Operating manual en

Model:

CBB 350(200)/18(31) LITRONIC

Serial number:

162894

003 - 29.04.2014
 Product ID
Commercial name: Ship's Crane
Type: SK CBB
Model/Version: HD V003

Document ID
ORIGINAL OPERATING MANUAL
Author: LWN / Technical Publication Department
Issued: 2014-04-18

Manufacturer
Liebherr-Werk Nenzing GmbH
P.O. Box 10
6710 Nenzing
Austria

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 Artikelcode/Item Code: 959985114
LOAD DIAGRAMM Ausgabe/Edition: 003

LIEBHERR
CBB 350(250)200/18(25)31
LOAD DIAGRAMM

2-FALL OPERATION
MAIN HOIST
SIGN. WAVE HEIGHT : 0,0[m]

400

350

300

250
SWL [t]

200

150

100

50

0
0 5 10 15 20 25 30 31 35
Radius [m]

2-FALL OPERATION
AUXILARY HOIST
SIGN. WAVE HEIGHT : 0,0[m]

40

35

30

25
SWL [t]

AUXILARY HOIST
20
MAN RIDING

15

10

5
2
0
0 5 10 15 20 25 30 34 35 40
Radius [m]

Dieses Dokument darf ohne unsere Genehmigung weder kopiert, noch vervielfältigt werden.
Item Code: 959985114
This document shall not be copied or transferred to others without our consent. Revision: 003
 Item code 983993214
LIEBHERR - Utility Requirements Edition 3

Crane: CBB 4200

Order: 162703-704 Serie

Unit Req./Unit No. of Unit Total Type

1. Winch(es):
- Main Hoist Winch 44 l 1 44 l Gear Oil
- Luffing Winch 41 l 1 41 l Gear Oil
- Auxiliary Hoist Winch 14,5 l 1 14,5 l Gear Oil

2. Slewing Gear(s): 39 l 3 117 l Gear Oil

3. Grease:
- All sheaves, bearings 1,4 kg 1 1,4 kg Grease
- All other grease lines 1,8 kg 1 1,8 kg Grease
- Slewing ring + greasing lines 37,5 kg 1 37,5 kg Grease
- Spur gear Hoisting Winch 10 kg 1 10 kg Grease

4. Cabin:
- Windscreen washer 5l 1 5l Anti Freeze Mixture

5. Gearbox: 9l 2 18l Gear Oil

6. Hydraulic System:
- Hydraulic tank 600 l 1 600 l Hydraulic Oil
- Hydraulic line system 250 l 1 250 l Hydraulic Oil

7. Electric Power Consumption:

- according to drawing - - - -
983881314 - Power Supply Survey

8. E-Motor:
- according to valid - - - -
983881314 - Power Supply Survey

NOTE: For oil type refer to the attached list "RECOMMENDED OIL TYPES FOR LIEBHERR SHIP- AND OFFSHORE CRANES"
11.06.2007 LWN Bargehr, TB-SK according LIKV workflow
Date Work Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
 Project / Order: 13328-K2/3
CRANE MAIN RECORDS Ausgabe/Edition: 00

type of crane [/] CBB 4200 CBB 350(250)200/18(25)31 - GL (Hook F.E.M.)

crane control [/] LITRONIC
power [kW] 280
power supply [V/Hz] 440/60
valid classification [-] GL (Hook F.E.M.)
SWLmax [t] 350
max. outreach [m] 31
min. outreach [m] 4,64
field of action [grad] 15°- 83°
trim angle / offlead angle [grad] 2(5) / 0
heel angle / sidelead angle [grad] 5 / 0
hoisting factor [/] 1,06
deadload factor [/] 1,02

geometries
L1 total length of crane at jib angle 0°, park position [mm] 38259
B1 total width of crane [mm] 4400
H1 total height of crane [mm] 14003
R1 interference radius slewing column [mm] 3890
D1 outer diameter base column [mm] 0
Rmax main hoist max. working radius at jib angle 15° [mm] 31000
Rmin main hoist min. working radius at jib angle 83° [mm] 4643
DH- negative load way deviation [mm] 0
DH+ positive load way deviation [mm] 12476

ropes
total length of hoisting rope [m] 176,4
hoisting rope diameter [mm] 76
total length of luffing rope [m] 254
luffing rope diameter [mm] 50

speeds
[m/min]
max. hoisting speed without load, last layer 6,0
[m/min]
max. hoisting speed with load, last layer 3,2
min. luffing time, max. to min.workradius with corresponding load [sec] 249
-1
max. slewing speed at even keel [min ] 0,40

Dieses Dokument darf ohne unsere Genehmigung weder kopiert, noch vervielfältigt werden.
This document shall not be copied or transferred to others without our consent.
1/3 ]
 Project / Order: 13328-K2/3
CRANE MAIN RECORDS Ausgabe/Edition: 00

reaction forces and moments

at interface slew bearing to pedestal adapter (tolerances ±4)
MSY actual overturning moment [kNm] -86709
MSZ max. cran torque [kNm] 10456
PSX shearing force [kN] 612
PSY shearing force [kN] 644
PSZ total vertical load [kN] -5732

weights and centers of gravity (tolerances ±4%)

SX-jib center of gravity boom cpl. relate to pivot point X-axis [mm] 16493
SY-jib center of gravity boom cpl. relate to pivot point Y-axis [mm] 15
SZ-jib center of gravity boom cpl. relate to pivot point Z-axis [mm] -427
mjib weight boom cpl. [kg] 72675
SX-SC center of gravity slewing column cpl. X-axis [mm] -34
SY-SC center of gravity slewing column cpl. Y-axis [mm] -20
SZ-SC center of gravity slewing column cpl. Z-axis (slew bearing) [mm] 4320
mSC weight slewing column cpl. [kg] 124656
SX-cpl center of gravity crane cpl. X-axis [mm] 5841
SY-cpl center of gravity crane cpl. Y-axis [mm] 15
SZ-cpl center of gravity crane cpl. Z-axis (slew bearing) [mm] 2632
mcpl weight crane cpl.incl. loose parts [kg] 215906

hoisting heights
hook travel absolut [m] 38,50
Z2 min. hoisting height under slew bearing [m] 22,58
Z3 min. hoisting height above slew bearing at 15° [m] 3,44
Z3' max. hoisting height above slew bearing at appr.83° [m] 26,36
free hoisting winch capacity for hoisting height of [m] 31,50

Dieses Dokument darf ohne unsere Genehmigung weder kopiert, noch vervielfältigt werden.
This document shall not be copied or transferred to others without our consent.
2/3 ]
 Project / Order: 13328-K2/3
CRANE MAIN RECORDS Ausgabe/Edition: 00

Dieses Dokument darf ohne unsere Genehmigung weder kopiert, noch vervielfältigt werden.
This document shall not be copied or transferred to others without our consent.
3/3 ]
 Foreword

The name Liebherr doesn't just stand for products and services. It has become a
byword for ideas and innovations. For progress which has proved its worth in the
marketplace.
We constantly strive to extend and improve our diverse range of products and
services. This requires ongoing cooperation and sharing of experience with our
customers and business partners throughout the world. We are therefore grateful
for any ideas and suggestions for improvements.
Inform Liebherr customer service if the machine is sold or bought by a previous
owner.
Please contact:
Liebherr-Werk Nenzing GmbH
Postfach 10
Dr. Hans Liebherr Strasse 1
6710 Nenzing
Austria / Europe
Tel: +43 50809 41-0
Fax: +43 50809 41-500
E-mail: info.lwn@liebherr.com
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Foreword

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 Notes regarding the documentation

Handling the documentation

The provided documentation enables you to:
– safely operate the machine,
– use it for all admissible application situations,
– service it at regular intervals.
The prerequisite for this is that you know how to use this multi-part documentation.
The documentation consists of:
Operating manual
This includes information about commissioning, operating and servicing.

Technical information
Contains information about the electric and hydraulic installations of the machine.

Spare parts catalogue

Contains information about purchasing spare parts.

The complete documentation is saved on the CD-ROMs. The displayed symbols

provide information about the content of the CD-ROM.

Minimum requirements for using the CD-ROMs

Hardware:
– Intel® Pentium II® 500 MHz
– 128 MB RAM working memory
– CD-ROM drive
– Resolution 800 x 600 pixels, high-colour depth
Software:
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– Windows 2000, XP
– Internet Explorer 5.5
– Acrobat Reader 7.0
Pop-up blockers may not be activated when working with Liebherr parts. Please
note that the pop-up blocker function may be contained in certain web browsers as
well as in personal firewalls (software firewalls). The pup-up blocker function can
usually be turned off via the options in the respective programme.

Latest version of the documentation

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Notes regarding the documentation

The provided documentation was compiled exclusively for the stated serial number
and cannot be applied to other machines of the same series.
To ensure the documentation is always complete and up to date:
– Do not remove individual documents.
– Replace any missing or unreadable pages by reprinting them from the CD-ROM
or request them from Liebherr after sales service.
– Insert immediately new documents supplied as a result of modifications.
– Replace amended documents and destroy the old version (particularly in the
case of load charts).
– Always replace the CD-ROM by a new version, e.g. from revision documents.
– Update all languages to the latest version in the case of multilingual documen-
tation.

Storage of documentation
Always keep the operation manual at hand in the cabin.
The currently required load chart must be kept in the cabin.
The spare parts catalogue and the technical information must be available to
maintenance personnel when required.

Layout of the operating manual

The operating manual consists of individual, consecutively numbered chapters.
The table of contents provides information about the content and structure of the
individual chapters.
The documentation is supplied in paper form in a ring binder and on CD-ROM in
the shape of electronic data.

Illustration conventions

Numerical values and units

The machine is constructed in accordance with the metric system. The numerical
values used in the imperial system were converted and rounded.

Symbols

Symbol Meaning
* Optional equipment (retrofit kit)

Requirement must be met

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Performing an action

Consequence of an action

Symbols

Symbols in illustrations

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 Notes regarding the documentation

Symbol Meaning

Actions

Mandatory sequence of several

actions in an illustration
Arbitrary sequence of several
actions in an illustration

Consequences of actions

Consequences of actions with

mandatory sequence
Consequences of actions with arbi-
trary sequence

Exact enlargement of a section

Enlargement of a section or compo-

nent in the same perspective as in
the illustration

Enlargement of a section or compo-

nent in a different perspective than in
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the illustration

Symbols in illustrations

Marking of warning notices

All warning notices in the operating manual comply with standards in acc. with
ANSI Z535.6.

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Notes regarding the documentation

Name Description
1 Warning sign Warns of possible risks of injury
2 Signal word For further information see: Signal words
3 Causes and conse- Explanation of the danger (contexts, conse-
quences of the danger quences of non-observance and possible further
information required for understanding)
4 Measures Measures to prevent the danger

Designation of the warning notices

Signal words

DANGER
Marks an imminently dangerous situation which will result in death or severe bodily
harm if not prevented.
u Refers to the current action to be taken to reduce or prevent the danger(s).

WARNING
Marks a dangerous situation which may result in death or severe bodily harm if not
prevented.
u Refers to the current action to be taken to reduce or prevent the danger(s).

CAUTION
Marks a dangerous situation which may result in slight or somewhat serious bodily
harm if not prevented.
u Refers to the current action to be taken to reduce or prevent the danger(s).
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NOTICE
Marks a dangerous situation that may result in damage to assets if not prevented.
u Refers to the current action to be taken to reduce or prevent the danger(s).

Further markings/indications

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 Notes regarding the documentation

Note
Indicates useful pointers and tips.
u Refers to the current action and shows an easier way to perform activities.

Publisher's imprint
Version
In the interest of our customers, we reserve the right to make changes in line with
technical developments. This documentation therefore corresponds to the technical
situation at the time of delivery of the machine, and not to the current state of
development at the manufacturer.
Copyright notice
Litronic is a registered trademark of Liebherr.
The documentation is protected by copyright. The copying and duplication of load
charts in connection with the operational planning and use of the machine is
expressly permitted. Otherwise, the documentation may not be duplicated, repro-
duced, microfilmed, translated or converted for storage and processing in computer
systems, either wholly or partially, without the written consent of Liebherr-Werk
Nenzing GmbH.
© Copyright by
Liebherr-Werk Nenzing GmbH
6710 Nenzing / Austria
All rights reserved.
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 Contents

1 Product description 23
1.1 Type plate 23
1.2 Appropriate use 25
1.3 Inappropriate use 27
1.4 Load charts 29
1.5 Whole machine 30
1.5.1 Whole machine overview 30
1.5.2 Technical data 30
1.5.3 Safety devices 31
1.6 Slewing column 32
1.6.1 Slewing column overview 32
1.6.2 Machinery room 34
1.6.3 Aggregate 35
1.6.4 Cabin 36
1.7 Boom 37
1.8 Hand pump for emergency operation 38
1.8.1 Hand pump without tank* 38
1.8.2 Hand pump with tank* 39
1.9 Central lubrication system* 40

2 Safety instructions 43
2.1 Technical condition of the machine 43
2.2 Areas of responsibility 43
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2.2.1 Manufacturer 43
2.2.2 Owner 43
2.2.3 Machine operator 44
2.2.4 Rigger 44
2.2.5 Banksman 44
2.2.6 Maintenance and service personnel 44

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2.3 Requirements to personnel 45

2.3.1 Machine operator 45
2.3.2 Rigger 45
2.3.3 Banksman 46
2.3.4 Maintenance personnel 46
2.4 Personal protective equipment 46
2.5 Work area 47
2.6 Danger zone 47
2.7 Meaning of the safety signs 48
2.7.1 Prohibition signs 48
2.7.2 Warning signs 49
2.7.3 Fire protection signs 51
2.7.4 Mandatory signs 52
2.8 Hazards 53
2.8.1 Mechanical action 53
2.8.2 Electrical energy 54
2.8.3 Hydraulic energy 54
2.8.4 Burns 55
2.8.5 Chemical burns 56
2.8.6 Fire and explosion 57
2.8.7 Poisoning and suffocation 58
2.8.8 Electromagnetic influence 59
2.8.9 Exposure to wind 59
2.8.10 Snow and ice loads 61
2.8.11 Lightning strike 61
2.8.12 Environment 62
2.9 What to do in dangerous situations 63
2.9.1 How to respond in the event of a current transfer 63
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2.9.2 How to respond in the event of a fire 63

2.9.3 Firefighting 64
2.10 Working at heights 66
2.11 Regulations for tandem lifting mode 66
2.11.1 Main factors when planning the tandem lifting operation 67
2.12 Hand signals 68
2.12.1 General hand signals in accordance with BGV A8 68

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2.12.2 Special hand signals for attachment operations 71

2.12.3 Hand signals for lifting operations in accordance with ASME/ANSI
B30.5 74

3 Control and operating elements 81

3.1 Control stand 82
3.2 Left control lever 83
3.2.1 Function assignment of left control lever buttons 83
3.2.2 Function assignment of left control lever movement directions 84
3.3 Right control lever 85
3.3.1 Function assignment buttons of right control lever 85
3.3.2 Function assignment movement directions of right control lever 86
3.4 Explanation of symbols used 87
3.5 Control panel X20 88
3.6 Control panel X23 91
3.7 Control panel X24 93
3.8 Control panel spreader operation* 95
3.9 Air conditioning* 98
3.10 Monitor 100
3.11 PA amplifier* 109
3.12 Switch cabinet X1 111
3.13 Central lubrication system* 113

4 Operation 117
4.1 Steps 117
4.1.1 Entering the cabin 117
4.2 Checks before start up 119
4.2.1 Walk round 119
4.2.2 Checking the position of the hydraulic oil tank* gate valve 120
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4.3 Start-up 122

4.3.1 Activating main power supply 122
4.3.2 Turning on the ignition 122
4.3.3 Starting the e-motor 122
4.3.4 Moving the boom out of parked position 123
4.4 Lighting 124
4.4.1 Turning on the floodlight* 124

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4.4.2 Turning on the cabin lighting 125

4.4.3 Turning on the crane lighting 125
4.4.4 Turning on the obstacle light* 125
4.5 Air conditioning* 126
4.5.1 Operating the air conditioning 126
4.6 Windscreen wipers 127
4.6.1 Turning on the windscreen wipers 127
4.6.2 Operating the windscreen wiper system 127
4.7 Central lubrication system* 129
4.7.1 Setting the lubrication time 129
4.7.2 Setting the pause time 129
4.7.3 Interim lubrication 129
4.8 Additional cab equipment 130
4.8.1 Operating the signal horn 130
4.9 Swing 131
4.9.1 Slewing gear operation 131
4.10 Hoisting gear 133
4.10.1 Operating hoisting gear 133
4.11 Luffing gear 135
4.11.1 Luffing gear operation 136
4.12 Hook operation 138
4.12.1 Mounting the hook 138
4.12.2 Selecting hook mode 138
4.12.3 Operating the hook 139
4.13 Motor grab mode* 141
4.13.1 Installing the motor grab 141
4.13.2 Selecting motor grab mode 143
4.13.3 Operating the motor grab 143
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4.13.4 Deinstalling the motor grab 145

4.14 Rotator* 146
4.14.1 Installing the rotator 146
4.14.2 Operating the rotator 148
4.15 Spreader operation* 150
4.15.1 Installing the spreader 151
4.15.2 Activating spreader mode 153

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4.15.3 Adjusting the spreader to the container 153

4.15.4 Balancing the spreader 153
4.15.5 Moving containers 154
4.15.6 Deinstalling the spreader 155
4.16 Diagonal pull display* (VLF) 157
4.16.1 Operating the vertical line finder 157
4.17 Mode Sycratronic* 164
4.17.1 Selecting Sycratronic mode 165
4.17.2 Operating machines 166
4.17.3 Overload 169
4.17.4 Deselecting Sycratronic mode 171
4.17.5 Operating Sycratronic emergency lowering system 172
4.18 Dynamic anti-collision system (DACS)* 174
4.18.1 Operating the dynamic anti-collision system 174
4.18.2 Bypassing the dynamic anti-collision system 175
4.19 Data recorder* 176
4.19.1 Taring the load 176
4.19.2 Setting the trigger point 176
4.19.3 Recording a load cycle 177
4.19.4 Saving data 178
4.19.5 Data structure of the flash card 178
4.19.6 Exchanging data 179
4.20 Rope measuring system 181
4.20.1 Initialise rope measuring system 181
4.21 Special lift mode* 182
4.21.1 Selecting special lift mode 182
4.21.2 Deselecting special lift mode 182
4.22 Emergency descent rescue equipment 183
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4.22.1 Using the emergency descent rescue equipment 183

4.23 Emergency stop 187
4.23.1 Operation emergency stop 187
4.24 Shutdown 188
4.24.1 Short interruption of work 188
4.24.2 Long interruption of work 188
4.24.3 Very long interruption of work 190

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4.25 Emergency mode 192

4.25.1 Emergency mode in case of failure of a power pack 193
4.25.2 Lowering the load 194
4.25.3 Slewing the slewing column 195
4.25.4 Lowering the boom 195

5 Operational faults, diagnosis 199

5.1 Litronic® testing system 199
5.1.1 Litronic testing system overview 199
5.1.2 Screen pages 200

6 Maintenance 211
6.1 Maintenance and inspection schedule 211
6.2 Lubricants and consumables 220
6.2.1 Lubrication diagram 221
6.2.2 Oil filling schedule 222
6.2.3 Filling capacities table 222
6.2.4 Lubrication chart 223
6.2.5 Diesel engine lubricating oil 226
6.2.6 Fuel 228
6.2.7 Diesel engine coolant 229
6.2.8 Hydraulic oil 231
6.2.9 Preservation medium (anti-corrosion coating) 232
6.2.10 Liebherr oil diagnosis system 234
6.3 Implementation instructions for the maintenance 237
6.4 Electric motor 238
6.4.1 Greasing the ball bearings 239
6.5 Distributor gearbox 240
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6.5.1 Checking the gearbox oil level 241

6.5.2 Topping up the gearbox oil 241
6.5.3 Draining the gearbox oil 242
6.6 Swing 243
6.6.1 Checking the gearbox oil level 243
6.6.2 Topping up the gear oil 244
6.7 Swing connection 245

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6.7.1 Greasing the toothing 245

6.7.2 Checking the bearing lubrication 245
6.7.3 Measure slewing ring tilt clearance 246
6.8 Main hoisting winch 249
6.8.1 Checking the gearbox oil level 249
6.8.2 Topping up the gearbox oil 250
6.8.3 Draining the gearbox oil 251
6.8.4 Checking the rope kicker* 252
6.9 Rope reeving winch 253
6.9.1 Checking the gearbox oil level 253
6.9.2 Topping up the gear oil 254
6.9.3 Draining the gearbox oil 255
6.10 Hydraulic system 256
6.10.1 Check hydraulic system for leaks and state of hoses, fittings, valves,
blocks, motors, pumps, and cylinders. 256
6.11 Hydraulic oil tank 257
6.11.1 Checking the hydraulic oil level 257
6.11.2 Carrying out a hydraulic oil analysis 258
6.11.3 Topping up with hydraulic oil 258
6.11.4 Draining the hydraulic oil 259
6.11.5 Cleaning the magnetic rod in the return filter 260
6.12 Tank filling unit* 264
6.12.1 Tanking hydraulic oil 265
6.13 Hydraulic filter 266
6.13.1 Changing the pressure filter 266
6.14 Accumulator 268
6.14.1 Checking the accumulator 268
6.14.2 Changing the accumulator 269
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6.15 Hydraulic cylinders 270

6.15.1 Check that the hydraulic cylinder fits properly and does not leak 270
6.15.2 Protecting the piston rods of the hydraulic cylinders from corrosion 270
6.15.3 Preserving the piston rods of the hydraulic cylinders in case of longer
periods of non-use 270
6.16 Hydraulic hoses 271
6.16.1 Checking hydraulic hoses and hose lines 271
6.17 Electrical system 272

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6.17.1 Replacing fuses and lamps 272

6.17.2 Cleaning the slip ring unit 272
6.17.3 Replacing filter mats 272
6.17.4 Check screw and clamp connections 273
6.18 Limit switch 274
6.18.1 Checking hoist and luffing gear limit switch for function 274
6.19 Emergency stop 275
6.19.1 Checking the emergency stop 275
6.20 Fire extinguishers 276
6.20.1 Checking the proper seals and inspection dates on the fire
extinguishers 276
6.21 Personal protective equipment 277
6.21.1 Checking personal protective gear 277
6.22 Emergency descent rescue equipment 278
6.22.1 Checking the emergency descent rescue equipment 278
6.23 Lubrication system* 279
6.23.1 Checking the function of the central lubrication 279
6.23.2 Checking the fill level of the lubrication pumps 279
6.23.3 Checking the time intervals of the lubrication pumps 280
6.23.4 Checking the lubrication points 281
6.24 Ropes 282
6.24.1 Check ropes for wear, tight fit and lubrication 283
6.24.2 Selecting ropes 292
6.24.3 Storing ropes 292
6.24.4 Transporting ropes 292
6.24.5 Winding ropes 293
6.24.6 Luffing ropes 295
6.24.7 Retract ropes 296
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6.24.8 Lubricate ropes 297

6.25 rope drive 298
6.25.1 Checking the rope drive 298
6.26 Rope pulleys 300
6.26.1 Rope tensioning pulleys of the winch drums 300
6.26.2 Check pulleys for ease of movement 300
6.26.3 Checking steel pulleys for wear 300

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6.26.4 Checking plastic pulleys for wear 301

6.26.5 Checking pulleys for damage 302
6.26.6 Lubricating the pulley bearings 303
6.26.7 Checking the bearing for proper seating and position 303
6.26.8 Cleaning plastic pulleys 303
6.27 Cab 305
6.27.1 Check the windows of the cab for damage 305
6.27.2 Checking that the cab door and the door lock work properly 305
6.27.3 Changing the windscreen wipers 305
6.27.4 Filling the windscreen cleaning system 306
6.28 Operator's seat 308
6.28.1 Check function of operator's seat 308
6.29 Air conditioning* 309
6.29.1 Checking air conditioning 309
6.30 Machine care 310
6.30.1 Cleaning the machine 310
6.30.2 Cleaning the hydraulic, water and air coolers 311
6.30.3 Preserving the machine 311
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 Product description 1

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1 Product description

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 1 Product description

The chapter Product description deals with the following issues:

– Application options of the machine
– Wrong or improper use of the machine
– Machine components
– Technical data
The illustrations in this operation manual are for general information purposes.
They may be shown as diagrams and do not necessarily correspond to the current
machine setup.

1.1 Type plate

The type plate is attached on the right of the cabin.

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Fig. 1: Type plate

1 CE label
If the machine corresponds to guideline 2006/42/EU, the type plate bears the CE
label 1.
Enter the relevant data in the table below.

Machine data
Type
Serial number

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Product description
Type plate

Machine data
Model year
Date of commissioning (day/month/year)

Tab. 1: Machine data

This information is required e.g. when ordering spare parts.

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 Product description
Appropriate use

1.2 Appropriate use

The supplied equipment determines the possible applications of the machine.

The machine is only designed and constructed for the intended use stated and
described in the operation manual.
The machine may only be operated in admissible setup condition and mode.
Special machine tasks that deviate from the tasks described in the operation
manual must be coordinated with the machine manufacturer beforehand.
Intended use of the machine is a basic requirement of safe operation.
Non-observation of the intended machine use results in grave consequences:
– Life-threatening or fatal injuries
– Severe damage to the machine, assets or contamination of the environment for
which the manufacturer of the machine cannot be held liable.
– Loss of warranty and guarantee claims
– Utilization not described in the operation manual must be authorized in writing
by the manufacturer. Any other use of the machine without written consent of
the manufacturer is deemed inappropriate use.
Appropriate use of the machine is exclusively defined as follows:
– Utilization in working ranges and under the conditions of use listed and
described in the operation manual.
– Use of exchangeable equipment provided or approved by the machine manu-
facturer.
– Lifting and lowering as well as horizontal transport of loads with corresponding
rigging equipment whose mass and center of gravity is known.
– The following applies in addition for a TCC (Travelling Cargo Crane):
• Moving the machine without load with rigging equipment in accordance with
the applicable load chart and supervision by a signalman.
• Moving the machine with lifted load in accordance with the applicable load
chart and supervision by a signalman.
• A signalman must observe travelling of the machine within the admissible
travelling range with suspended and admissible load and in admissible posi-
tion of the uppercarriage and the boom.
• Use of the machine as a tractor within the admissible limit values (e.g.
hopper).
Appropriate use the machine observing the following specifications and require-
ments:
– Complete safety equipment is installed and functioning properly.
– All maintenance and repair work stated in the maintenance and inspection plan
of the operation manual was performed according to specifications by qualified
maintenance personnel or authorized qualified personnel.
– All safety instructions in this operation manual are being observed.
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– All valid national and international safety regulations (e.g. oil or gas industry)
are observed by the operator, if applicable.
– The operating materials listed in the operation manual are being used.
– All persons involved meet the requirements on staff according to the operation
manual.
– All persons involved meet their responsibilities according to the operation
manual.
– The technical information values are being observed.
– Load charts are being observed.
– The machine is operated exclusively with the rigging equipment approved by
the manufacturer under consideration of the corresponding mode and load

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Product description
Appropriate use

curve and observation of the operation manual, warning and safety equipment
and the valid load chart.
– The "ISO 12480-1 Cranes-Safe use - Part 1: General" is observed with respect
to lifting gear.
– Instructions on intended and inappropriate use of the exchangeable equipment
are being observed.
– The following applies in addition for a SK (Ship Crane):
• Operation of the machine with solidly lashed or anchored floating construc-
tions (e.g. ship, pontoon) on which the machine stands or is installed.
– The following applies in addition for a FTS (Floating Transshipment):
• Operational restrictions are being observed.
– The following applies in addition for a FCC (Fixed Cargo Crane):
• Operation of the machine with solidly lashed or anchored floating construc-
tions (e.g. ship, pontoon) on which the machine stands or is installed.

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 Product description
Inappropriate use

1.3 Inappropriate use

Use contrary to purpose corresponds to reasonably predictable wrong use in line

with machine directive 2006/42/EG.
Use of the machine is deemed not according to purpose under the following condi-
tions:
– Any structural modification of the machine and equipment that affects opera-
tional safety and that has been carried out without the written declaration of
approval of the manufacturer.
– Installation of spare parts and use of media or exchangeable equipment not
approved and authorized by the manufacturer.
– Operation of the machine outside of the limit values approved by the manufac-
turer, like e.g. ambient temperature range, load chart (load/radius), wind speed,
operating restrictions, wave height and diagonal pull.
– Start-up or operation of the machine without knowledge of the operation manual
and/or without qualification of the machine operator demanded by national regu-
lations.
– Start-up or operation of the machine if operation is not admissible according to
the specifications of the machine's location due to explosion hazard indicated
on the machine's type plate.
– Machine operator does not possess the necessary skills to comprehend the
operation manual.
– Start-up or operation of the machine by persons not authorized by the operator.
– Any kind of work with the machine that endangers operational safety.
– Start-up or operation of the machine without approval test or recurring inspec-
tion if this is prescribed by national or international directives and standards.
– Start-up or operation of the machine without properly installed or not properly
functioning safety installations and safety equipment.
– Performance of repairs not authorized by the manufacturer.
– Bypass or change of the required safety installations set in the factory.
– Transport of persons along with the load or with rigging equipment not intended
for this purpose.
– Operation of the machine in an unapproved mode.
– Operation of the machine with open cabin door.
– Pulling or dragging a load on the ground.
– Breakaway of stuck loads under slack rope or with other components besides
the hoisting gear intended for this purpose.
– Breakaway of stuck tools, rigging equipment or equipment parts (e.g. drilling
equipment, piling equipment or grab).
– Start-up of the machine if other persons apart from the machine operator are
located outside of the cabin or on the machine.
– Start-up or operation of the machine with incomplete operation manual (e.g.
missing or illegible pages).
– Start-up or operation of the machine of the operation manual is not available in
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the contractually agreed language.

– Lifting of loads attached to several load lifting devices without consideration of
ISO 12480-1.
– Lifting of persons with the exception of machines with valid EC-type examina-
tion certificate and the corresponding machine configuration or approval by
national authorities.
– Lifting of persons other than in lifting persons mode.
– Lifting of persons for entertainment purposes, for example shows, “bungee
jumping”, “suspended restaurants” or lifting of other devices on or beneath
which persons are located.

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Inappropriate use

– Use of the machine in special modes not listed in the operation manual, not
approved by the manufacturer and without the corresponding adaptations on
the machine.
– Increasing the mass of already lifted loads.
– Operation of the machine not in conformity with the current machine configura-
tion (e.g. counterweights, boom components, reeving) with the programed
setup.
– Lifting loads on the ground with other components/kinematics than the hoisting
gear intended for this purpose.
– Initial start-up of machine.
– Operation of the machine without active fire alarm system and fire extinguishing
system (if available).
– Alteration of the machine configuration (e.g. boom, counterweight) without the
presence of a Liebherr service technician.
– Lifting of loads in manriding mode with the exception of a workman basket with
the admissible number of persons.
– Operation of the machine above the specified crane group without reduction of
the loads.
– Assembly work or disassembly work that exceeds the extent of the mainte-
nance work described in the operation manual.
– The following applies in addition for a SK (Ship Crane):
• Sea travel without observation of the specifications in the operation manual.
• Lifting of loads or persons with the tugger winch (unless the tugger winch is
designed for lifting loads).
• Moving the floating construction (e.g. ship, pontoon, jackup platform) on
which the machine stands or is installed with a load suspended on the
rigging equipment or if the machine is not located in the defined parked posi-
tion.
– The following applies in addition for a FTS (Floating Transshipment):
• Sea travel without observation of the specifications in the operation manual.
• Lifting of loads or persons with the tugger winch (unless the tugger winch is
designed for lifting loads).
– The following applies in addition for a FCC (Fixed Cargo Crane):
• Risky work like lifting hazardous materials, chemical/gases or lifting fused
metals that may release large volumes of thermal energy.
• Moving the floating construction (e.g. ship, pontoon, jackup platform) on
which the machine stands or is installed with a load suspended on the
rigging equipment or if the machine is not located in the defined parked posi-
tion.
– The following applies in addition for a TCC (Travelling Cargo Crane):
• Tilting the machine.
• Moving the machine with reduced visibility and without signalman.
• Operation of the machine on floating structures (e.g. ship, barge under sea
state conditions) without manufacturer's declaration of approval.
• Towing the machine without the presence of a Liebherr service technician.
• Operating the machine on uneven, bumpy tracks that are not attached or
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installed on soft ground not approved for the respective wheel loads.
• Suspension of loads above manned vehicles.
• Risky work like lifting hazardous materials, chemical/gases or lifting fused
metals that may release large volumes of thermal energy.

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 Product description
Load charts

1.4 Load charts

The load charts are located directly behind the cover page of this operating
manual.
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Product description
Whole machine

1.5 Whole machine

1.5.1 Whole machine overview

The diagram below provides an overview of the machine components.

Fig. 2: Whole machine overview

1 Boom 4 Slewing column
2 Rope of luffing winch 5 Base column
3 Cabin

1.5.2 Technical data

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Specifications
The technical specifications are right behind the cover sheet of this operation
manual.

