Liebherr Crawler Crane HS 885 HD Operating Manual SN 187612 – PDF DOWNLOAD

Operating manual

EN

Type:

HS 885 HD Serial number:

187 612

ORIGINAL

001 - 30.06.2015 / lwnscj0

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187 612

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

SAFETY INSTRUCTIONS ..................................3

CHAPTER SUMMARY

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

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

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

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

HS 885 HD TT V019 (js) LWN - TD24/6/2015

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

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

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

187 612

187 612

INDEX

INDEX 1.

INTRODUCTION 1.1

Foreword

1-1

1.2

Handling of documentation

1-2

HS 885 HD TT V019 (js) LWN - TD24/6/2015

1.2.1

How are the Operating instructions set up?

1-3

1.2.2

System requirements of the computer for use of CD-ROMs

1-3

1.2.3

Storage of documentation

1-3

1.2.4

Current status of documentation

1-4

1.2.5

Display conventions

1-5

1.2.6

Symbols

1-6

1.3

Legal notice

1-8

1.4

Conversion tables

1-9

1.4.1

Length

1-9

1.4.2

Surface area

1-9

1.4.3

Weight (Mass)

1 - 10

1.4.4

Volume

1 - 10

1.4.5

Pressure

1 - 10

1.4.6

Temperature

1 - 11

1.4.7

Speed

1 - 11

1.4.8

Force

1 - 11

1.4.9

Torque

1 - 11

1.4.10

Performance

1 - 12

Declaration of conformity

1 - 13

PRODUCT DESCRIPTION

2-1

1.5

2.

1-1

2.1

General

2-1

2.2

Intended use

2-2

2.2.1

State-of-the-art technology

2-3

2.2.2

Machine classification

2-3

2.2.3

Appropriate use

2-5

2.2.4

Inappropriate use

2-7

2.3

Machine overview

2-9

2.4

Boom

2 - 10

2.4.1

Information on boom designations

2 - 10

2.4.2

Main boom

2 - 11

2.5

Superstructure

2 - 28

2.6

Central power unit (MAN)

2 - 30

2.7

Central power unit (LIEBHERR)

2 - 32

2.8

Undercarriage

2 - 34

2.9

Undercarriage

2 - 36

2.10

Ballast

2 - 38

2.10.1

2 - 38

Rear counterweight

0-5 187 612

INDEX 2.11

2.12

3.

Technical data

2 - 39

2.11.1

2 - 41

Dimensions and weights

2 - 48

Technical data US 2.12.1

Dimensions and weights

2 - 48

2.12.2

Conditions of use (MAN)

2 - 55

2.12.3

Emissions

2 - 56

2.12.4

Engine (MAN)

2 - 56

2.12.5

Conditions of use (LIEBHERR)

2 - 57

2.12.6

Emissions

2 - 57

2.12.7

Engine (LIEBHERR)

2 - 58

2.12.8

Hydraulic system

2 - 59

2.12.9

Winches

2 - 60

2.12.10

Swing

2 - 61

2.12.11

Crawlers

2 - 61

2.12.12

Control

2 - 62

SAFETY INSTRUCTIONS

3-1

3.1

Technical condition of the machine

3-1

3.2

Areas of responsibility

3-2

3.3

3.2.1

Manufacturer

3-2

3.2.2

Owner

3-2

3.2.3

Machine operator

3-2

3.2.4

Rigger

3-2

3.2.5

Signalman

3-3

3.2.6

Maintenance personnel

3-3 3-4

Requirements of personnel 3.3.1

Machine operator

3-4

3.3.2

Rigger

3-4

3.3.3

Signalman

3-4

3.3.4

Maintenance personnel

3-5

3.4

Personal protective gear

3-6

3.5

Work area

3-7

3.5.1 3.6

3-8

Danger zone

3-9

Safety and monitoring devices 3.6.1

Safety devices

3-9

3.6.2

Monitoring devices

3 - 11

3.7

Safety signs on the machine

3 - 13

3.8

Safety signs on the machine (US market)

