LIEBHERR Mobile crane with telescopic boom LTM 1095-5.1 Operating instructions Manual – PDF DOWNLOAD

Liebherr Mobile crane with telescopic boom LTM 1095-5.1 LTM 1095-5-1-000

Operating instructions BAL-No.: 15800-01-02 Pages: 962

Werk-Number Date

The operating manual is part of the crane!

It must always be carried and be ready for use!

Comply with all traffic regulations and specifications for crane operation!

Liebherr-Werk Ehingen GmbH Postfach 1361 D-89582 Ehingen / Donau : +49 (0) 7391 502–0 Fax: +49 (0) 7391 502–3399 : info.lwe@liebherr.com www.liebherr.com

1

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Foreword General This crane has been built according to the present level of technology and recognized safety technical regulations. Despite that, dangers to body and life for the user and/or third persons or damage to the crane and /or other material assets can occur.

This crane may only be used in flawless technical condition and according to its mission as well as with constant awareness of safety and dangers. Any problems, which could affect safety must be fixed immediately.

Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen GmbH. Operating instructions These operating instructions are intended to put you in a position to operate the crane safely and utilize the reliable usage options that it provides. The instructions also provide information on how to use important equipment and systems.

Certain expressions are used in these operating instructions. In order to avoid misunderstandings the same expressions should always be used.

Danger!

Risk of accident if crane is not operated correctly! ! Only qualified, trained personnel are permitted to work on the crane.

The operating instructions and on-site regulations and specifications (such as accident prevention regulations) must be followed.

The use of these operating instructions: – makes it easier to become familiar with the crane – avoids faults due to improper operation Observing these operating instructions: – increases reliability in use – extends the service life of your crane – reduces repair costs and downtime Always keep these operating instructions handy in the driver's or crane cab.

The operating instructions belong with the crane!

Only operate the crane if you are well familiarized with the equipment, and always follow these operating instructions.

If you have received additional information about the crane from us such as technical information letters, this information must also be followed and kept with the operating instructions.

If there is anything in the operating instructions or the individual chapters that you do not understand, please contact us before starting the relevant work.

The information and illustrations contained in these operating instructions may not be copied or distributed, nor used for the purposes of competition. All rights are expressly reserved in accordance with copyright laws.

All accident prevention guidelines, operating instructions, etc. are based on destined use of the crane.

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Destined use The destined use of the crane consists soley in vertical lifting and lowering of free and non-adhered loads, whose weight and center of gravity are known.

To do so, a hook or hookblock approved by Liebherr must be reeved on the hoisting cable and it may only be operated in the permissible crane configurations.

Driving with the crane, with or without an attached load is only permissible if a corresponding driving or load chart is available. The crane configurations intended for it and the safety conditions must be observed according to the corresponding operating instructions.

Any other use or any other exceeding utilization is not destined use.

Part of destined use is also adherence of required safety regulations, conditions, preconditions, crane configurations and working steps as noted in the crane documentation (operating instructions, load chart, operation planer).

The manufacturer is not liable for damages, which are caused by non-destined use or improper usage of the crane. Any associated risk it is carried solelyby the owner, the operator and the user of the crane.

Non-destined use Non -destined use is: – Working outside the permissible crane configurations according to the load chart – Working outside the permissible projection radii and turning ranges according to the load chart – Selecting load values, which do not correspond to the actual crane configuration – Selecting LMB-Codes, which do not match the actual crane configuration – Working with bypassed load moment limiter or bypassed hoist limit switch – Increasing the projection radius of the lifted load after a LMB shut off, for example by diagonally pulling the load – Using the supporting pressure indicator as safety function against tipping over – Using equipment or attachment parts which are not approved for the crane – Usage at sports and recreational events, especially for 'Bungee' jumps – Driving on a public road in non-permissible driving condition (axle load, dimension) – Driving the equipped crane in a non-permissible driving condition – Pushing, pulling or lifting loads with the leveling regulation, the sliding beams or the support cylinders – Pushing, pulling or lifting loads by actuating the slewing gear, the luffing gear or the telescoping gear – Ripping stuck objects loose with the crane – Utilizing the crane for a longer period of time for material handling tasks – Releasing the crane suddenly (grapple or dumping operation) The crane may not be used for: – letting persons drive along outside the driver's cab – transporting personnel in the crane cab while driving – transporting personnel with the lifting equipment and on the load – transporting personnel with containers, if no written approval of the corresponding job safety board has been issued – transporting loads on the chassis – two hook operation without auxiliary equipment – continued operation without sufficiently long breaks The operating instructions must be read and used by all persons who are involved in the usage, operation, assembly and maintenance of the crane.