Noise measurement data

Name Value
Guaranteed sound pressure level LPA in the cabin 73.7 dB(A)

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Whole machine

Name Value
Guaranteed sound power level LWA of the machine 102 dB(A)

Tab. 2: Technical data noise measurement data

Vibrations

Name Value
Vibrations affecting the operator's upper limbs < 2.5 m/s2
Vibrations affecting the operator's entire body < 0.5 m/s2

Tab. 3: Technical data for vibrations

The measurement inaccuracy is defined in the standard EN 12096:1997, table D.1

“Inaccuracy K for different measured values a”.

1.5.3 Safety devices

The safety devices include the following components:
– Emergency stop
– Fire extinguisher (poss. provision by customer)
– Acoustic signalling transmitters

Emergency stop

Fig. 3: Emergency stop

An emergency stop is located in the following positions:

– Switch cabinet
– Cabin (inside)
– Ladder
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– Base column (inside)

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Product description
Slewing column

1.6 Slewing column

1.6.1 Slewing column overview

Fig. 4: Slewing column - front view

1 Hoisting winch pulley 5 Slewing bearing
2 Obstacle light 6 Windscreen wipers
3 Maintenance crane* 7 Floodlight (2x)
4 Hatch 8 Signal horn
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 Product description
Slewing column

Fig. 5: Slewing column - rear view

1 Oil cooler cover
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Product description
Slewing column

1.6.2 Machinery room

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Fig. 6: Machinery room

1 Hydraulic oil tank 4 Main hoisting winch
2 E-motor (2x) 5 Luffing winch
3 Slewing gear (3x) 6 Switch cabinet X1

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Slewing column

1.6.3 Aggregate
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Fig. 7: Aggregate
1 Ventilation 7 Coupling
2 Oil level sensor 8 E-motor (2x)
3 Return filter 9 Terminal box for e-motor
4 Inspection hatch 10 Hoisting gear pump (2x)
5 Boom hoist pump (2x) 11 Slewing gear pump (2x)
6 Suction (4x) with gate valve 12 Sight glass for checking oil level

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Product description
Slewing column

1.6.4 Cabin

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Fig. 8: Cabin
1 Emergency descent rescue equip- 7 Screen Load display*
ment
2 Air conditioning system* 8 Litronic screen
3 Left control lever 9 Right control lever
4 Operator's seat 10 Control panel X20
5 Foot pedal Load lifting equipment* 11 Switch unit X20
6 Foot switch Slewing gear free-
wheel*

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 Product description
Boom

1.7 Boom

Fig. 9: Boom
1 Hoisting winch rope 4 Hoisting gear pulley (2x)
2 Pivot point (2x) for slewing column 5 Floodlight (2x)
3 Boom hoist pulley (3x) 6 Hook
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Product description
Hand pump for emergency operation

1.8 Hand pump for emergency operation

The hand pump is located in the slewing column.

1.8.1 Hand pump without tank*

Fig. 10: Hand pump without tank

1 Restrictor valve 4 Intake port
2 Lever 5 Pump cylinder
3 Pressure connection
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Hand pump for emergency operation

1.8.2 Hand pump with tank*

Fig. 11: Hand pump with tank

1 Tank 4 Lever
2 Oil dipstick and oil inlet 5 Pressure gauge
3 Ventilation 6 Pressure connection
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Product description
Central lubrication system*

1.9 Central lubrication system*

Fig. 12: Central lubrication system

1 Supply container 4 Filling nipple
2 Positive pressure relief valve 5 Interim lubrication button
3 Pump outlet 6 Control unit

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 Safety instructions 2

162894
2 Safety instructions

162894
 2 Safety instructions

The chapter Safety instructions deals with the following issues:

– Areas of responsibility and required personnel
– Dangers and remaining risks despite proper use
– Measures to prevent danger

2.1 Technical condition of the machine

For the machine to be operated safely, the following requirements in terms of its
technical condition must be met:
– The machine must be in perfect condition
– Unauthorised conversion or modification is not permitted
– Maintenance must be performed regularly
– Safety devices must be in good working order

2.2 Areas of responsibility

2.2.1 Manufacturer
The manufacturer:
– is responsible for the impeccable safety state of the machine with accessories
and documentation when surrendering to the operator.
– is aware of its duty to monitor product performance and document all mainte-
nance and repair work carried out by authorized service personnel.
– ensures that the machine is kept in an operational state by a worldwide mainte-
nance and repair service.
– runs a training center and provides training for the owner's operating and main-
tenance personnel as a service.

2.2.2 Owner
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The owner:
– ensures that the machine is operated and maintained by qualified personnel
only.
– checks that all individuals who come into contact with the machine are fully
qualified, and authorises them to work.
– specifies the skills and responsibilities of all those working with or near the
machine.
– provides all necessary protective equipment to individuals working with or near
the machine.

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Safety instructions
Areas of responsibility

– regularly checks that personnel carry out their work in a safety-conscious

manner.
– is responsible for the impeccable safety state of the machine with accessories
and documentation as of surrender from the manufacturer.
– completely removes the machine from use upon the discovery of any faults that
may affect safety.
– performs inspections on the machine based on national regulations in addition
to the inspections stipulated by Liebherr.
– informs the manufacturer of any accident involving the machine leading to
serious injury or major damage to property.
– allows authorized service personnel unlimited access to the machine in order
that they may fulfill their duty to monitor the product.
– carefully and conscientiously carries out work planning for the machine.
– will not carry out any alterations on the machine without first consulting the
manufacturer.
– must only use original Liebherr spare parts.

2.2.3 Machine operator

The machine operator:
– have read and understood the operation manual.
– operates the machine for the purposes intended, within the limit values speci-
fied in the load chart and in accordance with the setup and the operation
manual.
– wear personal protective equipment.
– reports to the owner any alteration to the machine that affects safety.
– halts operation immediately if safe operation is no longer possible.
– will not carry out any alterations on the machine without first consulting the
manufacturer.
– must only use original Liebherr spare parts.
– must ensure that a co-driver rides in the intended seat and wears a safety belt
(if a co-driver is intended and permitted by the manufacturer).

2.2.4 Rigger
The rigger:
– is responsible for the correct selection and fitting/removal of the lifting device on
the load or rigging material.
– gives the machine operator signals relating to the movement of the machine
and loads.
– is responsible for ensuring that only one person gives signals to the machine
operator and that the machine operator knows who this person is.
– wear personal protective equipment.
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2.2.5 Banksman
The banksman:
– forwards signals from the rigger to the machine operator if the rigger has no
visual contact with the machine operator.
– wear personal protective equipment.

2.2.6 Maintenance and service personnel

The maintenance and service personnel:
– maintain the machine to ensure that it remains in a safe and reliable condition.

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 Safety instructions
Requirements to personnel

– have read and understood the operation manual.

– wear personal protective equipment.
– perform all specified maintenance work.
– will not carry out any alterations on the machine without first consulting the
manufacturer.
– must only use original Liebherr spare parts.

2.3 Requirements to personnel

2.3.1 Machine operator

The machine operator:
– are of the statutory minimum age.
– must be physically capable (adequate eyesight and hearing, quick reactions) of
safely operating the machine.
– is authorised to operate the machine.
– is capable of accurately estimating distances, heights and clearances.
– is trained:
• to operate this type of machine
• in attaching and signalling
• to operate fire extinguishing equipment
– is aware of the escape routes in the event of an emergency.
– do not suffer from any physical or psychological ailments that lower any of the
specified requirements.
– are not under the influence of alcohol or drugs.

2.3.2 Rigger
The rigger:
– are of the statutory minimum age.
– is physically capable (adequate eyesight and hearing, quick reactions) of safely
using/moving lifting devices.
– is authorised to rig loads.
– is capable:
• of accurately estimating distances, heights and clearances
• of accurately estimating mass and load distribution
• of operating walkie-talkies and using them to give clear instructions
• of guiding the load and ensuring the safe movement of the load and the
machine
– is trained:
• in attaching lifting devices
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• in signalling and knows the signal signs

• in selecting the correct lifting device
• in securing against unexpected detachment
• in preventing damage to lifting devices
– do not suffer from any physical or psychological ailments that lower any of the
specified requirements.
– are not under the influence of alcohol or drugs.

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Safety instructions
Personal protective equipment

2.3.3 Banksman
The banksman:
– are of the statutory minimum age.
– are physically capable (adequate eyesight and hearing, quick reactions).
– is authorised to give signal signs.
– is capable:
• of accurately estimating distances, heights and clearances
• of operating walkie-talkies and using them to give clear instructions
• of guiding the load and ensuring the safe movement of the load and the
machine
– is trained in signalling and knows the signal signs.
– do not suffer from any physical or psychological ailments that lower any of the
specified requirements.
– are not under the influence of alcohol or drugs.

2.3.4 Maintenance personnel

Maintenance personnel:
– are of the statutory minimum age.
– are physically capable (adequate eyesight and hearing, quick reactions).
– are familiar with the machine and the hazards.
– are familiar with all maintenance procedures and measures.
– are trained to perform maintenance duties, including on specialist equipment.
– do not suffer from any physical or psychological ailments that lower any of the
specified requirements.
– are not under the influence of alcohol or drugs.

2.4 Personal protective equipment

The machine operator, slinger, signalman and maintenance personnel must take
personal responsibility for:
– Wearing the required personal protective gear.
– Regular cleaning and care of the protective gear.
– Replacing any defective items of protective gear promptly.
The personal protective gear comprises:
– Safety helmet, if head injuries are possible due to:
• collision,
• swinging, falling, toppling or flying objects
– Safety goggles, if eye injuries are possible due to:
• corrosive or pressurised liquids
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• loose flying parts

– Ear protection, if the sound level is likely to be excessive
– Breathing mask, where there is danger from health-threatening gases, vapour,
smoke or dust in the working environment
– Protective gloves, if hand injuries are possible due to:
• Burns
• pointed or sharp objects
– Reflective, boldly-coloured clothing if prompt recognition by other personnel
is necessary.
– Safety shoes, if foot injuries are possible due to:
• collision or trapping
• pointed or sharp objects

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 Safety instructions
Danger zone

• swaying or falling objects

– Special protective clothing, where there is a risk of burns, hypothermia,
chemical burns, stabbing or cutting injuries to the body

2.5 Work area

In accordance with the EU Machinery Directive, the following guidelines have been
laid down for operation of the machine by one machine operator.
Required operating personnel: one machine operator
Workplace: Cabin
Banksman: one additional person
Ensure that the following conditions are fulfilled:
– No one other than the machine operator is on the machine or within the danger
zone around the machine.
– The machine operator must remain in the cab all the time.
Use operating elements exclusively from the operator's seat. Using any operating
elements through the open cabin door is prohibited.
Requirements for a safe working environment:
– Keep cab clean.
– Do not place any articles on the control panels.
– Do not keep tools in the cab.
– Hang any clothing on the hook provided for this purpose.
– Keep the entrance to the cabin clean and free of snow and ice; do not obstruct
the entrance or block the escape routes.
– Keep the screens and mirrors (internal and external) clean and free of conden-
sation and ice.

2.6 Danger zone

The danger zone is the area surrounding the machine, in which people may be
injured by:
– working movements of the machine.
– a swinging or falling load.
– optional equipment on the machine.

DANGER
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Machine in use!
u Make sure that no-one is standing in the danger area.
u Leave the danger area.

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Safety instructions
Meaning of the safety signs

Fig. 13: Danger zone

1 Working area at maximum radius x Travel of swinging load
2 Danger zone

2.7 Meaning of the safety signs

Safety signs are divided into different groups that differ with respect to shape and
colour.

2.7.1 Prohibition signs

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Characteristics of prohibition signs:

– Round
– Red rim
– Red diagonal bar
– White background
– Black pictogram
Prohibition signs prohibit behavior that causes danger.

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Meaning of the safety signs

No fire, naked flames or smoking

No access for unauthorised personnel

No access for persons with a cardiac pacemaker

Stepping on surface prohibited

Pedestrians forbidden

Switching prohibited

Do not lift load

No climbing for unauthorised personnel

High-pressure cleaning prohibited

2.7.2 Warning signs

Characteristics of warning signs:
– Triangular
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– Black rim
– Yellow background
– Black pictogram
Warning signs indicate risks or hazards.
Danger area

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Safety instructions
Meaning of the safety signs

Dangerous spot/observe operation manual

Danger through electrical voltage

Danger through suspended load

Danger of getting drawn in

Danger of getting drawn in

Danger of getting drawn in

Danger from hot surfaces

Slip hazard

Fall hazard

Stumble hazard

Crushing hazard
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Crushing hazard

Crushing hazard

Risk of crushing

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 Safety instructions
Meaning of the safety signs

Crushing hazard

Crushing hazard

Roll-over hazard

Roll-over hazard

Danger through ropes and winches

Danger through electromagnetic waves

Danger from pressure reservoirs

Danger through batteries

Danger through hydraulic oil

2.7.3 Fire protection signs

Characteristics of fire protection signs:
– Square
– No rim
– Red background
– White pictogram
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Fire protection signs mark the location of fire alarms or fire extinguishing equip-
ment.
Fire extinguishers

Fire extinguishers

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Safety instructions
Meaning of the safety signs

Fire detector

2.7.4 Mandatory signs

Characteristics of instruction signs:
– Round
– No rim
– Blue background
– White pictogram
Instruction signs indicate safety-relevant behavior.
General mandatory signs

Wear safety helmet

Wear hearing protection

Wear safety gloves

Wear facial protection

Wear foot protection

Use safety belt

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Use harnesses

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 Safety instructions
Hazards

2.8 Hazards

2.8.1 Mechanical action

WARNING
Mechanical actions due to moving machinery!
When operating the machine, numerous hazards and situations can arise that can
cause life-threatening injuries.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Wear suitable personal protective equipment.
u Only work on non-moving parts.

Examples of mechanical actions:

Standing under a suspended load.

Danger of being drawn in by moving drive units or machine parts.

Danger of falling when working without safety gear.

Danger of crushing due to unsecured components such as doors or sliding

elements.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
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• Act - make the situation safe.

2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid

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Safety instructions
Hazards

2.8.2 Electrical energy

WARNING
Electricity in conductive machine parts!
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Only carry out work with the electrical supply switched off.
u Secure the machine to prevent unauthorised startup.

Examples of electrical energy:

– External power supply
– Generator

WARNING
Live machine parts!
risk of electric shock.
u Before recovering an injured party ensure that there is no further risk of electro-
cution.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid

Note
u Seek medical attention after electrical accidents. The person affected may
experience symptoms of an irregular heartbeat some time after the accident.

2.8.3 Hydraulic energy

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WARNING
Escaping hydraulic oil under high pressure!
Leakages in hydraulic lines can cause injuries to skin, destroy tissue and can
cause blood poisoning due to the high pressures involved.
u Observe handling and situation-specific safety notes.

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Note
Observe the following safety notes:
u Repairs to hydraulic systems may only be carried out by qualified technicians
with specialised knowledge and experience of hydraulics.
u Before starting work ensure that the whole system has been depressurised.
u Never attempt to locate the leakage point with your hand or other part of the
body
u Damaged hydraulic components must be replaced immediately with original
Liebherr spare parts.

Examples of hydraulic energy:

Tissue damage from leaks.

Sepsis from hydraulic oil entering bloodstream.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid
• Gently cover injured area(s) with a sterile anti-bacterial bandage.
• Rinse eyes with pure drinking water.

2.8.4 Burns

CAUTION
Contact with hot surfaces and consumables!
High surface and equipment temperatures can lead to burns or scalding.
u Observe handling and situation-specific safety notes.
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Note
Observe the following safety notes:
u Always wear suitable protective gloves when working on hot components.
u Only carry out work on the machine after it has cooled down and is stopped.

Examples of burns and scalding:

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Burns from contact with the entire drive system.

Scalding from steam exiting from the cooling system or hydraulic oil from the drive
system.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid
With first-degree burns (redness of the skin):
• Cool the affected body part by rinsing with cold fresh water.
• Gently cover injured area(s) with a sterile anti-bacterial bandage.
With second-degree burns (blisters on the skin):
• Cool the affected body part by rinsing with cold fresh water.
• Gently cover the area using a sterile anti-bacterial bandage. Do not apply
pressure.
With third-degree burns (charring of the skin and tissue):
• Gently cover the area using a sterile anti-bacterial bandage. Do not apply
pressure.

2.8.5 Chemical burns

CAUTION
Contact with corrosive consumables!
Acids and bases cause chemical burns to skin and tissue, and blindness if they
come in contact with the eye.
Acids and bases will damage clothing.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
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u When working with acids always wear suitable safety goggles or face protec-
tion, protective clothing and gloves.

Examples of chemical burns:

Chemical burns from handling acidic consumables.

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Chemical burns from leaking battery acid.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid
• Removing clothing from injured body parts.
• Rinse injured areas with drinking water.
• Gently cover the area with a sterile anti-bacterial bandage.

2.8.6 Fire and explosion

WARNING
No fire, naked flames or electrostatic discharges!
Flammable materials or any gases arising from them can cause a fire and explo-
sion hazard.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Do not store any flammable materials or carry them in the machine, only in fire-
proof containers.
u Wipe any spilled diesel fuel off the machine and neutralise it on the ground with
bonding agents
u Do not clean the machine with flammable fluids.
u Do not store cleaning cloths in the engine compartment and remove flammable
residues such as oil leakages, ash and waste paper.
u Only refuel the machine in a well ventilated area or provide fresh air.
u Make sure there is good metallic contact between the pump nozzle and the filler
neck during refuelling. If possible, ground the machine at the fuelling station
while it is being refuelled.
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u No open fire when handling flammable materials.

Examples of fire and explosion hazards:

F Escaped fuel is a fire hazard.

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E – Detonating gas in combination with a spark when charging or discharging

batteries.
– Vapourised fuel in combination with an electrostatic discharge between the
machine and the fuel rig.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid
• (For more information see: 2.8.4 Burns, page 55)
• (For more information see: 2.9.3 Firefighting, page 64)

2.8.7 Poisoning and suffocation

WARNING
Inadequate ventilation or fresh air!
Poisonous vapours or other atmospheres hazardous to health can lead to
poisoning or suffocation.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Ensure adequate ventilation in the cab.
u Use breathing apparatus when working with hazardous materials.

Examples of poisoning and dangers of asphyxiation:

– Engine exhaust gases contain carbon monoxide and other hazardous gases.
– If the machine is used in areas where hazardous substances are present,
contact with hazardous gases is a possibility.
– The refrigerant from the air conditioning system circuit displaces the oxygen in
the air.
First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
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• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid

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2.8.8 Electromagnetic influence

WARNING
Electromagnetic influence when the machine is deployed near transmitting
stations, radar stations or directional radio systems!
Malfunctions or failure of electronic implants (pacemakers).
Malfunction or failure of the control system.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u The machine must be stopped if there is suspected electromagnetic interfer-
ence to the controls.

Examples of electromagnetic influence:

– Malfunction or failure of control systems if operating the machine near transmit-
ters, directional radio systems or radar stations.
– Environmental influence through the use of electromagnetic rigging material or
integrated radio devices.

2.8.9 Exposure to wind

DANGER
Exposure to wind can have fatal consequences!
Damage to the machine.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Observe the permitted wind speeds in the applicable load chart.
u Find out and take into consideration the wind conditions at the site and the
weather forecasts for the period of operation.
u The machine operator must know the weather report and the current wind
speed at the site where the machine is operating before starting work. If exces-
sive wind speeds are expected within the next few hours, work must not start
and precautions must be taken to protect against storm damage.
u Watch out for dangerous gusts of wind.
u Do not lift any large-surface parts.
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u Reduce loads and maximum boom angle.

u Hoist the loads slowly and carefully and do not let them become unstable.

DANGER
Wind speed exceeds the maximum permitted speed (greater than specified in the
applicable load chart)!
Damage to the machine.
u Set down and secure the load.
u Bring machine into parked position 0°.

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Wind impact on machine and load:

– acts like an additional load on the hook.
– is particularly dangerous at maximum boom angle without a load.
– causes the load to sway.
– increases the swing radius.
– generates additional diagonal pull.
If no anemometer is mounted on the slewing column, the following table allows
approximation of the wind speed. The wind speed at the boom may be greater than
the wind speed at or near ground level.

Wind force Wind speed

Wave Description of the conditions at sea
Beaufort Designation Knots
height (m)
0 Calm 0 0 Mirror-smooth sea.
1 Light air 2 0,1 Small flaky-looking ripples without white crests.
2 Light breeze 5 0,2 Small, short waves. Glassy, non-breaking crests.
Small, short waves. Crests begin to break. Mostly
3 Gentle breeze 9 0,6 transparent foam. Occasional small, white foam
heads.
4 Moderate breeze 13 1 Small, longer waves. Many have white crests.
Moderate longer waves. Widespread white
5 Fresh breeze 19 2
crests. Isolated froth.
Large waves. Crests break and leave large white
6 Strong breeze 24 3
areas of foam. Some froth.
Sea heaps up. White foam begins to streak in
7 Near gale 30 4
wind direction.
Moderately high waves with considerably long
crests. Crest edges begin to froth. Foam covers
8 Gale 37 5,5
the surface in pronounced streaks in the wind
direction.
High waves. Thick strips of foam in the wind
9 Severe gale 44 7 direction. Wave crests roll over one another. Sea
begins to “roll”. Froth can affect visibility.
Very high waves with long breaking crests. The
resulting foam lies on the surface in thick white
10 Storm 52 9 streaks in the wind direction. Sea is white from
foam. Strong intermittent “rolling” of the sea. Visi-
bility affected by froth.
Exceptionally high waves (small and medium-
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sized ships are momentarily hidden from view

behind the waves). Sea is completely white from
11 Violent storm 60 11,5
foam, which streaks in the wind direction. Edges
of the wave crests turn to froth. Visibility limited
by froth.
Air filled with foam and froth. Sea completely
12 Hurricane <64 <14
white with froth. Visibility is extremely limited.

Tab. 4: Wind strengths according to the Beaufort scale

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2.8.10 Snow and ice loads

DANGER
Snow or ice on the machine!
Structural breakdown.
u Observe handling and situation-specific safety notes.

WARNING
Falling chunks of snow and ice!
u Never work with a boom that is iced up or covered in snow.

Note
Observe the following safety notes:
u Lay down the boom and carefully remove any large accumulations of ice and
snow.
u Remove snow and ice from all sensitive parts such as limit switches, guides,
etc.
u Snow and ice loads increase the boom weight and the area exposed to the
wind.

These factors will lead to a premature shutdown of the Load Moment Limiter (LML)
- it will no longer be possible to work at the maximum permitted lifting capacity.

2.8.11 Lightning strike

WARNING
Electric shock from lightning!
Coming into contact with a direct or indirect current flow caused by a voltage flash-
over or step voltage can be fatal.
Fall hazard when working at heights.
It can also cause a total loss of control, damage to the electronics or to local
welding spots on supports, especially on the swing ring.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u Lay down the boom before a storm breaks.
u During a storm, keep away from large, free-standing metal parts (e.g. the
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machine).
u Earth machines where the steel structure does not have a direct contact to
ground.
u Only evacuate the cab in the case of fire.

The closed machine operator's cab acts as a Faraday cage. The charge is chan-
neled through the machine and into the ground.
Promptly lay down the boom if any of the following criteria apply:
– On sites that experience frequent storms

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Measures to take after a lightning strike on the machine has been observed
or is suspected:
– Thoroughly inspect the machine paying particular attention to any damaged
cables, hoses and ropes.
– Check the operational capability of the control system.
– Slowly move the slewing gear and listen for any unusual noises.
– Inspect the boom for damage.
– Contact Liebherr after sales service.
First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, shock prevention
4. Additional first aid
• (For more information see: 2.9.1 How to respond in the event of a current
transfer, page 63)

2.8.12 Environment

NOTICE
Risk of damage to the environment caused by pollutants!
If their release is not controlled, fuels, oils, cleaning agents, coolant, etc. can enter
the ground or rivers and cause environmental damage.
u Observe handling and situation-specific safety notes.

Note
Observe the following safety notes:
u If the machine leaks, immediately collect the escaping liquid and seal the leak.
u Bind any spilled liquid with binding agent or neutralise it with suitable agents.
u When draining or catching liquids use suitable containers (capacities and
resistant to chemicals).
u Carry out cleaning work on firm well-drained ground.
u Observe the national and international environmental regulations for the
disposal of chemicals or waste.
u Notify the emergency services and authorities if large amounts of substances
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that are harmful to the environment escape.

Examples of environmental hazards:

– Leakages
– Refilling consumables incorrectly

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2.9 What to do in dangerous situations

2.9.1 How to respond in the event of a current transfer

First response to a current transfer

– Remain calm.
– Alert the relevant power supply company.
Do not leave the cab.
• The cabin acts as a Faraday cage. Remaining in the operator's cabin is safer
than staying outside.
• Only evacuate the cab in the case of fire.
– If the Litronic control system is still functioning:
• Move the machine out of the danger area.
• Remain in the cab until current is no longer being conducted through the
machine.
First aid
– Alert the emergency services.
– Personnel are to rescued by experts only.

Note
u Seek medical attention after electrical accidents. The person affected may
experience symptoms of an irregular heartbeat some time after the accident.

2.9.2 How to respond in the event of a fire

WARNING
Incorrect behaviour in event of fire!
u Observe handling and situation-specific safety notes.

– Switch off the engine.

– Alert the emergency services.
– Move people out of the danger zone, administer first aid if required (For more
information see: 2.8.4 Burns, page 55) .
– Only start to fight the fire if there is no risk to your personal safety (For more
information see: 2.9.3 Firefighting, page 64) .

WARNING
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Danger of backflash!
Even if the fire appears to be extinguished, escaping fuel or oil coming in contact
with hot components may reignite.
Once the risk of backflashing no longer persists:
u Start assessing the damage.

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2.9.3 Firefighting

Fire classes

WARNING
Appropriate extinguishers must be used!
If unsuitable extinguishers are used, they may be ineffective or even introduce
additional hazards.
u Use an extinguisher that is appropriate for the fire class.

Fires involving solid and chiefly organic materials that normally smoulder

Fires involving liquids or liquefying materials

Fires involving gases

Fires involving metals

Use of the fire extinguisher

Note
Fire extinguishers are subject to national regulations!
u Arrange for the plant operator to provide fire extinguishers, replace them as
necessary and inspect them periodically.

– Take fire extinguishers on the machine off the holders and ready them for oper-
ation.
– Fight the source of the fire with several short bursts.
– While fighting the fire, ask your colleagues to alert the fire brigade.
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Incorrect Correct

Fight the fire with the wind behind you

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Incorrect Correct

Extinguish the fire from the front to the

back and from the bottom to the top

But: Extinguish dropping and liquid fires

from the top to the bottom

Do not use extinguishers in succession

but use several extinguishers at the
same time

Make sure that the fire does not reignite

- always extinguish glowing embers with
water
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Do not put the fire extinguishers back in

place after use - refill them

Tab. 5: Use of the fire extinguisher

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2.10 Working at heights

WARNING
Working at heights without precautions!
Fall from machine.
u Secure yourself against falling.
u Observe international and national regulations.

2.11 Regulations for tandem lifting mode

Lifting loads with two or more machines requires more attention in planning and
supervision than lifting with just one machine, because the effects of the relative
movement between the machines generate additional strain for the machine, the
load and the load lifting equipment.

Note
u The operator takes sole responsibility for tandem lifting mode.

Requirements:
– The machine has a valid and current certificate issued by the authority in
charge. The machines must be in good condition. Make sure that all required
certificates and other documents are available.
– The operator has to ensure safe working conditions and risk monitoring.
– The national regulations must be observed when lifting heavy loads and with
tandem lifting operations.
– The traverse is completely certified and suited for the intended lifting operations
(the certificates must be provided to the expert). The spreader must be in good
condition.
– The precise weight of the loads to be lifted must be known and the point of
gravity of the load must be as central as possible so that the load is distributed
evenly beneath the involved machines.
– The SWL (or the ratio of load to radius) of a machine may not be exceeded
under any circumstances during the lifting operation.
– The machine operator must be very experienced in tandem lifting.
– The machine operator has to ensure that there are no collisions between a
machine and the load nor between the load and other obstacles.
– The traverse must stay horizontally during lifting.
– When planning, ensure that the lifting ropes remain vertical. The machines may
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not be subjected to forces that are greater than the forces which occur during
the individual lifting operations with their respective rated capacity.
– The two machine operators must have a clear view of the load at all times and
must be able to communicate effortlessly with each other. For safe tandem
lifting operations, it is of essential importance that the entire personnel can
clearly communicate in one language.
– The machine operators must ensure that the area for tandem lifting is suffi-
ciently illuminated at twilight and in darkness.
– One of the two machine operators is appointed head crane operator and
assumes the responsibility for the lifting operation. Alternatively, an employee
on the ground who has a free view of the load at any time can take on the

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responsibility for the lifting operation. For this purpose, he must be in uninter-
rupted contact with both machine operators.
– The lifting operations must be performed in a controlled fashion while ensuring
minimum heeling and good weather conditions.
– The local regulations and conditions must be observed.
– All work must be planned so that it can be performed safely under consideration
of all foreseeable risks. Planning must be performed by persons with the corre-
sponding expertise, which is appointed for this purpose.
– Prior to lifting, the lifting rope must be perpendicular.
– The machine operator must have a clear and unobstructed view of the load and
the work area. If this is not the case, the machine operator follows the instruc-
tions of the rigger or signalman who must be positioned in such a way that he
has a clear and unobstructed view.

2.11.1 Main factors when planning the tandem lifting opera-

tion

Mass of the load

The total mass and its distribution must either be known or calculated.

Center of gravity
With different loads, the center of gravity may not be precisely known and the
share of the load carried by each individual machine may therefore be unknown. If
necessary, corresponding steps must be initiated beforehand to determine the
center of gravity.

Mass and capacity of the load lifting equipment

The mass of the load lifting equipment is a part of the calculated load acting on the
machine. The mass of the load lifting equipment and the hook blocks as well as
their distribution must also be exactly known. The applied load lifting equipment
must have a capacity that by far exceeds the capacity required for the load.

Synchronization of the machine movements

If deviations from the direction and the extent of the forces that act upon the
machine during the tandem lifting operation must be kept to a minimum, the
machine movements must be performed synchronously under all circumstances.
The rated capacity of a machine is calculated under the assumption that the load is
lifted vertically. The machine structure must be designed in such a way that it with-
stands the lateral strains generated by acceleration during different machine move-
ments. The movements of the applied machines must be perfectly synchronized.
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Instruments
Instruments are available for constant monitoring of the individual lifting ropes
during the lifting operation.

Supervision
A responsible person supervises and controls the entire tandem lifting operation.
This is the only person entitled to give instructions to the personnel operating or
driving machines. A stop signal known to all persons involved may only be issued

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Hand signals

by any person observing a situation if this leads to danger. If it is not possible to

observe all necessary areas from one location, additional personnel must be
stationed at different positions to monitor the area and inform the person in charge
of the lifting operation accordingly.

Requirement on the rated capacity during the tandem

lifting operation
If the person in charge has convinced himself that all relevant factors are deter-
mined exactly and monitored with the help of instruments, the cranes can be
applied up to their rated capacity. If it is not possible to assess all factors exactly,
all cranes must be downgraded accordingly. The downgrade may be 25% or more.

2.12 Hand signals

The hand signals:

– are used for communication purposes when there is visual contact between
machine operator and signalman or other site personnel
– are clearly defined in national and international standards

Note
u All persons involved must decide among themselves which hand signals are to
be used.

The following overview comprises:

– hand signals in accordance with BGV A8 (Germany)
– hand signals in accordance with ASME/ANSI B30.5 (United States of America)

2.12.1 General hand signals in accordance with BGV A8

Warning, Start, Stop
– Hold the right arm stretched vertically upwards
– Palm facing forwards
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Stop, Interruption
– Stretch out both arms to the side horizontally
– Palms facing forwards

Stop - Danger
– First stretch out both arms horizontally to the sides
– Palms facing forwards
– Now alternately bend in and stretch out the arms

Lift
– Bend the right arm and hold upwards
– Palm facing forwards
– The hand makes a small, circular movement

Lower
– Stretch out the right arm downwards
– Palm facing inwards
– The hand makes a small, circular movement
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Slowly
– Stretch out right arm horizontally
– Palm facing downwards
– Move hand slowly up and down

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Depart
– Bend the right arm and hold upwards
– Palm facing forwards
– Move the arm back and forth sideways

Approach
– Bend both arms
– Palms facing inwards
– Beckon with the forearms

Remove
– Bend both arms
– Palms facing outwards
– Wave away with the forearms

Travel right (from the signalman's viewpoint)

– Bend right arm slightly while holding horizontal
– Move the arm back and forth sideways

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Travel left (from the signalman's viewpoint)

– Bend left arm slightly while holding horizontal
– Move the arm back and forth sideways

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Indicate distance reduction

– Hold both palms parallel and move them toward each other to indicate the
distance

2.12.2 Special hand signals for attachment operations

Lift load slowly
– Bend the right arm and hold upwards
– The outstretched finger points upwards
– The right hand makes small, circular movements
– Stretch out the left hand and hold it over the right hand

Lower load slowly

– Hold the right arm downwards
– The outstretched finger points downwards
– The right hand makes small, circular movements
– Hold the left hand under the right hand

Raise the main boom

– Bend the right arm and hold upwards
– The outstretched thumb points upwards
– Stretch out the left hand and hold it over the right hand
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Lower the main boom

– Bend the right arm
– The outstretched thumb points downwards
– Stretch out the left hand and hold it under the right hand

Lift main boom and hold load

– Bend the right arm and hold upwards
– The outstretched thumb points upwards
– Make a fist with the left hand and hold it under the right hand

Lower main boom and hold load

– Bend the right arm
– The outstretched thumb points downwards
– Make a fist with the left hand and hold it under the right hand

Raise main boom and lower load

– Bend the right arm and hold upwards
– The outstretched thumb points upwards
– Stretch out left arm and point index finger down
– Move the left hand in circles and hold it under the right hand
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Lower main boom and lift load

– Bend the right arm
– The outstretched thumb points downwards
– Bend left arm and point index finger up
– Move the left hand in circles and hold it under the right hand

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Swing uppercarriage to the right

– Bend the left arm and hold it up
– The thumb points outwards in the direction of rotation
– Stretch out the right arm downwards
– Point index finger down and make circles

Swing uppercarriage to the left

– Bend the right arm and hold it up
– The thumb points outwards in the direction of rotation
– Stretch out the left arm downwards
– Point index finger down and make circles

Open grab
– Stretch out right arm horizontally
– Open hand downwards

Close grab
– Stretch out right arm horizontally
– Close the hand into a fist
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2.12.3 Hand signals for lifting operations in accordance with

ASME/ANSI B30.5
Lift load
– Bend the right arm and hold upwards
– The outstretched index finger points upwards
– The hand makes a small, circular movement

Lower load
– Stretch out the right arm downwards
– The outstretched index finger points downwards
– The hand makes a small, circular movement

Use main winch

– Tap the safety helmet with the fist
– Then give further hand signals

Use auxiliary winch

– Bend the right arm and hold upwards
– Tap the underside of the right elbow with the left hand
– Then give further hand signals
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Raise the main boom

– Stretch out right arm horizontally
– The outstretched thumb points upwards

Lower the main boom

– Stretch out right arm horizontally
– The outstretched thumb points downwards

Move slowly
– Give the appropriate signal with one hand. (e.g.: Lift load)
– Hold the other hand above or below the other hand

Raise main boom and lower load

– Stretch out right arm horizontally
– The outstretched thumb points upwards
– Stretch and bend the remaining fingers alternately for as long the load has to be
lowered
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Lower main boom and lift load

– Stretch out right arm horizontally
– The outstretched thumb points downwards
– Stretch and bend the remaining fingers alternately for as long the load has to be
raised

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Swing
– Stretch out right arm horizontally
– Palm facing downwards
– The extended fingers point in the direction of rotation

Stop
– Stretch out one arm horizontally
– Palm facing downwards
– Swing arm back and forth horizontally

Emergency stop
– Stretch out both arms horizontally
– Palms facing downwards
– Swing both arms back and forth horizontally

Drive
– Bend one arm
– Palm facing forwards
– Make a movement in the travel direction with the open hand
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Shut down and secure machine

– Hook your hands in front of your body

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 Safety instructions
Hand signals

Travel with both crawler chains

– Hold both fists in front of the body
– Indicate travel direction with circular motions

Travelling with one crawler track

– Bend the arm and hold up a fist on the same side as the stationary crawler track
– Bend the other arm in front of the body on the side of the moving track
– Indicate the travel direction by making circular movements with the fist

Extend boom
– Hold both fists in front of the body
– Thumbs facing outwards

Retract boom
– Hold both fists in front of the body
– The thumbs point towards each other
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Retract boom (one-handed signal)

– Hold one fist in front of your chest
– Your thumb points to your chest

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Safety instructions
Hand signals

Extend boom (one-handed signal)

– Hold one fist in front of your chest
– Thumb facing outwards

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Control and operating elements 3

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3 Control and operating elements

162894
 3 Control and operating elements

The chapter Control and operating elements deals with the following issues:
– Alignment of control and operating elements
– Names of control and operating elements
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Control and operating elements
Control stand

3.1 Control stand

Fig. 136: Control stand

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1 Control panel X20 6 Foot pedal Load lifting equipment*

2 Switch unit X20 7 Foot switch Slewing gear free-
wheel*
3 Operator's seat 8 Screen Load display*
4 Left control lever 9 Litronic screen
5 Fan heater 10 Right control lever

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 Control and operating elements
Left control lever

3.2 Left control lever

3.2.1 Function assignment of left control lever buttons

Fig. 137: Function assignment of left control lever buttons

Button on Preselection or addi- Pictogram of

Mode Function
control lever tional button function
Bypass sector

1 All modes
Bypass sector.

2 [Not used]
3 [Not used]
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4 [Not used]
5 [Not used]
Signal horn
6 All modes
Turn signal horn on or off.
7 [Not used]
8 [Not used]

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Control and operating elements
Left control lever

Button on Preselection or addi- Pictogram of

Mode Function
control lever tional button function
Enable control
9 All modes
Enable control.

Tab. 6: Function assignment buttons of left control lever

3.2.2 Function assignment of left control lever movement

directions

Fig. 140: Function assignment of left control lever movement directions

Movement Preselection or addi- Pictogram of

Mode Function
direction tional button function

A All modes Lower boom

B All modes Lift boom

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C All modes Slew machine to the left

D All modes Slew machine to the right

Tab. 7: Function assignment movement directions of left control lever

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 Control and operating elements
Right control lever

3.3 Right control lever

3.3.1 Function assignment buttons of right control lever

Fig. 145: Function assignment buttons of right control lever

Button on Preselection or addi- Pictogram of

Mode Function
control lever tional button function
1 [Not used]
Rotating the crossbar
2 All modes
Rotate crossbar.

3 [Not used]
Constant hook height
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4 All modes Adjust hook height in line with

boom.

5 [Not used]
6 [Not used]
7 [Not used]
8 [Not used]

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Control and operating elements
Right control lever

Button on Preselection or addi- Pictogram of

Mode Function
control lever tional button function
Enable control
9 All modes
Enable control.

Tab. 8: Function assignment buttons of right control lever

3.3.2 Function assignment movement directions of right

control lever

Fig. 148: Function assignment movement directions of right control lever

Movement Preselection or addi- Pictogram of

Mode Function
direction tional button function

A All modes Lower load

B All modes Lift load

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Turn hook crossbar counter-

C All modes
clockwise

D All modes Turn hook crossbar clockwise

Tab. 9: Function assignment movement directions of right control lever

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 Control and operating elements
Explanation of symbols used

3.4 Explanation of symbols used

Display

Display

Button

Button with display

Button with display

Button with LED

LED lights up: Function active.
LED not on: Function inactive.

Switch

Key switch
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Control and operating elements
Control panel X20

3.5 Control panel X20

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Fig. 161: Control panel X20

Ignition
Turn the ignition on or off.
– Position 1: OFF
– Position 2: ON

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 Control and operating elements
Control panel X20

E-motor
Turn e-motor on or off.

Power management system*

Checks whether landside power supply is available.
Lit when power supply is available.
Ignition turned on
Ignition is turned on.

Starting recording*
Recording of load cycles starts.

Pausing recording*
Recording of load cycles pauses.

Setting sector point*

Set sector point for load cycle recording.

Cabin lighting
Turn cabin lighting on or off.

Crane lighting
Turn crane lighting on or off.

Floodlight
Turn floodlight on or off.

Windscreen wipers
Select function mode of windscreen wiper.
– Position 1: OFF
– Position 2: Interval mode
– Position 3: Permanent mode
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Windscreen wiper system

Turn on windscreen wiper system.

Tandem hoist mode

Activate/deactivate tandem hoist mode.

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Control and operating elements
Control panel X20

Maintenance connection
Maintenance connection for authorized maintenance personnel.

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 Control and operating elements
Control panel X23

3.6 Control panel X23

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Fig. 176: Control panel X23

1 Left control lever

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Control and operating elements
Control panel X23

Hoisting gear
Select hoisting gear.
– Position 1: Main hoist
– Position 2: Auxiliary hoist

Bypass hook fixing point

Activate or deactivate bypass hook fixing point.

Special lift mode*

Activate/deactivate special lift mode.

Motor grab mode*

Turn motor grab mode on or off.

Bypass slack rope protection hoisting gear

Activate or deactivate bypass slack rope protection hoisting gear.

Bypass slack rope protection boom hoist

Activate or deactivate bypass slack rope protection boom hoist.

Bypassing load moment limiter

Activate or deactivate bypass load moment limiter.

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 Control and operating elements
Control panel X24

3.7 Control panel X24

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Fig. 184: Control panel X24

1 Right control lever
Emergency stop
Activate or deactivate emergency stop.

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Control and operating elements
Control panel X24

Bypassing parked position

Activate or deactivate bypass parked position.

Bypassing limit switch release

Activate or deactivate bypass limit switch release.
– Position 1: OFF
– Position 2: ON

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 Control and operating elements
Control panel spreader operation*

3.8 Control panel spreader operation*

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Fig. 188: Control panel spreader operation

Activating spreader mode

Activate spreader mode.
Lit when spreader mode is activated.

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Control and operating elements
Control panel spreader operation*

Deactivating spreader mode

Deactivate spreader mode.

Spreader width
Increase or decrease spreader width.
– Position 1: 20 ft
– Position 2: Initial position
– Position 3: 40 ft

Folding the green flipper down

Fold green flipper down.

Folding the black flipper down

Fold black flipper down.

Folding the white flipper down

Fold white flipper down.

Folding the red flipper down

Fold red flipper down.

Folding all flippers up

Fold all flippers up.

Spreader landed
Lights up when spreader is down.

Locking twistlocks
Lock twistlocks.
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Lit when twistlocks are locked.

Unlocking twistlocks
Unlock twistlocks.
Lights up with unlocked twistlocks.

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 Control and operating elements
Control panel spreader operation*

Balancing the spreader

Balance spreader horizontally.
– Position 1: Balance spreader to black flipper
– Position 2: Initial position
– Position 3: Balance spreader to white flipper
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Control and operating elements
Air conditioning*

3.9 Air conditioning*

Fig. 201: Air conditioning

Main switch
Turn main switch on or off.
– Position 1: On
– Position 2: Off

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Fig. 203: Control unit air conditioning system

1 Switch Fan speed 2 Switch Cabin temperature

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 Control and operating elements
Air conditioning*

Fan speed
Select the fan speed.
– Position 1: High
– Position 2: Medium
– Position 3: Low
– Position 4: Off
Cabin temperature
Select cabin temperature.
– Position 1: Cold
– Position 2: Off
– Position 3: Hot
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Control and operating elements
Monitor

3.10 Monitor

Fig. 206: Monitor sections

1 Status bar 3 Menu bar
2 Display area 4 Submenu bar

Status bar
Hook mode main hoist
Hook mode main hoist is activated.

Hook mode auxiliary hoist*

Hook mode auxiliary hoist is activated.

Special lift mode

Special lift mode is activated.

Dynamic anti-collision system in tandem mode* (DACS)

Dynamic anti-collision system in tandem mode* is activated.
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Motor grab mode*

Motor grab mode is activated.

Manriding*
Manriding is activated.

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 Control and operating elements
Monitor

Spreader mounted
Spreader is mounted.

Top hoisting gear limit switch

Lift hoisting gear is stopped.

Bottom hoisting gear limit switch

Lower hoisting gear is stopped.

Top luffing gear limit switch

Lift luffing gear is stopped.

Bottom luffing gear limit switch

Lower luffing gear is stopped.

Left slewing gear limit switch

Slew machine to the left is stopped.

Right slewing gear limit switch

Slew machine to the right is stopped.

Menu bar
Operation
Switch to the screen Operation.

Information
Switch to the screen Information.

Operating hours
Switch to the screen Operating hours.

Set rope length to zero

Set rope length of hoisting winch to zero.

Set load display main hoist to zero

Set load display main hoist to zero (taring).
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Set load display auxiliary hoist to zero

Set load display auxiliary hoist to zero (taring).

Error message
Switch to the screen Error message.

Reeving main hoist

Select main hoist reeving.

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Control and operating elements
Monitor

Warning buzzer
Deactivate warning buzzer. Only visible if an operation error occurs.

Error message screen

Error message
Switch to the screen Error message.

Fig. 230: Error message screen

Fig. 231
1 Consecutive number 4 Acknowledge error message
2 Error number 5 Identification of the respective I/O
module
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3 Error description 6 Number of error messages

Previous error message
Display previous error message.

Next error message

Display next error message.

Previous error screen

Switch to previous error screen.

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 Control and operating elements
Monitor

Next error screen

Switch to next error screen.

Acknowledge error message

Acknowledge error message.

Operation screen
Operation
Switch to the screen Operation.

The operation screen provides the machine operator with the most important infor-
mation during operation.

Fig. 238: Operation screen

Dynamic anti-collision system activated* (DACS)

Dynamic anti-collision system is activated.

Dynamic anti-collision system deactivated* (DACS)

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Dynamic anti-collision system is deactivated.

Dynamic anti-collision system limitation*

Shows the distance to the collision point.

Stop dynamic anti-collision system limitation*

Shows the distance to the collision point.

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Control and operating elements
Monitor

Twistlocks unlocked
Twistlocks are unlocked.

Twistlocks locked
Twistlocks are locked.

Spreader landed
Spreader is landed.

Fig. 246: Screen section tandem mode values

1 Tared load 3 Current load
2 Maximum permitted load 4 Current load radius
Tandem mode values
Shows values of the machine operated in tandem mode.

Fig. 247

Rotating the crossbar around the hook of the leading machine

Rotate crossbar around hook of leading machine.
Rotating the crossbar around the crossbar center
Rotate crossbar around crossbar center.

Fig. 249: Screen section diagonal pull display (illustration of principle)

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1 Symbol slewing gear left 3 Symbol slewing gear right

2 Symbol lower boom 4 Symbol lift boom
High load moment utilization
Load moment utilization exceeds 90%.

Excess load moment utilization

Load moment utilization exceeds 100%.

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 Control and operating elements
Monitor

Load chart error

Error reading load chart.

Pausing recording
Recording of load cycles pauses.

Recording started
Recording of load cycles starts.

Recording stopped
Recording of load cycles is stopped.

Sector point set

Sector point for load cycle recording is set.

Sector limitation
Sector limitation display blinks in case of error.

Wind speed
Displays the current wind speed.

E-motor turned on
E-motor is turned on.
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Fig. 260: Main screen

1 Current load utilization 5 Current load
2 Tared load 6 Maximum load radius
3 Maximum load 7 Current load radius
4 Main machine or subsequent 8 Boom angle
machine

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Control and operating elements
Monitor

Information screen
Information
Switch to the screen Information.

Fig. 262: Information screen

Working pressure hoisting winch

Shows the working pressure of the hoisting winch.

Working pressure slewing gear left

Shows the working pressure of the slewing gear.

Working pressure slewing gear right

Shows the working pressure of the slewing gear.
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Hydraulic oil temperature

Shows the hydraulic oil temperature.

Memory capacity
Shows the memory capacity.

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 Control and operating elements
Monitor

Operating hours screen

Operating hours
Switch to the screen Operating hours.

Fig. 271: Operating hours screen

Operating hours e-motor1

Total operating hours of e-motor1.
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Operating hours e-motor2

Total operating hours of e-motor2.

Main hoist operating hours

Total operating hours of main hoist.

Auxiliary hoist operating hours

Total operating hours of auxiliary hoist.

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Control and operating elements
Monitor

Luffing gear operating hours

Total luffing gear operating hours.

Operating hours slewing gear

Total slewing gear operating hours.

Sycratronic operating hours

Total Sycratronic operating hours.

Dynamic anti-collision system* operating hours (DACS)

Total operating hours of the dynamic anti-collision system.

Tugger winch operating hours

Total tugger winch operating hours.

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 Control and operating elements
PA amplifier*

3.11 PA amplifier*

Fig. 281: PA amplifier

1 XLR microphone input 6 ATT switch
2 DIN microphone input 7 Mono switch
3 Volume control microphone input 8 AUX input
4 Volume AUX input 9 ON/OFF switch
5 Sound control
XLR microphone input
Use microphone with XLR plug.

DIN microphone input

Use microphone with DIN plug.

Volume control microphone input

Control volumes of both microphone inputs.

Volume AUX input

Controlling the volume of the AUX input.

Sound control
Control the sound.
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ATT switch
Turn down AUX input for microphone announcements.
Mono switch
Switch AUX input from stereo to mono.
AUX input
Use car radio, CD player, MP3 player, etc.

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Control and operating elements
PA amplifier*

ON/OFF switch
Turn PA amplifier on or off.

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 Control and operating elements
Switch cabinet X1

3.12 Switch cabinet X1

Fig. 291: Switch cabinet X1

1 Operating hours counter engine1 4 Emergency stop
2 Obstacle light* 5 Auxiliary supply
3 Operating hours counter engine2
Operating hours counter engine1
Shows the machine's operating hours.

Obstacle light*
Turn obstacle light on or off.
– Position 1: OFF
– Position 2: ON
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Operating hours counter engine2

Shows the machine's operating hours.

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Control and operating elements
Switch cabinet X1

Emergency stop
Actuate emergency stop.

Auxiliary supply
Turn the auxiliary supply on or off.
– Position 1: OFF
– Position 2: ON

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 Control and operating elements
Central lubrication system*

3.13 Central lubrication system*

Fig. 297: Operating elements central lubrication system

Lubrication time
Set lubrication time.

Break time
Set break time.

Indicator light (lit yellow)

Is lit yellow 1.5 seconds after turning on the e-motor and signals readiness for
operation.
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Interim lubrication
Perform interim lubrication with the programmed lubrication time.

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Control and operating elements
Central lubrication system*

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 Operation 4

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4 Operation

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 4 Operation

The chapter Handling deals with the following issues:

– Secondary machine functions
The chapter Operation deals with the following issues:
– Safe commissioning of the machine
– Main machine functions
– Safe shutdown of the machine

4.1 Steps

4.1.1 Entering the cabin

WARNING
Unauthorized machine access during operation!
Grave injury.
u Only access machine when engine is turned off.
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Operation
Steps

Fig. 302: Entering the cabin

u Enter cabin.
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 Operation
Checks before start up

4.2 Checks before start up

DANGER
Unauthorized use of a damaged machine!
u Do not use a machine that is damaged in any way.
u All defects and errors are to be reported to the relevant supervisor and to Lieb-
herr customer service.

NOTICE
Do not start up a preserved machine if it has been preserved for storage or stand-
still for up to two months!
Damage to machine
u Ensure that the machine and all functions are in operation every two months for
three hours.
u Ensure that the machine is treated with permitted lubricants.
u Ensure that all oil levels are correct.

Ensure that the following conditions are satisfied:

q All maintenance and inspection work was carried out according to specifica-
tions.
q The operation manual has been read and understood.
q The operation manual and load chart is ready at hand in the cabin.
q There are no unauthorized persons in the danger zone.
q The working area is sufficiently illuminated.

4.2.1 Walk round

Check the following when performing inspections on the machine:
– no leaks (hydraulic oil, engine oil and gearbox oil, coolant, fuel).
– There is no damage.
– Machine is not dirty.
– All safety devices are in place.
– All pin connections and screw fastenings are securely tightened.
– Check that ropes and pulleys do not show any sign of wear.
– There are no obstacles in the work range.
– Slewing column can turn without restriction.
– All safety signs are present and legible.
– Snow and ice has been removed from the machine.
– Check that there is good visibility from the cab.
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– Windscreen wiper system is filled with appropriate screenwash fluid.

– Vent flaps on the door of the base column are open.
– Fuses in switch cabinets X1 and X2 are in perfect condition.
– Electric cable of the landside power supply is in perfect condition.
– Insulation resistance of the e-motor is at least 500 mOhm.
– Hydraulic oil level is admissible.
– Gearbox oil level of the slewing gears is admissible.
– Gearbox oil level of the winches is admissible.
– Gearbox oil level of the distribution gearboxes is admissible.
– Central lubrication pump is optimally adjusted:
– Lubrication time: 16 minutes
– Break time: 30 minutes

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Operation
Checks before start up

4.2.2 Checking the position of the hydraulic oil tank* gate

valve

Fig. 303: Checking the position of the hydraulic oil tank gate valve
1 Hydraulic oil tank gate valve 2 Hydraulic oil tank gate valve
closed opened

NOTICE
Inadmissible start-up of machine with closed hydraulic oil tank gate valve!
Damage to the hydraulic system.
u Only start up machine with open hydraulic oil tank gate valve.

u Check position of the hydraulic oil tank gate valve.

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 Operation
Checks before start up

Fig. 304: Opening the hydraulic oil tank gate valve

If the hydraulic oil tank gate valve is closed:

u open hydraulic oil tank gate valve.
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Operation
Start-up

4.3 Start-up

Ensure that the following conditions are fulfilled:

q Checks before start-up have been carried out.
q No one other than the machine operator is on the machine or within the danger
zone around the machine.
q All emergency stops are unlocked.
q The following hatches and doors are closed in operation:
• Base column
• Slewing column
• Maintenance hatches
• Cabin door

4.3.1 Activating main power supply

u Set switch Main power supply on switch cabinet X2 to position “ON” 1.

4.3.2 Turning on the ignition

u Set key switch Ignition on control panel X20 to position “ON” 2.

w Display Ignition ON is lit:

Fig. 307: Display Ignition ON

4.3.3 Starting the e-motor

Starting the e-motor without power management system*
u Press the button E-motor on control panel X20.
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w Button is lit.

Starting the e-motor with power management system*

u Press the button Power management system* on control panel X20.
If power supply on ship is available:
w Button is lit.

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 Operation
Start-up

u Press the button E-motor on control panel X20.

w Button is lit.

4.3.4 Moving the boom out of parked position

u Set key switch Release bypass limit switch on control panel X24 to position
“ON” 2.

u Move boom into working range.

u Set key switch Release bypass limit switch on control panel X24 to position
“OFF” 1.
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Operation
Lighting

4.4 Lighting

4.4.1 Turning on the floodlight*

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Fig. 313: Floodlight

1 Floodlight boom (2x) 2 Floodlight cabin (2x)
u Press the button Floodlight on control panel X20.
w Floodlight is on.

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 Operation
Lighting

4.4.2 Turning on the cabin lighting

u Press the button Cabin lighting on control panel X20.
w Cabin lighting is on.

4.4.3 Turning on the crane lighting

u Press the button Crane lighting on control panel X20.
w Crane lighting is on.

4.4.4 Turning on the obstacle light*

u Set switch Obstacle light on switch cabinet X1 to position “ON” 2.
w Obstacle light is on.
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Operation
Air conditioning*

4.5 Air conditioning*

WARNING
Leaks in air conditioning coolant circuit in an enclosed space!
Difficulty breathing up to apnoea.
If there is a high refrigerant concentration in the air:
u Immediately leave the closed room (cab).

4.5.1 Operating the air conditioning

u Set main switch to position “ON” 1.
u Set desired temperature.
u Set desired blower stage.

Note
Liebherr recommends:
u Close all doors and windows.
u Make sure all air outlets are clean.

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 Operation
Windscreen wipers

4.6 Windscreen wipers

4.6.1 Turning on the windscreen wipers

Fig. 319: Windscreen wipers

1 Windscreen wipers
u Set switch Windscreen wipers on control panel X20 to position “Interval
mode” 2.
w Windscreen wipers interval mode is active (windscreen wiper wipes at
certain intervals).
u Set the switch Windscreen wipers on control panel X20 to position “Contin-
uous” 3.
w Windscreen wiper permanent mode is activated.
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4.6.2 Operating the windscreen wiper system

WARNING
Flammable fluid in container of windscreen wiper system!
Fire, explosion.
u Fill container of windscreen wiper system exclusively with non-flammable fluids.

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Operation
Windscreen wipers

Ensure that the following conditions are fulfilled:

q Windscreen cleaning fluid is topped up.
q At low ambient temperatures: sufficient antifreeze for windscreen wiper system
has been added.
u Press the Windscreen wiper system button on control panel X20.
w Windscreen cleaning fluid is sprayed on.
w Windscreen wiper runs in permanent mode.

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 Operation
Central lubrication system*

4.7 Central lubrication system*

The slewing ring bearing is lubricated automatically in line with the set lubrication
and break times.
Switching on the e-motor starts the lubrication process.

NOTICE
Insufficient lubrication!
Damage to the slewing ring bearings and slewing ring tooth flanks.
u Always remain within the lubrication and pause times set in the factory.

NOTICE
Incorrect adjustment of the positive pressure relief valve!
Damage to the central lubrication system.
u Retain manufacturer's settings on the positive pressure relief valve.

4.7.1 Setting the lubrication time

The range of adjustment for lubrication time is from 1 to 16 minutes. The factory
setting for lubrication time is 13 minutes.
u Set the Set lubrication time switch to the desired lubrication time.

4.7.2 Setting the pause time

The range of adjustment for pause time is from 0.5 to 8 hours. The factory setting
for pause time is 4 hours.
u Set the Set break time switch to the desired break time.
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4.7.3 Interim lubrication

u Press the Interim lubrication button

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Additional cab equipment

4.8 Additional cab equipment

4.8.1 Operating the signal horn

Fig. 325: Operating the signal horn

1 Signal horn
u Press the button signal horn on the left operating lever.
w Warning signal sounds.

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Swing

4.9 Swing

WARNING
People or obstacles in the swing range!
Bodily injuries.
u Ensure that there are no people or obstacles in the swing range.
u Leave the danger area.

4.9.1 Slewing gear operation

Slewing the machine to the left

Fig. 326: Slewing the machine to the left

1 Button Control release
u Move left control lever to the left and press and hold the button Control
release 1 at the same time.
w Machine slews to the left.
When the end limit switches are reached:
w Slewing gear stops.
w Symbol Slewing gear stop left is displayed on the monitor:

Fig. 327: Symbol Slewing gear stop left

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Swing

Slewing the machine to the right

Fig. 328: Slewing the machine to the right

1 Button Control release
u Move left control lever to the right and press and hold the button Control
release 1 at the same time.
w Machine slews to the right.
When the end limit switches are reached:
w Slewing gear stops.
w Symbol Slewing gear stop right is displayed on the monitor:

Fig. 329: Symbol Slewing gear stop right

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Hoisting gear

4.10 Hoisting gear

4.10.1 Operating hoisting gear

Lift load

Fig. 330: Lifting a load

1 Button Control release
u Move right control lever backwards and press and hold the button Control
release 1 at the same time.
w Load lifts.
When the end limit switches are reached:
w Hoisting gear stops.
w Symbol Lift hoisting gear stop is displayed on the monitor:

Fig. 331: Symbol Stop hoisting gear lift

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Hoisting gear

Lowering the load

Fig. 332: Lowering a load

1 Button Control release
u Move right control lever forwards and press and hold the button Control
release 1 at the same time.
w Load lowers.
When the end limit switches are reached:
w Hoisting gear stops.
w Symbol Lower hoisting gear stop is displayed on the monitor:

Fig. 333: Symbol Stop lowering hoisting gear

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Luffing gear

4.11 Luffing gear

Fig. 334: Boom positions

1 Vertical parked position 4 Bottom luffing gear limit switch
2 Top luffing gear limit switch 5 Parked position 0°
3 Working range
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Operation
Luffing gear

4.11.1 Luffing gear operation

Lifting the boom

Fig. 335: Lifting the boom

1 Button Control release
u Move the left control lever backwards and press and hold the button Control
release 1 at the same time.
w Boom lifts.
When the end limit switches are reached:
w Luffing gear stops.
w Symbol Lift luffing gear stop is displayed on the monitor:

Fig. 336: Symbol Stop luffing gear lift

Lowering the boom

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Fig. 337: Lowering the boom

1 Button Control release

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Luffing gear

u Move the left control lever forwards and press and hold the Button control
release 1 at the same time.
w Boom lowers.
When the end limit switches are reached:
w Luffing gear stops.
w Symbol Lower luffing gear stop is displayed on the monitor:

Fig. 338: Symbol Stop lowering luffing gear

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Hook operation

4.12 Hook operation

WARNING
Incorrect handling of motor grab!
Serious material damage and personal injury.
u Service and store hooks according to the valid manufacturer guidelines.
u Observe the safety and operating instructions of the manufacturer.
u When changing lifting devices and with service operation winch, make sure that
additional authorised personnel monitors the winches to prevent rope slacking.

4.12.1 Mounting the hook

u Place sling gear (e.g. motor grab) approx. 15 m away from crane on the ground.

Note
Ropes do not lower by their dead weight alone.
u Pull and secure ropes into position, using suitable accessories if necessary.

Fig. 339: Lowering sling gear

u Move right control lever forwards.

u Lower sling gear to the ground.
u Deinstall sling gear (e.g. motor grab).
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u Rig hook.
u Remove the securing ropes.

4.12.2 Selecting hook mode

The machine is automatically in hook mode if no special mode is selected. The
selected mode is saved and selected automatically at the next machine start.
Ensure that the following conditions are fulfilled:
q Control levers are set to zero position.
q No load on hook.

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Hook operation

u Set switch Hoisting gear on control panel X23 to position Main hoist 1.

w Main hoist is selected.

w Symbol Main hoist mode is displayed on the monitor:

Fig. 341: Symbol Main hoist mode

u Set switch Hoisting gear on control panel X23 to position Auxiliary hoist 2.

w Auxiliary hoist is selected.

w Symbol Auxiliary hoist is displayed on the monitor:

Fig. 343: Symbol Auxiliary hoist mode

4.12.3 Operating the hook

Lifting the hook

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Fig. 344: Lifting the hook

u Move right control lever backwards.

w Hook lifts.

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Hook operation

Lowering the hook

Fig. 345: Lowering the load

u Move right control lever forwards.

w Hook lowers.

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Motor grab mode*

4.13 Motor grab mode*

WARNING
Improper use of load lifting equipment and sling gear by other manufacturers!
Severe injuries and damage to the machine.
u Make sure that load lifting equipment and sling gear was approved for this Lieb-
herr machine.
u Observe the safety notices and operation manual of the load lifting equipment
manufacturer.
u Ensure that load lifting equipment and sling gear are in perfect state.
u Control lifting operations and ensure minimum heel and good weather condi-
tions.

4.13.1 Installing the motor grab

Note
Liebherr recommends:
u Place wood beneath the motor grab.

u Position motor grab in front of machine.

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Operation
Motor grab mode*

Fig. 346: Installing the motor grab

1 Sling chain (2x) 2 Electric cable

DANGER
Unauthorized use of damaged sling chains 1!
Load breakaway.
u Ensure that sling chains 1 are in perfect state.
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u Position hook over sling chains 1.

u Rig motor grab with sling chains 1 on hook.
u Turn machine off.

WARNING
Missing protective conductor on motor grab plug!
Motor grab is live.
Death through electric shock.
u Ensure that the protective conductor is connected to the plug.

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Motor grab mode*

NOTICE
Inadmissible connection of dirty or damp electric connectors!
Damage to machine.
u Make sure that electric connectors are clean and dry.

u Connect electric cable 2 of motor grab with electricity cable 2 of cable drum.
w Motor grab is installed.

4.13.2 Selecting motor grab mode

Ensure that the following conditions are fulfilled:
q Control levers are set to zero position.
u Press the button Motor grab mode on control panel X23.

w Motor grab mode is selected.

w Symbol Motor grab mode activated is displayed on the monitor:

Fig. 348: Display Motor grab mode activated

4.13.3 Operating the motor grab

Lifting the motor grab

u Lift motor grab (For more information see: Lift load, page 133) .

Lowering the motor grab

u Lower motor grab (For more information see: Lowering the load, page 134) .

Swinging the motor grab to the left

u Swing motor grab to the left (For more information see: Slewing the machine to
the left, page 131) .

Swinging the motor grab to the right

u Swing motor grab to the right (For more information see: Slewing the machine
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to the right, page 132) .

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Operation
Motor grab mode*

Closing the motor grab

Fig. 349: Closing the motor grab

1 Foot pedal for load lifting equip-
ment
u Push the foot pedal Load lifting equipment 1 forward.
w Motor grab closes.

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 Operation
Motor grab mode*

Opening the motor grab

Fig. 350: Opening the motor grab

1 Foot pedal for load lifting equip-
ment
u Push the foot pedal Load lifting equipment 1 backward.
w Motor grab opens.

4.13.4 Deinstalling the motor grab

Note
Liebherr recommends:
u Place wood beneath the motor grab.

u Put motor grab down.

u Turn machine off.
u Disconnect cable 1 of motor grab from electric cable 2 of cable drum.
u Detach motor grab and sling chains 1 from hook.
w Motor grab is deinstalled.
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Operation
Rotator*

4.14 Rotator*

WARNING
Improper use of load lifting equipment by other manufacturers!
Severe injuries and damage to the machine.
u Make sure that load lifting equipment was approved for this Liebherr machine.
u Observe the safety notices and operation manual of the load lifting equipment
manufacturer.
u Ensure that load lifting equipment and sling gear are in perfect state.