3 - 16

3.9

Meaning of the safety signs

3 - 19

3.9.1

Prohibition signs

3 - 19

3.9.2

Warning signs

3 - 19

3.9.3

Fire protection signs

3 - 21

3.9.4

Mandatory signs

3 - 21

3.10

Meaning of the machine-specific safety signs

3 - 23

3.11

Hazards

3 - 25

0-6 187 612

INDEX

3.12

3 - 25

3.11.2

Electrical energy

3 - 26

3.11.3

Hydraulic energy

3 - 27

3.11.4

Burns

3 - 28

3.11.5

Chemical burns

3 - 29

3.11.6

Fire and explosion

3 - 30

3.11.7

Poisoning and suffocation

3 - 31

3.11.8

Electromagnetic influence

3 - 32

3.11.9

Exposure to wind

3 - 33

3.11.10

Snow and ice loads

3 - 37

3.11.11

Ground bearing strength

3 - 37

3.11.12

Lightning strikes

3 - 38

3.11.13

Overhead power lines

3 - 39

3.11.14

Excavation work

3 - 42

3.11.15

Environment

3 - 44 3 - 45

What to do in dangerous situations 3.12.1

How to respond in the event of a current transfer

3 - 45

3.12.2

Procedure in the event of fire

3 - 47

3.12.3

Firefighting

3 - 47

Working at heights

3 - 51

3.14

Application on floating devices

3 - 53

3.16

HS 885 HD TT V019 (js) LWN - TD24/6/2015

Mechanical action

3.13

3.15

4.

3.11.1

3.14.1

Operation of the machine on floating devices

3 - 54

3.14.2

Transport of the machine on floating devices

3 - 55

3.14.3

Higher risk of machine corrosion on floating devices

3 - 55 3 - 56

Use at low temperatures 3.15.1

Operation of the machine down to -20 °C (-4 °F) (standard)

3 - 57

3.15.2

Operation of the machine down to -25 °C (-13 °F)*

3 - 57

3.15.3

Operation of the machine down to -40 °C (-40 °F)*

3 - 57 3 - 58

Hand signals 3.16.1

General hand signals in accordance with BGV A8

3 - 59

3.16.2

Special hand signals for attachment operations

3 - 61

3.16.3

Hand signals for lifting operations in accordance with ASME/ANSI B30.5

3 - 64

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

Operator's cab

4-4

4.4.1

Operator's cab overview

4-4

4.4.2

Control stand overview

4-6

4.4.3

Overview of control stand from above

4-8

4.5

4 - 11

Overview of the LCD screen 4.5.1

Main areas of the screen

4 - 11

4.5.2

Description of the main areas of the screen

4 - 11

4.5.3

Sequence of mode screens

4 - 13

0-7 187 612

INDEX 4.6

Left-hand control panel (X12)

4 - 15

4.7

Left-hand control panel (X11)

4 - 17

4.8

Litronic service panel on the LCD screen

4 - 19

4.8.1

Menu bar

4 - 19

4.8.2

Keyboard menu

4 - 20

4.9

Right-hand control panel (X23)

4 - 22

4.10

Right-hand control panel (X23) (optional)

4 - 27

4.11

Emergency shut-down switch

4 - 33

4.10.2

Joysticks, pedals, handwheels

4 - 34

Operating the machine - auxiliary functions

4 - 36

4.11.1

Adjusting the controls

4 - 36

4.11.2

Driver's seat

4 - 37

4.11.3

LCD screen adjustments

4 - 38

4.11.4

Windshield wiper

4 - 38

4.11.5

Interior lighting in the superstructure

4 - 40

4.11.6

Cab lighting

4 - 40

4.11.7

Radio

4 - 40

4.11.8

Hooter

4 - 40

4.11.9

Cigarette lighter

4 - 40

4.11.10

Cab adjustment cylinder *

4 - 41

4.11.11

Cab height adjustment *

4 - 41

4.12

Operator guidance on the display screen

4 - 43

4.13

Start-up screen

4 - 43

4.14

Set-up screens

4 - 44

4.14.1

Set-up screen 1 for main boom

4 - 45

4.14.2

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

4 - 51

4.14.3

Example of a load capacity chart for load moment limitation *

4 - 53

4.15

"Mode screen" page

4 - 55

4.16

"Operating modes" screen

4 - 62

4.17

"Power unit monitoring" screen

4 - 64

4.18

Motor error message

4 - 67

4.19

5.

