Operating Manual

EN

Type:

Serial number:

Operating manual

ORIGINAL 001 - 19.04.2011 / lwnrai0

FCC-CBG 45(45)/32 LITRONIC

165 124

Artikelcode/Item Code: 950968314Ausgabe/Edition: 002

Item Code: 950968314Revision: 2

IT MUST BE GUARANTEED THAT NO SIGNIFICANT RELATIVE MOVEMENTS BETWEEN CRANEBARGE AND THE TRANSPORT VESSELS CAN OCCUR !

MAX. CRANE INCLINATION ±1°

MAX. CRANE INCLINATION ±3°

LOAD DIAGRAMM

LIEBHERRCBG 45(45)/32

LOAD DIAGRAMM

32.06.0

12.0

9.0

0

5

10

15

20

25

30

35

40

45

50

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0Radius [m]

SWL

[t]

OPEN SEA OPERATION (DYN. FACTOR 2,1)GRAB OPERATION (DYN. FACTOR 1,55)

32.06.00

5

10

15

20

25

30

35

40

45

50

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0

Radius [m]

SWL

[t]

GRAB SERVICE

HOOK SERVICE(OVERRIDE SWITCH)

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

CBG_HD / V001 1

User Guide

This operation manual has been written for the machine operator. It contains

all the information necessary to operate, control and carry out simple maintenance on the machine.

The operation manual must be read with care and obeyed by everyone who:

� works with the machine.

� is instructed to carry out work on the machine.

Work with or on the machine includes:

� Commissioning, operation, including the changing of slinging tackle

� Maintenance, servicing, inspection and repair, dealing with supplies andauxiliary materials

The operation manual and the relevant load chart belong with the ma

chine and must therefore be ready to hand in every cabin.

Compliance with the operation manual by maintenance personnel:

� increases reliability while in use.

� increases the service life of the machine.

� reduces repair costs and downtime.

Contact Liebherr after sales service for all other questions (also if you sell

the machine or purchase it from a previous owner).

Latest version of the documentation

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 inthe case of load charts).

� Always replace the CD-ROM by a new version, e.g. from revision docu

ments.

� Update all languages to the latest version in the case of multilingual documentation.

Storage of documentation

� Always keep the operation manual ready to hand in the cabin.

� The spare parts catalogue and technical information must be available to

maintenance and service personnel if required.

CBG_HD / V0012

Structure and content of the documentation:

The operation manual contains:

� “Product description

� “Safety

� "Operating elements"

� “Operation

� “Maintenance

The technical information contains:

� General diagrams

� Hydraulic diagrams

� Electrical diagrams

The documentation accompanying the product contains documentation re

garding any:

� Attachments, e.g. cable drums, air conditioning systems, etc.

� Rigging material, e.g. rotators, spreaders, grabs, etc.

The spare parts catalogue provides information about:

� All the spare parts used in the machine

� Spare part procurement

The CD-ROM contains all the machine documentation in digital form.

All images in this operation manual are symbolic and may differ from thedelivery state.

System requirements for use of the CD

Hardware (minimum)

� Intel® Pentium II® PC 500MHz, 128 MB RAM, CD-ROM drive,minimum resolution of 800 x 600 pixels, high-colour depth

Software

� Windows NT, Windows 2000, Windows XP, Internet Explorer 5.5, Adobe

Acrobat Reader 7.0

Ensure that no popup blockers are activated when using Liebherr Parts. Thepopup blocker function may be present in certain web browsers and firewalls.

CBG_HD / V001 3

Symbols, danger symbols and signal words:

An optional retrofit kit (NRS - NachRüstSatz (retrofit kit)) is indicated by an *.

Each description marked with an * does not have to correspond to the deliverystate of the machine. The optional retrofit kit actually fitted to the machine is

shown in the machine licence (see Product description).

� List entry

� List sub-entry

� equipment or retrofit kit contained in the machine licence

� equipment or retrofit kit not contained in the machine licence

� active handling instruction

� Consequence of the handling instruction

DANGER

Denotes an immediate dangerous situation which will result in death orserious injury if it is not avoided.

� Refers to action to be taken to reduce or prevent the danger.

WARNUNG

Denotes a dangerous situation which could result in death or serious injury ifit is not avoided.


VORSICHT

Denotes a dangerous situation which could result in minor or moderate injuryif it is not avoided.


ACHTUNG

Denotes a dangerous situation which could result in material damage if it isnot avoided.


HINWEIS

Denotes useful tips and hints.

� Refers to the current action and demonstrates how to perform tasks in a

straightforward manner.

*

CBG_HD / V0014

Entsorgung

Avoid the risk of environmental damage.

� Dispose of all hazardous materials, such as: waste oil, cooling liquid,

contaminated filter elements, etc., in accordance with national or regionalregulations.

ERSTE HILFE

Warranty claims arising from improper operation, inadequate maintenance,use of non-approved supplies or non-compliance with safety regulations will not

be admitted.

We reserve the right to modify the technical details of the machine as against

the descriptions and illustrations in this document.

This documentation is protected by copyright. The information and images in

this manual are not to be duplicated, reproduced, translated, converted for thepurposes of storing and processing in DP systems or used for competitive purposes either in whole or in part. The copying and duplication of load charts in

connection with work planning and the use of this machine is expressly permitted. All legal rights embodied in copyright law are expressly reserved.

Liebherr-Werk Nenzing GmbHP.O. Box 10

Dr. Hans Liebherr Strasse 16710 Nenzing

AUSTRIA / EUROPE

Telephone: +43 50809 41-0Fax: +43 50809 41-500

e-mail: [email protected]: www.liebherr.com

CBG_HD / V001 5

1. Product description 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Type plate 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 State-of-the-art technology 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Appropriate use 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Inappropriate use 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Technical description 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1 Complete machine 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.2 Slewing column - front view 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.3 Slewing column - rear view 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.4 Machinery room 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.5 Hydraulic oil tank 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.6 Hand pump with tank 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.7 Hand pump without tank 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.8 Central lubrication system 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.9 Cabin 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.10 Boom 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Technical data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Construction conditions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2 Environmental conditions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Safety equipment 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.1 Emergency stop 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Technical condition of the machine 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Areas of responsibility 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Manufacturer 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Owner 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 Machine operator 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 Rigger 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.5 Banksman 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.6 Maintenance personnel 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Requirements to personnel 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Machine operator 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Rigger 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Banksman 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V0016

2.3.4 Maintenance personnel 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Personal protective equipment 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Work area 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Danger zone 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Safety signs 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1 Meaning of the safety signs 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Hazards 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1 Mechanical action 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.2 Electrical energy 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.3 Hydraulic energy 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.4 Burns 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.5 Chemical burns 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.6 Fire and explosion 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.7 Poisoning and suffocation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.8 Electromagnetic influence 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.9 Exposure to wind 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.10 Snow and ice loads 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.11 Lightning strike 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.12 Environmental hazard 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 How to respond in dangerous situations 61. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.1 How to respond in the event of a current transfer 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.2 How to respond in the event of a fire 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.3 Firefighting 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Hand signals 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.1 General hand signals in accordance with BGV A8 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.2 Special hand signals for riggingoperations 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.3 Hand signals for lifting device operations in accordance with ASME/ANSI B30.5 72. . .

3. Inspection elements and operating elements 77. . . . . . . . .

3.1 Control station 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Control lever left 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Directions 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Buttons 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Control lever right 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Directions 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V001 7

3.3.2 Buttons 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Control panel operating elements 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Control panel X25 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Control panel X26 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.3 Windscreen wiper control panel 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Air conditioning* 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Litronic monitor 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 Monitor overview 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.2 Status indicator 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.3 Function key symbols 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.4 Home screen 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.5 Engine screen 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.6 Operating hours screen 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.7 Settings screen 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.8 Litronic test system screen 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.9 Hydraulics screen 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.10 Temperature screen 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.11 Sector limiting screen 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.12 Data recorder screen 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.13 Error screen 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 PA amplifier 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Switch cabinet X1 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Switch cabinet X2 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Central lubrication system* 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operation 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Access 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Entering the machine 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Inspections before daily commissioning 129. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Daily inspection 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Check hydraulic oil tank shut-off valve 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Daily commissioning 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Starting engine 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Operator's seat 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V0018

4.4.1 Adjusting the operator's seat 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Lighting 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Operating searchlights* 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Operating cabin lighting 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.3 Operating crane lighting 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.4 Operating helicopter warning light* 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.6.1 Operating the air conditioning system 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 PA amplifier* 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Operating the PA amplifier 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Windscreen wiper 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.1 Operating windscreen wiper 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.2 Operating the windscreen wash system 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Warning horn 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1 Using the warning horn 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 Central lubrication system* 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.1 Set lubrication time 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.2 Set pause time 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.3 Interim lubrication 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 Select operation mode 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11.1 Select hook operation 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11.2 Select winch service mode 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11.3 Select four-rope grab operation 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 Slewing gear 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12.1 Operating the slewing gear 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12.2 Slewing gear stop 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13 Hoisting gear 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13.1 Operating the hoisting gear 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13.2 Hoisting gear stop 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14 Luffing gear 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.1 Operating luffing gear 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.2 Luffing gear stop 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.3 Bypass luffing gear limit switch 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15 Hook operation 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V001 9

4.15.1 Attach hook 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15.2 Adjust hook position 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15.3 Operate hook 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16 Four-rope grab operation 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16.1 Assemble four-rope grab 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16.2 Adjust four-rope grab position 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16.3 Operate four-rope grab 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17 Data recorder* 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.1 Tare load 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.2 Set trigger point 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.3 Record load cycle 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.4 Selecting hatch cover 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.5 Store data 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.6 Exchange data 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17.7 Analyse data 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.18 Open Sea* 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.18.1 Select Open Sea 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.18.2 Deselect Open Sea 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.19 Slack rope safety device 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.19.1 Bypass slack rope safety device 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.20 Heavy lift operation* 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.20.1 Select heavy lift operation 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.21 Rope length metering 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.21.1 Initialise rope length metering 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22 Sector limitation* 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22.1 Select sector points 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22.2 Select sector 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22.3 Delete sector 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22.4 Bypass sector limitation 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.23 Specialised lifting* 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.23.1 Select specialised lifting 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.24 Winch synchronisation 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.24.1 Synchronise winches automatically 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.24.2 Synchronise winches manually 180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25 Litronic test system 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V00110

4.25.1 Overview 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25.2 Screen pages 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25.3 Starting the Litronic test system 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.26 Abseiling device 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.26.1 Use abseiling device 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.27 Emergency stop 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.27.1 Using emergency stop 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.28 Interruption of work 198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.28.1 Decommissioning before work interruption 198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.28.2 Commissioning after work interruption 199. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.29 Decommissioning 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.29.1 Lower boom to parked position 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.29.2 Switch off engine 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30 Emergency operation 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.1 Emergency operation for power unit fault 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.2 Emergency operation for fault on both power units 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.3 Open four-rope grab 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.4 Lower four-rope grab 209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.5 Lower hook (holding winch only) 209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.6 Lower hook (holding winch and closing winch) 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.7 Release slewing gear brakes 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.30.8 Lower boom 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Maintenance 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Maintenance schedule 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Lubricants and consumables 222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Lubrication chart 222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Filling capacitytable 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Lubrication chart 225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Hydraulic oil 229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.5 Conservative agent (anti-corrosion coating) 230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.6 Oil diagnosis system 231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Slewing gear 234. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Checking the gearbox oil level 234. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Topping up the gearbox oil 235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Electric motor 236. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V001 11

5.4.1 Lubricate ball bearings 237. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Distributor gearbox 238. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1 Check gearbox oil level 239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Topping up gearbox oil 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3 Draining gearbox oil 241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Slewing connection 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 Grease the toothing 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.2 Checking bearing lubrication 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.3 Slewing bearing tilt measurement 244. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Hoisting gear 248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




5.8 Luffing mechanism 252. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




5.9 Hydraulic system 256. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9.1 Check the hydraulic system for leaks 256. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 Hydraulic oil tank 257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10.1 Checking the hydraulic oil level 258. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10.2 Carrying out a hydraulic oil analysis 259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10.3 Topping up with hydraulic oil 259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10.4 Draining the hydraulic oil 261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10.5 Cleaning magnetic rod in return filter 262. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11 Fuelling system* 265. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11.1 Fill hydraulic oil tank 266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 Hydraulic oil filter 267. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12.1 Replace pressure filter 267. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 Pressure accumulator 269. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13.1 Check pressure accumulator 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13.2 Change pressure accumulator 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14 Hydraulic cylinders 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14.1 Check hydraulic cylinder for leaks 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14.2 Preserving hydraulic cylinders 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V00112

5.15 Hydraulic hoses and hose lines 272. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16 Electrical system 273. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16.1 Replace fuses and lamps 273. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16.2 Cleaning the slip ring unit 273. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16.3 Replacing of filter mat 274. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16.4 Checking screw and clamping connections 274. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.17 Limit switches 275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.17.1 Checking function of lifting and luffing gear limit switches 275. . . . . . . . . . . . . . . . . . . . . . .

5.18 Emergency stop 276. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.18.1 Check the emergency stop to ensure it is working correctly 276. . . . . . . . . . . . . . . . . . . . . .

5.19 Fire extinguishers 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.19.1 Checking fire extinguishers 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.20 Personal protective equipment 278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.20.1 Checking that personal protective equipment is in place, intact and complete 278. . . . . .

5.21 Lowering device 279. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.21.1 Checking the lowering device 279. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.22 Central lubrication system 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.22.1 Check that central lubrication system is working 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.22.2 Check fill level of lubrication pump 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.22.3 Check time interval on lubrication pump 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.22.4 Check lubrication points 282. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23 Ropes 283. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.1 Checking the rope diameter 284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.2 Checking ropes for deformations 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.3 Check ropes for corrosion 287. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.4 Check ropes for abrasion 288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.5 Check ropes for the effects of heat 289. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.6 Checking the number of permitted wire breaks 290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.7 Storing ropes 292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.8 Transporting ropes 293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.9 Winding ropes 294. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.10 Luffing ropes 296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.11 Retracting ropes 297. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.23.12 Lubricate ropes 298. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.24 Rope drive 299. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.24.1 Checking the rope drive 299. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V001 13

5.25 Rope pulleys 301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.25.1 Checking pulleys for ease of movement, signs of wear and damage 301. . . . . . . . . . . . . .

5.25.2 Lubricating pulley bearings 304. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.25.3 Cleaning plastic pulleys 304. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.26 Cabin 305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.26.1 Checking cabin windows for damage 305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.26.2 Checking that cabin door and door lock work properly 305. . . . . . . . . . . . . . . . . . . . . . . . . .

5.26.3 Changing the windscreen wipers 306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.26.4 Filling windscreen wiper system 307. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.27.1 Checking and cleaning the air conditioning system 308. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.28 Machine care 309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.28.1 Cleaning the machine 309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.28.2 Cleaning the hydraulic, water and air coolers 310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.28.3 Preserving the machine 310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V00114

1

1

Product description

CBG_HD / V001 15

1. Product description

This chapter provides information on

� The capabilities of the machine.

� The equipment and additional equipment of the machine.

� Assembly of the main components.

� Main technical data.

� Importance and arrangement of safety devices on the machine.

Product description

CBG_HD / V00116

1.1 Type plate

The type plate is attached to the inner surface of the cabin door. The details on

the type plate are useful when ordering spare parts.

� Please note following data:

� Serial number: _____________________________________________

� Type: _____________________________________________

� Year of manufacturing: _________________________________

Figure 1 CBG type plate

Product description

CBG_HD / V001 17

1.2 State-of-the-art technology

At the time of delivery, this machine represents state-of-the-art technology.

Nevertheless, the machine can pose dangers if the safety notes in this operation manual are not observed and implemented.

Product description

CBG_HD / V00118

1.3 Appropriate use

Possible applications are determined by the supplied equipment.

Use machine exclusively to carry out the operations listed and described in thisoperation manual.

Use of the machine is appropriate:

� if the relevant instructions for the operation modes described in the operation manual are followed.

� if the applicable national and international safety regulations are obser

ved.

� if all safety regulations in this operation manual are obeyed.

� if all the necessary safety devices are present and in good working order.

� if the usage conditions defined in this operation manual are adhered to.

� if all maintenance and inspection work is carried out using the specifiedfuels and lubricants.

Special operations must be discussed with the manufacturer before they arecarried out, and must be documented by both parties.

Any application for the machine that is different from or more complex thanthose described here is regarded as inappropriate without written agreement

from Liebherr service department.

The operator is responsible for any injury to people, animals or any damage tothe machine arising from inappropriate use!