4.14.1 Installing the rotator

NOTICE
Improper installation of load lifting equipment!
Ropes may become damaged.
u Pre-tension ropes prior to mounting load lifting equipment.

Note
Liebherr recommends:
u Place wood beneath the rotator.

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Rotator*

Fig. 351: Rotator (illustration of principle)

1 Damage to plug of boom cable 3 Cable of boom cable drum.
drum.
2 Rope 4 Pin
u Position rotator in front of machine.
u Lower cable of boom cable drum 3 all the way to the ground in manual mode.
u Turn machine off.
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WARNING
Missing protective conductor on rotator plug!
Rotator is live.
Death through electric shock.
u Ensure that the protective conductor is connected to the plug.

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Rotator*

NOTICE
Inadmissible connection of dirty or damp electric connectors!
Damage to machine.
u Make sure that electric connectors are clean and dry.

u Secure rotator with pins 4

u Connect cable of boom cable drum 3 and secure with a chain on the rotator.
u Start machine.

NOTICE
Improper operation of the boom cable drum!
Damage to plug.
u Slowly wind up or unwinding boom cable drum.

u Carefully tension the cable of the boom cable drum 3 with the right control lever.
u Deselect boom cable drum in manual mode.
w Rotator is installed.

4.14.2 Operating the rotator

Turn rotator counter-clockwise

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Fig. 352: Turn rotator counter-clockwise

1 Foot pedal Rotator
u Push the foot pedal Rotator 1 forward.
w Rotator turns counter-clockwise.

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Rotator*

Turn rotator clockwise

Fig. 353: Turn rotator clockwise

1 Foot pedal Rotator
u Push the foot pedal Rotator 1 backward.
w Rotator turns clockwise.
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Operation
Spreader operation*

4.15 Spreader operation*

WARNING
Improper use of load lifting equipment by other manufacturers!
Grave injury.
Damage to machine.
u Make sure that load lifting equipment was approved for this Liebherr machine.
u Observe the safety notices and operation manual of the load lifting equipment
manufacturer.
u Ensure that load lifting equipment and sling gear are in perfect state.

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Spreader operation*

4.15.1 Installing the spreader

Fig. 354: Relieving pressure on pin and deinstallation

1 Pin 3 Hook
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2 Nut
u Position spreader in front of machine.
u Lower pulley block until pin 1 is relieved.
u Remove pin 1.
u Remove hook.

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Operation
Spreader operation*

Fig. 355: Pinning the pulley block with spreader

1 Pin
u Position pulley block above spreader.
u Pin pulley block with spreader.
u Turn machine off.

WARNING
Missing protective conductor on spreader plug!
Spreader is live.
Death, electric shock.
u Ensure that the protective conductor is connected to the plug.

NOTICE
Inadmissible connection of dirty or damp electric connectors!
Damage to machine.
u Make sure that electric connectors are clean and dry.
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u Connect plug of cable drum to spreader.

w Spreader is installed.
w Symbol Spreader mounted is displayed on the monitor:

Fig. 356: Symbol Spreader mounted

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Spreader operation*

4.15.2 Activating spreader mode

Ensure that the following conditions are fulfilled:
q Machine is secured against unauthorized start-up.
u Press the button Activate spreader mode on control panel Spreader mode.
w Button Activate spreader mode is lit.

4.15.3 Adjusting the spreader to the container

Reducing the spreader width

u Set switch Spreader width on control panel Spreader mode to position “20 ft” 1.
w Spreader width is reduced from 40 ft to 20 ft.

Increasing the spreader width

u Set switch Spreader width on control panel Spreader mode to position “40 ft” 3.
w Spreader width is increased from 20 ft to 40 ft.

4.15.4 Balancing the spreader

An uneven load distribution of the spreader or container can be balanced out.
Ensure that the following conditions are fulfilled:
q Spreader is lifted.
If the spreader hangs down on the side of the black flipper:
u Set switch Balance spreader on control panel Spreader mode to Position
“Balance spreader to black flipper” 1 until spreader hangs horizontally.
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If the spreader hangs down on the side of the white flipper:

u Set the switch Balance spreader on the control panel Spreader mode to position
“Balance spreader to white flipper” 3 until spreader hangs horizontally.

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Operation
Spreader operation*

4.15.5 Moving containers

Ensure that the following conditions are fulfilled:
q Spreader is balanced.
q Spreader is positioned above container.

Folding the flipper down

The flippers serve for exact positioning of the spreader on the container.
The approach direction of the spreader to the container decides about the flipper
selection.
If the black flipper is required to position the spreader:
u Press the button Fold down black flipper on control panel Spreader mode.
w Black flipper folds down.

If the red flippers are required to position the spreader:

u Press the button Fold down red flippers on control panel Spreader mode.
w Red flippers fold down.

If the white flipper is required to position the spreader:

u Press the button Fold down white flipper on control panel Spreader mode.
w White flipper folds down.

If the green flippers are required to position the spreader:

u Press the button Fold down green flippers on control panel Spreader mode.
w Green flippers fold down.

Locking twistlocks
u Land spreader.
w Display Spreader landed is lit:

Fig. 366: Display Spreader landed

w Symbol Spreader landed is displayed on the monitor:
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Fig. 367: Symbol Spreader landed

u Press the button Lock twistlocks on control panel Spreader mode.

w Display of the button Lock twistlocks is lit.

w Twistlocks are locked.

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Spreader operation*

w Symbol Twistlocks locked appears on the monitor:

Fig. 369: Symbol Twistlocks locked

Lifting the container

u Lift container .

Lowering the container

u Lower container .

Swinging the container to the left

u Swing container to the left .

Swinging the container to the right

u Swing container to the right .

Folding the flippers up

Folding all flippers up simultaneously
u Press the button Fold up all flippers on control panel Spreader mode.
w All flippers are folded up.

Unlocking twistlocks
Ensure that the following conditions are fulfilled:
q Container is landed.
u Press the button Unlock twistlocks on control panel Spreader mode.

w Display of the button Unlock twistlocks is lit.

w Twistlocks are unlocked:
w Symbol Twistlocks unlocked appears on the monitor:
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Fig. 372: Symbol Twistlocks unlocked

4.15.6 Deinstalling the spreader

Ensure that the following conditions are fulfilled:
q All flippers are folded up.

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Operation
Spreader operation*

Note
Liebherr recommends:
u Place wood beneath the spreader.

u Lay down spreader.

u Turn machine off.
u Detach spreader from pulley block.

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 Operation
Diagonal pull display* (VLF)

4.16 Diagonal pull display* (VLF)

Diagonal pull display (VLF) informs the machine operator about the vertical posi-
tion of the load.
Angle sensors on the ropes determine the position of the load below the boom
head.

Fig. 373: Diagonal pull display (illustration of principle)

A Deviation of the load B Optimum position of the load
If the deviation A of the load to the boom head equals > 0.25 m the display
changes tooptimum position B. The maximum deviation A displayed is 1 m.

4.16.1 Operating the vertical line finder

NOTICE
Inadmissible lifting of load with diagonal pull!
Damage to machine and load.
u Compensate diagonal pull prior to lifting the load.

NOTICE
Improper operation of the diagonal pull display!
Wrong diagonal pull display.
u Ensure that the load is on the ground.
u Ensure that the rope is tensioned by the load.
If the diagonal pull display is observed after lifting the load:
u Observe that the diagonal pull display reacts with delay in case of a swinging
load.
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Diagonal pulls shown in the following may appear in combined form (e.g. right and
at the same time front diagonal pull).

Note
Liebherr recommends:
u Compensate combined diagonal pull simultaneously.

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Operation
Diagonal pull display* (VLF)

Compensating left diagonal pull

Fig. 374: Left diagonal pull (illustration of principle)

The boom head is positioned on the right above the load.

Fig. 375: Turning the slewing platform to the left

u Move left control lever to the left until boom is positioned vertically above the
load.
w Boom head is positioned vertically above the load:
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 Operation
Diagonal pull display* (VLF)

Fig. 376: Boom head is positioned vertically above load (illustration of principle)

Compensating right diagonal pull

Fig. 377: Right diagonal pull (illustration of principle)

The boom head is positioned on the left above the load.

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Operation
Diagonal pull display* (VLF)

Fig. 378: Turning the slewing platform to the right

u Move left control lever to the right until boom is positioned vertically above the
load.
w Boom head is positioned vertically above the load:

Fig. 379: Boom head is positioned vertically above load (illustration of principle) LWN/SK/HD V003///2014-04-18/en

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 Operation
Diagonal pull display* (VLF)

Compensating front diagonal pull

Fig. 380: Front diagonal pull (illustration of principle)

The boom head is positioned behind the load.

Fig. 381: Lowering the boom

u Move left control lever forward until boom is positioned vertically above the load.
w Boom head is positioned vertically above the load:
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Operation
Diagonal pull display* (VLF)

Fig. 382: Boom head is positioned vertically above load (illustration of principle)

Compensating rear diagonal pull

Fig. 383: Rear diagonal pull (illustration of principle)

The boom head is positioned in front of the load.

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 Operation
Diagonal pull display* (VLF)

Fig. 384: Lifting the boom

u Move left control lever backward until boom is positioned vertically above the
load.
w Boom head is positioned vertically above the load:

Fig. 385: Boom head is positioned vertically above load (illustration of principle)
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Operation
Mode Sycratronic*

4.17 Mode Sycratronic*

Two machines can be operated by one machine operator to jointly lift a load. You
determine which machine has control over the two machines by defining one as
leading and one as subsequent machine.

Fig. 386: Sycratronic* mode

1 Leading machine 3 Load
2 Subsequent machine
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 Operation
Mode Sycratronic*

DANGER
Improper use of Sycratronic mode!
Load breakaway, machine toppling over.
u Remedy all error causes and confirm error messages.
u Prevent collisions between machines and load.
u Prevent collisions between load and undefined moving obstacles.
u When utilizing the load-bearing capacity of one or both machines in excess of
75 %, do not deactivate Sycratronic mode.
u Observe national and international regulations (like e.g. ISO 12480:1997 -
Cranes - Safe Use) for heavy load hoist, tandem hoist or similar hoist types.
u Ensure that 100% utilization is always in conformity with ISO 12480:1997.
u Cease operation in case of load moment limiter error.
u Cease operation as of a wind speed of 12 m/s.
u Avoid diagonal pull when lifting loads.

4.17.1 Selecting Sycratronic mode

Ensure that the following conditions are satisfied:
q Diagonal pull is less than 1°.
q Machine operator is located in the cabin of the leading machine.
q Machine operator is located in the cabin of the subsequent machine.
q Main hoist is selected.
q Machines are in Sycratronic position.
q Both machine operators are in visual or radio contact.
q Signalmen are available.
q A competent person plans the lifting operation on site.
q The center of gravity and weight of the load are known.
q Chain of command between machine operator and signalmen is established.
q Crossbar in accordance with EN 13155 is available.
q Machines are started.
q Control levers are in neutral position.
q Manriding mode is deactivated.
q Hook mode or rotator mode are activated.
u Press the button Sycratronic on control panel X20 of the leading machine.

w Sycratronic mode is selected.

w leader is displayed on the monitor.
w Sycratronic values of the subsequent machine are displayed on the monitor:
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Fig. 388: Display Sycratronic values

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Operation
Mode Sycratronic*

u Press the button Sycratronic on control panel X20 of the subsequent machine.

w Sycratronic mode is selected.

w follower is displayed on the monitor.
w Sycratronic values of the leading machine are displayed on the monitor:

Fig. 390: Display Sycratronic values

4.17.2 Operating machines

If an emergency stop was triggered in Sycratronic mode, the leading machine and
the subsequent machine stop. The modes are deselected automatically in the
subsequent machine.
Behavior of the stop symbols on the monitor in Sycratronic mode:
– Stop symbols of own machine are displayed on the monitor without Sycratronic
symbol.
– Stop symbols of other machines are displayed on the monitor in combination
with Sycratronic symbol.
– Own stop symbols always take precedence over the stop symbols of the other
machine.

Rotating the crossbar

Selecting the pivot point of the crossbar

There are two ways of slewing the load:
– Rotating the crossbar around the hook of the leading machine (standard setting)
– Rotating the crossbar around the crossbar center
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 Operation
Mode Sycratronic*

Fig. 391: Selecting the pivot point of the crossbar

1 Button Rotate crossbar
u Press the button Rotate crossbar 1 on the right control lever.
w Rotate crossbar around the hook of the leading machine has been selected:

Fig. 392: Rotating the crossbar around the hook of the leading machine (illustration
of principle)
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w The symbol Rotate crossbar around hook of leading machine is displayed on

the monitor:

Fig. 393: Symbol Rotate crossbar around hook of leading machine

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Operation
Mode Sycratronic*

Fig. 394: Selecting the pivot point of the crossbar

1 Button Rotate crossbar
u Press the button Rotate crossbar 1 on the right control lever again.
w Rotate crossbar around the crossbar center has been selected:

Fig. 395: Rotating the crossbar around the crossbar center (illustration of principle)
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w The symbol Rotate crossbar around crossbar center is displayed on the

monitor:

Fig. 396: Symbol Rotate crossbar around crossbar center

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 Operation
Mode Sycratronic*

Rotating the crossbar clockwise

Fig. 397: Rotating the crossbar clockwise

u Move right control lever to the right.

w Crossbar turns clockwise.

Turning the crossbar counter-clockwise

Fig. 398: Turning the crossbar counter-clockwise

u Move right control lever to the left.

w Crossbar turns counter-clockwise.
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4.17.3 Overload
The following movements are locked at 102% utilization:
– Lift hoisting gear
– Lower hoisting gear
– Lower luffing gear

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Operation
Mode Sycratronic*

Shifting the top load center

u Lower leading machine or lift subsequent machine.
or
Lift leading machine or lower subsequent machine.
w Load center has shifted.

Fig. 399: Shifting the top load center

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F Force x Shift of center of gravity

Shifting the bottom load center

u Lower leading machine or lift subsequent machine.
or
Lift leading machine or lower subsequent machine.
w Load center has shifted.

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 Operation
Mode Sycratronic*

Fig. 400: Shifting the bottom load center

F Force x Shift of center of gravity

4.17.4 Deselecting Sycratronic mode

Ensure that the following conditions are fulfilled:
q Control levers in leading machine and subsequent machine are in zero position.
q Machine stands still.

Deselecting Sycratronic mode on the leading machine

u Press the button Sycratronic on control panel X20.
w Sycratronic mode is deselected.
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Deselecting Sycratronic mode on the subsequent machine

u Press the button Sycratronic on control panel X20.
w Sycratronic mode is deselected.

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Operation
Mode Sycratronic*

4.17.5 Operating Sycratronic emergency lowering system

Depending on the machine situation, various conditions have to be fulfilled to lower
the load. If it is not possible to lower the load, contact Liebherr after sales service.

Operating the machines in case of engine and control

failure
Ensure that the following conditions are satisfied:
q At least three persons are available.
q Persons have radio contact with each other.
q Load can be lowered.
u Operate emergency mode with first person in leading machine.
u Operate emergency mode with second person in subsequent machine.
u Monitor diagonal position of load and synchronous lowering of load with third
person.

Operating the machines in case of engine failure

Note
Liebherr recommends:
u Five persons required to run the emergency mode. One person is in each cabin
and monitors the degree of utilization and the diagonal pull display* on the
screen.

Ensure that the following conditions are satisfied:

q At least five persons are available.
q Persons have radio contact with each other.
q Load can be lowered.
u Operate emergency mode with first person in leading machine.
u Operate emergency mode with second person in subsequent machine.
u Monitor diagonal position of load and synchronous lowering of load with third
person.
u Monitor degree of utilization and diagonal pull display on the monitor of the
leading machine with fourth person.
u Monitor degree of utilization and diagonal pull display on the monitor of the
subsequent machine with fifth person.
The load must be lowered carefully and in small steps alternating by the leader
machine and the follower machine.
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u Lower load alternating in small steps.

Operating the machines in case of failure of one

machine
Ensure that the following conditions are satisfied:
q At least three persons are available.
q Persons have radio contact with each other.
q Load can be lowered.

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 Operation
Mode Sycratronic*

u Monitor degree of utilization and diagonal pull display on the monitor of the
functioning machine with first person.
The person operating emergency mode defines the lowering speed.
u Operate emergency mode with second person in defective machine.
w The functional machine follows.
u Monitor diagonal position of load and synchronous lowering of load with third
person.
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Operation
Dynamic anti-collision system (DACS)*

4.18 Dynamic anti-collision system (DACS)*

The dynamic anti-collision system prevents a collision between the machine's

boom with another machine with dynamic anti-collision system and defined obsta-
cles. It does not protect the machine from colliding with undefined obstacles. It
does not protect the machine from colliding with the swinging load.

WARNING
Improper operation of the dynamic anti-collision system!
Death, severe injuries and damage to the machine.
u Observe general safety notes.
u Observe specific safety notices for the load lifting equipment.

4.18.1 Operating the dynamic anti-collision system

The dynamic anti-collision system shows the distance of 6 m up to 0 m the boom of
the other machine and to defined obstacles.
If the machine enters the defined collision range:
u operate machine outside of the collision range.
w The symbol Dynamic anti-collision system limitation* is displayed on the
monitor:

Fig. 403: Symbol Dynamic anti-collision system limitation*

If the machine has reached the limit of the defined collision range:
u operate machine inside of the collision range.
w The symbol Stop dynamic anti-collision system limitation* is displayed on the
monitor:

Fig. 404: Symbol Stop dynamic anti-collision system limitation*

w Machine is stopped.
w The symbol Collision range in tandem mode* is displayed on the monitor:
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Fig. 405: Symbol Collision range in tandem mode*

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 Operation
Dynamic anti-collision system (DACS)*

4.18.2 Bypassing the dynamic anti-collision system

u Set the key switch Release bypass limit switch on control panel X24 to position
“ON” 2.

w The symbol Dynamic anti-collision system OFF is displayed on the monitor:

Fig. 407: Symbol Dynamic anti-collision system OFF

w The symbol Collision range in tandem mode* blinks on the monitor and the
warning buzzer sounds:

Fig. 408: Symbol Collision range in tandem mode*

w The symbol Stop dynamic anti-collision system limitation* disappears on the
monitor:

Fig. 409: Symbol Stop dynamic anti-collision system limitation*

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Operation
Data recorder*

4.19 Data recorder*

The data recorder records all load cycles performed with the machine and saves
the data to a memory card. However, the minimum load must be at least
approx. 3 tons and the minimum cycle duration 10 seconds.
A valid load cycle consists of:
– Raise load.
– Move load via a trigger point.
– Set down the load.
– Write load cycle to memory card.

4.19.1 Taring the load

It is necessary to tare the load:
– after every activation of the data recorder.
– after every change of the lifting device.
u Raise lifting device.
w Lifting device is in the air and stationary.
w Load indicator shows the same value constantly.
u Press the button Set load display main hoist to zero on the monitor.
w Load is tared.

4.19.2 Setting the trigger point

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Fig. 411: Trigger points

1 Ship 1 Crane
1 Trigger point 1 1 Trigger point 2
u Position the machine in such a way that trigger point 1 and 2 can be set in line
with the situation.

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 Operation
Data recorder*

u Press the button Main page on the monitor.

w Main page is displayed.

u Press the button Set sector point* on control panel X20 for approx. 3 seconds.

w Symbol Sector point set is displayed on the monitor:

4.19.3 Recording a load cycle

u Press the button Start recording on control panel X20.

w Button is illuminated.
w Load cycle recording starts and data is saved.
w Symbol Recording started is displayed on the monitor:

Fig. 416: Symbol Recording started

u Press the button Start recording on control panel X20 again.

w The LED in the button goes off.

w Recording of load cycles stops.
w Symbol Recording stopped is displayed on the monitor:

Fig. 418: Symbol Recording stopped

With detection of a valid load cycle:
w Slow blinking of the LED in the button recording started.
When saving a valid load cycle:
w Fast blinking of the LED in the button recording stopped.
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u Press the button Pause recording on control panel X20.

w Button is illuminated.
w Recording of load cycles is paused.
w Symbol Pause recording is displayed on the monitor:

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Operation
Data recorder*

Fig. 420: Symbol Pause recording

Note
Trigger of emergency stop!
When an emergency stop is actuated the current load cycle becomes invalid and is
thus not saved!
To obtain a valid load cycle after an emergency stop:
u Press the button Pause data recorder on the Litronic screen.
u Bring load to starting point.
u Press the button Pause data recorder on the Litronic screen again.
u Lift load and continue.

4.19.4 Saving data

All cycles recorded by the data recorder are saved automatically to the memory
card as soon as the data recorder is started.
u Start data recorder.
w Directory (LOAD000x) is created on the memory card.
u Stop data recorder.
w Directory (LOAD000x) is closed.
u Start data recorder again.
w A new directory is created.

4.19.5 Data structure of the flash card

Flash card directories

LOAD0001
LOAD0002
LOAD0003

Content of directories
LOAD0001 / head.txt
LOAD0001 / data.txt
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Structure of the file head.txt

LOAD RECORDER LOAD0001

start date 00.00.0000 Start date
start time 00:00:00 Start time
stop date 00.00.0000 Stop date
stop time 00:00:00 Stop time

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Data recorder*

load cycles 0 Number of cycles

sum load [t] 0,0 Total load
sum load hatch 1 [t] 0,0 Sum load hatch 1
sum load hatch 2 [t] 0,0 Sum load hatch 2
sum load hatch 3 [t] 0,0 Sum load hatch 3

Tab. 10: Structure of the file head.txt

Structure of the file data.txt

averag load in utiliza-

max.
date time start time stop e load rope tion hatch
load [t]
[t] [t] [%]
00.00.0000 00:00:00 00:00:00 0,0 0,0 0,0 0,0 1
00.00.0000 00:00:00 00:00:00 0,0 0,0 0,0 0,0 2
...

Tab. 11: Structure of the file data.txt

date Start date

time start Time of load pickup
time stop Time of load lowering
average load [t] Weight of the load when passing the trigger (excl.
rigging material)
load in rope [t] Weight of the total load when passing the trigger (incl.
rigging material)
max. load [t] Maximum load during the entire cycle
utilization [%] Utilization of device in percent

Tab. 12: Legend for table "Structure of the file data.txt"

4.19.6 Exchanging data

Note
u A flashcard slot on the computer is required for reading the flashcard.
u Only remove customer cards for data evaluation.
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Operation
Data recorder*

Fig. 421: Data exchange

1 Liebherr CPU 3 Memory card (flash card)
2 Card reader CF2 4 Flashcard slot

NOTICE
Unauthorised removal of flashcard!
Loss of data.
u Only remove memory card when the machine is off.
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u Remove customer card from card reader CF2.

u Insert memory card in flashcard slot in PC.
w Memory card is displayed as new drive in Windows Explorer.

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 Operation
Rope measuring system

4.20 Rope measuring system

The rope measuring system:

– shows the calculated rope length between boom head and load.
– informs the machine operator about the position of the load.
– is displayed separately for each winch.

4.20.1 Initialise rope measuring system

u Press the button Main page on the monitor.
w Main screen opens.

u Lift hook to desired lifting height.

u Press the button Set rope length to zero on the monitor.
w Rope length to zero is set to zero.
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Operation
Special lift mode*

4.21 Special lift mode*

Special lift mode allows switching between main hoist and auxiliary hoist without
having to lay down the load. The maximum working load of the main hoist is
reduced to the maximum working load of the auxiliary hoist.

4.21.1 Selecting special lift mode

Ensure that the following conditions are fulfilled:
q Control levers are set to zero position.
q Maximum working load of auxiliary hoist is not exceeded on main hoist.
u Press the button Special lift mode on control panel X23.

w Special lift mode is selected.

w The maximum working load of the main hoist is reduced to the maximum
working load of the auxiliary hoist.
w Symbol Special lift mode is displayed on the monitor:

Fig. 425: Symbol Special lift mode

4.21.2 Deselecting special lift mode

u Press the button Special lift mode on control panel X23 again.

w Special lift mode is deselected.

w Symbol Special lift mode is no longer displayed on the monitor:

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 Operation
Emergency descent rescue equipment

4.22 Emergency descent rescue equipment

4.22.1 Using the emergency descent rescue equipment

WARNING
Improper use of emergency descent rescue equipment!
Risk of falling from the cabin.
Grave injury.
u Observe operation manual of emergency descent rescue equipment.
u Use emergency descent rescue equipment exclusively after thorough training.
u Regularly check emergency descent rescue equipment and document the
results.
u Arrange for repairs to be carried out exclusively by the manufacturer.
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Fig. 427: Emergency descent eyelet and storage

1 Emergency descent rescue equip- 2 Emergency descent eyelet
ment
u Take emergency descent rescue equipment from storage in cabin.

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Operation
Emergency descent rescue equipment

Fig. 428: Emergency descent rescue equipment

1 Carabiner 3 Emergency descent rescue
harness
2 Rope
u Latch carabiner in emergency descent eyelet.
u Push bottom front window outward.
u Throw down rope through bottom front window.

Fig. 429: Putting on emergency descent rescue equipment

u Stand over the emergency descent rescue equipment with legs apart.
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 Operation
Emergency descent rescue equipment

Fig. 430: Latch D-rings

u Grasp the safety harness by the D-rings.

u Lift the safety harness until it is below the shoulders.
u Latch the D-rings into carabiner (of safety harness).

Fig. 431: Slipping the braces on

u Slip the “braces” on.

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Operation
Emergency descent rescue equipment

Fig. 432: Descending with the emergency descent rescue equipment

u Step over the cabin platform rail, suspended in the emergency descent rescue
equipment.

Fig. 433: Braking

u Hold on to the rope entering the emergency descent rescue equipment with left
hand.
u Operate the brake lever with the right hand.
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u Release the brake cautiously.

Stopping or braking:
u Hold on to feed rope.
u Let go of brake.

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 Operation
Emergency stop

4.23 Emergency stop

4.23.1 Operation emergency stop

DANGER
Machine under extreme stress under load during an emergency stop!
u The emergency stop is to be used as an emergency cut-off of the machine only.

Fig. 434: Emergency stop

u Press emergency stop.

w E-motor switches off.
w Multi-disc brakes close. Machine brakes abruptly.
If an emergency stop is triggered while a load is being moved:
u Have multi-disc brakes checked by Liebherr customer service.
u Unlocking the activated emergency stop: Gently depress the emergency stop
and turn to the right.
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Operation
Shutdown

4.24 Shutdown

WARNING
Unauthorized operation of machine!
u When leaving machine, protect it against unauthorized use, vandalism and
possible environmental harm.

When shutting machine down, a distinction must be made between:

– Short interruption of work
• Waiting time, breaks from work
• Machine operator remains on site.
– Long interruption of work
• Overnight or several days
• Machine operator leaves site.
– Very long interruption of work
• Two months' work interruption
• Machine operator leaves site.

4.24.1 Short interruption of work

Shutdown before short work interruption

u Set load down on ground.
u Put boom in parked position.
u Press the button E-motor on control panel X20.

4.24.2 Long interruption of work

Move boom into parked position

u Set key switch Release bypass limit switch on control panel X24 to position
“ON” 2.
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u Press and hold the button Bypass parked position on control panel X24.

u Move boom into parked position.

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 Operation
Shutdown

u Set key switch Release bypass limit switch on control panel X24 to position
“OFF” 1.

Turning off the e-motor

u Press the button E-motor on control panel X20.

Turning off the ignition

u Set the key switch ignition on control panel X20 to position “OFF” 1.

Deactivating the main power supply

NOTICE
Longer periods of machine standstill
u Keep auxiliary heating system turned on.
u Check lubrication and oil level prior to start-up.
u Operate machine at least once a week for one hour.
u Perform all maintenance work according to maintenance chart.
u Preserve machine if period of standstill exceeds three months.

u Set the switch Main power supply in switch cabinet X1 to position “OFF” 3.
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u Turn off air conditioning.

u Close all windows and doors.

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Operation
Shutdown

4.24.3 Very long interruption of work

Ensure that the following conditions are fulfilled prior to a 2-month work interrup-
tion:
q Auxiliary power supply is activated.
q Machine storage site is adequately secured.
q External energy supply for the safety equipment is secured (e.g. obstacle light).
q Load is placed on the ground.
q Boom is in parked position.
q Rope of luffing gear is slack.
q Pull up empty hook or use hook fixing point if available.
q Fill gearboxes of the slewing gears completely with appropriate gearbox oil
(approx. 5 l per gearbox).
q Fill gearboxes of the winch drives completely with appropriate gearbox oil
(approx. 11 l per hoisting winch, approx. 30 l with boom luffing winch, approx.
6.5 l with auxiliary winch).
q Fill distribution gearbox completely with appropriate gearbox oil (approx. 9 l per
distributor gearbox).
q There are no leaks (hydraulic oil, engine oil and gearbox oil, coolant, fuel).
q Main supply is switched off.
q Heating of slip ring transmitter, switch cabinet X1 and switch cabinet X2 func-
tions.
q Auxiliary heating functions.
q Tank heating and e-motor heating systems function.
q All doors, windows and hatches are closed.

Moving the boom into parked position

u Set key switch Release bypass limit switch on control panel X24 to position
“ON” 2.

u Press and hold the button Bypass parked position on control panel X24.

u Move boom into parked position.

u Set key switch Release bypass limit switch on control panel X24 to position
“OFF” 1.
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Turning off the e-motor

u Press the button E-motor on control panel X20.

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 Operation
Shutdown

Turning off the ignition

u Set the key switch ignition on control panel X20 to position “OFF” 1.

Deactivating the main power supply

NOTICE
Longer periods of machine standstill
u Keep auxiliary heating system turned on.
u Check lubrication and oil level prior to start-up.
u Operate machine at least once a week for one hour.
u Perform all maintenance work according to maintenance chart.
u Preserve machine if period of standstill exceeds three months.

u Set switch Main power supply on switch cabinet X2 to position “OFF” 2.

u Turn off air conditioning.

u Close all windows and doors.
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Operation
Emergency mode

4.25 Emergency mode

WARNING
Unauthorized or improper use of emergency mode!
u Only operate emergency mode in emergency situations.
u Cordon off a large area around the danger zone.
u Request a signalman for monitoring.
u Use emergency mode very carefully.

Possible movements:
– Lower load.
– Disengage slewing gear brake.
– Lower boom.

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 Operation
Emergency mode

Fig. 448: Overview emergency mode operation

1 Valves H62, H63 4 Valves D62A, D62B, D62C, H63
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2 Connection for hand pump 5 Valve D63

3 Valve E63

4.25.1 Emergency mode in case of failure of a power pack

The drive unit consists of two power packs that work independently of each other.
The machine is usually operated with both power packs.
If one power pack fails, the machine can still be operated with the other power
pack with maximum load but only at half the working speed.

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Operation
Emergency mode

Operation with both power packs

Ensure that the following conditions are fulfilled:
q Ignition is switched off.
q Engine is turned off.
u Set ball tap D - A to normal position.
u Set ball tap D - B to normal position.
u Open ball tap H-B1.
u Open ball tap H-B2.
u Open ball tap E-B1.
u Open ball tap E-B2.
u Start machine ( (For more information see: 4.3 Start-up, page 122) ).

Operation with power pack1

Ensure that the following conditions are fulfilled:
q Ignition is switched off.
q Engine is turned off.
u Set ball tap normal position to position DA.
u Set ball tap normal position to position DA.
u Open ball tap H-B1.
u Close ball tap H-B2.
u Open ball tap E-B1.
u Close ball tap E-B2.
u Start machine ( (For more information see: 4.3 Start-up, page 122) ).

Operation with power pack2

Ensure that the following conditions are fulfilled:
q Ignition is switched off.
q Engine is turned off.
u Set ball tap normal position to position DB.
u Set ball tap normal position to position DB.
u Close ball tap H-B1.
u Open ball tap H-B2.
u Close ball tap E-B1.
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u Open ball tap E-B2.

u Start machine ( (For more information see: 4.3 Start-up, page 122) ).

4.25.2 Lowering the load

u Connect pressure connection of the hand pump on the connection of the
hydraulic tank's suction line.
u Connect pressure connection of the hand pump on the intended connection
close to valve H62.
u Set hand valve H62A to emergency mode position.

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 Operation
Emergency mode

u Establish pressure with hand pump.

w Hoisting gear brake disengages.
u Slowly open restrictor valve H63.
u Regulate lowering speed with restrictor valve H63.
w Load lowers.
After completed emergency mode:
u Close valve H63.
u Set valve H62 to normal position.

4.25.3 Slewing the slewing column

u Set valve D62A to emergency mode position.
u Set valve D62B to emergency mode position.
u Connect pressure connection of the hand pump on the connection of the
hydraulic tank's suction line.
u Connect pressure connection of the hand pump on the intended connection
close to valve H62C.
u Set valve D62C to emergency mode position.
u Set valve D63 to emergency mode position.
u Establish pressure with hand pump.
w Slewing gear brake disengages.
u Slew machine with additional equipment (e.g. chain hoist).
After completed emergency mode:
u Set valve D63 to normal position.
u Set valve D62C to normal position.
u Set valve D62B to normal position.
u Set valve D62A to normal position.

4.25.4 Lowering the boom

u Connect pressure connection of the hand pump on the connection of the
hydraulic tank's suction line.
u Connect pressure connection of the hand pump on the intended connection
close to valve E62.
u Set hand valve E62 to emergency mode position.
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u Establish pressure with hand pump.

u Boom hoist brake disengages.
u Slowly open restrictor valve E63.
u Regulate lowering speed with restrictor valve E63.
w Boom lowers.
After completed emergency mode:
u Close restrictor valve E63.
u Set valve E62 to normal position.

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Operation
Emergency mode

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Operational faults, diagnosis 5

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5 Operational faults, diagnosis

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 5 Operational faults, diagnosis

The chapter Operation errors, diagnosis deals with the following issues:
– Operation errors of the machine and the corresponding diagnosis

5.1 Litronic® testing system

5.1.1 Litronic testing system overview

WARNING
Unauthorized changes to Litronic testing system!
Damage to machine.
u Only have adjustment values or correction values changed by Liebherr service
personnel.

The Litronic testing system is an extensive diagnosis tool and service tool available
on the monitor, on a service notebook or via a modem connection (if available).
The Litronic testing system serves to view the inputs and outputs, markers, internal
variables and statuses.
The Litronic® testing system provides the following functions:
– Display of the ID number of the installed software and the software version
– Display of the inputs and outputs of the modules with comment text
– Display of the internal variables with comment text
– Displays a selection list
– Displays correction values (machine parameters)
– Displays messages (message stack)
– Displays special functions:
• Modem configuration
• Memory card control (CF)
• CAN configuration status
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Operational faults, diagnosis
Litronic® testing system

Fig. 449: Litronic® testing system overview

1 Header: Name of the current 3 Input line: For display and correc-
screen tion of entered values, display of
status messages and input
prompts
2 Main window: Displays information 4 Menu bar: Buttons
The Litronic® testing system comprises a number of screen pages; the buttons are
used to move from page to page. Some pages have two menu bars that you can
toggle between using the button MENU 1/2. The first menu bar always appears
when a page is opened. When the Litronic® testing system is first started, the
homepage (Main Menu) is displayed. On each subsequent start, the page last
open when the system was exited is loaded. The other settings are also retained.
Certain commands can be executed several times in succession by entering the
number of repetitions (these appear in the input line) or by pressing the required
button. This includes PREVIOUS and NEXT for example.

5.1.2 Screen pages

Main screen page

Switch from the main screen to the different screens of the Litronic testing system.
Exit the current screen with the BACK button.
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The following pages can be reached from the main screen page:
– Screen INPUT/OUTPUT
– Screen MEMORY
– Screen SELECT
– Screen CORRECTION
– Screen MESSAGES
– Screen SPECIAL FUNCTIONS

Screen INPUT/OUTPUT
The INPUT/OUTPUT screen serves to view the inputs and outputs of the modules.

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 Operational faults, diagnosis
Litronic® testing system

Description of the buttons:

– NEXT CAN LINEmoves to the next CAN line.
– PREVIOUS MODULE and NEXT MODULE switches between the modules of
the selected CAN line.
– PREVIOUS and NEXT move the Cursor up and down to highlight a channel in
the selected module. The highlighted channel is displayed as an inverse I or O.
– The marked channel can be taken over into the select list with SELECT. If the
channel was already selected, the channel is deleted from the list again. The
inverse display shows whether a channel has been selected.
– MENU 1/2 switches between the two menu bars.
– DOCUMENT displays 16 channels (inputs or outputs) with comment text on one
page. With digital modules (32 channels) use PREVIOUS and NEXT to switch
to the second page.
– UNDOCUM displays all inputs or outputs on one page.
– IDENTIFY displays 16 inputs or outputs on one page with the identifier on one
page. With digital modules (32 channels) use PREVIOUS and NEXT to switch
to the second page.
– BACK returns to the main screen.

Screen MEMORY
The MEMORY screen shows the internally used buffer stores (markers).
Description of the buttons:
– NEXT SECTION moves between the 16 flag sections: X-B-W-D, 1-2-3-4.
– PREVIOUS PAGE and NEXT PAGE to switch between the pages. One page
contains 16 markers of the selected section.
– PREVIOUS and NEXT move between the flags. The highlighted flag is
displayed as an inverse M.
– The marked marker can be taken over into the select list with SELECT. If the
marker was already selected, the marker is deleted from the list again. The
inverse display of the marker shows whether a marker has been selected.
– MENU 1/2 switches between the two menu bars.
– DOCUMENT displays the markers with comment text.
– IDENTIFY displays the flags with the identifier.
– BACK returns to the main screen.

Screen SELECT
The values can be entered in the select list to prevent having to switch between the
input menu, output menu and marker menu pages. Now the entries can be viewed
and edited on the SELECT screen. The select screen may consist of several
pages. If the list is full and a new value is entered, the oldest value is deleted from
the list. The select lists can also be saved on memory cards and loaded from there.
How to add entries to the Select list:
– With the SELECT button on the INPUT/OUTPUT, MEMORY screens or
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CORRECTION
– With the ADD button on the SELECT screen by entering the IEC address
– With the LOAD FROM CARD button on the SELECT screen from a file
How to delete entries from the Select list:
– Reselect a selected value with the SELECT button on the INPUT/OUTPUT,
MEMORY or CORRECTION screens.
– Delete the marked entry with the DELETE button on the SELECT screen.
Description of the buttons:
– ADD adds a new entry to the Select list. A menu bar is displayed in which the
IEC address is entered.

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– DELETE deletes the marked entry from the select list.

– PREVIOUS and NEXT to switch between the individual select entries. The
marked entry is displayed with an inverted I, O or M.
– NEXT PAGE moves to the next page of the Select list so that more values can
be viewed.
– IDENTIFY displays the inputs, outputs and markers with the identifier.
– DOCUMENT displays the inputs, outputs and markers with comment text.
– LOAD FROM CARD loads a new Select list from a file A menu is then
displayed. The menu contains a list of files, one of which can be selected, and
also allows a specific file name to be entered .
– SAVE TO CARD saves the current Select list in a file. A menu appears from
which the name of the file can be selected .
– MENU 1/2 switches between the two menu bars.
– BACK returns to the main screen.

Screen Add Selection

The Add Selection screen is called up with the ADD button on the SELECT screen.
The IEC address of a new select entry can be entered this way. The ICE address
is entered with the corresponding buttons in the input field.
Example:
– Desired IEC address: %QW1.17.1
– %, Q and W are entered using the appropriate buttons.
– 1.17.1 is entered as a normal number and can be edited as necessary using the
button TAKE & BACK to apply the address.
Description of the buttons:
– Use M, I or Q to select the IEC type flag, input or output. These change each
time a key is pressed and appear in the input bar. A correction can be made by
pressing another type.
– Use X, B, W and D to select the size of the IEC entry. These change each time
a key is pressed and appear in the input bar. A correction is made by pressing
another size.
– TAKE & BACK returns to the SELECT screen and applies the IEC address from
the entry bar.

Screen Select File Load

A saved select list can be loaded from the memory card on the Select File Load
screen.
Description of the buttons:
– CHARACTER NEXT adds a new character to the end of the input bar. New
characters can also be added by entering numbers and letters.
– CHARACTER DOWN and CHARACTER UP change the last character on the
input bar.
– PREVIOUS and NEXT move the cursor up and down in the select list. When
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selecting a file, the name of the file is taken over into the entry bar.
– LOAD loads the selected file displayed in the entry bar and returns to the
SELECT screen.
– BACK cancels the process and returns to the SELECT screen.

Screen Select File Save

A select list can be saved on the memory card on the Select File Save screen.
Description of the buttons:
– CHARACTER NEXT adds a new character to the end of the input bar. New
characters can also be added by entering numbers and letters.

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– CHARACTER DOWN and CHARACTER UP change the last character on the

input bar.
– PREVIOUS and NEXT move the cursor up and down in the select list. When
selecting a file, the name of the file is taken over into the entry bar.
– SAVE saves the select list in a file (enter file name in the entry bar) and returns
to the SELECT screen.
– BACK cancels the process and returns to the SELECT screen.

Screen CORRECTION
The CORRECTION screen displays correction values.
Description of the buttons:
– NEXT SECTION switches between the four correction value sections: X-B-W-D.
– PREVIOUS PAGE and NEXT PAGE to switch between the pages. One page
contains 16 correction values of the selected section.
– PREVIOUS and NEXT move between the correction values. The highlighted
correction value is displayed as an inverse M.
– DOCUMENT displays the correction values with comment text.
– IDENTIFY displays the correction values with the identifier.
– BASE MIN & MAX displays the correction values with the default value and
upper and lower limits.
– SAVE TO CARD saves the current correction values in a file. The file name can
be selected from the menu that now appears. A standard file name (created
from the current date) is suggested. This name can be changed if required .
– Use SELECT to add the highlighted entry to the Select list. If the entry is
already selected, it will be removed from the list. The name of a correction value
will be displayed inverse if it is selected.
– MENU 1/2 switches between the two menu bars.
– BACK returns to the main screen.

Screen MESSAGES
The MESSAGES screen shows the saved application messages (e.g. sensor
errors) and all system errors (e.g. CAN bus, modules, central unit). The application
messages are buffered internally.
Description of the buttons:
– ALL lists all saved messages (maximum 15,000).
– PREVIOUS START and NEXT START move between all messages saved at
each start-up.
– PRIORITY MAXFILTER and PRIORITY MINFILTER list the saved messages
filtered by priority.
– GROUP FILTER lists the saved messages filtered by certain groups.
– SINCE START lists only the messages since the current machine start-up.
– LANGUAGE enables a different language for the messages. Messages that are
not found in the selected language will be displayed in English. Switching only
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has an effect on the MESSAGES screen .

– PREVIOUS and NEXT move between the messages.
– SAVE TO CARD saves all messages (ALL or SINCE START) in a file. The file
name can be selected from the menu that now appears. A standard file name
(created from the current date) is suggested. This name can be changed if
required .
– MENU 1/2 switches between the two menu bars.
– BACK returns to the main screen.

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Screen Language Selection

The message language can be selected on the Language Selection screen.
Description of the buttons:
– PREVIOUS and NEXT move between the different languages.
– SELECT is used to select and load the highlighted language.

Screen SPECIAL FUNCTIONS

From the SPECIAL FUNCTIONS screen, you can access various additional
screens or return to the main screen with the BACK button.

Screen Modem Function

The GSM modem can be configured and operated on the Modem Function screen.
The current modem status (e.g. Online, Offline, False PIN) can be viewed in the
entry bar.
Description of the buttons:
– DIAL dials a previously entered phone number.
– HANGUP terminates an active modem connection (hang up handset).
– RLP ON/OFF activates or deactivates the radio link protocol for GSM modem
connections. The settings first become effective after the next program start.
– V32/V110 activates the V32 protocol or V110 protocol for GSM modem connec-
tions. The settings first become effective after the next program start.
– PREVIOUS and NEXT change between the interfaces; the default Modem
Client is COM2.
– PIN INPUT allows the PIN codes for the GSM modem to be entered manually.
– MODEM CONNECT enables the modem server programme to be started on an
unused interface.
– MENU 1/2 switches between the two menu bars.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen Drive Function

The Drive Function screen displays information about the current drive.
Description of the buttons:
– REMOVE CARD must be performed before removing a memory card from the
drive. Switching off the Litronic control system is another option. The system
automatically recognises when a new card has been inserted.
– DIR LIST displays the files and directories (no subdirectories) of the current
drive.
– PREVIOUS DRIVE and NEXT DRIVE switch between the individual drives
known to the Litronic control system.
– CHECK CARD checks the current drive for errors.
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– BACK returns to the SPECIAL FUNCTIONS screen.

Screen Time Function

The Time Function screen shows the date and time.
Description of the buttons:
– DAYLIGHT SAVING switches to the summer time setting.
– TIMEZONE MOVE WEST moves the time zone setting one hour westwards.
– BACK returns to the SPECIAL FUNCTIONS screen.

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Priority Level screen (for Liebherr service personnel only)

The Litronic code can be entered on the Priority Level screen to access supervisor
level. The supervisor level is required to e.g. set the time.
Description of the buttons:
– When the LEVEL CHANGE key is pressed, the value in the input bar is copied
and examined to see whether it is a valid Litronic® code.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen CAN Configuration

The CAN Configuration screen shows all installed CAN modules with utilization
status.
Description of the buttons:
– NEXT PAGE switches to the next screen.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen CAN Line Information

The CAN Line Information screen shows the used CAN lines and settings.
Description of the buttons:
– MODULE INFO switches to the CAN Configuration screen.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen Display Configuration

On the Display Configuration screen, you can select options for the display of the
INPUT/OUTPUT screen.
Description of the buttons:
– ALL MODULES displays all CAN modules on the INPUT/OUTPUT screen.
– ONLY USED MODULES only displays the CAN modules set to “used” on the
INPUT/OUTPUT screen.
– With NUMBER STYLE the inputs, outputs and markers are switched between
standard display and hexadecimal display.
– UPDATE INTERVAL changes the update speed of the input, output and marker
display.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen System Language Selection

The system language can be selected on the System Language Selection screen,
whereby a language is selected or the internal standard language loaded.
The selected system language is only activated once the Litronic control system is
switched back on.
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Description of the buttons:

– PREVIOUS and NEXT move between the different languages.
– SELECT loads the marked language as new system language and returns to
the SPECIAL FUNCTIONS screen.
– USE DEFAULT loads the English language as new system language and
returns to the SPECIAL FUNCTIONS screen.
– MENU 1/2 switches between the two menu bars.
– BACK cancels the process and returns to the SPECIAL FUNCTIONS screen.

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Screen Sampling Trace

The Sampling Trace screen is used for the online data recording of previously
defined inputs and outputs. The Sampling Trace screen displays information about
the “sampling trace” and allows to change the status and save the recorded data.
Description of the buttons:
– SAMPLE ACTIVE activates “sampling trace” after the options were defined.
Serves to record and check the trigger conditions.
– TRIGGER MANUAL simulates the trigger conditions. TRIGGER MANUAL is
only available if “Sampling Trace” is activated and the trigger conditions were
not yet fulfilled.
– END MANUAL stops recording of the “sampling trace” and automatically leads
to ready state. END MANUAL is only available if the “sampling trace” is acti-
vated.
– LOAD FROM CARD loads a configuration from a saved “Sampling Trace” file. A
menu appears from which the name of the file can be selected .
– SAVE TO CARD saves the recorded data and the “Sampling Trace” configura-
tion in a file. A menu appears from which the name of the file can be selected .
– SAVE TO SELECT saves the variables used in the “Sampling Trace” in the
Select list. Existing entries in the Select list are deleted.
– LOAD FROM SELECT loads the selected variables into the “sampling trace”
list.
– PREVIOUS and NEXT switch between the configuration data. The marked
entry is displayed inverted.
– CHANGE changes the marked entry to the value in the entry bar. The value
must lie within the valid limits.
– MENU 1/2 switches between the two menu bars.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen System Status

The System Status screen shows the current system status (e.g. running, stopped)
and the timing of the SPS tasks.
Description of the buttons:
– SYSTEM TASKS displays information about the system tasks.
– BOARD INFO displays information about the circuit board (e.g. voltage, temper-
ature).
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen MDE/PDE
The MDE/PDE screen displays the status of the MDR (Machine Data Recording),
the PDR (Process Data Recording), and the data logger.
Description of the buttons:
– MDE displays the MDR data.
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– PDE displays the PDR data.

– SELECT GRAPHIC lists saved graphics (e.g. company logo) for printout of the
PDR data. The desired graphic can be selected.
– LOGGER displays the data logger.
– BACK returns to the SPECIAL FUNCTIONS screen.

Screen Clients
The Clients screen displays the status of the individual communication interfaces
(clients).

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Description of the buttons:

– PREVIOUS and NEXT move between the interfaces.
– BACK returns to the SPECIAL FUNCTIONS screen.
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 6 Maintenance

The chapter Maintenance deals with the following subjects:

– Maintenance and inspection of the machine
– Lubricants and consumables

6.1 Maintenance and inspection schedule

NOTICE
Improperly performed maintenance and inspection work!
Damage to machine.
u Observe the prescribed maintenance and inspection intervals according to the
maintenance plan.
u Perform all maintenance and inspection work according to specifications.
u Observe references to manufacturer's documentation and the regulations and
guidelines contained therein.

This chapter contains all maintenance work to be performed on the machine in

table form.
The maintenance and inspection intervals are specified in operating hours and
calendar times, whereby the first reached interval date is decisive. The intervals
are complementary. This means that if intervals with a higher number of hours/
calendar time are performed, the activities with a lower number of hours/calendar
time also have to be performed.
The stated maintenance and inspection intervals also apply for work referring to
the manufacturer's documentation. Observe the regulations and guidelines of the
manufacturer's documentation when performing maintenance and inspection work.
The maintenance work must be carried out conscientiously. The maintenance
intervals must not be exceeded, but can be shortened if necessary. Shortening of
intervals largely depends on the operating conditions.
The maintenance intervals must be reduced in case of the following operating
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conditions:
– High temperature differences on site
– Generally high temperatures
– Aggressive environment (e.g. chemical plant)
– Dirty, dusty air
– High strains during operation
Maintenance personnel
Trained personnel with the appropriate qualifications (machine operators) with
specialist knowledge and experience required to carry out the respective mainte-
nance work.

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Authorized service personnel

Specially trained personnel with comprehensive knowledge of components and
systems authorized by Liebherr to perform this work. This is first of all the Liebherr
service personnel that was trained and authorized directly by Liebherr or one of its
service centers.

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 Maintenance
Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

Whole machine
l Checking all control equipment and display devices
l Checking emergency stop for function without load on the hook and engine
turned off
l Visual inspection of the entire crane structure (brakes, ladder, platform)
l Checking entire crane for lose parts, rust, corrosion and fissures
l Performing all movements and check limit switch for function
l Performing disc brake test (if man riding is installed)
l Checking the operation of the boom angle indicator for function (if installed)
² Visual inspection of the entire crane after severe incidents (e.g. storm, over-
load, emergency stop with load, ...)
m Checking the rated load display
l Visual inspection of the paint for mechanical damage or corrosion
l Checking the rubber stoppers on the entire crane
l Checking the condition and screw connection of ballast and A-frame (if
installed)
l Checking the condition and suspension of the blow-back polyamide slabs (if
installed)
m Check tightening torque and corrosion of the pins of the boom flange connec-
tion. Re-lubricate if required
m Exchange pins of the boom flange connection every 10 years (if installed)
l Visual inspection of the boom pivot bearing
l Checking the mechanical conditions and impermeability of all lubrication spots
and lubrication pipes
l Re-lubricate all lubrication spots every 250h
Electric motor
l Checking the electric motor for function in dependence on air humidity and
weather conditions
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m Performing insulation measurement

l Keeping the motor and ventilation slots clean
l Check the state of the shaft seal. Replace if required
l Check the condition of the switch stack of the star-delta contactor. Replace if
required
² When replacing the electric motor, replace switch stack of the star-delta
contactor
l Checking the state of the fixing screws
l Checking the state of the ball bearings

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Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

ª Greasing the ball bearings (see lubrication information plate, point 5 on the 239
electric motor
Distributor gearbox
l Checking the gearbox oil level 241
l Bring system to working temperature, take gearbox oil sample. If required,
change gear oil
l Checking the vent
l Visual inspection of the fixing pins
Swing
l Checking the gearbox oil level 243
l Checking the vent screw
l Bring system to working temperature, take gearbox oil sample. If required,
change gear oil
m Check gearbox for leaks
l Checking fixing pins for tight fit
l Checking swing pinion and crown gear for wear and pitting
m Checking that the stopping brakes are working
Swing connection
m Check the tightening torque of the screw connection pins. If more than 10% of
the screw connection pins are below the required tightening torque, readjust all
screw connection pins
l Check toothing for sufficient lubrication. Re-lubricate if required 245
ª Lubricating the toothing prior to longer periods of standstill 245
l Take grease sample from slewing ring
l Check slewing ring for sufficient lubrication every 250h. Relubricate if neces- 245
sary
ª Lubricate slewing ring prior to longer periods of standstill. 245
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ª Performing a basic measurement of the pitch play after takeover 246

l Measure slewing ring tilt clearance 246
m Exchange slewing ring every 10 years
Winches
l Checking the gearbox oil level
ª Take an oil sample once after 100h. If required, change oil
l Bring system to working temperature, take oil sample. If required, change oil
l Check the state of the counter bearings. Re-lubricate if required
l Checking the vent

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Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

l Checking the suspension of limit switch and coupling

l Checking the function of the limit switch (if possible)
l Checking the pins/screw connections of the winch to the main crane structure
m Checking that the stopping brakes are working
l Checking the condition and wear of the outer disc brakes for man riding (if
installed)
l Checking the condition and wear of the rope kicker
ª Exchanging the rope kicker in case of excess wear
l Checking the overall mechanical condition of the winch like drum grooves,
flanged wheels, diagonal pipe connections, pinions, etc.
l Checking the correct winding of the rope on the winch drum
l Checking the correct installation of the rope on the rope fixing point and at the
fixing point itself
l Checking the condition and suspension of the press cylinders
l Checking the condition and suspension of the overspool safety device
Lifting device
l Checking hooks for corrosion, wear and damage
l Re-lubricating pulley bearings and hook bearings
l Checking function of slewing bearing
l Checking hook aperture safety for function and corrosion
l Check grabs for corrosion, wear and damage. Re-lubricate if required
l Checking the state of the shackles
l Sight inspection of the NEMAG quick-release links (with grabber operation)
l Sight inspection of the NEMAG quick-release links (with hook operation)
l MPI test of the NEMAG quick-release links (with grabber operation)
l MPI test of the NEMAG quick-release links (with hook operation)
l Check spreaders for corrosion, wear and damage. Re-lubricate if required
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l Checking all cables, distribution boxes and lights for condition, wear and
damage
l Check the condition, wear and attachment of the cable drum. Re-lubricate and
refill if required
l Checking the condition, wear and attachment of the hook fixing point
l Checking the function of tandem and anti-collision operation
Hydraulic system
l Check hydraulic system for leaks and state of hoses, fittings, valves, blocks, 256
motors, pumps, and cylinders.

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Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

m Check the pressure settings. Adjust if required

l Check the oil cooler for contamination. Clean if required
m Visual inspection for tooth profile wears of hydraulic motors and pumps
m Checking the function of the supply pressure switch (if installed)
l Checking the conditions and seal of all hydraulic drives and bulkhead plates
Hydraulic oil tank
l Checking the hydraulic oil level. 257
l Replacing the vent of the hydraulic oil tank
l Bring system to working temperature, take oil sample 10h after each hydraulic 258
oil change (reference measurement)
ª Bring system to working temperature, take oil sample after 500h 258
l Heat system to working temperature, take oil sample every 1,000h/annually 258
258
l If not using Liebherr hydraulic oil, change hydraulic oil every 2,000h/every 2 258
years 258
l If using Liebherr Hydraulic 37, change hydraulic oil every 4,000h/every 4 years 258
l If using Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic, change 258
hydraulic oil every 6,000h/every 6 years
l Cleaning the magnetic rod and return filter 260
l Cleaning the magnetic rod and return filter (weekly during the first 250h) 260
Hydraulic filter
l Exchanging the filter elements of all hydraulic filters
m
Accumulator
n Checking the accumulator 268
l Checking the accumulator 268
m Changing the accumulator 269
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Hydraulic cylinders
m Check that the hydraulic cylinder fits properly and does not leak 270
l Protecting the piston rods of the hydraulic cylinders from corrosion 270
l Preserving the piston rods of the hydraulic cylinders in case of longer periods 270
of non-use
Hydraulic hoses
l Visual inspection of rigid hoses 271
l Every 10000h/6 years - replace all outer hoses 271

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 Maintenance
Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

Electrical system
l Checking the condition and insulation of all electronic transmitters
l Replacing switching cabinet filter mats 272
l Checking terminals and vents of the switching cabinet 273
m Checking all terminals in the switching cabinet 273
l Checking the mechanic and electric condition of the distributor boxes
l Checking all threaded cable connections for correct installation
l Checking the correct installation and function of the instruments (e.g. cables,
sensors)
l Visual inspection of all instruments for corrosion and damage
l Checking the function of lighting and heating (also that of the electric motor
and slip ring)
l Clean the battery terminal (if installed). Lubricate if required
l Check the water fill level of the battery (if installed). If necessary, refill distilled
water
l Checking the equipotential bonding connection between moving components
(e.g. boom slewing column)
² Checking the condition and starting power of the main switch, the main fuses
(current, star, delta) and the terminal board (with electric motor)
l Checking the electric equipment in line with the (local) regulations or location-
specific standards
Slip ring unit
l Checking the screw connections and brushes of the slip rings
l Checking the tight fight of the screws on the terminals at random
l Checking the wear of the carbon brush every 150h or at latest every 6 months
l Checking the tight fight of the screw connections on the copper conductor rail
at random
l Removing metal particles on the insulation between the slip rings
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l Checking free movement of the cable loop (if installed)

l Checking cable loop for damage (if installed)
Fire extinguishers
l Check the proper seals and inspection dates on the fire extinguishers. 276
Replacing used fire extinguishers or fire extinguishers with expired test date or
having them checked by authorised personnel
Emergency descent rescue equipment
m Checking safety rope for cuts or fibre breaks
m Checking safety rope for chemical or mechanical damage

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Maintenance and inspection schedule

Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

m Checking safety rope for thickening, kinks, knots or loops

m Checking safety rope for rotting, excessive wear, abrasion or scorching
m Checking end termination (knot and seam) of safety rope for completion
m Check shrink hose fastening of rope end termination.
m Checking carabiners/safety hooks for mechanical damage, corrosion damage
and deformation
m Checking closure mechanism of carabiners/safety hooks
m Checking condition of springs/rivets/axles
m Checking that snap action of carabiners/safety hooks works smoothly
m Checking ease of movement of abseil rescue equipment cam
m Checking abseil rescue equipment for mechanical damage and corrosion
damage
m Checking brake cam (aluminium) of abseil rescue equipment for wear
m Checking brake cylinder (brass) of abseil rescue equipment for wear
m Checking legibility of type plate
Lubrication system*
l Checking the function of the central lubrication 279
l Checking fill level of lubrication pumps 279
Ropes
l Check that the ropes are guided correctly over the rope pulleys and that the
rope winds correctly onto the drum
l Check ropes for wear, tight fit and lubrication 283
ª Exchange the rope kicker on the winch when exchanging the rope (only with
CBB 2980 – CBB 4700)
ª Exchange the rope kicker on the winch in case of faulty layering (only with CBB
2980 – CBB 4700)
l Check status of the rope end screw connection
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ª Shorten rope by 1/3 of the winch circumference to compensate rope wear (with
multi-layer winding)
Rope pulleys
l Checking pulleys for ease of movement, signs of wear and damage
l Check condition and lubrication of the pulley bearings. Re-lubricate if required
l Renewing plastic pulleys every 8 years
n l Checking the rope tensioning pulleys of the winch drums
Cab
ª Exchanging the windshield wipers 305

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Customer:.................................Type/Type no.:............... Serial no.:....................... Service hours:................ Date:..................................................

Maintenance / inspection Tasks to be performed

after service hours
8h/Daily
40h/Weekly
500h/Quarterly
1000h/Every six months
2000h/Annually
4000h/2 years
6000h/3 years
Special intervals

See page
By maintenance staff By authorised specialist staff
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª As necessary ² As necessary
T Annually before the winter

l Checking the function of all operating elements

Air conditioning*
l Maintenance of air conditioning according to manufacturer's specifications 309
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6.2 Lubricants and consumables

Obeying the guidelines for lubrication and the use of fuels guarantees maximum
reliability and a long machine life.
Cleanliness is important when handling lubricants and operating materials.

Note
Environmental pollution!
u Fluids such as hydraulic oil, fuel and coolant must be disposed of in accordance
with national and international regulations and guidelines.

Lubricants have three main tasks:

– Reducing friction
– Preventing corrosion
– Removing dirt and abrasion particles
The higher the quality of the lubricant, the longer the service life of the components
and the lower the wear. Higher-quality lubricants have less moisture content, which
reduces consumption.
The specified lubrication intervals must not be exceeded, but can be shortened if
necessary. Shortening of intervals largely depends on the operating conditions.

NOTICE
Insufficient lubrication!
Damage to machine.
u The prescribed lubrication intervals on the lubrication diagram must be
observed.

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6.2.1 Lubrication diagram

Fig. 450: Lubrication diagram

1 Pulley 4 Luffing winch
2 Rope 5 Slewing ring
3 Hoisting winch 6 Hook
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6.2.2 Oil filling schedule

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Fig. 451: Oil filling schedule

1 Hydraulic oil tank 3 Main hoisting winch gearbox
2 Swing gear (3x) 4 Auxiliary hoisting winch gearbox

6.2.3 Filling capacities table

The filling capacity table is right behind the cover sheet of this operation manual.

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6.2.4 Lubrication chart

No. Lubrication Outside temperature Type Specification Liebherr

spots
ISO VG/SAE Lubricants
all year around SAE 10W-40 ACEA E4 Liebherr Motoroil 10W-40
to -20 °C API CF
below -20 °C with pre-
heating
all year around SAE 10W-40 ACEA E4 / E6 / Liebherr Motoroil 10W-40
E7 low ash required when
Engine, Motor, using particulate filters
1 to -20 °C API CF-4 / CG-4
oil-bath air filter
below -20 °C with pre- CH-4 / CI-4
heating
all year around SAE 5W-30 ACEA E4 Liebherr Motoroil 5W-30
to -30 °C API CF
below -30 °C with pre-
heating
Mechanical to -20 °C SAE 85W-90 API GL 5 Liebherr Hypoid EP 90
gearboxes,
2 to -40 °C SAE 75W-90 API GL 4; GL 5; Liebherr Syntogear Plus
winches and
MT 1 75W-90
drive axles
to -25 °C + 50 °C B) ISO VG 32 - DIN 51 524 / T3 Liebherr Hydraulic 37
46
SAE 10W-20 HVLP
ATF A) 1.DEXRON II D/E

to -25 °C + 50 °C B) ISO VG 46 DIN 51 524 / T3 Liebherr Hydraulic Plus

(32-68)
Hydrostatic SAE 10W-20 HVLPD HC
3 drive, hydro-
biodegradable in
steer
acc. with CEC-
L-33-A-93
to -50 °C + 30 °C ISO VG 15-46 DIN 51 524 / T3 Liebherr Hydraulic Plus
Arctic
SAE 0W-20 HVLPD HC
biodegradable in
acc. with CEC-
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L-33-A-93
Hydraulic addi- DIN 51 757 Liebherr special additive
4 tive for free-fall NL
DIN 51 562
brake

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No. Lubrication Outside temperature Type Specification Liebherr

spots
ISO VG/SAE Lubricants

Roller bearings, to -25 °C + 150 °C DIN 51 502 Liebherr Universal

friction bear- Grease 9900
For lubrication systems KP 2 K-30
ings, ball
to -20 °C + 150 °C Grease, KPF 2 N-25
bearing swing
5 lithium saponi-
rings, cardan to -60 °C + 140 °C DIN 51 502 Liebherr Universal
fied
joints, other Grease Arctic
grease lubrica- For lubrication systems KPFHC 1N-60
tion to -55 °C + 140 °C
to -25 °C + 150 °C DIN 51 502 Liebherr Universal
Grease 9900
For lubrication systems OGPF 2
to -20 °C + 150 °C
Open Lubrication
6 cogwheels and to -60 °C + 140 °C and preserva- OGPF 1 Liebherr Universal
crown gears tion Grease Arctic
For lubrication systems
to -55 °C + 140 °C
all sections OGPF 00 Liebherr spray paste
7 Ropes to -40 °C + 50 °C Liebherr WR-Lube SC
all sections DIN 51 502 Liebherr grease for tele-
Telescopic Special
8 scopic components 9613
boom instruction KP 2 K-30
Plus
to -37 °C DIN 51 757/4 Liebherr Antifreeze Mix
9 Coolant
DIN 51 432/2
Screenwash to -80 °C Rala Klirr
10
fluid

Tab. 13: Lubrication chart

A) The use of AFT oil is mandatory with lamella disk brakes if no Liebherr oil is being used.
B) With activated oil preheating, the outside temperature may be approx. 10 °C lower.

Note
The specifications indicated in the Liebherr lubricant table represent a qualitative
minimum standard for oils and greases.
Liebherr lubricants have been developed and tested to suit our products and their
applications to the highest level. There is no guarantee that third-party lubricants
will correspond to the quality and performance of original Liebherr lubricants and
LWN/SK/HD V003///2014-04-18/en

greases.
If the customer uses oils and grease by other manufacturers, the manufacturer
and/or supplier must confirm its conformity with the required specifications to the
customer. Due do the large number of lubricants and manufacturers, Liebherr is
not in a position to perform this test.
Warranty claims are still valid if the customer uses lubricants by another manufac-
turer of equal or higher quality that meet the specifications of the Liebherr lubricant
table.
u For any questions of Liebherr lubricants contact the Liebherr-Lubricant-Hotline
(+49 (0) 7354/80-6060 respectively lubricants@liebherr.com).

