Attach the fly jib to the fly jib pivot piece

6 - 232

6.12.21

Bolt the fly jib anchoring rods and A-frame 3 together

6 - 233

6.12.22

Reeving the pulley block (or load hook) on the 2320 boom head

6 - 235

6.12.23

Main boom rope reeving plans

6 - 235

6.12.24

Connecting the electrical system

6 - 246

6.12.25

Fit the hoisting limit switch to the 2320 boom head

6 - 248

6.12.26

Raising the main boom with adjustable fly jib

6 - 248

6.12.27

Reeve the pulley block/load hook on the 1916 fly jib head and tip boom*

6 - 252

6.12.28

Fly jib rope reeving plans

6 - 252

6.12.29

Reeving the tip boom*

6 - 255

6.12.30

Fit the hoisting limit switch to the 1916 fly jib head and tip boom*

6 - 256

6.12.31

Erecting the main boom and fly jib

6 - 257

6.12.32

Erectability with adjustable fly jib

6 - 259

6.12.33

Ending set-up mode

6 - 260

Fitting the 1916 Midfall* intermediate piece 6.13.1

135 033 (gl) LWN - TD10/11/2006

6.14

Installation position of the 1916 Midfall* intermediate piece

Converting the track width

6 - 261 6 - 263 6 - 265

6.14.1

Converting from wide to narrow track*

6 - 265

6.14.2

Converting narrow track* to wide track

6 - 273

6.15

Time-saving reconfiguring of the main boom

6 - 280

6.16

Dismantling of main boom with adjustable 1916 jib

6 - 284

6.16.1

Prerequisites

6 - 284

6.16.2

Overview of dismantling stages

6 - 285

6.16.3

Preparations for dismantling in crane operation

6 - 285

6.16.4

Activating set-up mode

6 - 285

6.16.5

Laying down the pulley block (or load hook)

6 - 286

0-9

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INDEX

6.17

6.18

0 - 10

6.16.6

Lowering the fly jib

6 - 286

6.16.7

Unreeving the hoisting rope on the 1916 fly jib head

6 - 289

6.16.8

Lowering the fly jib and main boom

6 - 290

6.16.9

Pull in the hoisting rope(s)

6 - 291

6.16.10

Disconnecting the electrical system

6 - 292

6.16.11

Connecting the fly jib pivot piece to A-frame 3

6 - 294

6.16.12

Detach the fly jib pivot piece from the fly jib

6 - 295

6.16.13

Move A-frames 2 and 3 towards the rear

6 - 296

6.16.14

Laying down A-frames 2 and 3

6 - 298

6.16.15

Pull out the fly jib luffing rope

6 - 301

6.16.16

Preparing the assembly crane

6 - 302

6.16.17

Removing the fly jib pivot piece

6 - 303

6.16.18

Removing the tip boom* from the 1916 fly jib head

6 - 304

6.16.19

Dismantling the main boom and fly jib

6 - 305

6.16.20

Loading up the equipment

6 - 306

6.16.21

Dismantling the 1916 Midfall

6 - 306

Dismantling the main boom with fixed 1008-1 fly jib

6 - 307

6.17.1

Prerequisites

6 - 307

6.17.2

Overview of dismantling stages

6 - 308

6.17.3

Preparations in crane operation

6 - 309

6.17.4

Activating set-up mode

6 - 309

6.17.5

Setting down the main boom with fixed 1008 fly jib

6 - 310

6.17.6

Lowering the main boom with fixed 1008 fly jib attached

6 - 312

6.17.7

Detaching the anemometer

6 - 314

6.17.8

Disconnecting the electrical system

6 - 315

6.17.9

Detaching the 1008 fly jib pivot piece

6 - 317

6.17.10

Dismantling the main boom and the main boom pivot piece

6 - 319

6.17.11

Dismantling the jib

6 - 319

6.17.12

Detaching the 1008 fly jib pivot piece

6 - 320

Dismantling the main boom with fixed 1008-2 fly jib boom

6 - 321

6.18.1

Prerequisites

6 - 321

6.18.2

Dismantling the 1008-2 fly jib boom

6 - 321

6.19

Dismantling the main boom with 2320/1916 reduction

6 - 322

6.20

Dismantling the tip boom* on the 2320 boom head

6 - 322

6.21

Dismantling the main boom with 2320 boom head

6 - 322

6.21.1

Prerequisites

6 - 322

6.21.2

Overview of dismantling stages

6 - 323

6.21.3

Preparations in crane operation

6 - 324

6.21.4

Activating set-up mode

6 - 324

6.21.5

Laying down the main boom

6 - 324

6.21.6

Laying down procedure

6 - 327

6.21.7

Laying down procedure with tip boom*

6 - 328

6.21.8

Dismantling the tip boom*

6 - 329

6.21.9

Pulling out the hoisting rope(s)

6 - 330

6.21.10

Disconnecting the electrical supply to the 2320 boom head

6 - 331

INDEX Inserting the bypass plug in the superstructure

6 - 333

6.21.12

Detach the main boom from the pivot piece

6 - 334

6.21.13

Detaching the main boom from the pivot piece

6 - 336

6.21.14

Preparing the basic machine as an assembly crane

6 - 338

6.22

Dismantle the main boom

6 - 340

6.23

Dismantling and loading the basic machine

6 - 341

6.24

7.

6.21.11

6.23.1

Prerequisites

6 - 341

6.23.2

Overview of assembly stages

6 - 342

6.23.3

Unbolting the rear counterweight from the superstructure and setting it down

6 - 346

6.23.4

Dismantling the central counterweight

6 - 354

6.23.5

Preparing to dismantle the crawler carriers

6 - 356

6.23.6

Supporting the basic machine

6 - 358

6.23.7

Removing the crawler carrier from the undercarriage

6 - 366

6.23.8

Loading the basic machine

6 - 373

6.23.9

Retracting the tilting-back support cylinders

6 - 374

6.23.10

Detaching the pivot piece from the basic rope

6 - 374

6.23.11

Detaching the multicoupling on the superstructure

6 - 376

6.23.12

Disconnecting the electrics from the superstructure

6 - 377

6.23.13

Dismantling the assembly crane

6 - 378

6.23.14

Taking the basic machine out of operation

6 - 380

Transport 6.24.1

Safety precautions for loading and unloading

6 - 381

6.24.2

Safety Precautions for transport on public roads

6 - 382

6.24.3

Transporting the basic machine with a low-loader

6 - 383

6.24.4

Transporting fittings

6 - 386

6.24.5

Loading the basic machine with an auxiliary crane

6 - 390

6.24.6

Transporting overseas

6 - 396

MAINTENANCE 7.1

7.2

7.5

7.6

7.7

Welding work

Work to be carried out

Diesel engine 7.3.1

7.4

7-1

Maintenance chart 7.2.1

7.3

7-1

General 7.1.1

135 033 (gl) LWN - TD10/11/2006

6 - 381

7-1 7-2 7-2 7 - 12

Check oil level and oil pressure

Fuel system

7 - 12 7 - 13

7.4.1

Draining condensation from the fuel prefilter

7 - 13

7.4.2

Bleeding the fuel system

7 - 14

Cooling system

7 - 15

7.5.1

Checking the coolant level

7 - 15

7.5.2

Filling with coolant

7 - 16

The dry air filter

7 - 17

7.6.1

7 - 18

Emptying the dust collection container

Travel gear 7.7.1

7 - 19 General

7 - 19

0 - 11

INDEX 7.7.2 7.8

7.9

7.10

7.11

7.12

7.13

Hydraulic system

7 - 19 7 - 20

7.8.1

General

7 - 20

7.8.2

Check oil level

7 - 20

7.8.3

Topping up with hydraulic oil

7 - 21

7.8.4

Cleaning the magnet plug

7 - 22

Pressure check in the piston area of the tilting-back supports

7 - 23

7.9.1

Overview of measurement points

7 - 23

7.9.2

Prerequisites for the pressure check

7 - 24

7.9.3

Measuring procedure

7 - 24

7.9.4

The following values must be indicated:

7 - 25

Slewing gear transmission/Rotary connection

7 - 26

7.10.1

Slewing gear transmission, checking the oil level

7 - 26

7.10.2

Lubricating the crown gear/pinion

7 - 26

Winches

7 - 27

7.11.1

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

7 - 27

7.11.2

Main boom adjusting winch and A-frame 1; rope deflection pulleys

7 - 27

7.11.3

Checking oil level of fly jib adjusting winch

7 - 28

Ropes

7 - 29

7.12.1

Rope guidance and rope winding

7 - 29

7.12.2

Rope deflectors on winches 1 and 2

7 - 29

7.12.3

Inspecting the pocket locks

7 - 30

7.12.4

Check the wire clamps and/or cast sleeves

7 - 31

7.12.5

Rope thimbles

7 - 31

7.12.6

Checking the ropes

7 - 32

7.12.7

Rope pulleys and balancers

7 - 39

Pulley blocks and load hooks

7 - 40

7.13.1

Pulley block with one or more pulleys

7 - 40

7.13.2

Pulley blocks with counterweight, with one or more pulleys

7 - 40

7.13.3

Load hook

7 - 41

7.14

A-frame erection cylinder

7 - 42

7.15

Main boom

7 - 43

7.16

7.17

0 - 12

Cleaning the travel gear

7.15.1

Main boom pivot piece

7 - 43

7.15.2

Main boom limit switch

7 - 43

7.15.3

Main boom head

7 - 44

7.15.4

Tip boom*

7 - 44

7.15.5

Hoisting limit switch

7 - 44

Fixed jib

7 - 45

7.16.1

Fly jib head

7 - 45

7.16.2

Hoisting limit switch

7 - 45

Adjustable jib

7 - 46

7.17.1

Locking flaps

7 - 46

7.17.2

Fly jib pivot piece with A-frames 2 and 3

7 - 46

7.17.3

Piston type accumulator for the tilting-back supports on the fly jib

7 - 47

7.17.4

Fly jib head

7 - 48

INDEX 7.17.5 7.18

7.19

7.20

Boom intermediate pieces

7 - 49

Checking the boom bolting and the anchoring rod connections

7 - 49

7.18.2

Checking tensioning and anchoring rods

7 - 50

Electrical system

7 - 53

7.19.1

7 - 53

Checking displays, lights etc.

Cab

7 - 54

7.20.1

Windshields

7 - 54

7.20.2

Cab door and door lock

7 - 54

7.20.3

Outside and inside mirrors

7 - 54

7.20.4

Hydraulic cab adjustment

7 - 54

7.21

Personal protective gear

7 - 55

7.22

Fire extinguishers

7 - 55

7.23

Lubricant requirements

7 - 56

7.24

Lubricant table

Diesel fuels 7.24.1

7 - 57 7 - 61

Diesel oils under cold conditions

7 - 61

7.25

Lubricants for diesel engines

7 - 63

7.26

Coolant

7 - 65

7.26.1

Approved anti-corrosive and anti-freeze agents

7 - 67

7.26.2

Use of DCA 4 concentrate without anti-corrosive agent/antifreeze

7 - 67

7.27

Lubrication chart

7 - 68

7.28

Repair-welding

7 - 71

7.28.1

General

7 - 71

7.28.2

Welding requirements

7 - 71

7.29

Conservation regulations 7.29.1

7.30

General

Resale - Decommissioning 7.30.1

135 033 (gl) LWN - TD10/11/2006

7 - 48

7.18.1

7.23.1

8.

Hoisting limit switch

General

7 - 72 7 - 72 7 - 72 7 - 72

OPTIONS

8-1

8.1

General

8-1

8.2

Boom walkway

8-2

8.3

Air conditioning

8-3

8.3.1

General

8-3

8.3.2

Air conditioning control elements

8-3

8.3.3

Notes on operating the air conditioning system

8-4

8.3.4

Components of the air conditioning system

8-5

8.3.5

Maintenance of the air conditioning system

8-5

8.3.6

The following maintenance should be carried out at the beginning and end of a cold period:

8-6

8.4

Air flap

8-8

8.5

Spark arrester

8-9

8.6

Helicopter light

8 - 10

8.7

External power supply

8 - 11

0 - 13

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