4.10.1

4.18.1

Serious motor error message

4 - 67

4.18.2

General motor error message

4 - 68 4 - 69

"Fault monitor" screen

OPERATION 5.1

5.3

5-1

General 5.1.1

5.2

5-1

Safe working with the machine

5-1 5-2

Checks before daily operation 5.2.1

Tour of inspection

5-2

5.2.2

Checks

5-2 5-4

Daily start up 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

0-8 187 612

INDEX

5.4

5.5

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 5 - 16

Starting the diesel engine 5.4.1

Prerequisites

5 - 16

5.4.2

Adjusting the engine speed

5 - 18

5.4.3

Lowering the safety lever (access lever)

5 - 19

Machine operation - main functions

5 - 20

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 - 24

5.5.4

Load pick-up equipment

5 - 26

5.5.5

Resetting the load capacity display to zero (taring)

5 - 26

5.6

Operating the hoisting winches

5 - 27

5.7

Lifting mode

5 - 31

5.8

5.9 HS 885 HD TT V019 (js) LWN - TD24/6/2015

5.3.4

5.7.1

Operating the hoisting winches

5 - 31

5.7.2

Lifting loads with the main boom head using runner attachment

5 - 34

5.7.3

Lifting loads with the tip boom (runner)

5 - 35

5.7.4

Lifting loads with the main boom head with fixed fly jib fitted

5 - 36

5.7.5

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

5 - 38

5.7.6

Lifting loads with the main boom head, with tip boom fitted*.

5 - 39

5.7.7

Lifting loads with the main boom head with fixed fly jib fitted

5 - 40

5.7.8

Twin hook operation

5 - 42

5.7.9

Combined two-hook operation with fixed fly jib

5 - 49 5 - 53

Winches overdrive 5.8.1

General

5 - 53

5.8.2

Preselection

5 - 53

5.8.3

Switching conditions

5 - 55

5.8.4

Safety functions

5 - 55

5.8.5

Briefly changing to heavy duty mode

5 - 56

5.8.6

Activating the slewing gear

5 - 57

5.8.7

Slewing gear free-wheel

5 - 60 5 - 62

A-frame position 5.9.1

Travelling with the machine

5 - 64

5.9.2

Travel gear overdrive

5 - 67

5.9.3

Adjust cylinder

5 - 69

5.9.4

Free-fall operation

5 - 71

5.9.5

Working in free-fall operation

5 - 79

5.9.6

Shutting down free-fall operation

5 - 80

5.9.7

Winch standstill monitoring

5 - 80

5.9.8

Lowering control (SWG control unit)

5 - 81

5.9.9

Interlock control

5 - 83

5.9.10

Winch synchronization (optional)

5 - 85

0-9 187 612

INDEX

5.10

5.11

5.12

5.13

6.

5.9.11

Grab control

5 - 86

5.9.12

Ramming control/chisel control

5 - 87

5.9.13

Casing oscillator

5 - 95 5 - 98

Litronic 5.10.1

Properties

5 - 98

5.10.2

General

5 - 98

5.10.3

Starting the Litronic

5 - 99

5.10.4

The menus

5 - 100

5.10.5

Main menu

5 - 100

5.10.6

INPUT/OUTPUT menu

5 - 101

5.10.7

MEMORY menu

5 - 101

5.10.8

SELECT menu

5 - 102

5.10.9

CORRECTION menu

5 - 105

5.10.10

MESSAGES menu

5 - 106

5.10.11

SPECIAL FUNCTIONS menu

5 - 107

Operating the machine - auxiliary functions

5 - 112

5.11.1

Adjusting the driver's seat

5 - 112

5.11.2

LCD screen adjustments

5 - 113

5.11.3

Windshield wiper

5 - 114

5.11.4

Windshield wiper

5 - 115

5.11.5

Lighting

5 - 117

5.11.6

Radio

5 - 118

5.11.7

Hooter

5 - 118

5.11.8

Ashtray

5 - 119

5.11.9

Cigarette lighter and socket in the cab

5 - 119 5 - 120

Shutting down the machine 5.12.1

Laying down the boom

5 - 121

5.12.2

Shutting down the diesel engine

5 - 122

5.12.3

Park position of the ignition starter switch

5 - 122

5.12.4

Checks before leaving the machine

5 - 123 5 - 124

Emergency operation control 5.13.1

Functions of the control desk

5 - 125

5.13.2

Using the emergency operation controller

5 - 126

ASSEMBLY AND DISASSEMBLY

6-1

6.1

General

6-1

6.2

Assembly, dismantling and reconfiguring

6-3

6.3

Operational planning

6-4

6.4

6.3.1

Defining the working range

6-4

6.3.2

Defining the setup

6 - 17

6.3.3

Assembling and preparing the equipment for transport

6 - 17

6.3.4

Required hoisting rope length

6 - 19

Safety precautions for assembly, dismantling and reconfiguring

6 - 21

6.4.1

Requirements for the erecting team

6 - 21

6.4.2

Requirements for the site

6 - 21

0 - 10 187 612

INDEX

6.5

6.4.3

Rules for executing the work

6 - 22

6.4.4

Lifting the crawler carriers and basic machine from the transport vehicle

6 - 23

6.4.5

Adjusting the crawler carriers via cylinders

6 - 24 6 - 25

Unloading the basic machine 6.5.1

Prerequisites

6 - 25

6.5.2

Unloading the basic machine without tilting-back supports on the uppercarriage (overview)

6 - 26

6.5.3

Unloading the basic machine with tilting-back supports on the uppercarriage (overview)

6 - 28

6.5.4

Unloading the basic machine without crawler side frames using the self-loading system (ove

6 - 30

6.5.5

Unloading the basic machine and crawler side frames using an assist crane (overview)

6 - 34

6.5.6

Preparing for assembly mode

6 - 35

6.5.7

Starting assembly mode

6 - 39

6.5.8

Preparing the mounting crane

6 - 42

6.5.9

Erecting the A-frame

6 - 43

6.5.10

Drive the machine off the low-loader

6 - 45

6.5.11

Removing the superstructure locking

6 - 46

6.5.12

Adjust crawler carrier on work track

6 - 47

6.5.13

Unloading the basic machine using the self-loading system

6 - 51

6.5.14

Basic machine used as an erection crane

6 - 60

6.5.15

Secure the components for installation work

6 - 61

6.5.16

Rope reeving diagram

6 - 63

6.5.17

Controlling the tilting-back supports (Figure 58)

6 - 65

6.5.18

Controlling the auxiliary winch

6 - 66

6.5.19

Attaching the crawler carrier

6 - 67

6.5.20

Mounting the crawler carrier under difficult conditions

6 - 82

6.5.21

Retract the support cylinders

6 - 87

6.5.22

Unloading the basic machine and crawler side frame using an assist crane

6 - 91 6 - 93

6.5.23 6.5.24

Turning the telescopic outriggers on the basic machine

6 - 94

6.5.25

Lifting the basic machine from the transport vehicle

6 - 97

6.5.26

Supporting the opposite telescopic outrigger

6 - 97 6 - 98

HS 885 HD TT V019 (js) LWN - TD24/6/2015

6.5.27 6.5.28

Pushing the crawler carrier onto the chord

6 - 99

6.5.29

Supply to the travel gear drive units

6 - 103

6.5.30

Attaching steps and ladders

6 - 104 6 - 104

6.5.31

6.6

6.5.32

Unloading the rear counterweight

6 - 105

6.5.33

Location of the rope pulleys on the rear counterweight

6 - 108

6.5.34

General

6 - 109

6.5.35

Mounting the rear counterweight (Figure 123).

6 - 110 6 - 114

Assembling the main boom 6.6.1

Prerequisites

6 - 114

6.6.2

Overview of assembly stages

6 - 114

0 - 11 187 612

INDEX

6.7

6.6.3

Unloading and positioning the boom head

6 - 115

6.6.4

Assembling the main boom

6 - 115

6.6.5

Assembling the main boom

6 - 116

6.6.6

Attaching the main boom to the pivot piece

6 - 121

6.6.7

Luffing the hoisting rope

6 - 125

6.6.8

Rope reeving plans

6 - 126

6.7.1 6.8

6.9

6.10

6 - 128

Reeve the cable

6 - 130

Connecting the electrics

6 - 133

Hoisting limit switch 6.8.1

Snap hook on hoisting limit switch weight (wedge)