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Warnings The following terms that are used in these operating instructions “Note”, “Caution”, “Warning” and “Danger” are intended to point out certain important rules of conduct to all persons who work with the crane.

Note: The term “Note” is used to draw attention to certain matters.

Caution: The term “Caution” is used to provide a warning about potential damage to property or minor personal injury.

Warning: The term “Warning” is used to provide a warning about potentially serious personal injury.

Danger: The term “Danger” is use to provide a warning about life-threatening hazards.

Safety equipment Special attention must be paid to the safety equipment built into the crane. The functionality of the safety equipment must be monitored at all times. The crane must not be operated if the safety equipment is not working or not working correctly.

Your motto must always be: !Safety first!

The crane had been built in accordance with the applicable crane operating and driving regulations and have been approved by the relevant authorities.

Danger!

The crane permit and the manufacturer's guarantee will be invalidated!

If any original installed parts are modified, manipulated or replaced (e.g. removal of parts, installation of non-original parts), both the crane permit and the manufacturer's guarantee will be invalidated. ! Do not modify original parts. ! Do not remove original parts. ! Always use Liebherr original spare parts.

Customer request Customer-specific equipment is marked with *.

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Contents

Contents

1.00 Description of crane

17

1.01 Terminology

17

1 Crane components

17

2 Additional boom

19

1.02 Product description

21

1 Crane chassis

21

2 Crane superstructure

22

3 Additional equipment

23

1.03 Technical data

25

1 Dimensions

25

2 Tires

25

3 Weights

25

4 Workplace-related emission value

26

5 Speeds

26

6 Hoisting heights

28

2.00 Safety

37

2.01 Traffic regulations

37

1 Traffic regulations 2.02 Break-in instructions

37 39

1 Crane break-in specifications 2.03 Operational planning

39 41

1 Planning crane operation 2.04 Safety technical notes

41 43

1 Crane operator responsibilities

43

2 Selecting the crane operating location

45

3 Slopes and excavations

45

4 Permissible soil pressure

45

5 Supporting

49

6 Crane operation with a load

50

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Contents

7 Grounding

52

8 Crane operation in case of thunderstorms

54

9 Welding work on the load

54

10 Safety instructions for external supplies (230 V AC)

55

11 Working in the vicinity of transmitters

57

12 Hand signals for guidance

59

13 Consideration of wind conditions

59

14 Interrupting crane operation

61

15 Stopping the vehicle

61

2.05 Signs on the crane

65

1 Warning signs

65

2 Warning notes

67

3 Command / prohibition sign

69

4 Notice signs

71

2.06 Antifall guards on the crane 1 Antifall guards on the crane

73

2 Fastening points

73

3 Attachment points on folding jib

75

4 Railings on the crane superstructure

79

3.00 Operation - crane chassis 3.01 Operation and control instruments - crane chassis 1 Vehicle operating and control instruments 3.02 Before starting up the vehicle

83 83 83 101

1 General checks before setting off

101

2 Driver's cab

109

3.03 Axle suspension / axle locking system

115

1 General

115

2 Axle suspension system

117

3 Axle locking system

123

3.04 Driving the crane

6

73

125

1 Crane driving conditions

125

2 Starting and stopping the engine

129

3 Driving

137

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Contents

4 Differential locks

177

5 Steering

183

6 Towing

193

3.05 The crane at the jobsite

195

1 General

195

2 Support control unit

201

3 The “Support” program

213

4 Before leaving the work site

223

4.00 Operation - crane superstructure 4.01 Operation and control instruments - crane superstructure 1 Operating and control instruments 4.02 LICCON computer system