Product description

CBG_HD / V001 19

1.4 Inappropriate use

Inappropriate use corresponds to misuse that can be foreseen if proceeding ina sensible manner.

Inappropriate use of the machine:

� results in life-threatening or fatal injuries.

� causes severe damage to machine and other objects.

� results in loss of warranty claim entitlement.

Use of the machine is inappropriate:

� if the machine is commissioned without an acceptance test, if one is stipulated by national legislation.

� if the machine is commissioned by persons who are not authorised by theoperating company.

� if the machine is commissioned without the requisite training and know

ledge of the operation manual.

� if the machine is commissioned without the prescribed safety devices.

� if the machine is commissioned without a valid load chart.

� if the machine is commissioned when the operation manual is incomplete

or unreadable.

� if structural modifications have been carried out which affect operationalsafety or have been carried out without the written consent of the manufacturer.

� if work is carried out in any way which endangers operational safety.

� if lifeboats are handled without a specially approved operating mode.

� if persons are transported without using a specially authorised operationmode.

� if fastened loads are pulled loose using slack rope or by operating the

slewing gear or luffing gear.

� if loads are raised from the ground using luffing gear alone.

� if several cranes together raise loads without a specially approved operating mode.

� if loads are raised diagonally.

� if a load is dragged on the ground.

� if spare parts or consumables are fitted or used which are not original

Liebherr products or approved by the manufacturer.

� if the load curve or the factory-fitted safety device are bypassed or modified.

� if the prescribed maintenance and inspection operations are not adhered

to.

Product description

CBG_HD / V00120

1.5 Technical description

1.5.1 Complete machine

Figure 2 Main components

1 Boom

2 Cabin

3 Slewing column

4 Counterweight

5 Base column

Product description

CBG_HD / V001 21

1.5.2 Slewing column - front view

Figure 3 Slewing column - front view

1 Wind speed sensor

2 Slewing ring bearing

Product description

CBG_HD / V00122

1.5.3 Slewing column - rear view

Figure 4 Slewing column - rear view

1 Rope pulleys

2 Oil cooler cover

3 Cabin access door

4 Cabin access platform

5 Winch access platform

6 Holding winch

7 Closing winch

Product description

CBG_HD / V001 23

1.5.4 Machinery room

Figure 5 Machinery room

1 Hydraulic oil tank

2 Switch cabinet X1

3 Switch cabinet X2

4 Luffing winch

5 Slewing gear

6 Electric motor

7 Set of hydraulic pumps

Product description

CBG_HD / V00124

1.5.5 Hydraulic oil tank

Figure 6 Hydraulic oil tank

1 Air breather

2 Oil level sensor

3 Return filter

4 Inspection hatch

5 Shut-off valve

6 Sight glass for checking oil level

Product description

CBG_HD / V001 25

1.5.6 Hand pump with tank

Figure 7 Hand pump with tank

1 Tank

2 Dip stick and oil inlet

3 Air breather

4 Hand lever

5 Pressure gauge

6 Pressure connection

Product description

CBG_HD / V00126

1.5.7 Hand pump without tank

Figure 8 Hand pump without tank

1 Restrictor valve

2 Hand lever

3 Measuring connection

4 Pressure connection

5 Suction connection

6 Pump cylinder

Product description

CBG_HD / V001 27

1.5.8 Central lubrication system

Figure 9 Central lubrication system

1 Supply container

2 Overpressure valve

3 Pump outlet

4 Filling nipple

5 Interim lubrication button

6 Control unit

Product description

CBG_HD / V00128

1.5.9 Cabin

Figure 10 Cabin

1 Video monitoring monitor

2 Microphone for PA amplifier

3 Abseiling device

4 Cabin lighting switch

5 Operator's seat

6 Control lever left

7 Control panel X26

8 Control lever right

9 Control panel X25

10 Monitor

Product description

CBG_HD / V001 29

1.5.10 Boom

Figure 11 Boom

1 Rope pulley

2 Hoisting rope

3 Luffing pulley

4 Luffing rope

5 Boom pivot bearing

6 Load pick-up equipment

7 Searchlight

Product description

CBG_HD / V00130

1.6 Technical data

1.6.1 Construction conditions

Classification, certifying authority

1.6.2 Environmental conditions

Ambient temperatureDesign temperatureRelative humidityMax. heel without loadMax. trim without loadMax. wind speed when machine is in useMax. wind speed when machine is in parked positionMax. wind speed when machine is in storm parked position

LRS (Lloyds Register of Shipping)

-25°C to +45°C-10°C

93 %3°3°20m/sec (0,245kN/m²)63m/sec63m/sec

Product description

CBG_HD / V001 31

1.7 Safety equipment

The safety equipment includes:

� Emergency stop

� Fire extinguisher (may be supplied by customer)

� Acoustic signal transmitters

1.7.1 Emergency stop

Emergency stop

Emergency stops located:

� by switch cabinetX1

� by engine

� in cab

� by access ladder

� in base column

� by winches

Product description

CBG_HD / V00132

2

2

Safety

CBG_HD / V001 33

2. Safety

This chapter provides information on

� warns user about other risks.

� provides information about dangers arising during appropriate use.

� provides information about how to avoid dangers.

2.1 Technical condition of the machine

Requirements for safe operation of machine in terms of its technical condition:

� Machine in perfect condition

� Unauthorised conversion or modification not permitted

� Regular maintenance

� Operational safety devices

Sicherheit

CBG_HD / V00134

2.2 Areas of responsibility

2.2.1 Manufacturer

The manufacturer:

� is responsible for the technically safe condition of the machine supplied,together with accessories and documentation.

� is aware of its duty to monitor the product and document all maintenance

and repair work carried out by Liebherr personnel.

� ensures that the machine is kept in an operational state by a worldwidemaintenance and repair service.

� runs a training centre and provides training for the owner's operating and

maintenance personnel as a service.

2.2.2 Owner

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 arefully qualified, and authorises them to work.

� specifies the skills and responsibilities of all those working with or nearthe machine.

� provides all necessary protective equipment to individuals working with ornear the machine.

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

manner.

� is responsible for ensuring the safe condition of the machine.

� completely removes the machine from use upon the discovery of anyfaults 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 leadingto serious injury or major material damage.

� allows Liebherr service personnel unlimited access to the machine in

order that they may fulfil 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 consultingthe manufacturer.

� uses only original Liebherr spare parts.

Safety

CBG_HD / V001 35

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 valuesspecified in the load chart and in accordance with the setup and the ope

ration manual.

� wear protective clothing.

� reports to the owner any alteration to the machine that affects safety.

� halts operation immediately if safe operation is no longer possible.



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 approval to move and/or accompany the load.


2.2.5 Banksman

The banksman:

� conveys signals from the rigger to the machine operator.

� is the only person to give signals to the machine operator.


2.2.6 Maintenance personnel

Maintenance personnel:

� maintain the machine to ensure that it remains in a safe and reliable con

dition.

� have read and understood the operation manual.


� perform all specified maintenance work.



Sicherheit

CBG_HD / V00136

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 for this type of machine.

� is trained in rigging and assisting.

� is trained in using fire extinguishing devices.

� 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:


� is physically capable (adequate eyesight and hearing, quick reactions) ofsafely using/moving lifting devices.

� is authorised to rig loads.


� is capable of accurately estimating mass and load distribution.

� is capable of operating walkie-talkies and using them to give clear instructions.

� is capable of guiding the load and ensuring the safe movement of the

load and the machine.

� is trained in attaching lifting devices.

� is trained in signalling and knows the signal signs.

� is trained in selecting the correct rigging.

� is trained in securing against unexpected detachment.

� is trained in preventing damage to rigging.

� do not suffer from any physical or psychological ailments that lower anyof the specified requirements.


Safety

CBG_HD / V001 37

2.3.3 Banksman

The banksman:


� are physically capable (adequate eyesight and hearing, quick reactions).

� is authorised to give signal signs.


� is capable of operating walkie-talkies and using them to give clear instructions.

� is capable 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 anyof the specified requirements.


2.3.4 Maintenance personnel

Maintenance personnel:


� 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.


Sicherheit

CBG_HD / V00138

2.4 Personal protective equipment

The operator and maintenance personnel have individual responsibility for:

� Wearing the required personal protective gear.

� Regular cleaning and care of protective equipment.

� Replacing defective items of protective equipment 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 fluids

� 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 personnelis necessary.

Safety shoes, if foot injuries are possible due to:

� collision or trapping

� Pointed or sharp objects

� Swaying or falling objects

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

Safety

CBG_HD / V001 39

2.5 Work area

In accordance with the EU Machinery Directive, the following guidelines have

been laid down for the operation of the machine:

Required operating personnel: one machine operator

Prescribed work area: Cabin

Banksman:one additional person

Ensure that the following conditions are satisfied:

� No one other than the machine operator may be on the machine or in thedanger zone of the machine

� The machine operator is in the operator's cab at all times.

Operating elements to be operated exclusively from operator's seat. Operatingany operating elements through the open cab door is prohibited.

Prerequisites for a safe working area:

� Keep the cab clean:

� Do not place newspapers or other objects on the control panels.

� Do not keep tools in the cabin.

� Articles of clothing, items of protective equipment or personnel effectsmust not hinder access to the cab or the operation of the machine.

� Keep the entrance to the cabin clean and free from snow and ice and any

other obstructions.

� Keep all screens of the machine clean and free of condensation and ice.

Sicherheit

CBG_HD / V00140

2.6 Danger zone

The danger zone is the area surrounding the machine, in which people can pos

sibly be injured by:

� working movements of the machine

� a swinging or falling load

� optional equipment on the machine

Figure 12 Danger zone

1 Working area at maximum radius

2 Danger zone

DANGER

Machine in use!

� Ensure that there are no persons in the danger zone.

� Leave the danger zone.

Safety

CBG_HD / V001 41

2.7 Safety signs

Important safety signs are fitted to the machine. If they are not observed, death

or serious injury can result.

DANGER

Missing, damaged or illegible safety signs!

� Constantly check safety signs to ensure they are complete and legible.

� Replace missing or illegible safety signs with new, original ones.

2.7.1 Meaning of the safety signs

The safety signs are divided into three main groups of different shapes and co

lours:

Prohibition signs

Prohibition signs:

� are circular and have a red signal colour.

� are located wherever a potentially dangerous action is prohibited.

No fire, naked flames or smoking

No access for unauthorised personnel

No persons with pacemakers

Pedestrians forbidden

Sicherheit

CBG_HD / V00142

Do not switch

Warning signs

Warning signs:

� are triangular and have yellow as the signal colour.

� should draw attention to equipment and circumstances in order to warn ofpotential injury and/or danger to life.

Danger area

Danger from electrical voltage

Danger from suspended load

Heeling hazard

Heeling hazard

Safety

CBG_HD / V001 43

Heeling hazard

Danger from hot surfaces

Slip hazard

Fall hazard

Stumble hazard

Crushing hazard

Crushing hazard

Sicherheit

CBG_HD / V00144

Crushing hazard

Rolling over hazard

Danger from ropes

Danger - electromagnetic waves

Danger from pressure reservoir

Danger from batteries

Safety

CBG_HD / V001 45

Fire protection signs

Fire protection signs:

� are square and have red as the signal colour

� should draw attention to equipment and information needed in case of

fire

Fire extinguishers

Fire extinguishers

Fire detector

Mandatory signs

Mandatory signs:

� are round and have blue as the signal colour.

� relate to protective equipment that must be worn to prevent physical injury.

General mandatory sign

Wear helmet

Sicherheit

CBG_HD / V00146

Wear ear protection

Wear face protection

Wear hand protection

Wear foot protection

Use safety harness

Safety

CBG_HD / V001 47

2.8 Hazards

2.8.1 Mechanical action

WARNUNG

Mechanical actions due to moving machinery!

When operating the machine, numerous danger areas and situations can cause

life-threatening injuries.

� Observe handling and situation-specific safety notes.

HINWEIS

Observe the following safety notes:

� Wear requisite personal protective equipment.

� 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 slidingelements.

ERSTE HILFE

� 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.

� Emergency call

� Emergency life-saving measures

� Recovery position

� Cardiac massage, artificial respiration and defibrillation

� Staunch bleeding, shock prevention

� Additional first aid

Sicherheit

CBG_HD / V00148

2.8.2 Electrical energy

WARNUNG

Electrical energy in live machine parts!


HINWEIS


� Carry out work exclusively with the electrical supply switched off.

� Secure the machine against unauthorised start-up.

Examples of electrical energy:� Landside power supply

WARNUNG

Live machine parts!

Electric shock!

� Before recovering an injured party ensure that there is no risk ofelectrocution.

ERSTE HILFE





� Emergency call






HINWEIS

� Always seek medical attention after electrical accidents. It is possible thatsymptoms of an irregular heartbeat may be experienced some time afterthe accident.

Safety

CBG_HD / V001 49

2.8.3 Hydraulic energy

WARNUNG

Escaping hydraulic oil under high pressure!

Leakages in hydraulic lines can cause skin injuries, destroy tissue and cause

blood poisoning, due to the high pressures involved.


HINWEIS


� Repairs to hydraulic systems must exclusively be carried out by qualified

technicians with specialised knowledge and experience of hydraulics.

� Before starting work ensure that the whole system is depressurised.

� Never attempt to locate the leakage point with your hand or other part ofthe body.

� Replace damaged hydraulic components immediately with originalLiebherr spare parts.

Examples of hydraulic energy:

Tissue damage from leaks.

Sepsis from hydraulic oil entering bloodstream.

ERSTE HILFE





� Emergency call






� Gently cover injured area(s) with a sterile anti-bacterial dressing

.

� Rinse eyes with pure drinking water.

Sicherheit

CBG_HD / V00150

2.8.4 Burns

VORSICHT

Contact with hot surfaces and consumables!

High surface and equipment temperatures can lead to burns or scalding.


HINWEIS


� Always wear suitable protective gloves when working on hot components.

� Only carry out work on the machine when it is cool and stopped.

Examples of burns and scalding:

Burns from contact with the entire drive system.

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

ERSTE HILFE

� 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.

� Emergency call


� Recovery position� Cardiac massage, artificial respiration and defibrillation



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 dressing.

With second-degree burns (blisters on the skin):� Cool the affected body part by rinsing with cold fresh water.

� Gently cover injured area with a sterile anti-bacterial dressing.

With third-degree burns (charring of the skin and tissue):� Gently cover injured area with a sterile anti-bacterial dressing.

Safety

CBG_HD / V001 51

2.8.5 Chemical burns

VORSICHT

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.


HINWEIS


� When working with acid always wear suitable safety goggles or face

protection, protective clothing and gloves.

Examples of chemical burns:

Chemical burns from handling acidic consumables.

Chemical burns from leaking battery acid.

ERSTE HILFE





� Emergency call






� Removing clothing from injured body parts.

� Rinse injured areas with drinking water.

� Gently cover the area with a sterile anti-bacterial dressing.

Sicherheit

CBG_HD / V00152

2.8.6 Fire and explosion

WARNUNG

No fire, naked flames or electrostatic discharges!

Danger of fire and explosion from flammable consumables or gas mixtures

arising from them.


HINWEIS


� o not transport any flammable fluids with the machine except in fireproofcontainers.

� Only store small amounts of fuel or highly flammable or self-ignitingmaterial.

� Wipe any spilled fuel off machine immediately and bind and neutralise iton the ground with appropriate agents.

� Clean the machine with non-flammable fluids.

� Do not store cleaning cloths in machinery room and remove flammableresidues, e.g. oil leaks, ash and waste paper.

� Refuel the machine exclusively in a well ventilated area or ensure fresh

air.

� Make sure there is good metallic contact between the pump nozzle and

the filler neck during refuelling. Where possible, connect the machine tothe fuelling unit earthing.

� Do not smoke when handling flammable materials.

Examples of fire and explosion hazards:

Escaped fuel is a fire hazard.

Detonating gas in combination with a spark when charging or dischargingbatteries.

Vaporised fuel in combination with electrostatic discharge

between machine and fueling unit.

Safety

CBG_HD / V001 53

ERSTE HILFE

� 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.

� Emergency call

� Emergency life-saving measures� Recovery position� Cardiac massage, artificial respiration and defibrillation� Staunch bleeding, shock prevention

� Additional first aid� (For further information see: 2.8.3 Firefighting)� (For further information see: 2.7.4 Burns)

Sicherheit

CBG_HD / V00154

2.8.7 Poisoning and suffocation

WARNUNG

Inadequate ventilation or fresh air!

Poisonous vapours or other atmospheres hazardous to health can lead to

poisoning or suffocation.


HINWEIS


� Ensure adequate ventilation in the cabin.

� 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 materials are present, contactwith hazardous gases is a possibility.

The refrigerant from the air conditioning system circuit displaces the oxygen in

the air.

ERSTE HILFE





� Emergency call






Safety

CBG_HD / V001 55

2.8.8 Electromagnetic influence

WARNUNG

Electromagnetic influence when the machine is deployed near transmittingstations, radar stations or directional radio systems!

Malfunctions or failure of electronic implants (pacemakers).

Malfunction or failure of the control system.


HINWEIS


� If electromagnetic interference with the control system is suspected, stop

machine operation.

Examples of electromagnetic influence:

Malfunction or failure of the control system if operating the machine near transmitters, directional radio systems or radar stations.

Environmental influence through the use of electromagnetic rigging material or

integrated radio devices.

Sicherheit

CBG_HD / V00156

2.8.9 Exposure to wind

DANGER

Exposure to wind!

Noncompliance with maximum permitted wind speed while operating machine

increases risk of accident!


HINWEIS


� Observe the permitted wind speed specified in the applicable load chart.

� Find out and take into consideration wind conditions and weatherforecasts at site for planned period of operation.

� Operators to find out weather forecast and current wind velocity at sitewhere machine is to be operated before starting work. If excessive wind

speeds are expected within next few hours, do not start machine and takeprecautions to protect against storm damage.

� Watch out for dangerous gusts of wind.

� Do not lift loads with large surface areas.

� Reduce lifting capacities and maximum main boom angles.

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

DANGER

Wind exceeds maximum permitted speed (higher than specified in loadcapacity chart).

Massive damage to the machine,

� Lay down and secure the load and place the machine in the parked

position (see section Operation).

Effects of exposure to wind on machine and lifting capacity:

� acts like an additional load on the rope hook.

� is particularly dangerous at maximum boom angle without a load.

� can overload tilting-back supports and destroy boom.

� causes load to sway.

� increases the swing radius.

� generates additional diagonal pull.

Safety

CBG_HD / V001 57

If no anemometer is fitted to boom head, use table below to estimate roughlyhow strong wind is. Wind speed at boom may be greater than wind speed at or

near ground level.

Wind force Wind speed Description of the conditions at sea

Beaufort

Designation

Knots Waveheight

(m)

0 Calm 0 0 Mirror-smooth sea.

1 Light air 2 0,1 Small flaky-looking ripples without white crests.

2 Lightbreeze

5 0,2 Small, short waves. Glassy, non-breaking crests.

3 Gentlebreeze

9 0,6 Small, short waves. Crests begin to break. Mostly transparentfoam. Occasional small, white foam heads.

4 Moderatebreeze

13 1 Small, longer waves. Many have white crests.

5 Freshbreeze

19 2 Moderate longer waves. Widespread white crests. Isolated froth.

6 Strongbreeze

24 3 Large waves. Crests break and leave large white areas of foam.Some froth.

7 Near gale 30 4 Sea heaps up. White foam begins to streak in wind direction.

8 Gale 37 5,5 Moderately high waves with considerably long crests. Crest edgesbegin to froth. Foam covers the surface in pronounced streaks inthe wind direction.

9 Severegale

44 7 High waves. Thick strips of foam in the wind direction. Wave crestsroll over one another. See begins to 'roll'. Froth can affect visibility.

10 Storm 52 9 Very high waves with long breaking crests. The resulting foam lieson the surface in thick white streaks in the wind direction. Sea iswhite from foam. Strong intermittent 'rolling' of the sea. Visibility affected by froth.

11 Violentstorm

60 11,5 Exceptionally high waves (small and medium-sized ships aremomentarily hidden from view behind the waves). Sea is completelywhite from foam, which streaks in the wind direction. Edges of thewave crests turn to froth. Visibility limited by froth.

12 Hurricane <64 <14 Air filled with foam and froth. Sea completely white with froth. Visibility is extremely limited.

Sicherheit

CBG_HD / V00158

2.8.10 Snow and ice loads

DANGER

Snow or ice on the machine!

Structural breakdown.


WARNUNG

Falling chunks of snow and ice!

� Do not operate if boom is covered in snow or ice.

HINWEIS


� Place boom in parked position and carefully remove large deposits of

snow and ice.

� Remove snow and ice from all sensitive parts such as limit switches,

guides, etc.

� Snow and ice loads increase the boom weight and the area exposed to

the wind.

These factors lead to premature shutdown of Load Moment Limiter (LML) - it isno longer possible to work at maximum permitted lifting capacity.

Safety

CBG_HD / V001 59

2.8.11 Lightning strike

WARNUNG

Electric shock from lightning!

Coming into contact with a direct or indirect current flow caused by a current

transfer 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 localwelding spots on supports, especially on the swing ring.


HINWEIS


� Before a thunderstorm, place boom in parked position.

� uring a thunderstorm, always keep away from large free-standing metalparts (e.g. the machine).

� Earth machines whose steel structure does not have direct contact toground.

� Do not leave cabin except in the event of fire.

The closed machine operator's cab acts as a Faraday cage. The charge is

channeled through the machine and into the ground.

If any of following criteria apply, place boom in parked position in good time.� on sites that experience frequent storms

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 service department.

ERSTE HILFE

� 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.

� Emergency call

� Emergency life-saving measures� Recovery position� Cardiac massage, artificial respiration and defibrillation� Staunch bleeding, shock prevention

� Additional first aid� (For further information see: 2.8.1 How to respond in the event of a cur

rent transfer)

Sicherheit

CBG_HD / V00160

2.8.12 Environmental hazard

VORSICHT

Environmental hazard 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.


HINWEIS


� If the machine leaks, immediately collect the escaping consumable and

seal the leak.

� Bind any spilled consumable with binding agent or neutralise it with

suitable agents.

� When draining or catching fluids use suitable containers (filling capacity

and resistant to chemicals).

� Carry out cleaning work on firm well-drained ground.

� Observe the national and international environmental protectionregulations for the disposal of fuels or waste.

� Notify the emergency services and authorities if large amounts ofsubstances that are harmful to the environment escape.

Examples of environmental hazards:

Leakages

Refilling consumables incorrectly

Safety

CBG_HD / V001 61

2.9 How to respond in dangerous situations

2.9.1 How to respond in the event of a current transfer

Procedure in event of current transfer:

� Remain calm.

� Alert relevant power supply company.

� Do not leave operators cabin:

� Remaining in the cabin is relatively safe, the operator's cab acts as a Faraday cage.

� Do not leave cabin except in the event of fire.

� If Litronic control system is still functioning:

� Move the machine out of the danger zone.

� Remain in cabin until current is no longer being conducted through machine.

ERSTE HILFE

� Make emergency call.

� Personnel to be rescued exclusively by experts.

HINWEIS

� Always seek medical attention after electrical accidents. It is possible thatsymptoms of an irregular heartbeat may be experienced some time afterthe accident.

Sicherheit

CBG_HD / V00162

2.9.2 How to respond in the event of a fire

WARNUNG

Incorrect behaviour in event of fire!


Procedure in the event of fire:

� Switch off engine

� Alert the emergency services.

� Evacuate individuals from the danger zone and administer first aid if needed(For further information see: 2.7.4 Burns).

� Only if there is no risk to your personal safety should you start to fight thefire (For further information see: 2.8.3 Firefighting).

WARNUNG

Risk of fire restarting!

Even if fire appears to be extinguished, escaping fuel or oil coming into contact

with hot components may cause it to reignite.

Once there is no longer any danger of fire restarting:

� Start assessing damage.

Safety

CBG_HD / V001 63

2.9.3 Firefighting

Fire classes

WARNUNG

Use of inappropriate extinguishing agents!

If inappropriate extinguishing agents are used, they may be ineffective or

dangerous.

� Use an extinguishing agent appropriate for fire class.

Fires involving solid and mainly organic materials that normally smoulder

Fires involving fluids and liquefying materials (e.g. paraffin, diesel, oils, hydraulic oil, etc.)

Fires involving gases

Fires involving metals

Handling of the fire extinguisher

HINWEIS

Fire extinguishers are subject to national regulations!

� Arrange for plant operator to provide fire extinguishers, replace them as

necessary and inspect them periodically.

� Remove the fire extinguisher from its mount on the machine and prepare it

for use (For further information see: 1.9 Safety devices).

� Locate the source of the fire and fight the fire with several short, targeted

bursts .

� While fighting the fire, employees must alert the fire brigade.

Sicherheit

CBG_HD / V00164

Incorrect Correct

Fight the fire with the wind behindyou.

Extinguish the fire from the front tothe back and from the bottom to thetop.

But: Extinguish dropping and liquidfires from the top to the bottom.

Do not use extinguishers in succession but use several extinguishers atthe same time.

Make sure that the fire does notreignite - always extinguish glowingembers with water.

Safety

CBG_HD / V001 65

Incorrect Correct

Do not put fire extinguishers back inplace after use - refill them.

Sicherheit

CBG_HD / V00166

2.10 Hand signals

Hand signals:

� are used for communication purposes when there is visual contact bet

ween machine operator and banksman or other personnel.

� are clearly defined in national and international standards.

HINWEIS

� All persons involved must decide among themselves which hand signalsare to be used.

The following overview comprises:

� Hand signals in accordance with BGV A8 (Germany)

� Hand signals in accordance with ASME/ANSI B30.5 (USA)

2.10.1 General hand signals in accordance with BGV A8

Caution, Start, Attention

� Hold right arm stretched vertically upwards. Palm of the hand faces forwards.

Stop, Interruption

� Do not continue movement. Stretch out both arms to the side horizon

tally. Palms of the hands face forward.

Safety

CBG_HD / V001 67

Stop - Danger

� First stretch out both arms horizontally to the sides. Palms of the hands

face forward. Now bend in and stretch out the arms alternately.

Lift, Up

� Hold the right arm up. Palm of the hand faces forward and makes a slowcircling motion.

Lower, Down

� Hold the right arm down. Palm of the hand faces inwards and makes aslow circling motion.

Slowly

� Stretch out right arm horizontally. Palm of the hand faces down and ismoved slowly up and down.

Depart

� Hold the right arm up. Palm of the hand faces forwards. Move the armfrom side to side.

Sicherheit

CBG_HD / V00168

Approach

� Bend both arms. Palms of the hands face inwards. Wave in with the fore

arms.

Remove

� Bend both arms. Palms of the hands face outwards. Wave away with the

forearms.

Travel right (from the banksman's viewpoint)

� Lightly bend the right arm while holding it out horizontally and move to

and fro to the side.

Travel left (from the banksman's viewpoint)

� Lightly bend in the left arm while holding it out horizontally and move to

and fro to the side.

Safety

CBG_HD / V001 69

Indicate distance reduction

� Hold both palms parallel and move them toward each other to indicate

the distance.

2.10.2 Special hand signals for riggingoperations

Lift load slowly

� Bend right arm and hold upwards. Extended index finger points upwards.Hand makes small, circular movements. Stretch out the left hand and

hold it over the right hand.

Lower load slowly

� Hold the right arm down. Extended index finger points downwards. Hand

makes small, circular movements. Hold the left hand below it. Hand surface faces upwards.

Lift boom slowly

� Bend the right arm. Thumb points upwards. Hold the left hand above it.

Sicherheit

CBG_HD / V00170

Lower boom slowly

� Bend the right arm. Thumb points downwards. Hold the left hand below

it. The back of the hand faces upward.

Lift boom and hold load

� Bend the right arm. Thumb points upwards. The left hand makes a fist

under the right hand.

Lower boom and hold load

� Bend the right arm. Thumb points downwards. The left hand makes a fist

under the right hand.

Raise boom and lower load

� Bend the right arm. Thumb points upwards. Stretch out the left arm. The

index finger points downwards. Hold the left hand under the right handand rotate.

Lower boom and lift load

� Bend the right arm. Thumb points downwards. Bend the left arm. Theindex finger points upwards. Hold the left hand under the right hand and

rotate.

Safety

CBG_HD / V001 71

Swing rotary platform to the right

� Bend the left arm and hold it up. The thumb points outwards in the direc

tion of rotation. Stretch out the right arm downwards. The index fingerpoints downwards. The hand makes small, circular movements.

Swing rotary platform 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. The index fingerpoints downwards. The hand makes small, circular movements.

Open grab

� Stretch out right arm horizontally. Hold the hand downwards with fingershalf-open.

Close grab

� Stretch out right arm horizontally. Close the hand into a fist.

Sicherheit

CBG_HD / V00172

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

Lift load

� Bend right arm and hold upwards. Extended index finger points upwards.The right hand makes small, circular movements.

Lower load

� Hold the right arm down. Extended index finger points downwards. Handmakes small, circular movements.

Use main winch

� Tap safety helmet with fist. Then give further hand signals.

Use auxiliary winch

� Bend the right arm and hold it upwards. Tap the underside of the elbow

with the left hand. Then give further hand signals.

Safety

CBG_HD / V001 73

Raise boom

� Stretch out right arm horizontally. Make a fist, but with the thumb pointing

upwards.

Lower boom

� Stretch out right arm horizontally. Make a fist, but with the thumb pointing

downwards.

Move slowly

� Give the hand signal for the desired movement with one hand. Hold the

other hand above/below. (e.g..: Lift load)

Raise boom and lower load

� Stretch out right arm horizontally. The thumb points upwards, stretch and

bend the remaining fingers alternately for as long the load has to be lowered.

Sicherheit

CBG_HD / V00174

Lower boom and lift load

� Stretch out right arm horizontally. The thumb points downwards, stretch

and bend the remaining fingers alternately for as long the load has to belowered.

Swing

� Stretch out right or left arm horizontally. Palm of the hand faces down,extended fingers point in the direction of rotation.

Stop

� Stretch out one arm horizontally. The palm faces down. Swing the arm

back and forth horizontally.

Emergency stop

� Stretch out both arms horizontally. The palms face down. Swing botharms back and forth horizontally.

Safety

CBG_HD / V001 75

Drive

� Stretch one arm out in front. The palm faces forwards and is slightly

raised. Make a movement in the travel direction with the open hand.

Shut down and secure machine

� Hook hands in front of body.

Drive with both crawler chains (when using a machine with crawler chains)

� Hold both fists in front of body. Indicate direction of travel with circularmotions (forwards or backwards).

Drive with one crawler chain (when using a machine with crawler chains)

� Bend arm with the fist raised on the side of the stopped crawler chain.Bend other arm in front of body. Indicate direction of travel via circular

movements with fist (forwards or backwards).

Sicherheit

CBG_HD / V00176

Extend boom (machines with telescopic arm)

� Hold both fists in front of body. The thumbs point outwards.

Retract boom (machines with telescopic arm)

� Hold both fists in front of body. The thumbs point toward each other.

Retract boom (machines with telescopic arm)

� One-handed signal: Hold one fist in front of chest. Your thumb points toyour chest.

Extend boom (machines with telescopic arm)

� One-handed signal: Hold one fist in front of chest. Your thumb points outwards.

3

3

Control and operating elements

CBG_HD / V001 77

3. Control and operatingelements

This section

� provides information on the configuration of the control and operatingelements.

� provides information on the designation of the respective element.


CBG_HD / V00178

3.1 Control station

Figure 13 Control station

1 Monitor

2 Video monitoring monitor

3 Control lever right

4 Microphone for PA amplifier

5 Control panel X25

6 Bypass

7 Emergency stop

8 Ignition

9 Control panel X26

10 PA system control panel

11 Windscreen wiper control panel

12 Operator's seat

13 Control lever left


CBG_HD / V001 79

Ignition

1 Ignition off

2 Ignition on

Bypass

1 Bypass off

2 Bypass on

Winch service mode

1 Holding winch

2 Normal operation

3 Closing winch


CBG_HD / V00180

3.2 Control lever left

3.2.1 Directions

Figure 14 Control lever left

A Preselection Function

- Raise boom

B Preselection Function

- Lower boom

C Preselection Function

- Swing to right

D Preselection Function

- Swing to left


CBG_HD / V001 81

3.2.2 Buttons

Figure 15 Control lever left

1 Preselection Function

- -


- -


- -


- -


- Warning horn


CBG_HD / V00182


Four-rope grab operation Grab bulk cargo


- -


- Bypass sector


- Control enable


CBG_HD / V001 83

3.3 Control lever right

3.3.1 Directions

Figure 16 Control lever right

A Preselection Function

- Raise load

B Preselection Function

- Lower load

C Preselection Function

Four-rope grab operation Open grab

D Preselection Function

Four-rope grab operation Close grab


CBG_HD / V00184

3.3.2 Buttons

Figure 17 Control lever right


Four-rope grab operation Raise grab


Four-rope grab operation Lower grab


- -


- -


- PA amplifier on


CBG_HD / V001 85


- -


- -


- -


- Control enable


CBG_HD / V00186

3.4 Control panel operating elements

Signal lights

Signal lights

Buttons

Buttons with signal lights

� LED on:

� Function active

� LED off:

� Function inactive


� LED on:

� Function active

� LED off:



1 Light Emitting Diode (LED)

� LED on:

� Function active

� LED off:


1


CBG_HD / V001 87

Switch

Key switch

Key switch

1 Key

2 Light Emitting Diode (LED)

3 Button

� LED on:

� Function active

� LED off:


HINWEIS

� The functions of each button are explained in the 'Operation' section.