6 - 135

6.8.2

Erecting the main boom

6 - 137

6.8.3

Erecting procedure

6 - 139

6.8.4

Cancelling mounting mode

6 - 140 6 - 141

Dismantling the main boom 6.9.1

Prerequisites

6 - 141

6.9.2

Overview of dismantling stages

6 - 141

6.9.3

Preparations in lifting operation

6 - 142

6.9.4

Select assembly mode

6 - 142

6.9.5

Lay down the main boom

6 - 143

6.9.6

Laying down procedure

6 - 145

6.9.7

Disconnecting the electrics

6 - 146

6.9.8

Pulling out the hoisting ropes

6 - 148

6.9.9

Detaching the main boom from the pivot piece

6 - 149

6.9.10

Dismantling the main boom

6 - 153 6 - 154

Dismantling the basic machine 6.10.1

Prerequisites

6 - 154

6.10.2

Overview of disassembly / uppercarriage with and without tilting-back supports

6 - 155

6.10.3

Overview of disassembly using the self-loading system

6 - 156

6.10.4

Overview of disassembly using the assist crane

6 - 158

6.10.5

Setting down the rear counterweight

6 - 159

6.10.6

Loading the rear counterweight

6 - 162

6.10.7

Adjusting crawler carrier on transport track

6 - 165

6.10.8

Basic machine used as an erection crane

6 - 169

6.10.9

Secure the components for dismantling

6 - 171

6.10.10

Rope reeving plan

6 - 173

6.10.11

Controlling the tilting-back supports (Figure 188)

6 - 175

6.10.12

Controlling the auxiliary winch

6 - 176

6.10.13

Preparing to dismantle the crawler carriers

6 - 177

6.10.14

Supporting the basic machine

6 - 179

6.10.15

Removing the crawler carrier from the undercarriage

6 - 187

6.10.16

Removing the crawler carrier under difficult conditions

6 - 194

6.10.17

Loading the basic machine

6 - 201

6.10.18

Setting down the A-frame

6 - 203

6.10.19

Setting down the A-frame

6 - 205

6.10.20

Attachment points

6 - 207

0 - 12 187 612

INDEX

6.11

7.

6.10.21

Fixing mounting chains on the superstructure and supporting the chords

6 - 207

6.10.22

Loosening the wedges on the telescopic outriggers

6 - 208

6.10.23

Disconnecting the hydraulic supply

6 - 208

6.10.24

Pushing the crawler carrier off the chord

6 - 209

6.10.25

Remove mounting chains from the superstructure

6 - 213

6.10.26

Transporting the basic machine

6 - 215

6.10.27

Turning the telescopic outriggers on the basic machine

6 - 215

6.10.28

Platforms on the superstructure

6 - 218

6.10.29

Remove steps and ladders

6 - 218

6.10.30

Fitting the superstructure locking

6 - 219

6.10.31

Drive the machine onto the low-loader

6 - 221

6.10.32

Setting down the A-frame

6 - 223

6.10.33

Taking the basic machine out of operation

6 - 225

6.11.1

Safety precautions for loading and unloading

6 - 226

6.11.2

Transporting the basic machine with a low-loader

6 - 227

6.11.3

Transporting the basic machine with a low-loader

6 - 229

6.11.4

Transporting attachments

6 - 231

6.11.5

Loading the basic machine with an auxiliary crane

6 - 233

6.11.6

Transporting overseas

6 - 235

MAINTENANCE 7.1

7.2

7.3

7.5

7.6

7.7

7-1

7.1.1

Lubricants

7-2

7.1.2

Welding work

7-2

7.1.3

Cylinder

7-2 7-3

Maintenance chart Work to be carried out

7-3 7 - 19

Diesel engine 7.3.1

7.4

7-1

General

7.2.1

HS 885 HD TT V019 (js) LWN - TD24/6/2015

6 - 226

Transport

Engine; check oil level and oil pressure

7 - 19 7 - 21

Fuel system (MAN engine) 7.4.1

Check the water separator on the fuel prefilter, drain off the condensate if necessary 7 - 22

7.4.2

Draining condensate from the fuel filter

7 - 24

7.4.3

Draining condensate from the fuel tank

7 - 26

7.4.4

Cleaning the fuel prefilter

7 - 28

7.4.5

Replacing the fuel filter

7 - 30

7.4.6

Bleeding the fuel system

7 - 32

Cooling system

7 - 34

7.5.1

7 - 34

Check coolant level, top up if necessary

7 - 35

The dry air filter (MAN / Liebherr) 7.6.1

Arrangement on the central power unit

7 - 35

7.6.2

Emptying the dust collection container

7 - 35 7 - 36

Power divider 7.7.1

General

7 - 36

7.7.2

Checking the gearbox oil level

7 - 36

0 - 13 187 612

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• Thank you very much for reading the preview of the manual.

• 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