227 227 227 241

1 General

241

2 LICCON computer system start-up

243

3 LICCON computer system operating elements

245

4 “Configuration” program

247

5 “Crane operation” program

263

6 “Telescoping” program

311

7 “Control parameter” program

315

8 The “Working range limitation” * program

325

9 The “Support” program

327

10 The “Engine monitoring” program

343

11 LICCON computer system in stand-by mode

351

4.03 Starting up the crane

355

1 Checks before starting up

355

2 Crane driver's cab workplace

359

3 Starting and stopping superstructure engine and chassis engine

367

4 LICCON computer system after engine start

379

4.04 Safety devices

383

1 General

383

2 LICCON computer system

383

3 General safety equipment

387

4 Other safety equipment

389

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Contents

5 Bypass button

391

6 Acoustic/visual warning overview

393

4.05 Crane operation

397

1 General

397

2 LICCON computer system

403

3 Luffing

405

4 Lifting / lowering

409

5 Turning

411

6 Telescoping

417

4.06 Rope reeving

429

1 General

429

2 Reeving the hook block in and out

429

3 Attaching and removing the load hook*

435

4 Reeving plans

439

4.07 Counterweight

453

1 General

453

2 Assembly

461

3 Disassembly

465

4.08 Working with a load

471

1 Technical safety instructions for working with loads

471

2 Checking before starting to work with the crane

471

3 Taking on a load

475

4 Crane operation

477

4.09 Driving with the attachment in place 1 Measures to be taken before driving with the equipment in place

481

2 Driving with the equipment in place

482

3 Charts for driving with the equipment in place

485

4.10 Driving from the crane operator's cab

8

481

535

1 General

535

2 Brakes

537

3 Driving mode

539

4 Important control instruments

543

5 Finishing driving operations

543

6 Differential locks

545

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Contents

7 Steering

549

4.12 Two hook operation

553

1 General

553

5.00 Equipment

561

5.01 Safety technical notes

561

1 Checking the retaining elements

561

2 Checking the ropes

561

3 Checks before supporting the crane

562

4 Checks before crane operation

562

5 Transporting components

562

6 Weights

562

7 LICCON bypass button

565

8 Assembly / dismantling

569

9 Setting-up and taking-down

586

5.02 Folding jib - TK

589

1 General

589

2 Assembling the folding jib

595

3 Reeving in the hoist rope

609

4 Changing the mechanical folding jib from 0° to 20° or 40°

611

5 Hydraulic connections

617

6 Electrical connections

619

7 Setting up

625

8 Adjusting the folding jib angle with a hydraulic folding jib

627

9 Changing the mechanical folding jib from 20° or 40° to 0°

629

10 Reeving out the hoist rope

635

11 Removing the folding jib

637

5.10 Boom nose - telescopic boom

653

1 General

653

2 Assembly

653

3 Disassembly

659

5.12 Auxiliary boom

663

1 General

663

2 Assembling the auxiliary boom

665

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Contents

3 Setting up

679

4 Dismantling the auxiliary boom

681

5.25 Telescopic boom extension 1 General

691

2 Assembly

693

3 Making electrical/hydraulic connections

695

4 Setting up

695

5 Disassembly

697

5.27 Erection and take-down charts

701

1 General

701

2 Set-up and take-down chart for T operation

701

3 Set-up and take-down chart for TK/TNZK operation

701

4 Set-up and take-down chart for TVK/TVNZK operation

702

6.00 Additional equipment

705

6.01 Heater / engine pre-heating

705

1 Heating the driver's cab

705

2 Heating the crane operator's cab

721

6.02 Emergency control

733

1 General

733

2 Failure of an inductive sensor

735

3 Emergency operation Telescoping with key switch -S81

737

4 LICCON-System-Bus 2 (LSB 2) defective

743

5 Tele status tipped

745

6 Electrical connection of the cable drum -N1 interrupted

747

7 Electrical connection of the cable drum -N2 interrupted

747

8 Length sensor defective

749

9 Angle sensor defective

749

10 Telescoping lock defective

751

11 Emergency operation Telescoping with ball valves

753

12 Emergency operation in the event of a failure of the LICCON computer system

759

13 Emergency operation of support

767

6.04 Sliding beam monitoring 1 General

10

691

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Contents

2 Support bases

771

3 Working with sliding beam monitoring

773

6.05 Emergency take-down

779

1 Emergency operation

779

7.00 Maintenance and service

787

7.01 Maintenance and service, general 1 General

787 787

7.02 Maintenance intervals - crane chassis 1 Crane chassis maintenance and inspection plan 7.03 Maintenance intervals - crane superstructure 1 Maintenance and inspection plan for crane superstructure 7.04 Maintenance guidelines - crane chassis