1

2

3


CBG_HD / V00188

3.4.1 Control panel X25

Figure 18 Control panel X25


CBG_HD / V001 89

Engine 1 main power supply on

Engine 1 main power supply tripped

Engine 2 main power supply on

Engine 2 main power supply tripped

Crane lighting

Searchlight


CBG_HD / V00190

3.4.2 Control panel X26

Figure 19 Control panel X26


CBG_HD / V001 91

Engine on / off

Hook operation

Four-rope grab operation

Winch service operation mode

Bypass lower luffing gear limit switch

Bypass slack rope protector

Heavy lift operation


CBG_HD / V00192

Special load operation


CBG_HD / V001 93

3.4.3 Windscreen wiper control panel

Figure 20 Windscreen wiper control panel

Front windscreen wiper intermittent operation

Front windscreen wash system

Roof window wiper intermittent operation


CBG_HD / V00194

Roof window wash system


CBG_HD / V001 95

3.5 Air conditioning*

��

12

Figure 21 Air conditioning main switch

1 Main switch off

2 Main switch on


CBG_HD / V00196

1

2

Figure 22 Air conditioning system control unit

1 Temperature

2 Fan speed


CBG_HD / V001 97

3.6 Litronic monitor

3.6.1 Monitor overview

1

2

3

Figure 23 Monitor overview

1 Status indicator

2 Status display

3 Function key symbols

3.6.2 Status indicator

The different status displays appear in the upper part of the monitor as sym

bols.

Overload

Four-rope grab open

Four-rope grab closed


CBG_HD / V00198

Harbour area

Open sea

Winches asynchronous

Hoisting gear lift stop

Hoisting gear lower stop

Luffing gear raise stop

Luffing gear lower stop

Slewing system stop left

Slewing system stop right


CBG_HD / V001 99

3.6.3 Function key symbols

The function key symbols are located in the lower area of the monitor.

The function key symbols can be selected by touching the monitor.

Home screen

Engine screen

Operating hours screen

Settings screen

Hydraulics screen

Temperature screen

Sector limiting screen

Data recorder screen

Error screen

Deactivate warning buzzer


CBG_HD / V001100

3.6.4 Home screen

HEEL/TRIM

0.6 °

Figure 24 Home screen

Current Heel / Trim

Engine status

Load taring

Rope taring

HEEL/TRIM

0.6 °


CBG_HD / V001 101

Time

Current load on the holding winch

Current load on the closing winch

Sector indicator


CBG_HD / V001102

1 2

3

9

10

65

7

16

4

1214

8

15 1113

1 Utilisation

2 Wind speed

3 Reeving

4 Load pick-up equipment

5 Max. outreach

6 Current outreach

7 Tared load

8 Removed load

9 Closing winch rope length

10 Closing winch hoisting speed

11 Holding winch hoisting speed

12 Holding winch rope length

13 Current load

14 Max. permissible load

15 Boom angle

16 Slewing angle


CBG_HD / V001 103

3.6.5 Engine screen

Figure 25 Engine screen

Engine on (green)

Engine off (white)

Engine protection switch on (green)

Engine protection switch off (white)


CBG_HD / V001104

Power supply on (green)

Power supply off (red)

Engine speed

Current consumption


CBG_HD / V001 105

3.6.6 Operating hours screen

Figure 26 Operating hours screen

Engine operating hours

Holding winch - operating hours

Closing winch - operating hours

Luffing gear - operating hours

Slewing gear - operating hours


CBG_HD / V001106

3.6.7 Settings screen

Figure 27 Settings screen

Max. heel / trim and wind

Select load chart

Select harbour area

Select open sea


CBG_HD / V001 107

Specialised lifting

Main hoist

Heavy load hoist

Store winch position

Current rope length difference

Store hook position

Stored rope length difference with hook operation

Store open four-rope grab position


CBG_HD / V001108

Stored rope length difference with four-rope grab open

Store closed four-rope grab position

Stored rope length difference with four-rope grab closed

Synchronise winches

Store lowering speed

Litronic test system

Diagnostic system

Select language

Select country / time zone


CBG_HD / V001 109

3.6.8 Litronic test system screen

+

-

+

-

+

-

+

-

Figure 28 Litronic test system screen

Start test system

Keyboard

Increase volume

Reduce volume

+

-


CBG_HD / V001110

Increase brightness

Reduce brightness

7 8 9

4 5 6

1 2 3

0 . P

+/- + E

--

+

E N T E R

Figure 29 Keyboard

Minimise

Numeric keypad

Negative numbers

+

-

7 8 9

4 5 6

1 2 3

0 . P

+/-


CBG_HD / V001 111

Increase brightness

Exponents

Reduce volume

Reduce brightness

Increase volume

Correction value screen

Crane screens

Litronic test system

Enter

Cursor back

Function key

Cursor forwards

+

E

-

-

+

E N T E R


CBG_HD / V001112

3.6.9 Hydraulics screen

Figure 30 Hydraulics screen

Hydraulic oil temperature

Luffing gear pressure


CBG_HD / V001 113

Slewing gear pressure

Slewing gear pressure

Holding winch pressure

Closing winch pressure


CBG_HD / V001114

3.6.10 Temperature screen

Figure 31 Temperature screen

Gearbox temperature

Luffing winch gearbox temperature


CBG_HD / V001 115

Holding winch gearbox temperature

Closing winch gearbox temperature


CBG_HD / V001116

3.6.11 Sector limiting screen

Figure 32 Anti-collision screen

Select sector

Delete selected sector

Select right sector point


CBG_HD / V001 117

Select left sector point

2

1

4

3

1 Inactive sector area

2 Active sector area

3 Current outreach

4 Current slewing angle


CBG_HD / V001118

3.6.12 Data recorder screen

94.9 °

12 3

0.0 t 0.0 t 0.0 t00 100

MB

%

94.9 °

2

0 t

3

0 t

4

0 t

5

0 t

6

0 t

Figure 33 Data recorder screen

Data recorder Start

Data recorder Pause

Data recorder Stop


CBG_HD / V001 119

94.9 °

12 3

0.0 t 0.0 t 0.0 t00 100

MB

%

94.9 °

2

0 t

3

0 t

4

0 t

5

0 t

6

0 t

1 42 3

9 5678

1 Set trigger point

2 Hatch cover

3 Hatch cover backwards

4 Hatch cover forwards

5 Current load

6 Tared load

7 Total loads

8 Load cycle counter

9 Storage capacity


CBG_HD / V001120

3.6.13 Error screen

Figure 34 Error screen

New error message

Confirmed error message (new display !!!)

1 2 3

1 Error number

2 Short error description

3 Identification of the responsible I/O module


CBG_HD / V001 121

3.7 PA amplifier

Figure 35 PA amplifier

1 XLR microphone input

2 DIN microphone input

3 Volume control for microphone input

4 Volume control for additional inputs

5 Sound control

6 ATT switch

7 Mono switch

8 ON / OFF switch

9 AUX input

XLR microphone input

This input allows the use of dynamic microphones with balanced and unbalan

ced output. If this input is used at the same time as the DIN input, both signalsare transmitted.

DIN microphone input

This input allows the use of dynamic microphones with balanced and unbalan

ced output. If this input is used at the same time as the XLR input, both signalsare transmitted. Special connections to the plug allow music to be turned downmanually (see ATT switch). LED lights up when microphone is plugged in.

Volume control for microphone inputs

The volume of both microphone inputs (XLR and DIN) is controlled by the volume control.


CBG_HD / V001122

Volume control for additional inputs

The volume of the AUX input is controlled by the volume control for the additional inputs.

Sound control

The high and low frequencies are controlled by the sound control. The mid-position is neutral.

ATT switch

The AUX input is turned down by the operation of the ATT switch. This functionis used to give priority to microphone announcements that would otherwise be

mixed with AUX signals.

Mono switch

Switching from STEREO to MONO for AUX input.

AUX input

The AUX input allows the connection of car radio, CD player, MP3 player, etc.


CBG_HD / V001 123

3.8 Switch cabinet X1

Figure 36 Switch cabinet X1

1 Helicopter warning light

2 Emergency stop

3 Auxiliary supply

Helicopter warning light

1 Helicopter warning light off

2 Helicopter warning light on

Auxiliary supply

1 Auxiliary supply off

2 Auxiliary supply on


CBG_HD / V001124

3.9 Switch cabinet X2

Figure 37 Switch cabinet X2

1 Power unit 1 main switch on

2 Power unit 1 operating hours counter

3 Power unit 1 main switch tripped

4 Power unit 2 operating hours counter

5 Power unit 2 main switch tripped

6 Power unit 2 main switch on

7 Emergency stop

8 Power unit 2 main power supply

9 Power unit 1 main power supply

Main power supply

1 Main power supply on

2 Main power supply tripped

3 Main power supply off

4 Main power supply reset


CBG_HD / V001 125

3.10 Central lubrication system*

Figure 38 Central lubrication system operating element

Set lubrication time

Set pause time

Yellow indication light

Interim lubrication


CBG_HD / V001126

4

4

Operation

CBG_HD / V001127

4. Operation

This section

� provides information on operating the machine.

� provides information on the operation modes.

� contains important operating instructions, which have a major influenceon work safety and machine service life.

Operation

CBG_HD / V001 128

4.1 Access

4.1.1 Entering the machine

Figure 39 Access CBG

WARNUNG

Unauthorised entry of machine during operation!

� Enter machine exclusively when it is shut down.

Operation

CBG_HD / V001 129

4.2 Inspections before daily commissioning

DANGER

Commissioning a damaged machine!

� Use machine exclusively in perfect condition.

� Report all defects and errors to the relevant supervisor and to theLiebherr service department.


� All maintenance and inspection work has been regularly carried out.

� The operation manual has been read and understood.

� The operation manual is ready to hand in the cabin.

� An up to date load chart required for the application is located in the

cabin.

4.2.1 Daily inspection

Before daily commissioning of the machine, perform the following visual inspections:

� There are no leaks (hydraulic, engine and gear oil, coolant, fuel).

� There is no (deliberate) damage.

� There is no excessive contamination of the machine.

� All safety devices (see 'Product description, safety devices' section) are

present.

� All pins and threaded connections are tight.

� Rope and pulleys do not show any signs of excessive wear.

� All safety signs are present and legible.

� There are no obstacles in the working area.

� Slewing column can turn without restriction.

� Free of snow and ice

� Unimpeded view from cabin (clean windows).

Operation

CBG_HD / V001130

4.2.2 Check hydraulic oil tank shut-off valve

Figure 40 Check hydraulic tank shut-off valve

1 Shut-off valve closed

2 Shut-off valve open

ACHTUNG

Closed shut-off valve!

Damage to the hydraulic system.

� Operate engine exclusively when shut-off valve is open.

� Check hydraulic oil tank shut-off valve.

Operation

CBG_HD / V001 131

4.3 Daily commissioning

4.3.1 Starting engine


� Pre-start checks have been carried out.

� No one other than the machine operator is on the machine or within thedanger zone around the machine.

� All emergency stops are unlocked.

� Set Power unit 1 main power supply switch at switch cabinet X2 to position

"Main power supply on".



If Main power supply switch at switch cabinet X2 is set to position "Main power

supply tripped":

� Engine 1 main power supply tripped signal light on control panel X25

lights up.

� Engine 1 main power supply tripped signal light on control panel X25lights up.

� Set Main power supply switch at switch cabinet X2 to position "Main powersupply reset".

� Set Main power supply switch at switch cabinet X2 to position "Main powersupply on".

� Set Ignition key switch to "Ignition on" position.

Operation

CBG_HD / V001132

� Engine 1 main power supply on signal light on control panel X25 lights upwhen hydraulic system is ready to start.


� Press Engine on / off button on control panel X26.

� Signal light lights up when engine is running.

� Check whether error messages are displayed.

If error messages are displayed:

� Check cause of error message.

� Rectify error.

� Lower boom into working area.

� Lower hook into working area.

Operation

CBG_HD / V001 133

4.4 Operator's seat

4.4.1 Adjusting the operator's seat

VORSICHT

Incorrect seat position and incorrect movement sequences!

� Adjust the seat position and the position of the control and operating

elements so that the latter are easy to see and reach.

Figure 41 Adjusting the operator's seat horizontally

� Press lever upwards.

� Moving the operator's seat horizontally.

Figure 42 Adjusting seat suspension

� Turn the adjustment wheel.

� The seat suspension is suited to your body weight.

Operation

CBG_HD / V001134

Figure 43 Adjusting the backrest


� Press your back gently against the backrest.

� The backrest tilts backwards.

� Press lever downwards.

� The seat back automatically tilts forwards.

Figure 44 Adjusting the armrest

� Twist adjusting knobs.

� Adjusting the armrest.

� Untwist adjusting knobs.

Operation

CBG_HD / V001 135

Figure 45 Adjusting the height of the front of the seat


� Pressing down on and relieving the front seating area adjusts its height.

Figure 46 Adjusting the height of the rear of the seat


� To adjust the height of the rear of the seat, press on it then release the

pressure.

Operation

CBG_HD / V001136

4.5 Lighting

4.5.1 Operating searchlights*

Figure 47 Cabin searchlight

1 Searchlight

Figure 48 Boom searchlight

1 Searchlight

� Press the Searchlights button on control panel X20.

� Searchlights light up.

Operation

CBG_HD / V001 137

4.5.2 Operating cabin lighting

� Press Cabin lighting button in the cabin.

� Cabin lighting lights up.

4.5.3 Operating crane lighting

� Press Crane lighting button on control panel X20 or in access area.

� Working lights in the slewing column light up.

4.5.4 Operating helicopter warning light*

� Set Helicopter warning light switch at switch cabinet X1 to the "Helicopterwarning light on" position.

� Helicopter warning lights light up.

Operation

CBG_HD / V001138


WARNUNG

Leaks in air conditioning coolant circuit in enclosed spaces!

Suffocation.

If there is a high refrigerant concentration in the air:

� Immediately leave the enclosed space (cabin).

4.6.1 Operating the air conditioning system

The air conditioning system is only effective if:

� all cabin doors and windows are closed.

� the air outlets are not blocked.

� Turn main switch to "Main switch on".

� Set desired temperature.

� Set desired fan speed.

Operation

CBG_HD / V001 139

4.7 PA amplifier*

ACHTUNG

Incorrect operation and handling of amplifier!

Damage

� Keep foreign bodies and liquids away from the amplifier.

� Protect amplifier against direct sunlight. Allow to cool down before use.

� Switch off immediately in the event of smoke or unpleasant smell.

� Do not overload the amplifier for long periods.

� Clean front of amplifier exclusively with a dry and clean cloth. Do not use

cleaning agents or chemicals.

Figure 49 PA amplifier control lever functions

1 PA amplifier on

4.7.1 Operating the PA amplifier

� Set volume control to minimum.

� Set ON / OFF switch to "On" position.

� Ensure that the LED is lit.

� Press the PA amplifier on button on the right master switch.

HINWEIS

� To prevent background noise and feedback, speak close to microphone.

Operation

CBG_HD / V001140

4.8 Windscreen wiper

4.8.1 Operating windscreen wiper

Figure 50 Windscreen wiper

1 Roof searchlight

2 Front windscreen wiper

� Press the Front windscreen wiper intermittent operation button on the windscreen wiper control panel.

� Intermittent windscreen wiper is active (windscreen wiper wipes at defined intervals).

� Press the Front windscreen wiper intermittent operation button on the wind

screen wiper control panel again

� The interval period becomes shorter.

� Press the Front windscreen wiper intermittent operation button on the wind


� Windscreen wiper continuous operation is active.

� Press the Front windscreen wiper intermittent operation button on the windscreen wiper control panel again

� Windscreen wiper is deactivated.

Operation

CBG_HD / V001 141

� Press the Roof windscreen wiper intermittent operation button on the windscreen wiper control panel.

� Intermittent windscreen wiper is active (windscreen wiper wipes at de

fined intervals).

� Press the Roof windscreen wiper intermittent operation button on the wind


� The interval period becomes shorter.



� Windscreen wiper continuous operation is active.



� Windscreen wiper is deactivated.

4.8.2 Operating the windscreen wash system

WARNUNG

Flammable fluids in windscreen washer bottle!

Fire, explosion!

� Fill windscreen washer bottle exclusively with non-flammable fluids.


� Windscreen cleaning fluid is topped up.

� At low ambient temperatures: sufficient antifreeze for windscreen wiper

system is added.

� Press the Front windscreen wash system button on the windscreen wipercontrol panel.

� Windscreen wiper running in intermittent mode.

� Windscreen cleaning fluid is sprayed.

� Press the Roof windscreen wash system button on the windscreen wipercontrol panel.

� Windscreen wiper running in intermittent mode.

� Windscreen cleaning fluid is sprayed.

Operation

CBG_HD / V001142

4.9 Warning horn

Figure 51 Warning horn control lever functions

1 Warning horn

4.9.1 Using the warning horn

� Press Warning horn button on left-hand control lever.

� Warning horn sounds.

Operation

CBG_HD / V001 143

4.10 Central lubrication system*

Lubrication of the swing ring bearing is performed automatically in accordancewith the specified lubrication and interval times.

The lubrication operation is started by turning the engine on.

ACHTUNG

Insufficient lubrication!

Damage to swing ring bearings and/or swing ring tooth flanks.

� Do not exceed the lubrication and pause times set in the factory.

ACHTUNG

Incorrect adjustment of the overpressure valve!

Damage to central lubrication system.

� Retain manufacturer's settings for the overpressure valve.

4.10.1 Set lubrication time

The range of adjustment for lubrication time is from 1 to 16 minutes. The factorysetting for lubrication time is 13 minutes.

� Set lubrication time regulator, turning it to desired lubrication time.

4.10.2 Set pause time

The range of adjustment for pause time is from 0.5 to 8 hours. The factorysetting for pause time is 4 hours.

� Set pause time regulator, turning it to desired pause time.

4.10.3 Interim lubrication

� Press the Interim lubrication button.

Operation

CBG_HD / V001 144

4.11 Select operation mode

4.11.1 Select hook operation


� Control levers are in neutral position.

� Press hook operation button on control panel X26.

� Signal light lights up when hook operation is selected.

4.11.2 Select winch service mode



� Set winch service mode key switch to "Holding winch" position.

� When hoisting gear is actuated, only the holding winch is operated.

� Set winch service mode key switch to "normal operation" position.

� When hoisting gear is actuated, the holding winch and closing winch areoperated.

� Set winch service mode key switch to "Closing winch" position.

� When hoisting gear is actuated, only the closing winch is operated.

4.11.3 Select four-rope grab operation



� Press four-rope grab operation button on control panel X26.

� Signal light lights up when four-rope grab operation is selected.

Operation

CBG_HD / V001 145

4.12 Slewing gear

WARNUNG

People or obstacles in turning area!

� Ensure that there are no people or obstacles in the turning area.

� Leave danger zone.

4.12.1 Operating the slewing gear

DANGER

Incorrect operation of the slewing gear!


� Accelerate and brake slewing gear slowly.

Figure 52 Slewing gear control lever functions

� Move left-hand control lever to the left.

� Slewing column rotates to the left (counter-clockwise).

� Move left-hand control lever back to neutral position.

� Slewing gear brake engages, slewing column stops rotating.

� Move left-hand control lever to the right.

� Slewing column rotates to the right (clockwise).


� Slewing gear brake engages, slewing column stops rotating.

Operation

CBG_HD / V001146

4.12.2 Slewing gear stop

The slewing gear stops automatically on reaching the limit switch and it is no

longer possible to move in the respective direction.

When the left-hand limit switch is reached the Slewing gear stop left status indicator on the Litronic monitor lights up.

When the right-hand limit switch is reached the Slewing gear stop right statusindicator on the Litronic monitor lights up.

Operation

CBG_HD / V001 147

4.13 Hoisting gear

4.13.1 Operating the hoisting gear

DANGER

Incorrect operation of hoisting gear!


� Accelerate and brake hoisting gear slowly.

Figure 53 Hoisting gear control lever function

� Move right-hand control lever forwards.

� Load is lowered.

� Move right-hand control lever back to neutral position.

� Load stops moving.

� Move right-hand control lever backwards.

� Load is lifted.



Operation

CBG_HD / V001148

4.13.2 Hoisting gear stop

The hoisting gear stops automatically on reaching the limit switch and it is no


When the upper hoisting gear limit switch is reached, the Hoisting gear hoiststop status indicator on the Litronic monitor lights up.

When the lower hoisting gear limit switch is reached, the Hoisting gear lowerstop status indicator on the Litronic monitor lights up.

Operation

CBG_HD / V001 149

4.14 Luffing gear

WARNUNG

Persons or obstacles in luffing range!

� Ensure that there are no people or obstacles in the luffing range.

� Leave danger zone.

4.14.1 Operating luffing gear

DANGER

Incorrect operation of luffing gear!


� Accelerate and brake luffing gear slowly.

Figure 54 Luffing gear control lever functions

� Move left-hand control lever forwards.

� Boom luffs out.


� Boom stops moving.

� Move left-hand control lever backwards.

� Boom luffs in.


� Boom stops moving.

Operation

CBG_HD / V001150

4.14.2 Luffing gear stop

The luffing gear stops automatically on reaching the limit switch and it is no


When the upper luffing gear limit switch is reached, the Luffing gear hoist stopstatus indicator on the Litronic monitor lights up.

When the lower luffing gear limit switch is reached, the Luffing gear lower stopstatus indicator on the Litronic monitor lights up.

Figure 55 Boom positions

1 90° parked position

2 Upper luffing gear limit switch (minimum working radius)

3 Working area

4 Lower luffing gear limit switch (maximum working radius)

5 0° parked position

Operation

CBG_HD / V001 151

4.14.3 Bypass luffing gear limit switch

DANGER

Incorrect operation of luffing gear!


� Accelerate and brake luffing gear slowly.

� Press and hold down Bypass lower luffing gear limit switch button on controlpanel X26.


� Boom luffs out.

� When 0° parked position is reached, move left control lever back to neutral

position.

� Release the Bypass lower luffing gear limit switch button on control panelX26.

Operation

CBG_HD / V001152

4.15 Hook operation

WARNUNG

Incorrect handling of hook operation!

Serious material damage and personal injury.

� Observe values specified in the applicable load chart.

� When changing lifting devices and when in winch service mode, ensurethat additional authorised personnel are monitoring to prevent slack rope.

Figure 56 Four-rope grab

1 Closing ropes

2 Holding ropes

3 Nemag shackle

Operation

CBG_HD / V001 153

4.15.1 Attach hook

� Rest the attached lifting device (e.g. four-rope grab) on the ground approx.

15 m from the crane.

HINWEIS

Ropes do not lower by their dead weight alone.

� Pull and secure ropes into position, using suitable accessories if

necessary.

Figure 57 Lower hoisting gear control lever function

� Select holding winch service operation mode.


� Holding ropes are slackened.

� Select closing winch service operation mode.


� Closing ropes are slackened.

� Remove slung lifting device (e.g. four-rope grab).

� Sling hook.

� Remove securing ropes.

Operation

CBG_HD / V001154

4.15.2 Adjust hook position

Figure 58 Raise hoisting gear control lever function



� Holding ropes become taut.



� Closing ropes become taut.

� Select service mode, normal mode.

� Press the Settings page button on the Litronic monitor.

� Settings page opens.


� Hook is raised.

� Load on the ropes is equalised automatically.

� Press the Store hook position button on the settings page for the Litronic

monitor.

� Position of hook is stored.

Operation

CBG_HD / V001 155

4.15.3 Operate hook

� Select hook operation mode.

� Crane screen with hook is displayed on the main screen on the Litronicmonitor.

HINWEIS

� The selected operation mode is stored and automatically chosen the nexttime the machine is started.

Raise / lower hook

DANGER




Figure 59 Hoisting gear control lever functions


� Hook is lowered.


� Hook stops moving.


� Hook is raised.


� Hook stops moving.

Operation

CBG_HD / V001156

4.16 Four-rope grab operation

WARNUNG

Incorrect handling of four-rope grab operation!

Serious material damage and personal injury.

�Observe values specified in the applicable load chart.

� Carry out a visual check of the four-rope grab for damage, leakage, etc.

� Store four-rope grab according to the applicable guidelines of themanufacturer.

� Obey the safety instructions and operating instructions of the four-ropegrab manufacturer.

� When changing lifting devices and when in winch service mode, ensurethat additional authorised personnel are monitoring to prevent slack rope.

� If using a four-rope grab that is not part of the scope of supply, ensure thefour-rope grab is suitable for this machine.

Figure 60 Four-rope grab

1 Closing ropes

2 Holding ropes

3 Nemag shackle

Operation

CBG_HD / V001 157

4.16.1 Assemble four-rope grab

� Rest the attached lifting device (e.g. hook) on the ground approx. 15 m fromthe crane.

HINWEIS

Ropes do not lower by their dead weight alone.

� Pull and secure ropes into position, using suitable accessories if

necessary.

Figure 61 Lower hoisting gear control lever function



� Holding ropes are slackened.



� Closing ropes are slackened.

� Remove slung lifting device (e.g. hook).

ACHTUNG

Incorrect joining of ropes!

Damage to ropes

� Join ropes with lay direction to the right exclusively to ropes with laydirection to the right.

� Join ropes with lay direction to the left exclusively to ropes with laydirection to the left.

Operation

CBG_HD / V001158

HINWEIS

Rope lay direction.

� The ropes are colour-coded as standard.

Red - red / green - green

� Sling four-rope grab.

� Remove securing ropes.

4.16.2 Adjust four-rope grab position

Figure 62 Raise hoisting gear control lever function



� Holding ropes become taut.



� Closing ropes become taut.




Operation

CBG_HD / V001 159

ACHTUNG

Incorrect adjustment of four-rope grab!

Damage to four-rope grab.

� Mind the mechanical stop when opening!

� Close four-rope grab exclusively with reduced speed!

Prerequisite:

� Four-rope grab is on the ground in the open position.

� If four-rope grab is in closed position on the ground, first store closed po

sition.


� Four-rope grab is raised.


� Press the Store opened four-rope grab button on the settings page for theLitronic monitor.

� Position of the open four-rope grab is stored.

� Rope length difference with four-rope grab open is indicated.



� Four-rope grab closes.


� Raise and lower the closed four-rope grab 2 times.


� Press the Store closed four-rope grab button on the settings page for theLitronic monitor.

� Position of the closed four-rope grab is stored.

� Rope length difference with four-rope grab closed is indicated.

Operation

CBG_HD / V001160

4.16.3 Operate four-rope grab

� Select four-rope grab operation mode.

� Crane screen with four-rope grab is displayed on the main screen on the

Litronic monitor.

HINWEIS

� The selected operation mode is stored and automatically chosen the nexttime the machine is started.

Raise / lower four-rope grab

DANGER






� Four-rope grab is lowered.


� Four-rope grab stops moving.




� Four-rope grab stops moving.

Operation

CBG_HD / V001 161

Open / close four-rope grab

Figure 64 Open / close four-rope grab control lever function

� Move right-hand control lever to the left.


� Four-rope grab closed status indicator on the Litronic monitor continuesto flash whilst four-rope grab is closed.

� Four-rope grab closed status indicator on the Litronic monitor appearsilluminated constantly when four-rope grab is closed.


� Four-rope grab stops moving

� Move right-hand control lever to the right.

� Four-rope grab opens.

� Four-rope grab open status indicator on the Litronic monitor continues toflash whilst four-rope grab is open.

� Four-rope grab open status indicator on the Litronic monitor appears illu

minated constantly when four-rope grab is open.


� Four-rope grab stops moving

Operation

CBG_HD / V001162

Start to raise / lower four-rope grab

Raise means that when the four-rope grab closes, the holding winch also moves in the lifting direction. This prevents the four-rope grab from being overfilled.

Lower means that when the four-rope grab closes, the holding winch also moves in the lowering direction. The four-rope grab sinks further into the material.More material can thus be picked up.

� Press the Store lowering speed button on the settings page of the Litronic

monitor.

� Speed is adjusted in steps of 5%.

� When +50% is reached and the button is pressed again, the value re

verts to +45% and ends at -50%.

Positive value:

� Raise four-rope grab.

Negative value:

� Lower four-rope grab

Figure 65 Raise / lower four-rope grab control lever function

1 Raise four-rope grab.

2 Lower four-rope grab

Operation

CBG_HD / V001 163



� Whilst it is closing, also press the Raise four-rope grab button on the right-

hand control lever.

� Four-rope grab is raised at the set speed.

� Whilst it is closing, also press the Lower four-rope grab button on the right-hand control lever.

� Four-rope grab is lowered at the set speed.

Bulk cargo mode

If there is something between the blades of the four-rope grab and the grab

cannot be closed then the bulk cargo can be hoisted if bulk cargo mode isselected.

Figure 66 Bulk cargo mode control lever function

1 Grab bulk cargo



� Whilst it is closing, also press the Grab bulk cargo button on the left-hand

control lever.

� Tensile force on closing winch is maintained (identical to holding winch).



Operation

CBG_HD / V001164

4.17 Data recorder*The data recorder records all load cycles performed with the machine and sto

res the data on a memory card. However the minimum load must be approx. 3tonnes and the minimum duration of a cycle 10 seconds.

A valid load cycle consists of:

� Raise load.

� Move load via a trigger point.

� Set down load.

� Write load cycle to memory card*.

4.17.1 Tare load

Taring is necessary for every operation mode with data recorder:

� Check after every activation of the data recorder.

� After every change of lifting device.

� Raise lifting device.

� Lifting device is in the air and stationary.

� Load indication shows the same value constantly.

� Press the Home page button on the Litronic monitor.

� Home page opens.

� Press the Load taring button on the home page of the Litronic monitor.

� Load is tared.

Operation

CBG_HD / V001 165

4.17.2 Set trigger point

Figure 67 Trigger points

1 Ship

2 Trigger point 1

3 Crane

4 Trigger point 2

� Position machine so that trigger points 1 and 2 can be set situation-specifically.

� Press the Data recorder screen button on the Litronic monitor.

� Data recorder screen opens.

� Press the Set trigger point button on the data recorder screen of the Litronicmonitor.

� Small circle appears in the display.

Operation

CBG_HD / V001166

4.17.3 Record load cycle

� Press the Start data recorder button on the data recorder screen on theLitronic monitor.

� Recording of the load cycles starts and data is saved.

� Press the Stop data recorder button on the data recorder screen on the

Litronic monitor.

� Recording of load cycles stops.

� Press the Pause data recorder button on the data recorder screen on the

Litronic monitor.

� Recording of load cycles is interrupted.

HINWEIS

Emergency stop

� When an emergency stop is actuated, the current load cycle becomes

invalid and is thus not saved!

To retain a valid load cycle after an emergency stop:

� Press data recorder pause button.

� Bring load to start point.

� Press data recorder pause button again.

� Raise load and continue.

Operation

CBG_HD / V001 167

4.17.4 Selecting hatch cover

With this function the relevant hatch cover is selected to be loaded or unloaded.

2

0 t

3

0 t

4

0 t

5

0 t

6

0 t

1 2

Figure 68 Hatch covers

1 Inactive hatch cover

2 Active hatch cover

� Press the Hatch cover backwards button on the data recorder screen on the

Litronic monitor.

� Active hatch moves one position further to the left.

� Press the Hatch cover forwards button on the data recorder screen on theLitronic monitor.

� Active hatch moves one position further to the right.

4.17.5 Store data

All cycles recorded by the data recorder are automatically saved on the

memory card as soon as the data recorder is started:

� Start data recorder.

� Directory (LOAD000x) is created on the memory card.

� Stop data recorder.

� Directory (LOAD000x) is closed.

� Restart data recorder.

� A new directory is created.

Operation

CBG_HD / V001168

Data structure of the flash card:

Directories of the flash card:

LOAD0001

LOAD0002

LOAD0003

...

Content of the directories:

LOAD0001 / head.txt

data.txt

Structure of the file head.txt (example):

LOAD RECORDER LOAD0001

start date 05.12.2009 Start date

start time 14:24:35 Start time

stop date 06.12.2009 Stop date

stop time 07:06:48 Stop time

load cycles 10 Number of cycles

sum load [t] 244.0 Total load

sum load hatch 1 [t] 44.0 Hatch cover 1 total load



Structure of the file data.txt (example):

date time start time stop averageload [t]

load inrope [t]

max. load[t]

utilization[%]

hatch

05.12.2009 14:24:35 14:30:22 32,7 50.4 52.4 74.6 1

05.12.2009 14:31:40 15:00:17 33.7 53.4 54.4 87.6 2

05.12.2009 15:01:20 15:34:55 33.3 52.7 53.1 81.0 3

...

date Start date

time start Time of load take-up

time stop Time load set down

average load [t] Weight of the load when driving over trigger

(excl. lifting device)

load in rope [t] Weight of total load when driving over trigger (incl. lifting device)

max. load [t] Maximum weight during the entire cycle

utilization [%] Maximum utilization of the device as a percentage

Operation

CBG_HD / V001 169

4.17.6 Exchange data

HINWEIS

� A flashcard slot on the computer is a pre-requisite for reading theflashcard.

� Exclusively remove customer cards to analyse the data.

Figure 69 Data exchange

1 Liebherr CPU

2 Card reader CF2

3 Memory card (flash card)

4 Flashcard slot

VORSICHT

Removal of flashcard not permitted!

Data loss.

� Remove memory card exclusively when machine is switched off.

� Remove customer card from CF2 2 card reader.

� Insert memory card in flashcard slot on PC.

� Memory card is indicated in Windows Explorer as a new drive.

Operation

CBG_HD / V001170

4.17.7 Analyse data

HINWEIS

� Liebherr recommends the use of Microsoft Excel to analyse the data.

� Start Microsoft Excel.

� Click Import External Data on the Data menu.

� The Import Wizard is started.

� Select the desired txt file on the memory card. (head/data.txt)

� Use standard configuration in the wizard up to step 2.

� Select format in step 3:

� date = Date

� time = Standard

� load = Text

� Click Finish

� Paste data into a new or existing sheet.

Operation

CBG_HD / V001 171

4.18 Open Sea*

WARNUNG

Hoisting of loads when sea is rough!

Serious material damage.

� Outside harbour area hoist loads exclusively with Open Sea selected.

4.18.1 Select Open Sea

� Press the Select Open Sea button on the Settings page on the Litronic

monitor.

� Open Sea status indicator appears on the Litronic monitor.

� Load chart changes.

4.18.2 Deselect Open Sea

� Press the Select Harbour Area button on the Settings page on the Litronicmonitor.

� Harbour area status indicator appears on the Litronic monitor.

� Load chart changes.

Operation

CBG_HD / V001172

4.19 Slack rope safety device

The slack rope safety device is needed in order to prevent rope damage.

When a rope is slack, the following movements are stopped:

� Lower luffing gear

� Lower hoisting gear

4.19.1 Bypass slack rope safety device

ACHTUNG

Incorrect handling of slack rope safety device bypass!

Damage to winch, pulleys and rope

� After bypassing slack rope safety device, check winches, pulleys andrope for damage.

� Set Bypass key switch to position "Bypassing on".

� Press the Bypass slack rope safety devicebutton on control panel X26.

� Slack rope safety device is bypassed.

Operation

CBG_HD / V001 173

4.20 Heavy lift operation*

4.20.1 Select heavy lift operation


� Crane screen with hook is displayed on the main screen on the Litronic

monitor.

� Press the Heavy Load Hoist button on the settings page of the Litronic monitor.

� Crane screen with heavy load hook is displayed on the main screen onthe Litronic monitor.

Operation

CBG_HD / V001174

4.21 Rope length metering

Rope length metering:

� indicates the calculated rope length between boom head and hoistedload on the main screen.

� informs the machine operator of the exact position of the hoisted load.

� is displayed separately for each winch.

4.21.1 Initialise rope length metering

� Press the Home page button on the Litronic monitor.

� Home page opens.

� Position hook at the desired hoisting height

� Press Rope taring button on main screen of Litronic monitor.

� Rope length on holding winch and closing winch is initialised.

Operation

CBG_HD / V001 175

4.22 Sector limitation*

The purpose of sector limitation is to avoid collisions with objects in the workingarea.

This involves the definition of a sector that contains objects in the working area.

Slewing gear and luffing gear stop on reaching the sector boundary.

4.22.1 Select sector points

Figure 70 Sector points

1 Left-hand sector point

2 Right-hand sector point

� Position boom tip over right sector point.

� Press the Select right sector point button on the anti-collision screen on the

Litronic monitor.

� Right sector point is selected.

Operation

CBG_HD / V001176

� Position boom tip over left sector point.

� Press the Select left sector point button on the anti-collision screen on theLitronic monitor.

� Left sector point is selected.

4.22.2 Select sector

� Press the Select sector button on the anti-collision screen on the Litronic

monitor.

� Selected sector becomes inactive.

� Next stored sector becomes active.

4.22.3 Delete sector

� Press the Delete selected sector button on the anti-collision screen on theLitronic monitor.

� Selected sector is deleted.

4.22.4 Bypass sector limitation

Figure 71 Bypass sector control lever functions

1 Bypass sector

� Press Bypass sector button on left control lever.

� Slewing gear and luffing gear do not stop on reaching the sectorboundary.

Operation

CBG_HD / V001 177

4.23 Specialised lifting*

When specialised lifting is selected, the machine can be operated in a smallerworking radius.

4.23.1 Select specialised lifting


� Crane screen with hook is displayed on the main screen on the Litronic

monitor.

� Press the Specialised Lifting button on the settings page of the Litronicmonitor.

� Specialised lifting is selected.

Operation

CBG_HD / V001178

4.24 Winch synchronisation

ACHTUNG

Uneven load distribution due to non-synchronised winches!

Serious damage to winches and ropes.

� Synchronise winches.

The positions of the two winches are automatically controlled during operation.

The length of rope can change between the closing winch and the holdingwinch.

Winches synchronised

Closing winch not synchronised

Holding winch not synchronised

The maximum tolerance is A= ±0.3m.

� Ropes are out of tolerance:

� Hoisting gear turns off.

� Status indicator Winches notSynchronised flashes on the Litronic monitor.

Operation

CBG_HD / V001 179

4.24.1 Synchronise winches automatically



� Load is lowered.




� Load is lifted.



� Select holding winch service operation mode or closing winch service operation mode.

� Press the Synchronise winches button on the settings page of the Litronicmonitor.

� Raise or lower the hoisting gear.

� Button Synchronise winches becomes green.

� Winch synchronisation is active.

� Winches synchronise automatically.

� As soon as winches are synchronised, the winches not synchronised status indicator goes out.

� Press the Synchronise winches button on the settings page of the Litronicmonitor.

� Button Synchronise winches becomes white.

� Winch synchronisation is inactive.

Operation

CBG_HD / V001180

HINWEIS

� As soon as the status indicator Winches not synchronised goes out, theraising or lowering movement, depending on the control lever alignment,is executed immediately.

4.24.2 Synchronise winches manually

ACHTUNG

Incorrect handling of service mode!

Damage to the machine.

� Bring in additional authorised personnel to monitor winches and liftingdevice.




� Holding ropes are lowered.


� Holding ropes are raised.



� Closing ropes are lowered.


� Closing ropes are raised.

� Synchronise winches by eye.

Operation

CBG_HD / V001 181



� Press the Store winch position button on the settings page of the Litronic

monitor.

� Symbol Current rope length difference on the settings page of the Litronicmonitor is initialised.

Operation

CBG_HD / V001182

4.25 Litronic test system

4.25.1 Overview

WARNUNG

Unauthorised change to the Litronic test system!

� Changes to the setting and/or correction values are to be carried out

exclusively by Liebherr service personnel.

The Litronic test system is a comprehensive diagnosis and service tool available on the monitor, a service notebook and also via a modem connection (ifavailable).

It is used to monitor inputs and outputs, flags, internal system variables andstatuses.

The Litronic test system can be accessed completely independently from several interfaces at the same time (e.g. monitor, service notebook, GSM modem,

etc.).

The Litronic test system provides the following functions:

� Displays the installed software ID and version numbers.

� Displays all module I/Os with comments

� Displays the internal memory variables with comments

� Displays a selection list

� Displays correction values (machine set values)

� Displays messages (message stack)

� Displays special functions:

� Modem configuration*

� Memory card control (CF)

� CAN configuration/status

Operation

CBG_HD / V001 183

Figure 74 Litronic test system overview

1 Header: Name of the current screen

2 Main window: Displays information

3 Input bar: For display and correction of entered values, display ofstatus messages and input prompts

4 Menu bar: Function key symbols

The Litronic test system comprises a number of screen pages; the function keysymbols are used to move from page to page.

Some pages have two menu bars that you can toggle between using the function key symbol MENU 1/2 . The first menu bar is always active when a page

first opens.

The home page (main menu) is displayed when the Litronic test system is first

started. On each subsequent start, the page that was being used when the system was exited will be loaded. The other settings are retained.

Certain commands can be executed several times in succession by entering thenumber of repetitions (these appear in the input line) or by pressing the requiredfunction key symbol. These include, for instance PREVIOUS and NEXT.

Operation

CBG_HD / V001184

4.25.2 Screen pages

Main screen page

The various screen pages of the Litronic test system are linked from the main

screen menu. Leave the current screen page by pressing the function key symbol BACK.

The following pages can be reached from the main screen page:

� INPUT/OUTPUT screen page

� MEMORY screen page

� SELECT screen page

� CORRECTION screen page

� MESSAGES screen page

� SPECIAL FUNCTIONS screen page

INPUT/OUTPUT screen page

This screen page allows all the module I/Os to be viewed.

Description of the function key symbols:

� NEXT CAN LINE goes to the next CAN line.

� PREVIOUS MODULE and NEXT MODULE toggle between the modulesin 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 asan inverse I or O.

� Add the highlighted channel to the Select list using SELECT. If the

channel is already selected, it will be removed from the list. The name ofa channel will be displayed inverse if it is selected.

� MENU 1/2 toggles between the two menu bars.

� DOCUMENT displays 16 channels (inputs/outputs) with comments on a

page. In digital modules (32 channels) use PREVIOUS and NEXT toswitch to the second page.

� UNDOCUM displays all inputs and outputs on one page.

� IDENTIFY displays 16 inputs and outputs with the identifier on one page.

In digital modules (32 channels) use PREVIOUS and NEXT to switch tothe second page.

� BACK returns to the main menu.

Operation

CBG_HD / V001 185

MEMORY screen page

This screen page is used to display the internal flags that are being used.


� NEXT SECTION moves between the 16 flag sections: X-B-W-D, 1-2-3-4.

� PREVIOUS PAGE and NEXT PAGE toggle between the pages. Eachpage contains 16 flags from the selected section.

� PREVIOUS and NEXT move between the flags. The highlighted flag ap

pears as an inverse M.

� Add the highlighted flag to the Select list using SELECT. If the flag isalready selected, it will be removed from the list. The name of a flag will

appear inverse if it is selected.


� DOCUMENT displays flags with additional comments.

� IDENTIFY displays flags with their identifiers.


SELECT screen page

To avoid having to always switch between the I/O and the flag menus, valuescan be added to the Select list. These entries can then be viewed and edited on

the SELECT screen page at the same time. The Select list can consist of several pages.

If a new value is added to the Select list when the list is already full, the oldestvalue is removed from the list.

These Select lists can also be backed up on the memory card and reloadedfrom there.

How to add entries to the Select list:

� Use the function key symbol SELECT directly on the INPUT/OUTPUT,MEMORY or CORRECTION screen page (grouping of entries).

� Use the function key symbol ADD on the SELECT screen page by ente

ring the IEC address.

� Reading from a file with the LOAD FROM CARD function symbol on theSELECT screen page.

How to delete entries from the Select list:

� Use the function key symbol SELECT directly on the INPUT/OUTPUT,MEMORY or CORRECTION screen page to reselect a selected value.

� Use the function key symbol DELETE on the SELECT screen page to

delete the selected entry.

Operation

CBG_HD / V001186


� ADD adds a new entry to the Select list. A menu bar is displayed in which

the IEC address is entered.

� DELETE removes the selected entry from the list.

� PREVIOUS and NEXT move between the separate select entries. Thehighlighted entry is displayed as an inverse I, O or M.

� NEXT PAGE moves to the next page of the Select list so that more va

lues can be viewed.

� IDENTIFY displays the inputs and outputs or tags with the identifier.

� DOCUMENT displays the inputs and outputs or tags with the comments.

� LOAD FROM CARD loads a new Select list from a file. A menu is thendisplayed. The menu contains a list of file names, 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 appearsfrom which the name of the file can be selected.



Add Selection screen page

This page is accessed using the ADD function symbol from the SELECT screen

page. This enables the IEC address of a new Select entry to be entered. TheIEC address is entered in the input line using the corresponding function sym

bols and the numeric keys on the Litronic service panel.

Example:

� Desired IEC address: %QW1.17.1

� %, Q and W are entered using the corresponding function keys.

� 1.17.1 is entered as normal numbers and can be edited as necessaryusing function key symbol TAKE & BACK to accept the address.


� Use M, I or Q to select the IEC type flag, input or output. The output ischanged each time a key is pressed and appears in the input bar. A cor

rection can be made by pressing another type again.

� X, B, W, D are used to select the size of the IEC entry. The IEC entry ischanged each time a key is pressed and appears in the input bar. A correction is made by pressing a different size again.

� TAKE & BACK calls up the SELECT screen page again and copies theIEC address from the input line.

Operation

CBG_HD / V001 187

Select File Load screen page

On this screen page a saved Select list can be loaded from the memory card.


� CHARACTER NEXT adds a new character to the end of the input line.

New characters can also be added by entering numbers and letters.

� CHARACTER DOWN and CHARACTER UP modify the last character inthe input line.

� PREVIOUS and NEXT move the cursor up and down in the list. When a

file is selected, its name is copied to the input bar. This is the easier wayto select the desired file.

� LOAD loads the file displayed in the input bar and returns to the SELECT

screen page.

� BACK abandons the operation and returns to the SELECT screen page.

Select File Save screen page

On this screen page a saved Select list can be saved to the memory card.


� CHARACTER NEXT adds a new character to the end of the input line.New characters can also be added by entering numbers and letters.

� CHARACTER DOWN and CHARACTER UP modify the last character inthe input line.

� PREVIOUS and NEXT move the cursor up and down in the list. When afile is selected, its name is copied to the input bar.

� SAVE saves the select list in a file (enter file name in the input bar) andreturns to the SELECT screen page.

� BACK abandons the operation and returns to the SELECT screen page.

Operation

CBG_HD / V001188

CORRECTION screen page

This screen page is used to display the correction values.


� NEXT SECTION moves between the 4 correction value sections:X-B-W-D.

� PREVIOUS PAGE and NEXT PAGE toggle between the pages. Each

page contains 16 correction values from 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 additional comments.

� IDENTIFY displays the correction values with the identifier.

� BASE MIN & MAX displays the correction values with the default value

and the upper and lower limits.

� SAVE TO CARD saves the current correction values in a file. The filename can be selected from the menu that now appears. A standard file

name (created from the current date) is suggested. This name can bechanged.

� Add the highlighted entry to the Select list using SELECT. If the entry isalready selected, it will be removed from the list. The name of a correc

tion value will be displayed inverse if it is selected.



MESSAGES screen page

This screen page displays the saved application messages (e.g. sensor errors)

and all system errors (CAN bus, modules, CPU, etc.). These application messages are buffered internally.


� ALL lists all saved messages (max. 15,000).

� PREVIOUS START and NEXT START move between all messages saved at each start-up.

� PRIORITY MAXFILTER and PRIORITY MINFILTER list the saved mes

sages filtered by priority.

� GROUP FILTER lists the saved messages filtered by certain groups.

� SINCE START lists exclusively the messages since the machine wasstarted.

� LANGUAGE enables a different language to be loaded for the messages.

Messages that are not found in the selected language are displayed inEnglish. This language change applies only to the MESSAGES screen

page and not to the Litronic test system.

� PREVIOUS and NEXT move between the messages.

Operation

CBG_HD / V001 189

� 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 stan

dard file name (created from the current date) is suggested. This namecan be changed.



Language Selection screen page

The language in which the messages are displayed is selected on this screenpage.


� PREVIOUS and NEXT move between the separate languages.

� SELECT is used to select and load the highlighted language.

SPECIAL FUNCTIONS screen page

Various other screen pages are accessed from this screen page. It is also possible to return to the main menu by pressing the function symbol BACK.

The following screen pages can be accessed from the SPECIAL FUNCTIONS

screen page:

� Modem Functions screen page

� Drive Functions screen page

� Time Functions screen page

� Priority Level screen page

� CAN Configuration screen page

� Can Line Information screen page

� Display Configuration screen page

� System Language Selection screen page

� Sampling Trace screen page

� System Status screen page

� MDE/PDE screen page

� Clients screen page

Operation

CBG_HD / V001190

Modem Functions screen page

This screen page is used to configure and control the GSM modem.

The current modem status (Online, Offline, False PIN etc.) may be viewed inthe input bar.


� DIAL dials a previously entered phone number.

� HANGUP terminates an active modem connection (hang up handset).

� RLP ON / OFF switches the radio link protocol for GSM modem connec

tions on or off. This setting does not become active until the next time themachine is switched on.

� V32/V110 switches on the V32 or V110 protocol for GSM modem con

nections. This setting does not become active until the next time the machine is switched on.

� PREVIOUS and NEXT change between the interfaces; the default is Mo

dem Client COM2.

� PIN INPUT allows the PIN code for the GSM modem to be entered manually.

� MODEM CONNECT enables the modem server program to be started on

an unused interface.

� MENU 1/2 toggles between the two menu bars

� BACK returns to the SPECIAL FUNCTIONS screen page.

Drive Functions screen page

This screen page displays information about the current drive.


� REMOVE CARD must be pressed before removing a memory card fromthe drive. Switching off the Litronic control system is another option. Thesystem automatically recognises when a new card has been inserted.

� DIR LIST displays the files and directories (but no sub-directories) on the

current drive.

� PREVIOUS DRIVE and NEXT DRIVE change between the individualdrives available to the Litronic controller.

� CHECK CARD checks the current drive for errors.


Operation

CBG_HD / V001 191

Time Functions screen page

Date and time are displayed on this screen page.


� DAYLIGHT SAVING switches to the summer time setting.

� TIMEZONE MOVE WEST moves the time zone settings an hour to the

west.


Priority Level screen page (for Liebherr service personnel only)

The Litronic code, which provides access to the supervisor level, is entered onthis screen page. The supervisor level is necessary to change the time, for ex

ample.


� When the LEVEL CHANGE key is pressed, the value in the input line istaken in and checked to see whether it is a valid LITRONIC code.


CAN Configuration screen page

All the CAN modules that are inserted, together with their usage status, are dis

played on this screen page.


� NEXT PAGE moves to the next screen page.


Can Line Information screen page

This screen page displays the CAN lines being used and their settings.


� MODULE INFO changes to the CAN Configuration screen page.


Operation

CBG_HD / V001192

Display Configuration screen page

The display options for the INPUT/OUTPUT screen page are defined on thisscreen page.


� ALL MODULES is used to display all CAN modules ("used" and "notused") on the INPUT/OUTPUT screen page.

� ONLY USED MODULES: only CAN modules that are currently set to"used" are displayed on the INPUT/OUTPUT screen page.

� NUMBER STYLE switches the inputs, outputs and flags between standard and hexadecimal display.

� UPDATE INTERVAL changes the update rate of the input, output andflag displays.


System Language Selection screen page

On this screen page the system language can be changed by selecting a language or loading the internal standard language.

The selected system language is only activated once the Litronic control systemis switched back on.


� PREVIOUS and NEXT move between the separate languages.

� SELECT loads the marked language as the new system language and

returns to the SPECIAL FUNCTIONS screen page.

� USE DEFAULT loads English as the new system language and returns to

the SPECIAL FUNCTIONS screen page.


� BACK abandons the operation and returns to the SPECIAL FUNCTIONSscreen page.

Sampling Trace screen page

The Sampling Trace screen page is used for online tracing of data from previ

ously selected inputs and outputs.

This screen page displays "Sampling Trace" information, allows its status to be

modified, and also allows the recorded data to be saved.


� SAMPLE ACTIVE activates the "Sampling Trace" functionality once the

options have been defined. This enables recording and the trigger conditions are checked.

� TRIGGER MANUAL simulates the trigger conditions. This function symbol is only available if "Sampling Trace" is active and the trigger conditions are not yet satisfied.

� END MANUAL ends the "Sampling Trace" recording and returns automa

tically to status READY. This function symbol is only available if "Sampling Trace" is active.

� LOAD FROM CARD loads a configuration from a saved "SamplingTrace" file. A menu appears from which the name of the file can be selected .

Operation

CBG_HD / V001 193

� SAVE TO CARD saves the recorded data and the "Sampling Trace" configuration in a file. A menu appears from which the name of the file canbe selected.

� SAVE TO SELECT takes variables that were used in the "SamplingTrace" and saves them in the Select list. Existing entries in the Select listare deleted.

� LOAD FROM SELECT loads the currently selected variables into the

"Sampling Trace" list.

� PREVIOUS and NEXT move between the configuration values. The highlighted (active) entry is displayed inverse.

� CHANGE is used to change the highlighted entry to the value in the input

bar. This only happens, however, if the value is within the permittedlimits.



System Status screen page

This screen page displays the current system status (running, stopped, , etc.)

and the timing of the PLC tasks (Programmable Logic Controller).


� SYSTEM TASKS displays information about the system tasks.

� BOARD INFO displays information about the main board (voltage, temperature, etc.).


MDE/PDE screen page

This screen page shows the status of the MDE (Machine Data Acquisition), thePDE (Process Data Acquisition) and the data logger.


� MDE displays the MDE data.

� PDE displays the PDE data.

� SELECT GRAPHIC lists the saved graphics (e.g. company logo) for

printing the PDE data. The desired graphic can be selected.

� LOGGER displays the data from the data recorder.


Operation

CBG_HD / V001194

Clients screen page

This screen page shows the status of the individual communication interfaces(clients).


� PREVIOUS and NEXT move between the interfaces.


4.25.3 Starting the Litronic test system

WARNUNG

No error messages from the Litronic control system may be displayed in theLitronic test system!

� Carry out crane work exclusively on the power operation screen.

� Press the Litronic test system button on the settings page of the Litronic

monitor. (at any time, including during operation)

� The Litronic test system page is displayed on the monitor.

� Press the Start test system button on the Litronic test system page of theLitronic monitor.

� The Litronic test system main menu is displayed on the monitor.

Operation

CBG_HD / V001 195

4.26 Abseiling device

4.26.1 Use abseiling device

VORSICHT

Incorrect use of abseil rescue equipment!

Fall from cabin.

� Observe operating manual for abseil rescue equipment.

� Use abseil rescue equipment exclusively after thorough training.

� Regularly check the abseil rescue equipment (see Maintenance,Maintenance Schedule section) and document results.

� Arrange for repairs to be carried out exclusively by the manufacturer!

1 Abseil eye

2 Abseil rescue equipment

� Take the abseil rescue equipment out of its storage in the cabin.

1 Cover

2 Storage compartment

3 Rescue harness, rope, karabiner

� Hook karabiner through the abseil eye.

� Throw rope over hand rail.

� Stand over the abseil rescue equipment with legs apart.

Operation

CBG_HD / V001196

� Grasp rescue harness by the D-rings

� Lift rescue harness up to below the shoulders.

� Latch D-rings into the karabiner (of the rescue harness).

� Slip "braces" up.

� Step over the cabin platform hand rail, suspended in the abseil rescue

equipment.

� Hold the rope that is running through the abseil rescue equipment firmly in

left hand.

� Operate brake lever with right hand.

� Carefully release brake!

HINWEIS

� To stop or slow down, hold the running rope tightly and / or release brakelever.

Operation

CBG_HD / V001 197

4.27 Emergency stop

4.27.1 Using emergency stop

DANGER

Machine under extreme stress under load during an emergency stop!

� Use emergency stop exclusively as an emergency machine cut-off.

As soon as an emergency stop button is pressed:

� the engine cuts out.

� the multi-disc brakes are applied, thereby abruptly braking the machine.

Figure 75 Emergency stop

Figure 76 Emergency stop

If emergency stop is triggered while a load is being moved:

� have multi disc brakes inspected by Liebherr service department.

� Unlock activated emergency stop: gently depress the emergency stop andturn to the right.

Operation

CBG_HD / V001 198

4.28 Interruption of work

DANGER

Unauthorised commissioning of machine!

� Secure machine against unauthorised commissioning when leaving it.

4.28.1 Decommissioning before work interruption

� Lower boom down to lower luffing gear limit switch.

� Press and hold down Bypass lower luffing gear limit switch button on controlpanel X26.


� Boom luffs out.

� When 0° parked position is reached, move left control lever back to neutral

position.

� Release the Bypass lower luffing gear limit switch button on control panel

X26.

� Set down and secure the load.


� Set Ignition key switch to "Ignition off" position.

Operation

CBG_HD / V001199

4.28.2 Commissioning after work interruption



� Engine 2 main power supply on signal light on control panel X25 lights up

when hydraulic system is ready to start.



Operation

CBG_HD / V001 200

4.29 Decommissioning

DANGER

Unauthorised commissioning of machine!

� Secure machine against unauthorised commissioning when leaving it.

4.29.1 Lower boom to parked position


� Press and hold down Bypass lower luffing gear limit switch button on control

panel X26.


� Boom luffs out.

� When 0° parked position is reached, move left control lever back to neutralposition.

� Release the Bypass lower luffing gear limit switch button on control panelX26.

� Set down and secure the load.


Operation

CBG_HD / V001201

4.29.2 Switch off engine



� Set Power unit 1 main power supply switch at switch cabinet X2 to position"Main power supply off".


"Main power supply off".

� Switch off air conditioning system.

� Close all windows and doors.

� Leave Auxiliary supply switch at control cabinet X1 set at position "Auxiliary

supply on".

� Anti condensation heater is switched on.

ACHTUNG

Extended machine shutdown time!

� Leave anti-condensation heater switched on.

� Check lubrication and oil level before commissioning.

� Operate machine for one hour at least once a month.

� Carry out all maintenance work in accordance with maintenance chart.

� Preserve machine if shutdown times lasts longer than three months.(Contact Liebherr after sales service)

Operation

CBG_HD / V001 202

4.30 Emergency operation

4.30.1 Emergency operation for power unit fault

The machine is driven by two power units. In the event of a fault on one powerunit, the machine can be operated with only one power unit.

When the machine is operated with only one power unit, it is possible:

� to hoist the maximum permissible load.

� to drive at half the operating speed.

Operation with power unit 1 and 2





� Set ball valve D-A to position "both power units active".

� Set ball valve D-B to position "both power units active".

Operation

CBG_HD / V001203

� Open ball valve H-B1.




� Open ball valve E-B1.












Operation

CBG_HD / V001 204

Operation with power unit 1






� Set ball valve D-A to position "power unit 1 active".

� Set ball valve D-B to position "power unit 1 active".


� Close ball valve H-B2.




� Close ball valve E-B2.

Operation

CBG_HD / V001205

� Set Power unit 1 main power supply switch at switch cabinet X2 to position"Main power supply on".






Operation

CBG_HD / V001 206

Operation with power unit 2






� Set ball valve D-A to position "power unit 2 active".

� Set ball valve D-B to position "power unit 2 active".





� Close ball valve E-B1.


Operation

CBG_HD / V001207

� Set Power unit 2 main power supply switch at switch cabinet X2 to position"Main power supply on".






Operation

CBG_HD / V001 208

4.30.2 Emergency operation for fault on both power units

WARNUNG

Unauthorised or improper use of emergency operation!

� Execute emergency operation exclusively when machine is at a complete

standstill.

� Cordon off a large danger zone.

� Employ a banksman to monitor the situation.

Emergency operation is initiated by switching the hand valves and building up

pressure with the hand pump.

The following movements can be made:

� Lower load

� Release slewing gear brakes

� Lower boom

All connections for the hand pump and valves are arranged around the electricmotor.

4.30.3 Open four-rope grab

� Connect hand pump to the hoisting gear connection and by the tank

� Set valve H62A to emergency operation position.

� Set valve H62C to emergency operation position.

� Build up pressure using hand pump.

� Multi-disc brake Z61U releases.

� Four-rope grab opens for as long as the hand pump is operated.

If four-rope grab does not open:



When the four-rope grab is fully open:

� Set valve H63A to normal position.


� Set valve H62C to normal position.

Operation

CBG_HD / V001209

4.30.4 Lower four-rope grab


� Set valve H62 to emergency operation position.


� Set valve H62B to emergency operation position.


� Simultaneously set valves H63 and H63A to emergency operation position.


� Multi-disc brakes H61U and Z61U release.

� Four-rope grab is lowered for as long as the hand pump is operated.

After completed emergency operation:

� Set valve H63 to normal position.




� Set valve H62B to normal position.


4.30.5 Lower hook (holding winch only)






� Multi-disc brake H61U releases.

� Hook is lowered for as long as the hand pump is operated.





Operation

CBG_HD / V001 210

4.30.6 Lower hook (holding winch and closing winch)






� Simultaneously set valves H63 and H63A to emergency operation position.


� Multi-disc brakes H61U and Z61U release.

� Hook is lowered for as long as the hand pump is operated.








Operation

CBG_HD / V001211

4.30.7 Release slewing gear brakes

� Connect hand pump to the slewing gear connection and by the tank

� Move valve D62A to emergency operation position.

� Move valve D62B to emergency operation position.

� Move valve D62C to emergency operation position.


� Multi-disc brakes D61U, D61V, D61W and D61X release.

� Turn crane using additional equipment (e.g. chain hoist).


� Set valve D62A to normal position.

� Set valve D62B to normal position.

� Set valve D62C to normal position.

4.30.8 Lower boom

� Connect hand pump to the luffing gear connection and by the tank

� Move valve E62 to emergency operation position.


� Multi-disc brake E61V releases.

� Slowly open restrictor valve E63.

� Regulate lowering speed with restrictor valve E63.


� Close restrictor valve E63.

� Set valve E62 to normal position.

Operation

CBG_HD / V001 212

5

5

Maintenace

CBG_HD / V001 213

5. Maintenance

WARNUNG

Inadequate maintenance and inspection work!

� Maintenance and inspection work must only be carried out when the

machine is switched off.

� Secure the machine to prevent unauthorised startup.

� Observe general safety notes.

Make sure that the persons carrying out the maintenance on the machine:

� have read and understood this operation manual.

� have received instruction on the machine.

� have received training on this machine at the Liebherr training center.

� use only Liebherr original spare parts.

If the machine will be permanently out of operation for longer than 3 months, allexposed parts must be covered and protected against the environment. This

protection must be removed before recommissioning the machine.

Lubricants

Lubricants have 3 essential functions:

� Reducing friction

� Preventing corrosion

� Removing dirt and abrasion particles

Furthermore note that the higher the quality of the lubricant, the longer the service life of the components or the lower the amount of wear. High-quality lubricants also have a lower moisture content, which means they last longer.

The specified lubrication intervals must not be exceeded, but can be shortenedif necessary. Shortening of intervals largely depends on the operating con

ditions.

ACHTUNG

Insufficient lubrication!

Damage to machine.

� The prescribed lubrication intervals as per the maintenance schedulemust be observed.

Maintenance

CBG_HD / V001214

5.1 Maintenance schedule

Maintenance operations are divided into two groups identified as follows:

Symbols with colour fill:

� The machine operator or his maintenance personnel carry out the

maintenance work under their own responsibility.

� Maintenance personnel:Trained personnel with the appropriate qualifications, specialist know

ledge and experience needed to carry out maintenance tasks.

Symbols without colour fill:

� Authorised and qualified personnel of LIEBHERR or its authoriseddealers carry out these maintenance and inspection tasks.

� Authorised and qualified personnel:Specially trained personnel with comprehensive and in-depth knowledgeof components and systems who have been authorised by LIEBHERR to

carry out this work.These are primarily Liebherr service engineers who have been trained by

the manufacturer itself or one of its service agents.

Special intervals are intervals for maintenance to be carried out at the time indi

cated.

HINWEIS

� The spare parts catalogue lists all spare parts need for carrying outmaintenance and inspection work.

ACHTUNG

Non-compliance with maintenance intervals!

Premature wear or damage to the machine.

� Observe maintenance intervals in accordance with maintenance chart.

HINWEIS

Notes regarding maintenance intervals:

� To determine maintenance intervals, use the mechanical operating hours

counter on the switch cabinet (see chapter: Controls, switch cabinet)

� If necessary, carry out the maintenance and inspection tasks before the

specified intervals.

� Clean or change contaminated filters before the specified intervals.

� � � �

� � �

Maintenace

CBG_HD / V001 215

Maintenance/inspection according

to

operating hours

WORK TO BE CARRIED OUT

8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als

by trained by authorised

maintenance personnel specialist personnel

� one-off task � one-off task

� repetition interval � repetition interval

� when necessary � when necessary

Overall machine

� Check all control devices and displays

� Check that the emergency stop switch is working correctly with no loadon the hook and with the engine off

� Visual inspection of the entire crane structure (brakes, ladder, platforms)

� Inspect the entire crane for loose parts, rust, corrosion and cracks

� Perform all movements and check that limit switches are working correctly

� Execute disc brake test procedure (if passenger transport is installed)

� Check that the mechanical boom angle indicator is working correctly (iffitted)

� Visual inspection of the entire crane following extreme events (e.g. storm,overload, emergency stop with load, etc.).