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Ordering data

Engine oil

5 l canister 20 l canister 210 l drum 1000 l container

Liebherr Motoroil 10W-40 10 29 05 06 10 33 02 39 10 33 02 46 10 28 62 79
Liebherr Motoroil 10W-40 low ash 10 32 61 13 10 32 61 12 10 32 61 11 10 32 61 10
Liebherr Motoroil 5W-30 10 42 57 12 10 42 57 13 10 42 57 15 10 42 57 19

Tab. 14: Engine oil ordering data

Gear oil

5 l canister 20 l canister 210 l drum 1000 l container

Liebherr Hypoid 90 EP 10 66 48 74 10 66 48 75 10 66 48 76 10 44 16 36
Liebherr Syntogear Plus 75W-90 10 33 02 85 10 33 02 87 10 33 02 88 10 29 64 77

Tab. 15: Gearbox oil ordering data

Hydraulic oil

5 l canister 20 l canister 210 l drum 1000 l container

Liebherr Hydraulic 37 10 66 48 65 10 66 48 67 10 66 47 12 10 66 48 56
Liebherr Hydraulic Plus 10 29 64 80 10 33 02 72 10 33 02 76 10 29 64 81
Liebherr Hydraulic Plus Arctic 10 29 64 79 10 33 02 77 10 33 02 78 10 29 64 78

Tab. 16: Hydraulic oil ordering data

Oil concentrate

5 l canister 20 l canister 210 l drum 1000 l container

Liebherr special additive NL 10 51 53 00 10 51 57 52

Tab. 17: Oil concentrate ordering data

Grease

400 g cartridge 5 kg tub 10 kg tub 25 kg tub

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Liebherr universal grease 9900 10 29 68 16 10 29 68 13 10 29 68 12

Liebherr universal grease Arctic 10 29 68 28 10 29 68 25 10 29 68 24
Liebherr paste spray 10 33 03 08
10 33 03 11
(950 g)
Liebherr grease for telescopic
86 13 036 08
components 9613 Plus
Liebherr WR-Lube SC 10 17 33 71 (600 ml) aerosol can

Tab. 18: Grease ordering data

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Coolant

5 l canister 20 l canister 210 l drum 1000 l container

Liebherr Antifreeze Mix 10 65 18 38 10 30 12 13 10 45 54 46 10 35 90 77

Tab. 19: Coolant ordering data

Screenwash fluid

5 l canister 20 l canister 210 l drum 1000 l container

Windscreen wash -80 °C 89 03 108 14

Tab. 20: Screenwash fluid ordering data

Oil analysis kit

88 56 018 14

6.2.5 Diesel engine lubricating oil

Lubricating oil specification

Modern diesel engines only use lubricating oils with a high additive content. Such
lubricating oils consist of basic oils mixed with additives. The Liebherr diesel
engine lubrication guide is based on the following specifications and requirements:

Designation Specification
ACEA (Association des constructeurs E4, E6, E7. Warning: Particle filter oper-
Européens de l'Automobile) classifica- ation only permitted with E6.
tion
API (American Petroleum Institute) clas- CH-4, CI-4. Warning: Observe shorter
sification oil change intervals.

Tab. 21: Lubricating oil specification

Lubricating oil viscosity

The choice of lubricating oil viscosity is based on the SAE (Society of Automotive
Engineers) classification.
The critical factor for choosing the SAE class is the ambient temperature. The SAE
class does not give any clue as to the quality of a lubricating oil.
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If the lubricating oil is too viscous it will be difficult to start the engine, if the
viscosity is too low lubricating efficiency may be lost.
The temperature ranges shown in the following chart are guideline values only.
Each end of the temperature range may be violated briefly.

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Fig. 452: Temperature-dependent selection of SAE class

Liebherr recommends the following lubricating oils for ambient temperatures from
-20 °C to 45 °C:
– Liebherr Motoroil 10W-40, ACEA E4 specification
– Liebherr Motoroil 10W-40 low ash, ACEA E6 specification
Liebherr reccomends the following lubricating oil for ambient temperatures from
-30 °C to 30 °C:
– Liebherr Motoroil 5W-30, ACEA E4 specification

Lubricating oil change intervals

Lubricating oil change intervals: (For more information see: 6.1 Maintenance and
inspection schedule, page 211) .
If the specified number of operating hours during the year is not reached: change
the lubricating oil and filter at least once a year.
Various aggravating factors alter the maintenance interval.
Aggravating factors:
– Frequent cold starts
– Sulphur content in fuel
– Operating temperature
If aggravating factors are present: change the lubricating oil and filter according to
the following tables.

Aggravating factor Lubricating oil grade

CH-4, CI-4 E4, E7 A)
Operating temperature Sulphur content of diesel fuel Interval
to 0.5 % 250 Bh 500 Bh
to -10 °C
from 0.5 % to 1 % 125 Bh 250 Bh
to 0.5 % 125 Bh 250 Bh
below -10 °C
from 0.5 % to 1 % is prohibited 125 Bh
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Tab. 22: Lubricating oil change intervals depending on aggravating factors, part 1

A) TBN at least 13 mgKOH/g

Aggravating factor Lubricating oil grade

E6
Operating temperature Sulphur content of diesel fuel Interval

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Aggravating factor Lubricating oil grade

to 0.005 % 500 Bh
to -10 °C from 0.005 % to 0.05 % 250 Bh
from 0.05% to 0.1% 125 Bh
to 0.005 % 250 Bh
below -10 °C from 0.005 % to 0.05 % 125 Bh
from 0.05% to 0.1% is prohibited

Tab. 23: Lubricating oil change intervals depending on aggravating factors, part 2

6.2.6 Fuel

Fuel specifications
Fuels must satisfy the minimum requirements of the following fuel specifications.
Permitted fuel specifications:
– DIN EN 590
– ASTM D 975 (89a) 1D and 2D

Sulphur content in fuel

Only use fuels whose sulphur content is less than 1 % (10000 mg/kg).
Liebherr recommends: in the case of diesel engines with external exhaust gas
recirculation (eEGR), use fuels with a sulphur content of less than 0.005%
(50 mg/kg).
If the diesel engine uses E6 engine oil and a standard lubricating oil change
interval regime (500 Bh) is in operation: Only use fuels whose sulphur content is
less than 0.005 % (50 mg/kg).
(For more information see: Lubricating oil change intervals, page 227)
According to the HFRR (60) test, the fuel lubricity must not exceed 460 μm
[lubricity of corrected wearscar "diameter" (1.4) at 60 °C]. Fuel standard ASTM D
975 does not require fuels to have passed a fuel lubricity test. A written confirma-
tion from the fuel supplier must be provided. Additives should be added by the fuel
supplier. The fuel supplier is responsible for the quality of the fuel. The addition of
secondary lubricity additives by the customer is not recommended.

Fuel at low temperatures (winter operation)

A cetane number for fuels of at least 45 is required according to ASTM D 975. At
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temperatures below 0 °C, a cetane number of over 50 is required.

As the external temperature drops, paraffin crystals separate out from the fuel.
Paraffin crystals increase the flow resistance in the fuel filter and restrict the supply
of fuel to the diesel engine.
The addition of petroleum or regular fuel is forbidden for safety as well as technical
reasons. Special fuels are available for arctic conditions. Use a starting aid (e.g.
fuel filter heater) if the diesel fuel flow is sluggish or the temperature is below
-20 °C.

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6.2.7 Diesel engine coolant

Coolant specification
The coolant is a mixture of water and anticorrosion and antifreeze additives.
Coolant:
– can be mixed with the following products.
– is available in a pre-mixed form (premix).
The cooling system only works reliably when under pressure. Keep the cooling
system clean and free of leaks. The coolant shut-off and working valves must be in
good working order. Maintain the required coolant level.
The antifreeze agents approved by Liebherr:
– guarantee adequate protection against freezing, corrosion and cavitation.
– do not attack seals and tubes.
– do not foam.
Coolants cause cavitation or corrosion damage in the cooling system if they
contain unsuitable anticorrosion/antifreeze agents or are prepared incorrectly.
Thermally-insulating deposits on heat-conducting components will result in over-
heating and failure of the diesel engine.
Emulsifiable anticorrosion oils are prohibited.
Anticorrosion agents without any antifreeze (e.g. DCA) are never used. Their use is
possible under certain circumstances (see "Permitted anticorrosion agents (inhibi-
tors) without antifreeze").

Water (fresh water)

Colourless, clear, free from mechanical contamination, potable tap water with the
following restricted analysis values is suitable.
Sea water, brackish water, brine or industrial waste water are not suitable.

Designation Value
Total alkaline earths (water hardness) 0.6 mmol/dm3 to 3.6 mmol/dm3
pH value at 20 °C 6.5 to 8.5
Chloride ion content maximum 80 mmol/dm3
Sulphate ion content maximum 100 mmol/dm3

Tab. 24: Fresh water quality

Designation Value
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Total alkaline earths (water hardness) 0.6 mmol/dm3 to 2.7 mmol/dm3

pH value at 20 °C 6.5 to 8.0
Chloride ion content maximum 80 mmol/dm3
Sulphate ion content maximum 80 mmol/dm3

Tab. 25: Fresh water quality when using DCA 4

Ask the relevant municipal authority for their water analysis results.

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Coolant mixing ratio

Throughout the year the coolant must contain not less than 50 % anticorrosion/
antifreeze agent.

Outside temperature Mixing ratio

Anticorrosion/antifreeze
Water
agent
to -37 °C 50 % 50 %
to -50 °C 40 % 60 %

Tab. 26: Temperature-dependent mixing ratio of water and anticorrosion agent

Fig. 453: Temperature-dependent mixing ratio of water and anticorrosion agent

A Proportion of anticorrosion/anti-
freeze agent in coolant in %

Approved anticorrosion/antifreeze agents

Product description Manufacturer

Liebherr Antifreeze Concentrate Liebherr

Tab. 27: Approved anticorrosion/antifreeze agents

Note
If Liebherr coolant is not available locally:
u use a coolant that conforms to the "Coolant specification for Liebherr diesel
engines 10652041" (contact after sales service).

Mixing different anticorrosion/antifreeze agents will degrade the properties of the

coolant.

Approved pre-mixed coolants

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Product description Manufacturer

Liebherr Antifreeze Mix (ready-mixed:: Liebherr
50 % water, 50 % anticorrosion/anti-
freeze agent)

Tab. 28: Approved pre-mixed coolants

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Note
If Liebherr coolant is not available locally:
u use a coolant that conforms to the "Coolant specification for Liebherr diesel
engines 10652041" (contact after sales service).

Mixing different anticorrosion/antifreeze agents will degrade the properties of the

coolant.

Approved anticorrosion agents (inhibitors) without

antifreeze
If it can be demonstrated that no approved anticorrosion agent is available: In
exceptional cases and where ambient temperatures are permanently above
freezing point, mix the water with the following anticorrosion agents:
– Product DCA 4 (Diesel Coolant Additives 4)
– Caltex / Chevron / Havoline / Total
Change the coolant every year in this case.
Check the concentration during maintenance work.

Note
If changing between antifreeze and anticorrosion agents:
u Drain coolant.

Product description Manufacturer

DCA 4 Diesel Coolant Additives Fleetguard / Cummins Filtration
Caltex XL Corrosion Inhibitor Concen- Chevron Texaco
trate
Chevron Heavy Duty Extended Life Chevron Texaco
Corrosion Inhibitor Nitrite Free (ELC)
Havoline Extended Life Corrosion Inhib- Chevron Texaco
itor (XLI)
Total WT Supra Total, Paris

Tab. 29: Approved anticorrosion agents (inhibitors) without antifreeze

6.2.8 Hydraulic oil

Initial filling
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The information sign on the hydraulic tank filler neck displays the hydraulic oil with
which the machine was first filled.
If the initial filling was performed by Liebherr, the machine was initially filled with a
Liebherr hydraulic oil 37 or higher as standard. In exceptional cases (low-tempera-
ture package, bio application), the machine is initially filled with a special hydraulic
oil.

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Mixing

Note
Mixing rapidly biodegradable third-party ester-based oils with mineral oils may
result in damage to the hydraulic system!
Liebherr recommends:
u do not mix rapidly biodegradable third-party oils from different manufacturers.
u Do not mix rapidly biodegradable third-party oils with mineral oils.

Third-party oils are oils from other manufacturers.

The use of rapidly biodegradable hydraulic oil must be agreed with Liebherr.
Oils on vegetable basis are inadmissible due to the adverse temperature stability.
Using Liebherr hydraulic oils ensures that none of the disadvantages listed above
will occur.

Mixing of Liebherr hydraulic oils

Liebherr mineral oils with each other Can be mixed at any ratio
Liebherr mineral oils with biodegrad- Can be mixed at any ratio
able Liebherr oils
To ensure biodegradability, mixing in
more than 2 % mineral oil is not
permitted (in accordance with the regu-
lations in most European countries)
Liebherr oils with oils by other manu- To prevent changing the characteristics
facturers of the oils, it is not permitted to mix in
more than 10 % oil made by other
manufacturers

Tab. 30: Mixing of Liebherr hydraulic oils

6.2.9 Preservation medium (anti-corrosion coating)

WARNING
Incorrect use of anti-corrosion coating agents!
u When not being used, store the anti-corrosive agent in a cool, dry place
(storage temperature approx. 15 °C to 20 °C).
u Keep container away from naked flames, fire, sparks and other sources of igni-
tion.
u In the event of a fire, use CO2 extinguishers, foam or a chemical extinguisher.
LWN/SK/HD V003///2014-04-18/en

u Do not use water to extinguish the fire under any circumstances!

u When fighting a fire, wear appropriate safety apparel and breathing apparatus.

Note
Liebherr recommends:
u Use the following preservatives as anti-corrosive.

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Product name ID no. (batch) Application Disposal

DINITROL 3650 890036814 (20 l) Use DINITROL 3650 for Remove protective film
preservation of layered with petroleum spirit or
DINITROL 3650 is a soft,
sheeting. Apply DINITROL similar solvent-containing
waxy protective coating
3650 by immersion, cleaning agents.
with excellent creep char-
brushing or spraying. Seal
acteristics.
the preserved parts after a
drying time of 24 hours
with DINITROL 4010.
DINITROL 4010 890036914 (20 l) Apply DINITROL 4010 by Within 2 weeks of applica-
brushing or by airless tion, the DINITROL 4010
DINITROL 4010 is a hard,
spraying or airmix protective film can be
waxy protective coating.
spraying. removed with petroleum
spirit. If left to dry thor-
oughly for 2 weeks, DINI-
TROL 4010 will resist a
high-pressure wash
containing alkaline addi-
tives.
LPS 1 861009914 (aerosol can) Use LPS 1 on electrical The protective film dries
and electronic systems and out and does not need to
LPS 1 is a non-greasy 861010014 (25 l)
control cabinets. The be removed.
lubricant that penetrates
grease-free protective film
deeply, dries quickly and is
protects electrical and
dirt repellent and dust
electronic components and
repellent. As it repels mois-
does not cause short-
ture, it is ideal for drying
circuits.
electrical and electronic
modules.
LPS 2 861009714 (aerosol can) Use LPS 2 for door locks,
hinges, joints, etc.
LPS 2 is a highly stable 861009814 (20 l)
lubricant that loosens
rusted up and stuck
components. The non-
drying lubricant film
provides long-term protec-
tion against corrosion.
LPS 3 861009614 (aerosol can) LPS 3 for fittings on The protective film dries
pendant straps and back- out and does not need to
LPS 3 has extra deep 861009514 (5 l)
stay straps, pin connec- be removed.
penetration capabilities
861009414 (200 l) tions, etc. LPS 3 only
and repels water. LPS 3
preserves for storage. The
dries to form a transparent,
preservation must be
soft, waxy film that
applied every year. Do not
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provides effective protec-

use in the engine compart-
tion against moisture, air,
ment.
acids, alkaline vapors and
other corrosive media.

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Product name ID no. (batch) Application Disposal

Denso Tape 603231914 (roll 50 mm x Use Denso tape on Take off Denso tape and
10 m) exposed piston rods, remove any residue with a
valves, threaded joints of degreaser or solvent-
Denso tape is a 1 mm thick 693058914 (roll 100 mm x
hydraulic components, etc. based cleaner.
petrolatum tape. Its web is 10 m)
made of a non-rotting
chemical fabric suitable for
insulation and seals.
CORTEC VCI 368 861008714 (5 l) Use CORTEC VCI 368 on Remove protective film
pins that are to be driven in with petroleum or petro-
CORTEC VCI 368 is a
again (pinning of boom leum spirit.
drying, film-forming
sections, etc.).
concentrate of highly-effec-
tive corrosion inhibitors
bound in a mineral-oil
based carrier substance.
CORTEC VCI 368 does
not contain nitrates, phos-
phates, chromates or
heavy metals. It is also
PCB and PCT-free.
CORTEC VCI 369 11262917 (400 ml aerosol Apply CORTEC VCI 369 Remove protective film
can) by brushing, rolling or with petroleum or petro-
spraying. Use CORTEC leum spirit.
CORTEC VCI 369 is a 861008614 (5 l can)
VCI 369 for piston rods of
semi-fluid grease concen-
the hydraulic cylinder.
trate made of highly-effec-
tive corrosion inhibitors
bound in a mineral oil
based carrier substance.
CORTEC VCI 369 does
not contain solvents,
nitrites, phosphates or
chromates, PCB and PCT.

Tab. 31: Preservation medium (corrosion protection)

Note
Liebherr recommends:
u Order the different preservatives directly from Liebherr using the ID number.

First-aid measures when coming into contact with DINITROL:

– Skin contact: Rinse with clear water and soap.
– Eye contact: Rinse corrosion protection medium immediately with clear water
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for some minutes. Contact a physician immediately.

– Ingestion: Drink milk or water. Do not induce vomiting. Contact a physician
immediately.
– Inhalation: Go outside, breathe fresh air. Contact a physician immediately.

6.2.10 Liebherr oil diagnosis system

Note
u Perform the first oil change for the relevant unit as scheduled, since increased
levels of contamination are to be expected during the running-in phase.

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The Liebherr oil diagnosis system is a preventive maintenance system for the
machine's main components.
The Liebherr oil diagnosis system is based on oil analyses and has the following
tasks:
– Prevent machine breakdowns.
– Reduce standstills and downtimes.
– Minimize repair costs.
– Indicate abnormal wear.
– Detect possible causes of damage early.

Taking an oil sample

Ensure that the following conditions are fulfilled:
q Liebherr oil analysis set (ID no. 885601814) is available.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
q The respective module or component has warmed up for 15 minutes (operating
temperature).
The oil samples are taken either directly out of the housing of the respective
module or component or from the draining oil when performing an oil change. Prior
to sampling, drain at least 250 ml oil before filling the container with thoroughly
mixed oil.

Fig. 454: Liebherr oil analysis set (ID no. 885601814)

1 Cover syringe container 5 Polymer hose
2 Syringe container 6 Shipping carton
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3 Syringe neck 7 Sample data sheet

4 Adapter
u Screw polymer hose 5 with adapter 4 onto syringe container 2.

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Maintenance
Lubricants and consumables

Fig. 455: Taking an oil sample

u Take at least 200 ml of oil.

u Complete all sections of the sample data sheet.
u Place the oil sample and the sample data sheet into the shipping carton and
send to the pre-printed address.

Understanding the oil diagnosis report

The oil diagnosis report shows the detailed result of the oil sample analysis and
provides information about the measures to be taken. Four different symbols are
used for this purpose:

Symbol Meaning
Normal

High values, take second oil sample for counter-check

Oil change required

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Repair required

Tab. 32: Oil diagnosis report

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 Maintenance
Implementation instructions for the maintenance

6.3 Implementation instructions for the main-

tenance

WARNING
Unauthorized dwelling in the working zone and the danger zone while the machine
is running!
Death, risk of crushing limbs.
u Ensure that the machine operator is located in the cabin while the machine is
running.
u Perform work on the machine with visual contact and radio contact to the
machine operator.
When working on machine without presence of machine operator:
u Switch off the battery main switch.
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Maintenance
Electric motor

6.4 Electric motor

CAUTION
Beware of hot surfaces, live and rotating parts.
These can cause burns, electric shock and bruising.
u E-motor must be shut off for inspection.
u Wear protective clothing.

CAUTION
Inadmissibly deactivated auxiliary supply!
Damage to electric motor through condensation.
Deactivated auxiliary heating.
u Make sure that the auxiliary supply is always on.

CAUTION
Overheating of electric motor!
Damage to electric motor.
u Make sure that the machine room is sufficiently supplied with fresh air.
u Do not place any objects close to the electric motor.

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Fig. 460: Electric motor

1 Grease nipple 2 Electric motor

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 Maintenance
Electric motor

6.4.1 Greasing the ball bearings

NOTICE
Inadmissible grease!
Damage to electric motor.
u Only use lubricant in line with lubrication information plate (attached to the elec-
tric motor).

Ensure that the following conditions are satisfied:

q Protective clothing is being worn.
q Grease gun with suitable grease is available.

Fig. 461: Lubrication opening

1 Lubrication opening closed 2 Lubrication opening open
u Open lubrication opening.
w Lubrication channels are open.
u Start electric motor.
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u Apply grease gun to grease nipple.

u Press in suitable grease in line with the lubrication information plate of the elec-
tric motor.
w Grease spreads throughout ball bearing.
u Leave motor running 1 to 2 hours.
w Excess grease is pressed out of ball bearing.
u Close lubrication opening.

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Maintenance
Distributor gearbox

6.5 Distributor gearbox

CAUTION
Hot gearbox components and gearbox oil!
Burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
u Wear protective gear.

Fig. 462: Top view distributor gearbox

1 Oil dipstick and filler neck

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Fig. 463: Bottom view distributor gearbox

1 Drive for pump 3 Driven by engine
2 Oil drain

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 Maintenance
Distributor gearbox

6.5.1 Checking the gearbox oil level

Ensure that the following conditions are satisfied:

q The motor has been switched off for five minutes.
q The machine is secured to prevent unauthorised operation.
q Wear protective clothing.

CAUTION
Hot gearbox components and gearbox oil!
Risk of burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
u Wear protective equipment.

u Clean the area around the oil dipstick.

u Pull out the oil dipstick.
u Clean oil dipstick.
u Insert the oil dipstick as far as it will go.
u Pull out the oil dipstick again.
u Check the gearbox oil level .
If the gearbox oil level is below the MIN mark:
u Top up using the appropriate gearbox oil according to the lubrication chart (For
more information see: 6.5.2 Topping up the gearbox oil, page 241) .
If the gearbox oil level is above the MAX mark:
u Drain the gearbox oil.

6.5.2 Topping up the gearbox oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Wear protective clothing.

CAUTION
Hot gearbox components and gearbox oil!
Risk of burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
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u Wear protective equipment.

NOTICE
Dirt and foreign bodies in the distributor gearbox!
The distributor gearbox is liable to be damaged.
u Ensure that no dirt or foreign bodies enter the filler neck.

u Clean the area around the oil dipstick.

u Pull out the oil dipstick.

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Maintenance
Distributor gearbox

u Clean oil dipstick.

u Open vent.

NOTICE
Incorrect or contaminated gearbox oil!
The distributor gearbox is liable to be damaged.
u Top up exclusively using the appropriate gearbox oil according to the lubrication
chart (For more information see: 6.2.4 Lubrication chart, page 223) .
u Make sure that no contaminated gearbox oil is used.

u Top up the gearbox oil until the MAX mark.

u Insert the oil dipstick as far as it will go.
u Close vent.
u Start engine.
u Leave engine to run 10 minutes at idling speed.
u Turn engine off.
u Check gearbox oil level again after 1 minute.

6.5.3 Draining the gearbox oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Wear protective clothing.
q A suitable and sufficiently large collecting container is to hand.
q An oil drain hose is to hand.

CAUTION
Hot gearbox components and gearbox oil!
Burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
u Wear protective gear.

u Open vent.
u Place the collecting container in position.
u Open oil drain.
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u Attach the oil drain hose.

w Oil drains out.
u Detach the oil drain hose.
u Close oil drain.

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 Maintenance
Swing

6.6 Swing

Fig. 464: Swing

1 Sight glass 3 Filler neck
2 Vent screw 4 Pinion

6.6.1 Checking the gearbox oil level

Ensure that the following conditions are satisfied:

q The motor has been switched off for five minutes.
q The machine is secured to prevent unauthorised operation.
q Slewing gear housing has normal operating temperature.
q Protective clothing is being worn.
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u Check the gearbox oil level in the sight glass.

If no gearbox oil is visible in the sight glass:
u Top up using the appropriate gearbox oil according to the lubrication chart (For
more information see: 6.2.4 Lubrication chart, page 223) .

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Maintenance
Swing

6.6.2 Topping up the gear oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Slewing gear housing has normal operating temperature.
q Protective clothing is being worn.

NOTICE
Dirt and foreign bodies in the swing gear!
Damage to swing gear.
u Ensure that no dirt or foreign bodies enter the filler neck.

u Remove the venting screw from the filler neck.

NOTICE
Incorrect or contaminated gearbox oil!
Damage to swing gear.
u Top up using only the appropriate gearbox oil according to the lubrication chart
(For more information see: 6.2.4 Lubrication chart, page 223) .
u Make sure that no contaminated gearbox oil is filled in.
u Clean the area around the filler neck.

u Top up the gearbox oil up to halfway on the sight glass.

u Attach vent screw to filler neck.
u Close vent screw on filler neck.
u Start engine.
u Leave engine to run 10 minutes at idling speed.
u Move the swing in both directions.
u Turn engine off.
u Check gearbox oil level again after 1 minute.
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 Maintenance
Swing connection

6.7 Swing connection

6.7.1 Greasing the toothing

Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q Protective clothing is being worn.
If the swing teeth are not lubricated by a central lubrication:
u Lubricate the swing teeth using the requisite grease or alternatively apply an
even coating of graphite spray (For more information see: 6.2.4 Lubrication
chart, page 223) .
u Turn the machine on and operate the slewing gear in both directions.
w Toothing is evenly lubricated.

6.7.2 Checking the bearing lubrication

Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q Protective clothing is being worn.

CAUTION
Rotating slewing column!
Risk of crushing limbs.
u Ensure that nobody enters the danger area during the lubrication process.
u Leave the danger area.

If the slewing ring is not lubricated by a central lubrication system:

u Check bearing lubrication.
If no grease collar is visible:
u Use the grease gun to press grease into the grease nipple.
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Fig. 465: Grease collar

1 Grease collar

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Maintenance
Swing connection

u Turn the slewing column by 45° after each lubrication process (per grease
nipple).
w The grease distributes itself better in the swing ring.
w Grease collar is visible.

6.7.3 Measure slewing ring tilt clearance

Wear of the bearing tracks increases the clearance of the slewing ring.

Measuring points
The following overview shows the possible measuring points.

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Fig. 466: Measuring points ball-bearing swing ring

1 Slewing column (turning) 3 Base column (not turning)
2 Slewing ring

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 Maintenance
Swing connection

Fig. 467: Measuring points roller-bearing swing ring

1 Slewing column (turning) 3 Base column (not turning)
2 Slewing ring

Measurement
Ensure that the following conditions are fulfilled:
q First measurement (basic tilt measurement) is performed in new state.
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Fig. 468: Crane positions

Measuring method 1 (recommended)

u Establish 0° boom position and mark.
u Raise boom without load until it reaches the upper luffing gear limit switch.
u Set dial gauge to 0 at position 1 and 2.

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Maintenance
Swing connection

u Lower boom until it reaches the lower luffing gear limit switch.
u Only load boom with 10 % to 50 % of the maximum admissible load according
to load chart.
u Read off measuring value on gauge.
u Enter measuring value on gauge.
u Swivel crane by 90°.
u Repeat slewing ring tilt clearance measurement (set gauge on position 3 and 4
to 0).
Measuring method 2 (alternative)
u Lower boom in parked position 0°.
or
Place boom in boom storage.
u Attach jack up cylinder to position 1 between base and slewing column.
u Set dial gauge to 0 at position 1.
u Lift up jack up cylinder 1 until the measuring value remains constant.
u Read off measuring value on gauge.
u Enter measuring value on gauge.
u Repeat measurements on positions 2 to 4.
Repeated measurement
u Measurement under the same conditions (hook size, boom radius, measuring
device, load, position of the jack up cylinders).

Admissible pitch play

Basic tilt max. wear max. tilt

in new
state
Ball slew bearing with outer diameter up to 0.5 mm 1.5 mm 2 mm
2500 mm
Ball slew bearing with outer diameter 0.5 mm 2.5 mm 3 mm
above 2500 mm
Roller slew bearing 0.5 mm 1 mm 1,5 mm

Tab. 33: Limit value chart

If the limit value of the slewing ring clearance is reached when measuring the limit
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values:
u Replace ball and/or roller bearing slewing rim.

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 Maintenance
Main hoisting winch

6.8 Main hoisting winch

Fig. 469: Main hoisting winch

1 Oil drain gearbox 4 Inspection glass brake
2 Oil drain brake 5 Brake filler neck
3 Inspection glass gearbox 6 Brake oil level

6.8.1 Checking the gearbox oil level

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
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q The machine is secured to prevent unauthorised operation.

q Protective clothing is being worn.

CAUTION
Hot winch components and hot gearbox oil!
Risk of burns.
u Maintenance and inspection work on the winches may only be carried out when
the machine is switched off and has cooled down.
u Wear protective equipment.

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Maintenance
Main hoisting winch

NOTICE
Dirt and foreign bodies in the winch gearbox!
The winch gearbox is liable to be damaged.
u Ensure that no dirt or foreign bodies enter the filler neck.

u Clean area around inspection glass.

u Check the gearbox oil level.
If the gearbox oil level is below the MIN mark:
u Top up using the appropriate gearbox oil according to the lubrication chart (For
more information see: 6.8.2 Topping up the gearbox oil, page 250) .
If the gearbox oil level is above the MAX mark:
u Draining the gear oil.

6.8.2 Topping up the gearbox oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q The machine is secured to prevent unauthorised operation.
q Protective clothing is being worn.

CAUTION
Hot winch components and hot gearbox oil!
Burns and open wounds.
u Maintenance and inspection work on the winches may only be carried out when
the machine is switched off and has cooled down.
u Wear protective equipment.

NOTICE
Dirt and foreign bodies in winch gearbox!
The winch gearbox will be damaged.
u Ensure that no dirt or foreign bodies enter the filler neck.

u Clean area around inspection glass.

u Open vent.

NOTICE
Incorrect or contaminated gearbox oil!
The winch gearbox will be damaged.
u Top up using only the appropriate gearbox oil according to the lubrication chart
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(For more information see: 6.2.4 Lubrication chart, page 223) .

u Check the purity of the gearbox oil.

u Top up the gearbox oil until the MAX mark.

u Close vent.
u Start engine.
u Leave engine to run 10 minutes at idling speed.
u Move the winch in both directions at low speed.

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 Maintenance
Main hoisting winch

u Turn engine off.

u Check gearbox oil level again after 1 minute.

6.8.3 Draining the gearbox oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Protective clothing is being worn.
q A suitable and sufficiently large collecting container is to hand.
q An oil drain hose is to hand.

CAUTION
Hot gearbox components and gearbox oil!
Burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
u Wear protective gear.

u Open vent.
u Place the collecting container in position.
u Open oil drain.
u Attach the oil drain hose.
w Oil drains out.
u Detach the oil drain hose.
u Close oil drain.
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Maintenance
Main hoisting winch

6.8.4 Checking the rope kicker*

Fig. 470: Rope kicker

u Check the wear of the rope kickers.

NOTICE
Different wear of screws and rope kicker!
Ropes may become damaged.
u Use only original Liebherr spare parts.

If rope kickers are worn:

u exchange rope kickers.
u Check whether the screws are sunk.
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 Maintenance
Rope reeving winch

6.9 Rope reeving winch

Fig. 471: Rope reeving winch

1 Filler neck 3 Oil dipstick
2 Oil drain

6.9.1 Checking the gearbox oil level

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Ensure that the following conditions are satisfied:

q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Wear protective clothing.

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Maintenance
Rope reeving winch

CAUTION
Hot winch components and hot gearbox oil!
Burns.
u Maintenance and inspection work on the winches may only be carried out when
the machine is switched off and has cooled down.
u Wear protective gear.

NOTICE
Dirt and foreign bodies in the winch gearbox!
The winch gearbox is liable to be damaged.
u Ensure that no dirt or foreign bodies enter the filler neck.

u Clean the area around the oil dipstick.

u Pull out oil dipstick and clean.
u Insert the oil dipstick as far as it will go.
u Pull out the oil dipstick again and check the gearbox oil level.
If the gearbox oil level is below the MIN mark:
u Top up using the appropriate gearbox oil according to the lubrication chart (For
more information see: 6.9.2 Topping up the gear oil, page 254) .
If the gearbox oil level is above the MAX mark:
u Draining the gear oil.

6.9.2 Topping up the gear oil

Ensure that the following prerequisites are fulfilled:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Wear protective clothing.

CAUTION
Hot winch components and hot gearbox oil!
Burns and open wounds.
u Maintenance and inspection work on the winches may only be carried out when
the machine is switched off and has cooled down.
u Wear protective gear.

NOTICE
Dirt and foreign bodies in the winch gearbox!
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The winch gearbox is liable to be damaged.

u Ensure that no dirt or foreign bodies enter the filler neck.

u Clean the area around the oil dipstick.

u Pull out oil dipstick and clean.
u Open vent.

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 Maintenance
Rope reeving winch

NOTICE
Incorrect or contaminated gearbox oil!
The winch gearbox is liable to be damaged.
u Top up using only the appropriate gearbox oil according to the lubrication chart
(For more information see: 6.2.4 Lubrication chart, page 223) .
u Check the purity of the gearbox oil.

u Top up the gearbox oil until the MAX mark.

u Reinsert the oil dipstick as far as it will go.
u Close vent.
u Start the engine and allow it to idle for 10 minutes.
u Move the winch in both directions at low speed.
u Switch off the engine and wait 1 minute before checking the gearbox oil level
again.

6.9.3 Draining the gearbox oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Wear protective clothing.
q A suitable and sufficiently large collecting container is to hand.
q An oil drain hose is to hand.

CAUTION
Hot gearbox components and gearbox oil!
Burns.
u Maintenance and inspection work must only be carried out when the distributor
gearbox is switched off and the motor has cooled down.
u Wear protective gear.

u Open vent.
u Place the collecting container in position.
u Open oil drain.
u Attach the oil drain hose.
w Oil drains out.
u Detach the oil drain hose.
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u Close oil drain.

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Maintenance
Hydraulic system

6.10 Hydraulic system

6.10.1 Check hydraulic system for leaks and state of hoses,

fittings, valves, blocks, motors, pumps, and cylinders.

Ensure that the following conditions are satisfied:

q The machine is secured to prevent unauthorised operation.

CAUTION
Hot hydraulic oil!
Danger of burns.
u Carry out maintenance and inspection work on hydraulic system exclusively
when engine is switched off.
u Wear protective equipment.

u Check hydraulic system for leaks.

u Check state of hoses, fittings, valves, blocks, motors, pumps, and cylinders.
If the hydraulic system shows leaks or if the hoses, fittings, valves, blocks, motors,
pumps and cylinders are not in perfect state:
u Switch off machine.
u Contact Liebherr after sales service.

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 Maintenance
Hydraulic oil tank

6.11 Hydraulic oil tank

Fig. 472: Hydraulic oil tank

1 Vent 4 Inspection hatch
2 Oil level sensor 5 Sight glass for checking oil level
3 Return filter

6.11.1 Checking the hydraulic oil level

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Ensure that the following conditions are satisfied:

q The motor has been switched off for five minutes.
q The machine is secured to prevent unauthorised operation.
q All hydraulic cylinders are retracted.

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Maintenance
Hydraulic oil tank

CAUTION
Hot hydraulic oil!
Danger of burns.
u Do not carry out any maintenance and inspection work on the hydraulic system
until the engine has been switched off and has cooled down.
u Wear protective equipment.

u Check the hydraulic oil level in the sight glasses.

If no hydraulic oil is visible in the lowest sight glass:
u Top up using the appropriate hydraulic oil according to the lubrication chart (For
more information see: 6.2.4 Lubrication chart, page 223) .

6.11.2 Carrying out a hydraulic oil analysis

(For more information see: 6.2.10 Liebherr oil diagnosis system, page 234)

6.11.3 Topping up with hydraulic oil

Note
u If replacing “mineral oil-based hydraulic oil” with “synthetic oil-based hydraulic
oil”, please contact Liebherr after sales service.

Ensure that the following conditions are satisfied:

q Torque wrench with 69 Nm is available.
q The machine is secured to prevent unauthorised operation.

CAUTION
Hot engine parts and hydraulic oil!
Danger of burns.
u Do not open the cover of the return filter unless the engine is switched off and
the temperature of the hydraulic oil is 40° or less.
u Wear protective equipment.
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Fig. 473: Opening the return filter

u Undo all hexagonal screws.

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 Maintenance
Hydraulic oil tank

NOTICE
Inadmissible hydraulic oil or incorrect filling of hydraulic oil!
Damage to the hydraulic system.
u Top up with suitable hydraulic oil only (For more information see: 6.2.4 Lubrica-
tion chart, page 223) .
u Only fill in clean and water-free hydraulic oil.
u Only add admissible additives or concentrates (For more information see:
6.2.4 Lubrication chart, page 223) .
u Ensure that no dirt or foreign bodies enter the return filter.
u Only fill in pre-filtered hydraulic oil via the return filter.

u Remove the cover from the filter housing.

u Fill with hydraulic oil.
u Replace the filter housing cover and align it so that the screw holes match.

Fig. 474: Closing the return filter

u Tighten the screws by hand.

u Torque the screws to 69 Nm.

6.11.4 Draining the hydraulic oil

Ensure that the following conditions are satisfied:
q The motor has been switched off for five minutes.
q Machine is secured against unauthorized operation.
q Hydraulic oil has normal operating temperature.
q Protective clothing is being worn.
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q A suitable and sufficiently large collecting container is to hand.

q An oil drain hose is to hand.

Note
Environmental pollution!
u Fluids such as hydraulic oil, fuel and cooling liquid must be disposed of in
accordance with national and international regulations and guidelines.

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Maintenance
Hydraulic oil tank

Fig. 475: Hydraulic oil tank - oil drain valve

1 Oil drain valve
u Place collecting container under oil drain valve.
u Remove the oil drain valve cover.
u Connect the oil drain hose from the Liebherr tool kit to the oil drain valve.
u Drain the hydraulic oil.
u Close the oil drain valve cover.

6.11.5 Cleaning the magnetic rod in the return filter

Ensure that the following conditions are satisfied:

q Torque wrench 69 Nm is available.
q Machine is secured against unauthorized operation.

Opening the return filter

CAUTION
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Hot engine parts and hydraulic oil!

Risk of burns.
u Do not open the cover of the return filter unless the engine is switched off and
the temperature of the hydraulic oil is 40° or less.
u Wear protective equipment.

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 Maintenance
Hydraulic oil tank

Fig. 476: Opening the return filter

u Undo all hexagonal screws.

NOTICE
Dirt and foreign bodies in return filter!
Damage to the hydraulic system.
u Ensure that no dirt or foreign bodies enter the return filter.

u Remove the cover from the filter housing.

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Maintenance
Hydraulic oil tank

Cleaning the magnetic rod

Fig. 477: Cleaning the magnetic rod

1 Magnetic rod 4 Screw with locking ring
2 Seal ring 5 Filter element
3 Filter cover 6 Filter housing
u Carefully remove filter cover 3 and underlying seal ring 2.
u Pull magnetic rod 1 and used filter element 5 out of filter housing 6.
u Check magnetic rod 1 for metal dust and clean with a lint-free clean cloth.
u Clean all parts thoroughly.
u Check seal ring 2 for damage, replace if necessary.
u Thoroughly clean inside of the filter housing 6.
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u Insert new original filter element 5.

u Reassemble parts in reverse order.
u Observe cleanliness and correct fit of the seal ring 2.

Note
Environmental pollution!
u Fluids such as hydraulic oil, fuel and cooling liquid must be disposed of in
accordance with national and international regulations and guidelines.

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 Maintenance
Hydraulic oil tank

Closing the return filter

u Replace the filter housing cover and align it so that the screw holes match

Fig. 478: Closing the return filter

u Tighten the screws by hand.

u Torque the screws to 69 Nm.
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Maintenance
Tank filling unit*

6.12 Tank filling unit*

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Fig. 479: Tank filling system

1 Hydraulic oil tank 6 Filter unit
2 Tank filler neck 7 Aggregate
3 Tap valve 8 Suction hose
4 Conveyor hose 9 Supply container
5 Plug-type coupling

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 Maintenance
Tank filling unit*

6.12.1 Tanking hydraulic oil

NOTICE
Inadmissible hydraulic oil or incorrect filling of hydraulic oil!
Damage to hydraulic system.
u Top up with suitable hydraulic oil only (For more information see: 6.2.4 Lubrica-
tion chart, page 223) .
u Only fill in clean and water-free hydraulic oil.
u Only add admissible additives or concentrates (For more information see:
6.2.4 Lubrication chart, page 223) .
u Ensure that no dirt or foreign bodies enter the return filter.
u Only fill in pre-filtered hydraulic oil via the return filter.

NOTICE
Incorrect use of the tank filling system!
Environmental damage.
u Only operate the tank filling system if the filling process is supervised by 2
persons.
u Supervise supply container.
u Supervise hydraulic oil tank.

u Connect conveyor hose with plug-type coupling.

u Insert tap valve into tank filler neck.
u Immerse suction hose into supply container.
u Check the filter unit for contamination.
u Switch on aggregate.
w Hydraulic oil is tanked.
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Maintenance
Hydraulic filter

6.13 Hydraulic filter

6.13.1 Changing the pressure filter

Fig. 480: Filter overview

1 Upper housing section 5 Filter element
2 Pressure sensor 6 Lower housing section
3 Sealing ring 7 Nut (welded)
4 O-ring
u Undo the nut.
u Take off lower housing section.
u Carefully remove filter element and dispose of remaining oil from lower housing
section.
u Clean all parts thoroughly.
u Check O-ring and sealing ring for damage.
If the O-ring or sealing ring is damaged:
u Replace the O-ring or sealing ring.
u Thoroughly clean inside the filter housing.
u Insert a new filter element.
Check O-ring and sealing ring for cleanliness and correct fit.
u Reassemble the parts in the reverse order.
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u Tighten nut of lower housing section as far as it will go.

u Start engine.
u Leave engine to run 5 minutes at idling speed.
u Turn engine off.
u Tighten nut of lower housing section again as far as it will go.
u Start engine.
u Let engine run at idling speed.
u Check hydraulic system for leaks.

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 Maintenance
Hydraulic filter

If there is a leak in the hydraulic system:

u Contact Liebherr after sales service.
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Maintenance
Accumulator

6.14 Accumulator

Fig. 481: Accumulator

1 Connection for manometer 3 Drain valve
2 Accumulator

WARNING
Incorrect handling of accumulator!
Explosion and bursting.
u Only have accumulator serviced by authorised maintenance personnel.
u If in doubt, contact Liebherr after sales service.

CAUTION
Hot hydraulic oil escaping under high pressure!
Burns and open wounds.
u Wait a few minutes until the pressure has fallen to 0 bar and the temperature of
the hydraulic oil is no more than 40°C.
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u Wear protective clothing.

6.14.1 Checking the accumulator

Ensure that the following conditions are satisfied:

q The engine has been switched off.
q Machine is secured against unauthorized operation.
q Pressure gauge is available.
q Protective clothing is being worn.

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Accumulator

u Close gate valve on hydraulic oil tank.

u Open drain valve.
w Hydraulic oil is drained from accumulator.
u Connect the pressure gauge to the pressure gauge connection point.
u Compare the actual pressure displayed by the pressure gauge with the target
pressure indicated by the operating data of the accumulator.
If the actual pressure is lower than the target pressure:
u replace the pressure accumulator.

6.14.2 Changing the accumulator

Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q Original Liebherr accumulators are available.
q Pressure of hydraulic oil is 0 bar.
q Temperature of the hydraulic oil is 40°C.
q Suitable tools are available.
q Protective clothing is being worn.

NOTICE
Dirt and foreign bodies in hydraulic system!
Damage to the hydraulic system.
u Make sure the hydraulic system is free of dirt and foreign bodies.

u Close gate valve on hydraulic oil tank.

u Open drain valve.
w Hydraulic oil is drained from accumulator.
u Replace accumulator with a new original Liebherr accumulator.
u Accumulators must be thoroughly cleaned on the outside so that the markings
and operating data are clearly visible.
u Open gate valve on hydraulic oil tank.
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Maintenance
Hydraulic cylinders

6.15 Hydraulic cylinders

6.15.1 Check that the hydraulic cylinder fits properly and

does not leak

u Check that the hydraulic cylinder fits properly and does not leak.
If the hydraulic cylinder is leaking or loose:
u Contact Liebherr after sales service.

6.15.2 Protecting the piston rods of the hydraulic cylinders

from corrosion

The piston rods on all hydraulic cylinders are chrome-plated. Despite this, dirty and
aggressive materials can still damage the chrome coating. The chrome coating
only offers a certain level of protection.
u Ensure that the piston rods are in perfect condition and clean.
u Extend and retract piston rods at least once a week.

Fig. 482: Overlap piston rod (illustration of principle)

1 Extended piston rod X Overlap piston rod
2 Retracted piston rod
u Wrap overlap of piston rod X with Denso tape.

6.15.3 Preserving the piston rods of the hydraulic cylinders in

case of longer periods of non-use

u Wrap piston rods with Denso tape.

or
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Preserve piston rods with the protective agent CORTEC VCI 369.

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Hydraulic hoses

6.16 Hydraulic hoses

6.16.1 Checking hydraulic hoses and hose lines

Hydraulic hoses and hose lines are subject to a natural aging process. This limits
the storage time and service life.
Useful life will be shortened by use at the limit of permitted stress (very high/low
temperatures, high pulse frequencies, multi-shift operation, etc.).

CAUTION
Faulty repair of hydraulic hoses and hose lines.
Damage and injury.
u Hydraulic hoses and hose lines should only be renewed.
u Only use original Liebherr spare parts.
u If in doubt, contact Liebherr after sales service.

u Check hydraulic hoses and hose lines for damage to the outer layer as far as
the reinforcement (chafing, cuts and cracks, etc.).
u Check hydraulic hoses and hose lines for cracks in the outer layer (tears in the
hose material, etc.).
u Check hydraulic hoses and hose lines for deformation in the pressurised and
depressurised state, and at bends that do not correspond to the original state of
the hydraulic hose or hose line (layer separation, bubble formation, etc.).
u Check hydraulic hoses and hose pipes for leaks.
u Check hydraulic hoses and hose pipes for damage or deformation of hose
fitting, which reduces the strength of fitting or hose/fitting connection.
u Check hydraulic hoses and hose pipes for tight fit of the hose in the fitting.
u Check hydraulic hoses and hose pipes for corrosion of fitting, which impairs the
function or strength.
u Check hydraulic hoses and hose lines for expiration of the storage time and
period of use.
In case one of the stated test points occur:
u replace hydraulic hoses and hose lines.
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Maintenance
Electrical system

6.17 Electrical system

6.17.1 Replacing fuses and lamps

Ensure that the following conditions are satisfied:
q Engine is turned off.
q Machine is secured against unauthorized operation.
q Original Liebherr spare parts are available.
u Replace faulty fuses and lamps.
u Check that the new part is correctly seated.

6.17.2 Cleaning the slip ring unit

NOTICE
Improper cleaning with wet or damp cleaning cloths!
Damage to the slip ring unit.
u Use only dry methods (compressed air or vacuum cleaner) to clean the slip ring
unit.

Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q Ship's power supply is turned off and secured against reactivation.
q Compressed air or a vacuum cleaner is available.
u Remove the cover.

CAUTION
Swirling dust and dirt particles!
Eye injuries.
u Wear protective clothing (safety goggles and breathing mask).

u Clean the slip ring unit with compressed air and a vacuum cleaner.
u Check brushes for wear and correct position.
u Check tightening torque of the cable lug fixing screw.
u Reattach the cover.

6.17.3 Replacing filter mats

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Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q An original Liebherr filter mat is available.

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Electrical system

Fig. 483: Switch cabinet filter mat cover

1 Filter mat cover
u Remove the filter mat cover.
u Replace the old filter mat with a new original Liebherr filter mat.
u Reattach the filter mat cover.

6.17.4 Check screw and clamp connections

Ensure that the following conditions are satisfied:

q Engine is turned off.
q Machine is secured against unauthorized operation.
q Ship's power supply is turned off and secured against reactivation.
u Check all screws and clips for tight fit and tighten if necessary.
u Check tightening torque of the screws on main switch and star-delta contactor.
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Maintenance
Limit switch

6.18 Limit switch

6.18.1 Checking hoist and luffing gear limit switch for func-
tion
u Move luffing gear to upper and lower limit switch.
u Check triggering of the limit switches.
u Move hoisting gear to upper and lower limit switch.
u Check triggering of the limit switches.
If the limit switch triggers too early or not at all:
u Switch off machine.
u Contact Liebherr service department.

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 Maintenance
Emergency stop

6.19 Emergency stop

6.19.1 Checking the emergency stop

WARNING
Unauthorised triggering of the emergency stop!
u Only trigger the emergency stop while the diesel engine is running, the machine
is not moving and no load is attached.

u Check that all emergency stops are working.

If the engine does not switch off:
u Contact Liebherr after sales service.
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Maintenance
Fire extinguishers

6.20 Fire extinguishers

6.20.1 Checking the proper seals and inspection dates on the

fire extinguishers

Fig. 484: Fire extinguisher

NOTICE
Unsuitable or broken fire extinguishers!
u Note the type plate on the fire extinguisher.
u Observe national regulations.

The guidelines for checking hand extinguishers are nationally regulated.

u Check the proper seals and inspection dates on the fire extinguishers.
If the fire extinguishers are missing or the inspection dates have been passed:
u Replace the fire extinguishers or have them inspected.

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 Maintenance
Personal protective equipment

6.21 Personal protective equipment

6.21.1 Checking personal protective gear

WARNING
Inadequate protection!
Serious injury
u Observe the guidelines on care and maintenance of the safety equipment.
u Do not repair protective gear yourself.

u Check that the personal protective gear is in place, intact and complete (For
more information see: 2.4 Personal protective equipment, page 46) .
If the personal protective gear is not present, damaged, or incomplete:
u Complete the personal protective gear.
u Clean the personal protective gear.
u Have the personal protective gear cleaned.
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Maintenance
Emergency descent rescue equipment

6.22 Emergency descent rescue equipment

6.22.1 Checking the emergency descent rescue equipment

u Have the emergency descent rescue equipment inspected by a specialist.
u Have the result of the inspection entered in the warranty and inspection card.

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 Maintenance
Lubrication system*

6.23 Lubrication system*

Fig. 485: Lubricating pump

1 Control unit 4 Filling nipple
2 Supply container A Set lubrication time rotary control
knob
3 Maximum fill level “marker” B Set pause time rotary control knob
After the engine is switched on, the yellow indicator light lights up for 1.5 seconds,
indicating readiness for operation.

6.23.1 Checking the function of the central lubrication

u Press the Interim lubrication button.

w Interim lubrication with programmed lubrication time.
w After expiration of the programmed break time, the programmed lubrication
process continues.
If no interim lubrication takes place after pressing the Interim lubrication button:
u Contact Liebherr service department.

6.23.2 Checking the fill level of the lubrication pumps

Ensure that the following conditions are satisfied:

q The grease gun from the Liebherr tool kit is present and filled with grease (For
more information see: 6.2.4 Lubrication chart, page 223) .
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q The machine is switched off.

q The machine is secured to prevent unauthorised operation.

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Maintenance
Lubrication system*

NOTICE
Incorrect or impure grease!
Damage to machine.
u To prevent impurities: only fill the supply container with grease via the grease
nipple.
u Ensure purity of grease.
u Top up using only the appropriate grease according to the lubrication chart (For
more information see: 6.2.4 Lubrication chart, page 223) .

NOTICE
Grease supply container is empty!
The swing ring and tooth flanks will be insufficiently lubricated and damaged.
Expensive cleaning and venting work on central lubrication pumps.
u Ensure that supply containers are permanently topped up.

u Check the fill level of the lubrication pumps.

If the fill level lies well below the “Maximum fill level” marker:
u Top up with grease until the “Maximum fill level” marker is reached.

6.23.3 Checking the time intervals of the lubrication pumps

Ensure that the following conditions are satisfied:
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
For optimum lubrication, observe the following intervals set by the factory:

Machine type Lubrication interval Lubrication time

Hours min/interval
CBG 300 4 13
CBG 350 2 7
CBB 2640 2 5
CBB 2980 2 6
CBB 3450 1 7
CBB 4200 0.5 9
CBB 4700 0.5 10

Tab. 34: Intervals of lubrication pumps

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Machine type Lubrication interval Lubrication time

Hours min/interval
MPG Main arm 1 7
Load arm 2 7

Tab. 35: Intervals of lubrication pumps

u Check the time intervals of each lubrication pump.

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 Maintenance
Lubrication system*

If the lubrication pump settings do not match the specifications:

u Correct the settings to match the appropriate specifications.

6.23.4 Checking the lubrication points

Ensure that the following conditions are satisfied:
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
u Check the lubrication points for sufficient lubrication.
If no grease collars can be seen at the lubrication points:
u Check the settings of the lubrication pumps.
u Check the lines for damage.
u Contact Liebherr after sales service.
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Maintenance
Ropes

6.24 Ropes

Due to the limited service life of wire ropes, ropes must be checked at regular inter-
vals by a qualified rope inspector during use to correctly identify when the rope has
reached the end of its service life and to remove it from service before it fails
completely.
The degrees of severity of the following lowering criteria must be added for correct
evaluation of the rope status:
– Reduction of rope diameter
– External corrosion
– Wire breaks
In case of a degree of severity of 100 %, the rope must be laid down.
The following points are important when determining the inspection intervals and
may shorten the intervals:
– National and local regulations that apply in the country of use.
– The environmental conditions to which the machine is exposed.
– The first few weeks after a rope has been put on.
– Results of previous inspections.
– The length of time the rope has already been in use

DANGER
Rope damage is not noticed!
Load breakaway.
Following prolonged shutdown of the machine or incidents that could have resulted
in damage to the rope:
u Check rope and end attachments.

These rope changing criteria form part of ISO 4309. They describe the most
commonly occurring types of rope wear.

DANGER
Incorrect maintenance of ropes!
Load breakaway.
u All the listed criteria must be checked at the prescribed maintenance intervals.
u Check the rope in particular around the end attachment as it is subject to
increased mechanical stresses at this point.
If any doubts on the operational safety of a rope exist:
u Lay down the rope or have the rope inspected by a qualified engineer.
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Ensure that the following conditions are fulfilled:

q The machine is switched off.
q The machine is secured to prevent unauthorised operation.

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 Maintenance
Ropes

6.24.1 Check ropes for wear, tight fit and lubrication

Checking ropes for lubrication

Regular rope maintenance ensures safe operation of the crane and increases the
service life of the rope. Only lubricant equivalent to the original rope lubricant may
be used. The rope must be regularly lubricated where it bends around the winch
drums and the pulleys. Grease is applied using a brush. In exceptional cases, high-
pressure lubrication units are used (if these are used, the manufacturer's instruc-
tions must be followed). An alternative is to use solvent-based lubricants that can
be sprayed on the rope.

NOTICE
Operation with non-lubricated ropes!
Ropes may become damaged.
u Lubricate ropes.
u Lubricate ropes where they bend around the winch drums and the pulleys.

NOTICE
Wrong lubricant!
Risk of damage to the rope.
u Only use lubricant that fully matches the original rope lubricant.

The ropes must be lubricated.

u Check ropes for lubrication.
If the ropes are not lubricated:
u Lubricate ropes.
u Lubricate ropes where they bend around the winch drums and the pulleys.

Note
u Choose the lubrication intervals for the ropes based on the operating conditions.

Check the rope for diameter shrinkage

As a result of natural wear that occurs during use, ropes gradually become thinner
and must eventually be withdrawn from service. If the rope diameter has reduced
over long sections as a result of internal friction, corrosion, etc., the rope must be
replaced regardless of whether or not wire breaks have occurred.
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The following table describes the evaluation criteria for an even reduction of the
rope diameter for sections of the rope that are wound in one layer on a drum
and/or run in a steel pulley.

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Maintenance
Ropes

Even reduction of the rope diam- Rating of the degree of severity

Rope type eter in % of the nominal rope
diameter Description %

<6 — 0
6 to 7 Slight 20
7 to 8 Medium 40
Single-layer rope with fiber inlay
8 to 9 High 60
9 to 10 Very high 80
> 10 Laying down 100
< 3.5 — 0
3.5 to 4.5 Slight 20

Single-layer rope with steel inlay or 4.5 to 5.5 Medium 40

Parallellitzenseil 5.5 to 6.5 High 60
6.5 to 7.5 Very high 80
> 7.5 Discarding 100
<1 — 0
1 to 2 Slight 20
2 to 3 Medium 40
Non-rotating rope
3 to 4 High 60
4 to 5 Very high 80
>5 Discarding 100

Tab. 36: Evaluation criteria for an even reduction of the rope diameter indicating the necessity to lay down the rope

Ensure that the following conditions are satisfied:

q A caliper gauge with wide jaws is available.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.

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Fig. 486: Correct (left) and incorrect measurement (right) of rope diameter

u Measure the rope diameter on two separate points at least 1 m distant from
each other.
u Always measure the rope diameter twice at the same point.
The average corresponds to the rope diameter.
u Calculate the average of the four measurements.
If the reduction of the rope diameter has reached the degree of severity “discard”:
u Remove the rope.

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 Maintenance
Ropes

Note
If new ropes are to be attached:
u Check the rope drive.

Checking the ropes for deformations

Check for: Photographs of damage:

Pockets: These can occur when the outer layer of wires
loosens or the outer wire strands are longer than the
inner ones. Movement of the outer wires or strands in
relation to the inner ones causes movement of the
excess length at a particular location.

Loop formation: Single wires or groups of wires

emerge from the rope structure. The loops usually lie in
a series of strands.

Necking: is reductions in the diameter of the wire rope

over short lengths. Rope sections immediately before
the end attachment must be checked for necking with
particular care. Necking is often difficult to recognise at
these points.
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Maintenance
Ropes

Check for: Photographs of damage:

Knots: are deformations of the wire rope. They are
formed when a eyelet-shaped rope loop is pulled
straight without the wire rope being able to compensate
by turning on its axis.

Corkscrews: With this type of deformation, the axis of

the unloaded wire rope becomes helical. This does not
weaken the wire rope initially, though it might prevent
the rope drive from running smoothly. The resultant
damage can include increased abrasion and more wire
breaks. The rope must be withdrawn from service if the
area of greatest deformation exceeds 1/3 of the nominal
rope diameter.

Tab. 37: Checking the ropes for deformations

u Check the ropes for deformations.

If the rope meets one of the criteria above or exhibits specific damage:
u Switch off the machine and, if possible, determine the cause of the damage.
u Remove the rope and/or rope pair.

Check ropes for corrosion

The following table describes the discard criteria and states transition values of the
corrosion severity.

Type of corrosion Condition Severity rating

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Signs of surface oxidation but can be

Superficial = 0 %
wiped clean
External corrosion Wire surface rough to touch High = 60 % A)
Wire surface heavily pitted and loose wires
B) Discard = 100 %

Discard = 100% or, if deemed practicable

Visible signs of internal corrosion – i.e.
by a competent person, internal inspection
Internal corrosion corrosion debris exuding from the valleys
in accordance with the procedure
between the outer strands C)
described in Appendix C

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 Maintenance
Ropes

Type of corrosion Condition Severity rating

The process of fretting corrosion involves
the removal of fine steel particles from the
wires due to dry wires and strands Evidence of such a characteristic must be
constantly rubbing together and then further investigated and if there is any
Fretting corrosion
oxidizing, which results in the deposit of doubt about its severity, the rope must be
internal corrosion debris and manifests as discarded (100 %).
a fine, dry powder, similar to a polishing
agent.
PLEASE NOTE: An increase in diameter can result from internal or fretting corrosion.

Tab. 38: Discard criteria for corrosion and intermediate severity ratings

A) The oxidation of zinc-coated wires can result in a wire surface which is rough to the touch, but the overall condi-
tion might not be as serious as with uncoated wires. In such cases, the inspector may consider applying a lower
value towards the combined effect to that given above in this table.
B) For any other intermediate conditions, an assessment should be made as to its severity rating (i.e. contribution
towards the combined effect).
C) The assessment of the extent of internal corrosion is subjective. However, if there is even the slightest doubt
regarding the degree of severity of the internal corrosion, the rope must be discarded.

Check for: Photographs of damage:

Corrosion: occurs mostly in corrosive and salt water
atmospheres (e.g. prolonged storage of ropes in the
open air, salt water atmosphere, etc.). Two types of
corrosion occur: atmospheric corrosion (causes
"even" rust) and localized corrosion, such as pitting
(forms deep holes in places where the protective
sheath is missing or damaged). The photographs
both show atmospheric corrosion.

The diameter of the rope has reduced as a result of

corrosion. If the rope diameter has reduced by 10%
or more relative to the nominal dimension, the rope
must be changed regardless of whether or not wire
breaks have occurred.
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Tab. 39: Check ropes for corrosion

u Check ropes for corrosion.

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Maintenance
Ropes

If the rope meets one of the criteria above or exhibits specific damage:
u Switch off the machine and, if possible, determine the cause of the damage.
u Remove the rope and/or rope pair.

Check ropes for abrasion

Check for: Photographs of damage:

Abrasion: reduces both the static breaking force of
the rope due to reduction of the metallic cross-
section and its fatigue limit due to wear grooves. If
the rope diameter has reduced by 10% or more rela-
tive to the nominal dimension, the rope must be
changed regardless of whether or not wire breaks
have occurred.

Tab. 40: Check ropes for abrasion

u Check ropes for abrasion.

If the rope meets one of the criteria above or exhibits specific damage:
u Switch off the machine and, if possible, determine the cause of the damage.
u Remove the rope and/or rope pair.

Check ropes for the effects of heat

Check for: Photographs of damage:

Heat damage:If the temperature rises above300 °C
the tensile fibre structure of the wire rope caused by
cold deformation recrystallises and the wire loses
around 2/3 of its original strength. LWN/SK/HD V003///2014-04-18/en

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 Maintenance
Ropes

Check for: Photographs of damage:

An extreme form of heat damage is caused by light-
ning strike. The rope may heat up at the point of the
strike to such an extent that the steel starts to melt.
In all cases of exposure to high temperatures, the
rope must be changed regardless of whether or not
wire breaks have occurred.

Tab. 41: Check ropes for the effects of heat

Note
u For permitted operating temperatures for ropes and end attachments, refer to
EN 12385-3.

u Check ropes for significant heat damage.

If a rope displays signs of external heat damage, such as recrystallisation, melting.
etc.:
u Switch off the machine and, if possible, determine the cause of the damage.
u Remove the rope and/or rope pair.

Check the rope for number of permitted wire breaks

The table below shows the permitted number of wire breaks relative to a defined
control section of the rope.
Single-layer and Parallellitzenseile

Number of visible breaks in outer wires B)

Number of Rope section that runs over steel pulleys Rope section located
bearing wires in and/or is located as a single layer on the on the winch in multi-
the outer winch layer winding C)
Rope category strands of the
(RCN) wire rope A) Class M1 to M4 or unknown class D) All classes
Cross lay Lang lay Cross lay and lang lay
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on a on a on a on a on a on a
n length of length of length of length of length of length of
6d E) 30d E) 6d E) 30d E) 6d E) 30d E)
01 n ≤ 50 2 4 1 2 4 8
02 51 ≤ 75 3 6 2 3 6 12
03 76 ≤ 100 4 8 2 4 8 16
04 101 ≤ 120 5 10 2 5 10 20
05 121 ≤ 140 6 11 3 6 12 22

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Maintenance
Ropes

Number of visible breaks in outer wires B)

Number of Rope section that runs over steel pulleys Rope section located
bearing wires in and/or is located as a single layer on the on the winch in multi-
the outer winch layer winding C)
Rope category strands of the
(RCN) wire rope A) Class M1 to M4 or unknown class D) All classes
Cross lay Lang lay Cross lay and lang lay
on a on a on a on a on a on a
n length of length of length of length of length of length of
6d E) 30d E) 6d E) 30d E) 6d E) 30d E)
06 141 ≤ 160 6 13 3 6 12 26
07 161 ≤ 180 7 14 4 7 14 28
08 181 ≤ 200 8 16 4 8 16 32
09 201 ≤ 220 9 18 4 9 18 36
10 221 ≤ 240 10 19 5 10 20 38
11 241 ≤ 260 10 21 5 10 20 42
12 261 ≤ 280 11 22 6 11 22 44
13 281 ≤ 300 12 24 6 12 24 48
n > 300 0.04 x n 0.08 x n 0.02 x n 0.04 x n 0.08 x n 0.16 x n
PLEASE NOTE: Ropes with outer strands (Seale structure) in which the number of wires in each strand is 19 or
less (e.g. 6 × 19 Seale) are placed two rows above the row in this table in which the structure would normally be
listed due to the number of bearing wires in the outer layer of the strands.

Tab. 42: Reached or exceeded number of visible wire breaks occurring in single-layer and parallel strand ropes
indicating that the rope must be discarded

A) For the purposes of this international standard, filler wires are not regarded as load-bearing wires and are not
included in the value n.
B) A broken wire has two ends (counted as one wire).
C) The values apply to damage that occurs at cross-over zones and interference between winding layers due to
deviations (and not to those rope sections that only run in pulleys but are not spooled on drums).
D) Twice the number of broken wires listed may be applied to ropes on/in mechanisms whose classification is
known to be M5 to M8.
E) d = nominal rope diameter.
Non-rotating ropes

Number of visible breaks in outer wires B)

Number of outer
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strands and
Rope sections running in pulleys
total number of
Rope category and/or are spooled on a drum in a Rope sections spooling on a
bearing wires in
(RCN)
the outer layer
single layer (wire breaks are multi-layer drum C)
distributed arbitrarily)
of the rope
strands A)
on a length of on a length of on a length of on a length of
n
6d D) 30d D) 6d D) 30d D)
21 4 strands n ≤ 100 2 4 2 4

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Number of visible breaks in outer wires B)

Number of outer
strands and
Rope sections running in pulleys
total number of
Rope category and/or are spooled on a drum in a Rope sections spooling on a
bearing wires in
(RCN)
the outer layer
single layer (wire breaks are multi-layer drum C)
distributed arbitrarily)
of the rope
strands A)
on a length of on a length of on a length of on a length of
n
6d D) 30d D) 6d D) 30d D)
3 or 4 strands n ≥
22 2 4 4 8
100
At least 11 outer
strands
23–1 71 ≤ n ≤ 100 2 4 4 8
23–2 101 ≤ n ≤ 120 3 5 5 10
23–3 121 ≤ n ≤ 140 3 5 6 11
24 141 ≤ n ≤ 160 3 6 6 13
25 161 ≤ n ≤ 180 4 7 7 14
26 181 ≤ n ≤ 200 4 8 8 16
27 201 ≤ n ≤ 220 4 9 9 18
28 221 ≤ n ≤ 240 5 10 10 19
29 241 ≤ n ≤ 260 5 10 10 21
30 261 ≤ n ≤ 280 6 11 11 22
31 281 ≤ n ≤ 300 6 12 12 24
n > 300 6 12 12 24
PLEASE NOTE: Ropes with outer strands (Seale structure) in which the number of wires in each strand is 19 or
less (e.g. 18 × 19 Seale - WSC) are placed two rows above the row in this table in which the structure would
normally be listed due to the number of bearing wires in the outer layer of the strands.

Tab. 43: Reached or exceeded number of visible wire breaks occurring in non-rotating ropes indicating that the
rope must be discarded

A) For the purposes of this international standard, filler wires are not regarded as load-bearing wires and are not
included in the value n.
B) A broken wire has two ends.
C) The values apply to damage that occurs at cross-over zones and interference between winding layers due to
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deviations (and not to those rope sections that only run in pulleys but are not spooled on the drum).
D) d = nominal rope diameter.

DANGER
Unsuitable rope is used!
Load breakaway.
If a new rope is to be attached:
u Choose a rope where the rope diameter, the breaking load and the number of
bearing wires in the outer strands matches those of of the original rope.
u Choose a rope that meets the applicable national and international regulations.

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Ropes

u Check the number of wire breaks with the values in the table.
If the number of wire breaks exceeds the number of permitted wire breaks:
u Switch off the machine and, if possible, determine the cause of the damage.
u Remove the rope and/or rope pair.

6.24.2 Selecting ropes

DANGER
Impermissible use of ropes that do not conform to the manufacturer's specifica-
tions!
Load breakaway.
u Only use ropes approved by Liebherr-Werk Nenzing GmbH oder Liebherr-
MCCtec Rostock GmbH.

u Select ropes.

6.24.3 Storing ropes

NOTICE
Ropes are not labelled!
Ropes/rope winders could be mixed up.
If the label is missing or is no longer clearly legible,
u Rope winders according to the delivery documents.

u Check that the labeling of supplied ropes matches the material inspection docu-
ments and the order.
u Material inspection certificates should be carefully filed away.

NOTICE
Incorrect storage!
Ropes may become damaged.
u Ropes should be stored correctly.

u Store wire ropes in a dry, well-ventilated area.

u Protect rope and rope winder from the elements: Never store rope or rope
winder directly on the ground.
u Avoid storing them outdoors for prolonged periods.
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6.24.4 Transporting ropes

Ropes are very sensitive to external damage.

WARNING
Incorrect transport (loaded, unloaded)!
Ropes may become damaged.
u Ropes should be transported correctly.

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Ropes

Fig. 497: Lifting a rope winder correctly (left) and incorrectly (right) on a forklift truck

Correct procedures to avoid damage to ropes during transport:

u Lift rope winders using textile rigging (flat lifting slings or round slings).
u Ideally, rope winders should be lifted with a shaft pushed through their middle.
u Lift rope winders using forklift forks.

6.24.5 Winding ropes

Ropes will only function properly if they are undamaged and are laid without any
distortion.

NOTICE
Ropes are not handled correctly!
Ropes may become damaged.
u Spool ropes exclusively as described below.

If the winding area of the rope is more in the upper rope layer when operating
winches with multiple-layer spooling, the lower rope layer may become loose. This
results in a slight ovalisation of the rope that changes the winding diameter across
the width of the drum. This leads to gaps in the running rope layer, which impairs
the spooling properties and increases rope wear.
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NOTICE
Lower rope layer loosened!
Risk of damage to the rope.
u Improve the the spooling properties and decrease wear: completely unwind the
rope at regular intervals and then wind it up again under pre-tension (1 to 2% of
the rope minimum breaking force).

A rope works most economically when its entire length is used. It is therefore
recommended that an appropriate length of rope is used for lengthy operations.

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Ensure that personal protective equipment is worn at all times.

NOTICE
Incorrect handling of the rope!
Risk of damage to the rope.
u Do not brake the rope directly.
u Do not pull the rope along the ground.
In case of multi-layer spooling:
u 1. Pretension rope layer during stranding with at least 10% of SWL(max).

Fig. 498: Winding ropes without brake

u Unwind ropes from the rope winder in the winding direction A.

Unwinding to the side causes the rope to twist until it is destroyed by kink forma-
tion.
u Unwind ropes from a jacked up rope winder B.

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Fig. 499: Winding ropes with brake

u Unwind ropes from a rope winder A that is braked.

u Check the ropes for damage, deformation, wear, etc. while it is unwound.

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Ropes

If the rope shows any signs of damage, deformation, wear, etc.:

u Remove the rope.

6.24.6 Luffing ropes

NOTICE
Inadmissible rope change on single winches with dual winch operation!
Damage to the winch and rope, grave injuries.
u Ensure that only Liebherr service personnel switches the ropes on single
winches with dual winch operation.

When luffing the rope, pay attention to the following points:

– Make sure that the rope does not twist in our out.
– Observe admissible pull force (at least rope weight) when using an auxiliary
rope.
– If the old rope is used as the luffing rope, ensure that the new rope does not
become twisted.

WARNING
Rotating winches, moving rope!
Risk of crushing of limbs, death.
u Turn off the engine when working on winches.
u Ensure that there is nobody in the danger zone around the winches.
u Ensure that the machine operator is in visual and voice contact with his assis-
tant.

Ensure that the following conditions are satisfied:

q The engine has been switched off.
q The machine is secured to prevent unauthorised operation.
q The rope is checked before luffing for damage as a result of incorrect handling
or storage.
q Protective equipment is worn.
u Dismantle hook.

NOTICE
Rope deflexion angle is too large (more than 1.5°)!
Risk of damage to the rope.
u Position the rope winder some distance away and without any lateral deflection.

u Position rope winder with new rope in front of the boom.

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WARNING
Impermissible welding together of ropes!
Breaking as they pass over sheaves, damage to the machine and the rope, severe
injuries.
u Use a rope stocking to connect both ropes.
u Follow the instructions of the rope stocking manufacturer.
u Use an auxiliary rope.

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Ropes

u Attach a new rope with rope stocking to the old rope.

u Spool the old rope onto a winch.
w New rope is luffed.
u The rope must be pulled in until it reaches the winch.
u Detaching the rope stocking.
u Unwinding the old rope from the winch and winding it up onto the rope winder.
u Turn engine off.

WARNING
Improper detachment of the end of the rope from the drum!
Serious injury.
u Wear protective equipment.
u Ensure that the rope is free from tension.
u Unreel the rope from the drum carefully.

u Detach the rope fixation point on the winch.

u Attach new rope to the rope fixing point of the winch.
u Switch on the engine.
u Wind up rope observing the required tensioning force.
u Before use, check to ensure that the newly fit rope is located correctly in the
grooves on drums and pulleys.
u Have authorized service personnel check and adjust the rope limit switch.
u Hoist a light load (up to 10% of permitted rope pulling force) several times to
check that the rope is winding onto the drum correctly.

6.24.7 Retract ropes

NOTICE
Wrong winding of rope!
Damage to the rope, the winch and the pulleys.
u Do not exceed the prescribed maintenance and inspection intervals.
u Check winding state of the winch and pulleys.
u Check rigging material.
u Remedy errors and damage immediately.
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In order to ensure perfect winding:

u Perform 3 drive cycles at reduced speed (30% of v(max)) and reduced load
(10% of SWL(max)).
u Perform 2 drive cycles with 1/3 SWL(max).
u Perform 2 drive cycles with SWL(max) at max. radius in line with the load chart.
u Check winding behaviour.

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6.24.8 Lubricate ropes

Regular rope servicing maintains the safety of machine operation and increases
the service life of the rope.
q Wear protective clothing.
q Suitable lubricant is available.

Note
Third-party ropes
u Observe lubricant selection of the respective rope manufacturer.

u Apply more lubricant on bending zones on winch drums and pulleys.

u Apply grease with a brush or high-pressure lubrication unit.
or
Spray lubricants containing solvents on rope.
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rope drive

6.25 rope drive

6.25.1 Checking the rope drive

The service life of the rope depends to a large extent on checking of the rope drive.
Any fault on the rope drive will damage the rope. The rope will reach the end of its
service life more quickly due to increased wear. The grooves of the winching drums
and the pulleys are therefore checked for wear using test templates.
Test templates are related to the nominal groove base diameter.
Ensure that the following conditions are fulfilled:
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.

Checking winch drum groove base for wear

Ensure that the following conditions are fulfilled:
q A suitable test template is available.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.

Fig. 500: Permissible result when testing the groove base using a test template
1 Test template 2 Winch drum
The diameter of the measuring device (test template 1) must be virtually identical to
that of the groove base so that it fits easily into the groove. The groove diameter of
the winch drum 2 must be 4% to 8% larger than the diameter of the test template 1.
u Use the test template 1 to check each individual groove on the winch drum 2.
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rope drive

Troubleshooting
Is the diameter of the test template not the same as the groove base of the winch
drum? Is there a crescent-shaped gap between the test template and the groove
base?

Fig. 501: Impermissible result when testing the groove base using a test template
1 Test template 2 Winch drum
u Remove the rope.
u Smooth the surfaces of the grooves.
u Contact Liebherr after sales service.
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Rope pulleys

6.26 Rope pulleys

6.26.1 Rope tensioning pulleys of the winch drums

Ensure that the following conditions are satisfied:
q Machine is switched off.
q Machine is secured against unauthorized operation.
u Checking the rope tensioning pulleys for wear
If the rope tensioning pulleys show even wear, no further measures are required.
If the rope tensioning pulleys show uneven wear or if rope operation does not work
perfectly:
u replace rope tensioning pulleys.

6.26.2 Check pulleys for ease of movement

u Check pulleys for ease of movement.
If the pulleys do not move easily:
u Lubricate the pulley bearings (For more information see: 6.26.6 Lubricating the
pulley bearings, page 303) .

6.26.3 Checking steel pulleys for wear

The steel pulleys are checked in exactly the same way as the winch drum groove
base, in other words the radius of the grooves is checked using a test template.
The rope grooves often exhibit an imprint corresponding to the negative imprint of
the rope in question. The impressions of the individual strands in the rope grooves
are normal and not undesirable, since these produce a greater rope support
surface, which increases the service life of the rope. When the rope is changed,
the ridges must be removed and any sharp edges on the surface of the pulley
smoothed.
Ensure that the following conditions are satisfied:
q A suitable test template is available.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
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Rope pulleys

Fig. 502: Checking steel pulleys for wear

1 Test template A Maximum permissible wear on
pulley
2 Steel pulley
The maximum permissible wear A is 4% of the nominal rope diameter.
u Use the test template to check the radius of the groove in the pulley.
If the actual wear exceeds the maximum permissible wear:
u Replace the pulley.
u Contact Liebherr after sales service.

6.26.4 Checking plastic pulleys for wear

The rope grooves often exhibit an imprint corresponding to the negative imprint of
the rope in question. The impressions of the individual strands in the rope grooves
are normal and not undesirable, since these produce a greater rope support
surface, which increases the service life of the rope. When the rope is changed,
the ridges must be removed and any sharp edges on the surface of the pulley
smoothed.
Ensure that the following conditions are satisfied:
q A suitable test template is available.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
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Rope pulleys

Fig. 503: Checking plastic pulleys for wear

1 Test template A Maximum permissible wear on
pulley
2 Plastic pulley
The maximum permissible wear A is 50% of the nominal rope diameter.
u Use the test template to check the radius of the groove in the pulley.
If the actual wear exceeds the maximum permissible wear:
u Replace the pulley.
u Contact Liebherr after sales service.

6.26.5 Checking pulleys for damage

NOTICE
Pulleys placed in the ground without protection!
Damage to the pulleys.
u Pulleys must only be laid on the ground with protective equipment.

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Fig. 504: Damaged pulley

1 Crack 2 Nicks

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Rope pulleys

The pulleys must be aligned with the running direction of the rope. They must also
be in good condition, without wobbles or any other damage.
u Check pulleys for damage (nicks, wobbles, cracks, notches, etc.).
If the pulley is damaged:
u Replace the pulley.
u Contact Liebherr after sales service.

6.26.6 Lubricating the pulley bearings

Ensure that the following conditions are satisfied:
q Grease gun from Liebherr tool kit is at hand and filled with grease.
q The machine is switched off.
q The machine is secured to prevent unauthorised operation.
Ensure that the grease does not escape from or between the pulley bearings.
u Lubricate the pulley bearings on the slewing column head and boom head via
the grease nipples using a grease gun.

6.26.7 Checking the bearing for proper seating and position

u Check the bearing for proper seating and position.

If the seating and position of the bearing or circlip is not correct:
u Correct the seating and position of the bearing.
u Contact Liebherr after sales service.

6.26.8 Cleaning plastic pulleys

NOTICE
Using dirty pulleys!
Damage to the pulleys.
u Clean dirt, gum, etc. from the plastic pulleys.

NOTICE
Unauthorised cleaning agent!
Damage to the pulleys.
u Only clean plastic pulleys with suitable cleaning agents.

Plastic pulleys are resistant to:

– Mineral oil
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– Petrol
– Kerosene
– Diesel
Plastic pulleys are not resistant or not fully resistant to:
– Concentrated mineral acids (e.g. sulphuric acid, hydrochloric acid, nitric acid)
– Concentrated organic acids (e.g. formic acid)
– Concentrated bases (e.g. sodium, caustic potash solution or corrosive potas-
sium salts)
– Alcohol other than ethyl alcohol, methyl alcohol and propyl alcohol
– Inorganic chlorides, e.g. calcium, lithium chloride, magnesium chloride and zinc
chloride

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Rope pulleys

u Clean plastic rope pulleys using a cleaning cloth and authorised cleaning
agents.

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 Maintenance
Cab

6.27 Cab

6.27.1 Check the windows of the cab for damage

u Check the windows of the cab for damage.
If any of the cab windows are damaged:
u Change the window.
u Contact Liebherr after sales service.

6.27.2 Checking that the cab door and the door lock work
properly

Checking the operation of the cab door

u Check the operation of the cab door.
If the cab door does not move freely or does not latch in the open position:
u Spray the hinges with adhesive lubricant.
u Contact Liebherr after sales service.

Checking the operation of the door lock

u Check the operation of the door lock.
If the door lock is not operating correctly:
u Spray the locks with adhesive lubricant.
u Apply frost protection to the locks in the event of low ambient temperatures.
u Contact Liebherr after sales service.

6.27.3 Changing the windscreen wipers

Ensure that the following conditions are satisfied:

q A suitable lifting platform is available.
q Ring spanner with width across flats 13 is available.
q Open spanner with width across flats 13 is available.
q New Liebherr windscreen wiper is available.

NOTICE
Incorrect maintenance!
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Risk of damage to the windscreen wiper nozzles.

u Note the windscreen wiper nozzles on the windscreen wiper mount.

WARNING
Improper protection against falling.
Falling off the lifting platform
u Secure maintenance personnel with suitable safety equipment.
u Check personal safety equipment in line with manufacturer's specifications.

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Cab

Fig. 505: Windscreen wiper

u Hold the screw with the open spanner and undo the nut using the ring spanner.
u Change the windscreen wiper.
Only tighten the screw by a certain degree so that the windscreen wiper can still
move freely.
u Place the screw through the mount and windscreen wiper.
u Tighten the nut using the ring spanner.

6.27.4 Filling the windscreen cleaning system

Make sure that:
q suitable windscreen wash fluid is available.

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Fig. 506: Windscreen wiper system containers

1 Cover (2x) 2 Container (2x)

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Cab

The containers are behind the driver's seat in the cab.

u Open the cover.

NOTICE
Unsuitable windscreen washer fluid!
Damage to the system.
u Fill container exclusively with suitable windscreen washer fluid.

u Top up the windscreen washer fluid in the containers.

u Close the cover.
u If necessary clean the windscreen wiper nozzles on the windscreen wipers with
a needle.
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Operator's seat

6.28 Operator's seat

6.28.1 Check function of operator's seat

u Check function of operator's seat.
When the operator's seat is damaged or does not work properly:
u Contact Liebherr after sales service.

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 Maintenance
Air conditioning*

6.29 Air conditioning*

6.29.1 Checking air conditioning

WARNING
Incorrect maintenance of the air conditioning system!
Poisoning and frostbite.
u Work on the air conditioning system must only be carried out by authorised
Liebherr maintenance personnel.

u Check system to ensure it is in good working order, free from leaks, clean and
securely seated.
u Check the functioning of ventilation flaps and outlets to ensure they are clean
and in good working order.
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Machine care

6.30 Machine care

6.30.1 Cleaning the machine

Liebherr recommends that the external machine parts are cleaned regularly to
maintain an even surface quality. This is strongly advised following work with highly
corrosive materials.

NOTICE
Unsuitable cleaning agent is used!
The surfaces will be damaged.
u Do not use any aggressive cleaning agents.
u Do not use any abrasive cleaning agents.
u Do not use any phosphate cleaners.
u Do not use and solvents or solvent-containing cleaning agents.
u Only use cleaning agent with a pH value of ≤ 12.

Ensure that the following conditions are satisfied:

q Machine is switched off.
q Machine is secured against unauthorized operation.
q The machine has cooled down.
q Wear protective clothing.
q Electronic components are covered.

CAUTION
Hot vapour!
Danger of scalding.
u Wear protective equipment.
u Only use water temperature < 80 °C

NOTICE
Inadmissible use of the high-pressure cleaner!
Paint damage.
Damage to machine.
u Wash machine with at most 150 bar.
u Wash machine at a distance of at least 40 cm.
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The water jet must not be directed onto the following components:
– Intake manifolds for drawing air to cool the engine
– machinery room
– Electrical plug-in connections
– Cab interior
u Clean the machine using a high-pressure cleaner.

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Machine care

Note
Environmental pollution!
u Dispose of the oil-stained tools and cleaning agents in accordance with national
and international guidelines and regulations.
u Cleaning water must pass through an oil separator before it enters the sewer
system.

6.30.2 Cleaning the hydraulic, water and air coolers

Type of dirt Method

Dry dust Clean with compressed air (maximum working pressure
3-4 bar)
Wet dust Clean with steam jet (maximum working pressure 3-4
bar)
Oily dust Clean with steam jet, adding a mild cleaning agent
(maximum working pressure 3-4 bar)

Tab. 44: Type of dirt

6.30.3 Preserving the machine

Ensure that the following conditions are satisfied:
q Machine is switched off.
q Machine is secured against unauthorized operation.
q The machine has cooled down.
q Suitable preservation agents are available in sufficient quantities (For more
information see: 6.2.9 Preservation medium (anti-corrosion coating),
page 232) .
q The appropriate tools and accessories are available.
q Wear protective clothing.

WARNING
Insufficient or incorrect preservation agents are applied to the machine!
Risk of injury to the respiratory tract, suffocation.
u Wear breath protection.

u Spray all machined, but unpainted, parts external to the machine (e.g. pins,
bearings) with DINITROL 4010 or LPS 3 anti-corrosion coating agent.
u Spray all machined, galvanized, but unpainted, parts within the machine (e.g.
flanges, pins, screws, joints, casings, contact surfaces) with anti-corrosion
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coating agent DINITROL 4010 or LPS 3.

u Spray the entire engine compartment with DINITROL 3650 anti-corrosion
coating agent.
u Allow a drying time of 24 hours then spray the entire engine compartment with
DINITROL 4010 anti-corrosion coating agent.
u Spray electrical components inside switch cabinets and terminal boxes as well
as plug-in connections and limit switches with LPS 1 anti-corrosion coating
agent.
u Spray screws on railings, boom walkways, steps, moving parts and floodlights
with LPS 3 anti-corrosion coating agent.

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Maintenance
Machine care

u Wrap connections, threaded joints, valves of the hydraulic system with DENSO
tape.
u Do not use LPS 3 anti-corrosion coating agent in the engine compartment.

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 Check the rope for number of permitted wire
Index breaks 289
Check the windows of the cab for damage 305
Checking air conditioning 309
Checking hoist and luffing gear limit switch for
function 274
Checking hydraulic hoses and hose lines 271
Checking personal protective gear 277
Checking plastic pulleys for wear 301
Checking pulleys for damage 302
A Checking ropes for lubrication 283
Accumulator 216, 268 Checking steel pulleys for wear 300
Activating main power supply 122 Checking that the cab door and the door lock work
Activating spreader mode 153 properly 305
Additional cab equipment 130 Checking the accumulator 268
Adjusting the spreader to the container 153 Checking the bearing for proper seating and
Admissible pitch play 248 position 303
Aggregate 35 Checking the bearing lubrication 245
Air conditioning* 98, 126, 219, 309 Checking the emergency descent rescue
Appropriate use 25 equipment 278
Approved anticorrosion agents (inhibitors) without Checking the emergency stop 275
antifreeze 231 Checking the fill level of the lubrication pumps 279
Approved anticorrosion/antifreeze agents 230 Checking the function of the central lubrication 279
Approved pre-mixed coolants 230 Checking the gearbox oil level 241, 243, 249, 253
Areas of responsibility 43 Checking the hydraulic oil level 257
Checking the lubrication points 281
Checking the operation of the cab door 305
B Checking the operation of the door lock 305
Balancing the spreader 153 Checking the position of the hydraulic oil tank* gate
Banksman 44, 46 valve 120
Boom 37 Checking the proper seals and inspection dates on
Burns 55 the fire extinguishers 276
Bypassing the dynamic anti-collision system 175 Checking the rope drive 298
Checking the rope kicker* 252
Checking the ropes for deformations 285
C Checking the time intervals of the lubrication
Cab 218, 305 pumps 280
Cabin 36 Checking winch drum groove base for wear 298
Carrying out a hydraulic oil analysis 258 Checks before start up 119
Center of gravity 67 Chemical burns 56
Central lubrication system* 40, 113, 129 Cleaning plastic pulleys 303
Changing the accumulator 269 Cleaning the hydraulic, water and air coolers 311
Changing the pressure filter 266 Cleaning the machine 310
Changing the windscreen wipers 305 Cleaning the magnetic rod 262
Check function of operator's seat 308 Cleaning the magnetic rod in the return filter 260
Check hydraulic system for leaks and state of hoses, Cleaning the slip ring unit 272
fittings, valves, blocks, motors, pumps, and Closing the motor grab 144
cylinders. 256
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Closing the return filter 263

Check pulleys for ease of movement 300 Compensating front diagonal pull 161
Check ropes for abrasion 288 Compensating left diagonal pull 158
Check ropes for corrosion 286 Compensating rear diagonal pull 162
Check ropes for the effects of heat 288 Compensating right diagonal pull 159
Check ropes for wear, tight fit and lubrication 283 Content of directories 178
Check screw and clamp connections 273 Control and operating elements 81
Check that the hydraulic cylinder fits properly and Control panel spreader operation* 95
does not leak 270 Control panel X20 88
Check the rope for diameter shrinkage 283 Control panel X23 91
Control panel X24 93

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Index

Control stand 82 Function assignment buttons of right control lever 85

Coolant 226 Function assignment movement directions of right
Coolant mixing ratio 230 control lever 86
Coolant specification 229 Function assignment of left control lever buttons 83
Function assignment of left control lever movement
directions 84
D
Danger zone 47
Data recorder* 176 G
Data structure of the flash card 178 Gear oil 225
Deactivating the main power supply 189, 191 General hand signals in accordance with BGV A8 68
Deinstalling the motor grab 145 Grease 225
Deinstalling the spreader 155 Greasing the ball bearings 239
Deselecting special lift mode 182 Greasing the toothing 245
Deselecting Sycratronic mode 171
Diagonal pull display* (VLF) 157
Diesel engine coolant 229 H
Diesel engine lubricating oil 226 Hand pump for emergency operation 38
Distributor gearbox 214, 240 Hand pump with tank* 39
Draining the gearbox oil 242, 251, 255 Hand pump without tank* 38
Draining the hydraulic oil 259 Hand signals 68
Dynamic anti-collision system (DACS)* 174 Hand signals for lifting operations in accordance with
ASME/ANSI B30.5 74
Hazards 53
E Hoisting gear 133
Electric motor 213, 238 Hook operation 138
Electrical energy 54 How to respond in the event of a current transfer 63
Electrical system 217, 272 How to respond in the event of a fire 63
Electromagnetic influence 59 Hydraulic cylinders 216, 270
Emergency descent rescue equipment 183, 217, 278 Hydraulic energy 54
Emergency mode 192 Hydraulic filter 216, 266
Emergency mode in case of failure of a power Hydraulic hoses 216, 271
pack 193 Hydraulic oil 225, 231
Emergency stop 31, 187, 275 Hydraulic oil tank 216, 257
Engine oil 225 Hydraulic system 215, 256
Entering the cabin 117
Environment 62
Error message screen 102 I
Exchanging data 179 Implementation instructions for the maintenance 237
Explanation of symbols used 87 Inappropriate use 27
Exposure to wind 59 Increasing the spreader width 153
Information screen 106
Initial filling 231
F Initialise rope measuring system 181
Filling capacities table 222 Installing the motor grab 141
Filling the windscreen cleaning system 306 Installing the rotator 146
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Fire and explosion 57 Installing the spreader 151

Fire classes 64 Instruments 67
Fire extinguishers 217, 276 Interim lubrication 129
Fire protection signs 51
Firefighting 64
First response to a current transfer 63 L
Flash card directories 178 Left control lever 83
Folding the flipper down 154 Liebherr oil diagnosis system 234
Folding the flippers up 155 Lift load 133
Fuel 228 Lifting device 215
Fuel at low temperatures (winter operation) 228 Lifting the boom 136
Fuel specifications 228 Lifting the container 155

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 Index

Lifting the hook 139 Moving the boom into parked position 190
Lifting the motor grab 143 Moving the boom out of parked position 123
Lighting 124
Lightning strike 61
Limit switch 274 N
Litronic testing system overview 199 Noise measurement data 30
Litronic® testing system 199
Load charts 29
Locking twistlocks 154 O
Long interruption of work 188 Oil analysis kit 226
Lowering the boom 136, 195 Oil concentrate 225
Lowering the container 155 Oil filling schedule 222
Lowering the hook 140 Opening the motor grab 145
Lowering the load 134, 194 Opening the return filter 260
Lowering the motor grab 143 Operating hoisting gear 133
Lubricants and consumables 220 Operating hours screen 107
Lubricate ropes 297 Operating machines 166
Lubricating oil change intervals 227 Operating Sycratronic emergency lowering
Lubricating oil specification 226 system 172
Lubricating oil viscosity 226 Operating the air conditioning 126
Lubricating the pulley bearings 303 Operating the dynamic anti-collision system 174
Lubrication chart 223 Operating the hook 139
Lubrication diagram 221 Operating the machines in case of engine and control
Lubrication system* 218, 279 failure 172
Luffing gear 135 Operating the machines in case of engine failure 172
Luffing gear operation 136 Operating the machines in case of failure of one
Luffing ropes 295 machine 172
Operating the motor grab 143
Operating the rotator 148
M Operating the signal horn 130
Machine care 310 Operating the vertical line finder 157
Machine operator 44, 45 Operating the windscreen wiper system 127
Machinery room 34 Operation 117
Main factors when planning the tandem lifting Operation emergency stop 187
operation 67 Operation screen 103
Main hoisting winch 249 Operation with both power packs 194
Main screen page 200 Operation with power pack1 194
Maintenance 211 Operation with power pack2 194
Maintenance and inspection schedule 211 Operational faults, diagnosis 199
Maintenance and service personnel 44 Operator's seat 308
Maintenance personnel 46 Ordering data 225
Mandatory signs 52 Overload 169
Manufacturer 43 Owner 43
Mass and capacity of the load lifting equipment 67
Mass of the load 67
Meaning of the safety signs 48 P
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Measure slewing ring tilt clearance 246 PA amplifier* 109

Measurement 247 Personal protective equipment 46, 277
Measuring points 246 Poisoning and suffocation 58
Mechanical action 53 Preservation medium (anti-corrosion coating) 232
Menu bar 101 Preserving the machine 311
Mixing 232 Preserving the piston rods of the hydraulic cylinders in
Mode Sycratronic* 164 case of longer periods of non-use 270
Monitor 100 Priority Level screen (for Liebherr service personnel
Motor grab mode* 141 only) 205
Mounting the hook 138 Product description 23
Move boom into parked position 188 Prohibition signs 48
Moving containers 154

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Index

Protecting the piston rods of the hydraulic cylinders Selecting Sycratronic mode 165
from corrosion 270 Selecting the pivot point of the crossbar 166
Setting the lubrication time 129
Setting the pause time 129
R Setting the trigger point 176
Recording a load cycle 177 Shifting the bottom load center 170
Reducing the spreader width 153 Shifting the top load center 170
Regulations for tandem lifting mode 66 Short interruption of work 188
Replacing filter mats 272 Shutdown 188
Replacing fuses and lamps 272 Shutdown before short work interruption 188
Requirement on the rated capacity during the tandem Slewing column 32
lifting operation 68 Slewing column overview 32
Requirements to personnel 45 Slewing gear operation 131
Retract ropes 296 Slewing the machine to the left 131
Rigger 44, 45 Slewing the machine to the right 132
Right control lever 85 Slewing the slewing column 195
rope drive 298 Slip ring unit 217
Rope measuring system 181 Snow and ice loads 61
Rope pulleys 218, 300 Special hand signals for attachment operations 71
Rope reeving winch 253 Special lift mode* 182
Rope tensioning pulleys of the winch drums 300 Specifications 30
Ropes 218, 282 Spreader operation* 150
Rotating the crossbar 166 Starting the e-motor 122
Rotating the crossbar clockwise 169 Start-up 122
Rotator* 146 Status bar 100
Steps 117
Storing ropes 292
S Structure of the file data.txt 179
Safety devices 31 Structure of the file head.txt 178
Safety instructions 43 Sulphur content in fuel 228
Saving data 178 Supervision 67
Screen Add Selection 202 Swing 131, 214, 243
Screen CAN Configuration 205 Swing connection 214, 245
Screen CAN Line Information 205 Swinging the container to the left 155
Screen Clients 206 Swinging the container to the right 155
Screen CORRECTION 203 Swinging the motor grab to the left 143
Screen Display Configuration 205 Swinging the motor grab to the right 143
Screen Drive Function 204 Switch cabinet X1 111
Screen INPUT/OUTPUT 200 Synchronization of the machine movements 67
Screen Language Selection 204
Screen MDE/PDE 206
Screen MEMORY 201 T
Screen MESSAGES 203 Taking an oil sample 235
Screen Modem Function 204 Tank filling unit* 264
Screen pages 200 Tanking hydraulic oil 265
Screen Sampling Trace 206 Taring the load 176
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Screen SELECT 201 Technical condition of the machine 43

Screen Select File Load 202 Technical data 30
Screen Select File Save 202 Topping up the gear oil 244, 254
Screen SPECIAL FUNCTIONS 204 Topping up the gearbox oil 241, 250
Screen System Language Selection 205 Topping up with hydraulic oil 258
Screen System Status 206 Transporting ropes 292
Screen Time Function 204 Turn rotator clockwise 149
Screenwash fluid 226 Turn rotator counter-clockwise 148
Selecting hook mode 138 Turning off the e-motor 189, 190
Selecting motor grab mode 143 Turning off the ignition 189, 191
Selecting ropes 292 Turning on the cabin lighting 125
Selecting special lift mode 182 Turning on the crane lighting 125

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 Index

Turning on the floodlight* 124

Turning on the ignition 122
Turning on the obstacle light* 125
Turning on the windscreen wipers 127
Turning the crossbar counter-clockwise 169
Type plate 23

U
Understanding the oil diagnosis report 236
Unlocking twistlocks 155
Use of the fire extinguisher 64
Using the emergency descent rescue equipment 183

V
Very long interruption of work 190
Vibrations 31

W
Walk round 119
Warning signs 49
Water (fresh water) 229
What to do in dangerous situations 63
Whole machine 30, 213
Whole machine overview 30
Winches 214
Winding ropes 293
Windscreen wipers 127
Work area 47
Working at heights 66
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Index

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