791 791 799 799 807

1 Drive motor

807

2 Automated shift transmission

813

3 Transfer gearbox

817

4 Hydraulic system

819

5 Compressed air and brake system air dryer

829

6 Tires / wheels

829

7 Axles

833

8 Axle alignment

835

9 Tilting the cab

837

10 Electrical system - lighting

837

7.05 Maintenance guidelines - crane superstructure

841

1 Crane engine

841

2 Hydraulic system

845

3 Central lubrication system

853

4 Slewing ring connection

858

5 Winches

861

6 Air dryer of the compressed air system of the crane's superstructure

865

7 Slewing gear transmission

867

8 Counterweight plates

869

9 Electrical system - lighting

869

10 Telescopic boom

871

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Contents

7.06 Lubrication chart, filling levels 1 Crane chassis

873

2 Crane superstructure

875

7.07 Lubrication chart

877

1 Schmierstofftabelle

8.00 Crane inspections

877

887

8.01 Periodic crane inspections

887

1 General

887

2 Steel bearing structures inspection

888

3 Inspecting the hoist and luffing winches

905

4 Inspection of the load hooks

915

5 Inspection of the rope feed mechanics in the telescopic boom

915

6 Testing the operation of the inner and outer interlocking systems of the telescopic boom

915

7 Testing the interlocking systems on the jib stops

915

8 Testing the nitrogen storage tank

916

9 Inspecting the cable pulleys

916

10 Testing overload protection operation

916

11 Testing the roller slewing ring

916

12 Inspecting the mounting of the load bearing equipment

916

13 Inspecting the oil and fuel reservoirs

917

14 Inspection of the auxiliary reeving winch, towing winch and spare wheel winch

917

15 Appendix

918

8.04 Inspection of crane wire ropes

12

873

929

1 Introduction

929

2 Wire rope

929

3 Operating behaviour of steel ropes

934

4 Condition of equipment that is functionally associated with the rope

934

5 Rope checking log

934

6 Rope storage and marking

934

7 Wire ropes and rope end connections

934

8 Twisting caused by stretching in non-twisting ropes and remedying thereof

937

9 Appendix 1

939

10 Appendix 2

939

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Contents

11 Appendix 3

943

12 Appendix 4

943

8.07 Inspection of air brake system (drum brakes)

947

1 General

947

2 Visual inspection

947

3 Operation and performance test

947

4 Internal inspection of the wheel brakes

948

9.00 General notes

951

9.01 Bulletin - overload protection for boom cranes

951

9.02 Bulletin - fire prevention in the engine compartment and important service work

957

1 Inspection procedures

957

2 Exercise care when conducting maintenance and repairs

957

3 Important servicing

957

4 Maintenance notes for replacement parts

958

5 Recommendations for travel operation

958

6 Disposal

958

7 Wheel changes

958

8 Tire changes

958

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1.00 Description of crane

LIEBHERR

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026148-00

1.01 Terminology

B197830

16

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1.01

1.01 Terminology

026148-00

1 Crane components 1.1

Crane chassis 1 5-axle chassis 2 Tires 3 Drive motor 4 Driver cab 5 Sliding beams 6 Support pads

1.2

Crane superstructure 10 Crane engine 11 Crane cab 12 Counterweight 13 Luffing cylinders 14 Winch 1 15 Winch 2* 16 Hoist rope 17 Hook block

1.3

• with support cylinders

• with telescopic boom adjustment

Telescopic boom (T) 20 Articulated piece 21 Telescopic section 1 22 Telescopic section 2 23 Telescopic section 3 24 Telescopic section 4 25 Telescopic section 5

1.01

LIEBHERR

17

026148-00

1.01 Terminology

B197829

18

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1.01

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL