Liebherr Crawler Crane LR 1280 OPERATING MANUAL – PDF DOWNLOAD

OPERATING MANUAL

TYPE

LR 1280 SERIAL NUMBER

136 043 VERSION

136 043 (rk) LWN - TD14/10/2003

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

136 043 (rk) LWN - TD14/10/2003

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's passport

1-5

1.5

Conversion tables

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

Power

1 - 11

Conformity declaration

1 - 12

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

Machine overview

2-5

2.4

Boom

2-6

136 043 (rk) LWN - TD14/10/2003

2.3

2.5

2.4.1

Information on boom designations

2-6

2.4.2

Main boom with 2220-boom head.

2-7

2.4.3

Tip boom*

2 - 24

2.4.4

Main boom with reducing piece and 2018-boom head

2 - 27

2.4.5

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

2 - 34

2.4.6

Fixed jib on 2220-boom head

2 - 43

2.4.7

Fixed jib on 2018-boom head*

2 - 54

2.4.8

1916- luffing jib on 2220-boom head

2 - 58

2.4.9

Tip boom * for jib head with system no. 1916.21

2 - 72

Basic machine

2 - 74

2.5.1

2 - 75

Upper carriage

0-1

INDEX

2.6

3.

2.5.2

Central power unit

2 - 78

2.5.3

Diesel engine

2 - 80

2.5.4

Pump equipment

2 - 82

2.5.5

Lower carriage

2 - 84

2.5.6

Ballast

2 - 86

2.5.7

Overview of the hydraulic cylinders

2 - 89

Technical data

2 - 90

2.6.1

Dimensions and weights

2 - 90

2.6.2

Operating conditions

2 - 95

2.6.3

Emissions

2 - 95

2.6.4

Engine

2 - 96

2.6.5

Hydraulic system

2 - 97

2.6.6

Winches

2 - 98

2.6.7

Slewing gear

2 - 100

2.6.8

Travel gear

2 - 101

2.6.9

Control

2 - 105

SAFETY GUIDELINES 3.1

General

3-1

3.1.1

Appropriate use

3-1

3.1.2

Examples of inappropriate use

3-2

3.1.3

Danger symbols

3-3

3.1.4

Areas of responsibility

3-4

3.2

Personal requirements of the machine operator

3-5

3.3

Personal protective gear

3-6

3.4

Work area

3-7

3.5

Safety and monitoring devices

3-8

3.6

3.5.1

Safety devices

3-8

3.5.2

Monitoring devices

3 - 10

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 - 11 3 - 16 3 - 18

3.7.1

Injuries caused by mechanical action

3 - 18

3.7.2

Injuries due to hydraulic energy

3 - 19

3.7.3

Risk of burns

3 - 20

3.7.4

Risk of chemical burns

3 - 20

3.7.5

Risk of fire and explosion

3 - 21

3.7.6

Risk of poisoning and asphyxiation

3 - 24

3.7.7

Electromagnetic influences

3 - 25

3.7.8

Endangering the environment

3 - 26

Additional dangers

3 - 27

3.8.1

Influence of winds and storms

3 - 27

3.8.2

Ground composition at the site

3 - 31

3.8.3

Snow and ice loads

3 - 32

3.8.4

Lightning strikes

3 - 33

INDEX

4.

3.8.5

Overhead power lines

3 - 34

3.8.6

Underground cables

3 - 43

3.9

Notes on safety for the machine operator

3 - 48

3.10

Notes on safety for building site personnel

3 - 48

3.10.1

Signalman

3 - 48

3.10.2

Rigger

3 - 49

3.10.3

Hand signals

3 - 50

CONTROLS 4.1

General

4-1

4.2

Control elements on the lower carriage

4-2

4.3

Controls on the upper carriage

4-3

4.4

Cabin

4-4

4.4.1

Cabin overview

4-4

4.4.2

Overview of the control stand

4-6

4.4.3

Overview of the control stand from above

4-8

4.4.4

Switch levers and pedals

4 - 11

4.5

Left control panel

4 - 12

4.6

Control panel left (X12)

4 - 15

4.7

Control panel right (X23)

4 - 17

4.8

Litronic service panel

4 - 20

4.8.1 4.9

4.10

136 043 (rk) LWN - TD14/10/2003

Emergency shut-down switch

Overview of the LCD screen

4 - 21 4 - 22

4.9.1

Main areas of the screen

4 - 22

4.9.2

Description of the screen's main areas

4 - 22

4.9.3

Sequence of operation displays

4 - 24

Set-up screens

4 - 26

4.10.1

Set-up screen 1 for main boom

4 - 27

4.10.2

Set-up screen 2 for main boom with reducing piece

4 - 31

4.10.3

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

4 - 33

4.10.4

Set-up screen 4 for main boom with luffing fly jib

4 - 35

4.11

"Crane operation" screen

4 - 36

4.12

Screen " Monitoring of components"

4 - 42

4.13

"Fault monitors" screen

4 - 45

4.14

"Load capacity chart" screen

4 - 47

4.14.1

5.

4-1

Display load capacity chart for a boom configuration no. 4 set-up

OPERATION 5.1

5.2

5.3

5-1

General 5.1.1

4 - 48

5-1 Safe operation of the machine

Checks before daily operations

5-1 5-2

5.2.1

Tour of inspection

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.

Confirm current set-up

5-4

5.3.3

Check fuel level

5-5

5.3.4

Refuelling the machine

5-5

5.3.5

Select operating modes

5-6

5.3.6

Start diesel engine

5-6

5.3.7

Adjust the engine speed

5-7

Machine operation - main functions

5-9

5.4.1

Start up checks/activities

5 - 10

5.4.2

Activating the main boom

5 - 11

5.4.3

Adjusting the main boom or the adjustable jib

5 - 12

5.4.4

Using electronic load moment limiters (LML)

5 - 14

5.4.5

Load pick-up equipment

5 - 16

5.4.6

Resetting the load screen to zero (taring)

5 - 16

Crane operation

5 - 18

5.5.1

Activate hoisting winches

5 - 18

5.5.2

Lifting loads with the tip boom mounted on the main boom head*

5 - 22

5.5.3

Lifting loads with only the main boom head, with tip boom mounted*.

5 - 23

5.5.4

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

5 - 24

5.5.5

Lifting a load with the tip boom mounted on the fly-jib head*

5 - 26

5.5.6

Lifting loads with only the fly-jib head, with tip boom mounted*

5 - 27

5.5.7

Twin hook operation

5 - 28

5.5.8

Free-fall operation

5 - 39

5.5.9

Activating the swivel gear

5 - 45

5.5.10

Moving the machine

5 - 48

5.5.11

Travel gear overdrive

5 - 51

5.5.12

Adjusting the cylinders

5 - 52

Machine operation - ancillary functions

5 - 53

5.6.1

Driver's seat

5 - 53

5.6.2

LCD screen adjustments

5 - 54

5.6.3

Windshield wiper

5 - 55

5.6.4

Heating and air-conditioning system

5 - 57

5.6.5

Lighting

5 - 59

5.6.6

Radio

5 - 60

5.6.7

Hooter

5 - 60

5.6.8

Ash tray

5 - 61

5.6.9

Cigarette lighter and socket in the cabin

5 - 61

Shutting the machine down

5 - 62

5.7.1

Boom park position

5 - 62

5.7.2

Setting down the boom

5 - 63

5.7.3

Shutting down the diesel engine

5 - 64

5.7.4

Park position of the ignition switch

5 - 65

5.7.5

Checks when leaving the machine

5 - 66

ASSEMBLY AND DISMANTLING 6.1

0-4

5.3.2

General

6-1 6-1

INDEX 6.2

6.3

6.4

Operational planning 6.2.1

Defining the working range

6-2

6.2.2

Defining the set-up

6-7

6.2.3

Assemble and prepare the transport equipment

6-7

6.2.4

Required hoist rope length

6-8

Safety precautions for assembly, dismantling and conversion

6.6

136 043 (rk) LWN - TD14/10/2003

6.7

6.8

6 - 11

6.3.1

Requirements for the erecting team

6 - 11

6.3.2

Requirements for the site

6 - 11

6.3.3

Rules for executing the work

6 - 12

Information on set-up mode 6.4.1

6.5

6-2

Operation in set-up mode

Unloading and erecting the basic machine

6 - 13 6 - 13 6 - 16

6.5.1

Requirements

6 - 16

6.5.2

Summary of assembly stages

6 - 16

6.5.3

Preparing for set-up mode

6 - 20

6.5.4

Starting set-up mode

6 - 23

6.5.5

Swivelling the driver's cabin to the working position

6 - 25

6.5.6

Lowering A-frame 1 to the unloading position

6 - 27

6.5.7

Unloading the basic machine

6 - 28

6.5.8

Preparing the basic machine as a mounting crane

6 - 36

6.5.9

Attaching the crawler carrier

6 - 38

6.5.10

Attaching the central counterweight

6 - 52

6.5.11

Assembling the rear counterweight

6 - 57

6.5.12

Mounting and bolting the rear counterweight

6 - 68

Assembly of main boom

6 - 74

6.6.1

Requirements

6 - 74

6.6.2

Overview of assembly stages

6 - 74

6.6.3

Unload and position the main boom head

6 - 75

6.6.4

Unload and position the main boom intermediate pieces

6 - 75

6.6.5

Assembly of the main boom

6 - 75

6.6.6

Assemble main boom anchoring rods

6 - 76

6.6.7

Intermediate tensioners on the main boom

6 - 79

6.6.8

Arrangement of rope guide*

6 - 83

6.6.9

Position the load hook

6 - 85

Attaching the main boom pivot piece

6 - 86

6.7.1

General

6 - 86

6.7.2

Attach main boom pivot piece to upper carriage

6 - 87

6.7.3

Connecting the hydraulic pipes on the upper carriage

6 - 89

Attachment of main boom

6 - 90

6.8.1

General

6 - 90

6.8.2

Preparations for attachment

6 - 90

6.8.3

Attachment of main boom

6 - 93

6.8.4

Preparing connection of electrical plugs to the upper carriage

6 - 96

6.8.5

Connect the electrics to the upper carriage

6 - 97

6.8.6

Connect the electrics to the main boom head

6 - 98

0-5

INDEX

6.9

6.10

6.11

0-6

6.8.7

Mounting and connecting the anemometer

6 - 99

6.8.8

Luffing the hoisting rope

6 - 100

6.8.9

Choosing the correct load hook

6 - 105

6.8.10

Rope reeving plans

6 - 108

6.8.11

Hoisting limit switch

6 - 119

6.8.12

Erecting the main boom

6 - 121

6.8.13

Erecting procedure

6 - 124

6.8.14

Raisability of the main boom

6 - 125

6.8.15

Cancellation of set-up mode

6 - 126

Attachment of tip boom* to the 2220-boom head

6 - 127

6.9.1

Requirements

6 - 127

6.9.2

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

6 - 128

6.9.3

Bolt the tip boom* to the 2220-boom head

6 - 128

6.9.4

Mount the hoisting limit switch on the tip boom*

6 - 132

Assembly of main boom with reducing piece

6 - 134

6.10.1

Requirements

6 - 134

6.10.2

Overview of assembly stages

6 - 134

6.10.3

Unload and position the main boom with reducing piece

6 - 134

6.10.4

Assemble main boom with reduction

6 - 134

6.10.5

Assembling the anchoring rods

6 - 136

6.10.6

Intermediate tensioners on main boom with 2220/2018 reduction

6 - 138

6.10.7

Intermediate tensioners on main boom with 2220/1916 reduction

6 - 140

6.10.8

Further procedure

6 - 143

6.10.9

Rope reeving plans

6 - 143

6.10.10

Raisability of main boom with reducing piece

6 - 146

Assembling the main boom with fixed jib

6 - 147

6.11.1

Requirements

6 - 147

6.11.2

Overview of assembly stages

6 - 148

6.11.3

Unload and position the main boom head

6 - 149

6.11.4

Attach the jib pivot piece

6 - 150

6.11.5

Assemble the jib

6 - 151

6.11.6

Assembling the jib anchoring rods

6 - 153

6.11.7

Assembly of the main boom

6 - 154

6.11.8

Completing assembly of the boom

6 - 154

6.11.9

Attaching coupling links to the main boom

6 - 155

6.11.10

Attach the tensioning rods to the coupling links

6 - 156

6.11.11

Erecting A-frame 2

6 - 157

6.11.12

Attaching the tensioning rods to the crossbar

6 - 158

6.11.13

Position the jib pivot piece

6 - 159

6.11.14

Connecting the electrics

6 - 160

6.11.15

Reeving the load hook

6 - 162

6.11.16

Mount the hoisting limit switch weight

6 - 164

6.11.17

Erecting the main boom with fixed jib

6 - 166

6.11.18

Erecting procedure

6 - 166

6.11.19

Raisability with fixed jib

6 - 170

INDEX

136 043 (rk) LWN - TD14/10/2003

6.12

Assembly of main boom with adjustable jib

6 - 176

6.12.1

Requirements

6 - 176

6.12.2

Mounting instructions

6 - 176

6.12.3

Overview of assembly stages

6 - 177

6.12.4

Unload and position the 2220-boom head

6 - 178

6.12.5

Attaching the jib pivot piece

6 - 179

6.12.6

Assembling the jib

6 - 181

6.12.7

Assembling the jib anchoring rods

6 - 182

6.12.8

Intermediate tensioners on the jib

6 - 183

6.12.9

Attaching the jib head

6 - 186

6.12.10

Attach the tip boom* to the jib head

6 - 187

6.12.11

Assembling the main boom

6 - 188

6.12.12

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

6 - 189

6.12.13

Completing preparations on the boom

6 - 190

6.12.14

Attach the main boom pivot piece to the basic machine

6 - 190

6.12.15

Attaching the main boom to the main boom pivot piece

6 - 191

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

Ending set-up mode

6 - 219

6.12.32

Raisability with adjustable jib

6 - 219

6.13

Time-saving conversion of the main boom

6 - 226

6.14

Dismantling the main boom with adjustable jib

6 - 231

6.14.1

Requirements

6 - 231

6.14.2

Overview of dismantling stages

6 - 232

6.14.3

Preparations for dismantling in crane mode

6 - 232

6.14.4

Activate set-up mode

6 - 232

6.14.5

Setting down the load hook

6 - 233

6.14.6

Lowering the jib

6 - 233

6.14.7

Unreeving the hoisting rope on the jib head

6 - 235

6.14.8

Lowering the jib and main boom

6 - 236

6.14.9

Retracting the hoisting rope(s)

6 - 237

6.14.10

Disconnecting the electrics

6 - 238

0-7

INDEX

6.15

Connect jib pivot piece to A-frame 3

6 - 240

6.14.12

Detaching the boom pivot piece from the jib

6 - 241

6.14.13

Move A-frames 2 and 3 towards the rear

6 - 242

6.14.14

Lower A-frames 2 and 3

6 - 243

6.14.15

Pulling out the jib luffing rope

6 - 246

6.14.16

Retracting the tilting-back cylinders

6 - 246

6.14.17

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

6 - 247

6.14.18

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

6 - 247

6.14.19

Unbolt the main boom pivot piece from the main boom

6 - 247

6.14.20

Detaching the main boom pivot piece from the upper carriage

6 - 248

6.14.21

Preparing the mounting crane

6 - 248

6.14.22

Dismantling the jib pivot piece

6 - 248

6.14.23

Detaching the tip boom* from the jib head

6 - 249

6.14.24

Dismembering the main boom and jib

6 - 250

6.14.25

Loading up the equipment

6 - 251

Dismantling the main boom with fixed jib

6 - 252

6.15.1

Requirements

6 - 252

6.15.2

Overview of dismantling stages

6 - 253

6.15.3

Preparations for crane operation

6 - 254

6.15.4

Activate set-up mode

6 - 254

6.15.5

Setting down the main boom with fixed jib

6 - 255

6.15.6

Lowering the main boom with fixed jib attached

6 - 257

6.15.7

Detaching the anemometer

6 - 259

6.15.8

Disconnecting the electrics

6 - 260

6.15.9

Dismantling the jib pivot piece

6 - 262

6.15.10

Dismantling the main boom and the main boom pivot piece

6 - 263

6.15.11

Dismembering the jib

6 - 263

6.15.12

Dismantling the jib pivot piece

6 - 265

6.16

Dismantling the main boom with reduction

6 - 266

6.17

Dismantling the tip boom* on the main boom head

6 - 266

6.18

Dismantling the main boom

6 - 266

6.19

0-8

6.14.11

6.18.1

Requirements

6 - 266

6.18.2

Overview of dismantling stages

6 - 267

6.18.3

Preparations for crane operation

6 - 267

6.18.4

Activate set-up mode

6 - 268

6.18.5

Laying down the main boom

6 - 268

6.18.6

Laying down procedure

6 - 270

6.18.7

Laying down procedure with tip boom*

6 - 271

6.18.8

Dismantling the tip boom*

6 - 272

6.18.9

Pulling out the hoisting rope(s)

6 - 273

6.18.10

Disconnecting the electrics of the main boom head

6 - 275

6.18.11

Disconnecting the electrics from the upper carriage

6 - 277

6.18.12

Detaching the mounting cylinder from the basic rope

6 - 279

6.18.13

Detaching the main boom pivot piece from the main boom

6 - 280

Dismantling the main boom pivot piece

6 - 283

INDEX General

6 - 283

6.19.2

Uncoupling the hydraulic pipes from the upper carriage

6 - 284

6.20

Dismembering the main boom

6 - 290

6.21

Dismantling and loading the basic machine

6 - 291

6.22

7.

6.19.1

6.21.1

Prerequisites

6 - 291

6.21.2

Overview of dismantling stages

6 - 292

6.21.3

Unbolting the rear counterweight from the upper carriage and setting it down

6 - 295

6.21.4

Dismantling and loading up the rear counterweight

6 - 298

6.21.5

Dismantling the central counterweight

6 - 304

6.21.6

Prepare dismantling of crawler carriers

6 - 307

6.21.7

Supporting the basic machine

6 - 309

6.21.8

Removing the crawler carriers from the basic machine and loading up

6 - 314

6.21.9

Loading up the basic machine

6 - 320

6.21.10

Swinging the driver's cabin to the transport position

6 - 325

6.21.11

Turning off the basic machine

6 - 326

Transport 6.22.1

Safety precautions for loading and unloading

6 - 328

6.22.2

Transporting the basic machine with a low-loader

6 - 329

6.22.3

Transporting attachments

6 - 331

6.22.4

Loading the basic machine with an auxiliary crane

6 - 334

6.22.5

Transporting overseas

6 - 337

MAINTENANCE

7-1

7.1

General

7-1

7.2

Table of maintenance intervals

7-2

7.2.1 7.3

7.4

7.5

7.6

7-2 7 - 12

Check oil level and oil pressure

Fuel system

7 - 12 7 - 13

7.4.1

Diagrammatic view of the fuel system

7 - 13

7.4.2

Layout of the components

7 - 14

7.4.3

Draining condensation water at the water separator

7 - 15

7.4.4

Venting the fuel system

7 - 15

Cooling system

7 - 16

7.5.1

Checking the coolant level

7 - 17

7.5.2

Filling with coolant

7 - 18

Dry air filter 7.6.1

7.7

Work to be carried out

Diesel engine 7.3.1

136 043 (rk) LWN - TD14/10/2003

6 - 328

7 - 19 Emptying the dust collection container

Hydraulic system

7 - 20 7 - 21

7.7.1

General

7 - 22

7.7.2

Checking the oil level

7 - 22

7.7.3

Topping up with hydraulic oil

7 - 22

7.7.4

Cleaning the magnet plug

7 - 23

7.7.5

Suction pipe shut-off valve on the hydraulic tank

7 - 24

7.7.6

Checking the hydraulic system

7 - 25

0-9

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