� Check nominal load indication

� Visual inspection of paintwork for mechanical damage or corrosion

� Inspect all rubber stoppers on the crane

� Inspect condition and screw fitting of the counterweight and A-frame (iffitted)

� Inspect the condition and attachment of the recoil polyamide plates (iffitted)

Electric motor

� Dependent on humidity and weather conditions, check that electric motoris working correctly.

� Perform insulation measurement

� Keep engine and ventilation slits clean.

� Check condition of the gland seal. Replace if required.

� Check condition of star-delta circuit breaker contact set. Replace if required.

� If replacing electric motor, replace star-delta contact breaker contact set.

� Check condition of fastening screws

� Check condition of ball bearings

� Grease ball bearings (see lubrication information sign, location 5 on theelectric motor)

Distribution gearbox (if fitted)

Maintenance

CBG_HD / V001216

WORK TO BE CARRIED OUTMaintenance/inspection according

to

operating hours






Specia

l in

terv

als

6000h /

every

3

years

4000h /

every

2 y

ears

2000h /

yearly

8h /

daily

1000h /

half-y

early

500h /

3-m

onth

ly

40h /

weekly

� Check oil level

� Bring unit to working temperature, take oil sample, change oil if necessary

� Check air breather

� Visual inspection of fixing pin

Hydraulic system

� Visual inspection of condition of hoses, fittings, valves, blocks, engines,pumps and cylinders - check for leaks

� Visual inspection of the rigid hoses (if fitted)

� Every 10,000 hours / every 6 years - renew all external hoses

� Check oil level

� Renew filter elements of all hydraulic filters

� Renew air breather on hydraulic oil tank

� � Clean magnet and return filter (once per week during the first 250 hours)

� Check pressure settings and correct them if necessary

� Bring system up to working speed and take oil sample 10 hours afterevery hydraulic oil change (reference measurement)

� Bring system up to working speed and take oil sample every 500 hours

� Bring system up to working speed and take oil sample every 1000 hours /once per year

� If Liebherr hydraulic oil is not being used, change hydraulic oil every 2000hours / every 2 years

� If Liebherr Hydraulic 37 is being used, change hydraulic oil every 4000hours / every 4 years

� If Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic is being used,change hydraulic oil every 6000 hours / every 6 years

� � Check pressure accumulator

� Replace pressure accumulator

� Check oil cooler and clean if contaminated

� Visual inspection for tooth profile wear to hydraulic motors and pumps

� Check that the feed pressure filter is working correctly (if fitted)

� Check condition and sealing on all hydraulic drives and bulkhead plates

Maintenace

CBG_HD / V001 217


to

operating hours


8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als






Winches

� Check gearbox oil level

� Take an oil sample after 100 hours, change oil if necessary

� Bring system to working speed, take oil sample, change oil if necessary

� Check condition of the counter bearings (regrease if necessary)


� Check attachment of limit switch and coupling

� Check limit switch is working correctly (if possible)

� Inspect pin connection / threaded connection between winch and mainstructure of crane

� Checking that holding brake is working

� Inspect external disc brakes for passenger transport (if fitted) for condition and wear

� Inspect rope kicker for condition and wear

� If rope kicker exhibits excessive wear, change it

� Inspect the overall mechanical condition of the winch, such as drum grooving, on-board discs, transverse pipe connections, pinions, etc.

� Check that rope is wound correctly on the winch drum

� Check that rope is fitted correctly at the rope fixing point and at the fixingpoint itself

� Check condition and attachment of pressure rollers

� Check condition and attachment of overspool safety device

Slewing gear

� Check oil level


� Bring system to working speed, take oil sample, change oil if necessary

� Visual inspection for leaks

� Visual inspection of open gear pinion for wear and pitting

� Visual inspection of fixing pin

� Checking that holding brake is working

Maintenance

CBG_HD / V001218


to

operating hours


8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als






Slewing bearing

� Check every 250 hours that the slewing bearing is adequately lubricatedand regrease if necessary

� Check that the open gear is adequately lubricated and regrease if necessary

� Check that the central lubrication system (if installed) is working correctlyand check its fill level

� Visual inspection of open gear pinion for wear and pitting

� Take a grease sample from the slewing bearing

� Check tightening torque of slew bearing bolts

If more than 10% of these pins are tightened to below the required torque, they must all be adjusted

� � Perform tilt measurement and initial measurement following delivery

� Replace slewing bearings every 10 years

� If a lengthy period of downtime is anticipated, lubricate open gear andslewing bearing

Swing lock (if installed)

� Check condition of the structure, the locking pin and the bush

� Check lubrication and relubricate if necessary

Ropes and pulleys

� Check the condition, lubrication and spooling properties of the ropes andrelubricate them if necessary

� If the rope is replaced, replace the rope kicker on the winch (only on CBB2980 - CBB 4700)

� In the event of spooling problems replace the rope kicker on the winch(only on CBB 2980 - CBB 4700)

� Check condition of rope end screw fitting

� Check pulleys for damage and wear

� In order to even out wear on the rope, shorten the rope by 1/3 of thewinch circumference (with multi-layer spooling)

� Check condition and lubrication of pulley bearings, and relubricate them ifnecessary

� Renew all plastic pulleys every 8 years

Maintenace

CBG_HD / V001 219


to

operating hours


8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als






Rigging

� Inspect hook for corrosion, wear and damage, and relubricate ropesheave bearings and hook bearings

� Check that slewing bearing is working correctly

� Check that the hook aperture safety device is working correctly and inspect it for corrosion

� Inspect grab for corrosion, wear and damage, and relubricate if necessary

� Check condition of the shackles

� Visual inspection of NEMAG quick-tensioning links (in grab operation)

� Visual inspection of NEMAG quick-tensioning links (in hook operation)

� MPI inspection of NEMAG quick-tensioning links (in grab operation)

� MPI inspection of NEMAG quick-tensioning links (in hook operation)

� Inspect spreader for corrosion, wear and damage, and relubricate if necessary

� Inspect all cables, distributor sockets and lights for condition, wear anddamage

� Inspect condition, lubrication and wear of cable drums, check that theyare attached securely, relubricate and top them up if necessary

� Inspect condition of hook garage, check it for wear and check that it isattached securely

� Check that tandem and anti-collision operation are working correctly

Boom

� Check the tightening torque of the boom flange connecting pins, inspectthem for corrosion and relubricate them if necessary

� Replace boom flange connecting pins every 10 years (if fitted)

� Visual inspection of boom pivot bearing

Lubrication

� Check mechanical condition of all lubrication points and lubrication lines,and check that they are free of leaks

� Relubricate all lubrication points every 250 hours

Maintenance

CBG_HD / V001220


to

operating hours


8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als






Electrical system

� Inspect condition and insulation of all electronic transmitters

� Replace switch cabinet air filter

� Inspect all terminals and ventilators on the switch cabinet

� Check that all terminals in the switch cabinet are attached securely

� Inspect mechanical and electrical condition of the distributor sockets

� Check that all threaded cable connections are installed correctly

� Check that the instrumentation (e.g. cables, sensors) is installed and working correctly

� Visual inspection of all instrumentation for corrosion and damage

� Check that lighting and heating are working correctly (including electricmotor and slip ring)

� Clean battery terminal (if fitted), and lubricate if necessary

� Check water fill level in battery and top up with distilled water if necessary

� Check potential equalisation connection between moving parts (e.g.boom slewing column)

� Check condition and starting power of main switch, the main fuses (current, star, delta) and terminal board (on electric motor)

� Check electrical equipment in accordance with the (local) regulations orsite-specific standards

Slip ring unit (if fitted)

� Check threaded connection and brushes on the slip rings

� Check screws at random on the terminals to ensure that they are seatedsecurely

� Inspect carbon brush for wear every 1500 hours or at least once every 6months

� Check threaded connections on the copper busbar at random to ensurethat they are secure

� Clean metal particles from the insulation between the slip rings

Maintenace

CBG_HD / V001 221


to

operating hours


8h /

daily

40h /

weekly

500h /

3-m

onth

ly

1000h /

half-y

early

2000h /

yearly

4000h /

every

2 y

ears

6000h /

every

3

Specia

l in

terv

als






Cable loop (if fitted)

� Check mechanical function of the cable loop

Cabin

� Replacing windscreen wiper blades

� Air conditioning system as per manufacturer's instructions in the originaloperation manual

� Check that all operating elements are working correctly

BORNACK KE10 St crane abseil rescue equipment

� Check safety rope for cuts or fibre breaks.

� Check safety rope for chemical or mechanical damage.

� Check safety rope for thickening, kinks, knots or loops.

� Check safety rope for rotting, excessive wear, abrasion or scorching.

� Check end termination (knot and seam) of safety rope for completion.

� Check shrink hose fastening of rope end termination.

� Check carabiners/safety hooks for mechanical damage, corrosion damage and deformation.

� Check closure mechanism of carabiners/safety hooks.

� Check condition of springs/rivets/axles.

� Check that snap action of carabiners/safety hooks works smoothly.

� Check ease of movement of abseil rescue equipment cam.

� Check abseil rescue equipment for mechanical damage and corrosiondamage.

� Check brake cam (aluminium) of abseil rescue equipment for wear.

� Check brake cylinder (brass) of abseil rescue equipment for wear.

� Check legibility of type plate.

Maintenance

CBG_HD / V001222

5.2 Lubricants and consumables

Obeying the guidelines for lubrication and the use of fuels guarantees maximum

reliability and a long machine life.

Cleanliness is absolutely essential when using lubricants and fuels.

Entsorgung

Avoid the risk of environmental damage!

� Dispose of all hazardous materials, such as: waste oil, coolant,


5.2.1 Lubrication chart

Figure 77 Lubrication chart CBG

1 Pulleys and thrust bearings

2 Rope

3 Pulleys and thrust bearings

4 Closing winch counter bearing

5 Holding winch counter bearing

6 Luffing winch counter bearing

7 Slew bearing gear rim

8 Slewing gear

Maintenace

CBG_HD / V001 223

Oil top up plan

Figure 78 Oil top up plan CBG


2 Holding winch gearbox

3 Closing winch gearbox

4 Luffing winch gearbox

5 Slewing gearbox

6 Distributor gearbox

Maintenance

CBG_HD / V001224

5.2.2 Filling capacitytable

Figure 79 Filling capacity table

9843635140

Crane:Order:

No. of Unit Type

2 Gear Oil1 Gear Oil- -

4 Gear Oil- -

1 Grease1 Grease1 Grease

1 Anti Freeze Mixture

1 Gear Oil

1 Hydraulic Oil1 Hydraulic Oil

- -

- -

16.01.2008 LWNDate Work

- Auxiliary Hoist Winch

- Main Hoist Winch - Lu�ng Winch 10,5 l

42 l

-10,5 l

FCC-CBG 45(45)/32 LITRONIC162832 , 162851, 165046-047

1. Winch(es):

3. Grease:

2. Slewing Gear(s): - Slewing Gear(s) for sc - Slewing Gear(s) for main arm

- All other grease lines - All sheaves, bearings

- slewing ring + greasing lines

- Windscreen washer4. Cabin:

- Hydraulic tank

5. Gearbox:

6. Hydraulic System:

NOTE: For oil type refer to the attached list "RECOMMENDED OIL TYPES FOR LIEBHERR SHIP- AND OFFSHORE CRANES"

Prepared

according to drawing - Power Supply Survey -

No copying or duplication of this document without the permission of Liebherr.This document has been issued electronically and is valid without signature.

according LIKV work̃ owBargehr R.Checked Approved

8. Diesel Engine:

993921714 - Power Supply Survey

- Hydraulic line system

-

- according to drawing7. Electric Power Consumption:

--

250 l1200 l 1200 l250 l

5 l

6,5l 6,5l

1,4 kg1,8 kg

1,4 kg1,8 kg

23 l 92 l- -

21 l

-

LIEBHERR - Utility Requirements

Unit Req./Unit Total

Edition

Item code

37,5 kg

5 l

37,5 kg

Maintenace

CBG_HD / V001 225

5.2.3 Lubrication chart

No

.

Lubrication

points

Outside temperat

ure

Type ISO

VG/SAE

Specification Liebherr

Lubricants

1.Engine, oil bath airfilter

year-round to -20°C

below -20°C with preheating

SAE 10W-40 ACEA E4

API CF

Liebherr Motoroil 10W-40



SAE 10W-40 ACEA E4/E6/E7

API CF-4 / CG-4

CH-4 / CI-4

Liebherr Motoroil 10W-40 low ash

required when using a soot particle filter



SAE 5W-30 ACEA E4

API CF

Liebherr Motoroil 5W-30

2.

Mechan. gears and

winches

up to -20°C SAE 85W-90 API GL5 Liebherr Hypoid EP90

3. Drive shafts up to -40°C SAE 75W-90 API GL4; GL5, MT1 Liebherr Syntogear Plus 75W-90

4.

Hydrostatic drive

unit, hydraulic

steering

from -25°C to 50°C** ISO VG32-46

SAE 10W-20

ATF*

DIN 51 524 / T3

HVLP

1.DEXRON II D/E

Liebherr Hydraulic 37

from -25°C to 50°C** ISO VG46 (32-68)

SAE 10W-20

DIN 51 524 / T3

HVLPD HC

biodegradable in ac

cordance with CEC-

L-33A393

Liebherr Hydraulic Plus

from -50°C to 30°C ISO VG15-46

SAE 0W-20

DIN 51 524 / T3

HVLPD HC

biodegradable in ac

cordance with CEC-

L-33A393

Liebherr Hydraulic Plus Arctic

5.

Roller bearing, fric

tion bearing, ball/

roller-bearing

swing rings, univer

sal joints, other

grease lubrication

from -25°C to 150°C

For lubrication system

from -20°C to 150°CLubricating

grease, lithium

saponified

DIN 51 502

KP 2 K-30

KPF 2 N-25

Liebherr universal grease 9900




DIN 51 502

KPFHC 1N-60

Liebherr universal grease Arctic

Maintenance

CBG_HD / V001226

No

.

Liebherr

Lubricants

SpecificationType ISO

VG/SAE

Outside temperat

ure

Lubrication

points

6.

Open pinions and

open gears, ropes




Lubrication and

preservation

DIN 51 502

OGPF 2

Liebherr universal grease 9900




OGPF 1 Liebherr universal grease Arctic

All areas OGPF 00 Liebherr paste spray

7. Ropes from -40°C to 50°C Liebherr WR-Lube SC

8. Telescopic boom

All areas Special regulation DIN 51 502

KP 2 K-30

Liebherr grease for telescopic com

ponents 9613 Plus

9. Coolant

down to -37°C DIN 51,757/4

DIN 51 432/2

Liebherr Antifreeze Mix

10. Screenwash fluid down to -80°C Rala Klirr

* If Liebherr oil is not being used, ATF oil is compulsory for multi-disc brakes.

** When the oil preheater is activated, the outside temperature can be about

10°C lower.

The familiar specifications listed in the lubricant table are minimum oil grades

only.

High-quality Liebherr products have been developed and tested for compatibility. The correct function of the machine can only be guaranteed with original

Liebherr products. Products of other grades do not carry this guarantee.

HINWEIS

Authorisation to use third-party oils:

� Contact the Liebherr Lubricant Hotline (+49 (0) 7354/80-6060 or

[email protected]).

Maintenace

CBG_HD / V001 227

Ordering data

Engine oil

5l canister 20l canister 210l drum 1000l 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

Gearbox oil


Liebherr Hypoid 90 EP 10 66 48 74 10 66 48 75 10 66 48 76 10 44 16 36

Liebherr Syntogear Plus 75 W-90 10 33 02 85 10 33 02 87 10 33 02 88 10 29 64 77

Hydraulic oil


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

Grease

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

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 (950g) 10 33 03 11

Liebherr grease for telescopic com

ponents 9613 Plus

86 13 036 08

Coolant


Liebherr Antifreeze Concentrate 10 30 12 15 10 42 84 10 10 42 84 11

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

Maintenance

CBG_HD / V001228

Screenwash fluid


Screenwash -80°C 89 03 108 14

Oil concentrate


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

Oil analysis kit

Oil analysis kit: 88 56 018 14

Maintenace

CBG_HD / V001 229

5.2.4 Hydraulic oil

Initial filling

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 carried out by Liebherr, the machine will have been filled

with Liebherr Hydraulic 37 or higher grade hydraulic oil as standard. In exceptional cases (low temperature package, bio application) the machine is initially

filled with a special hydraulic oil.

Mixing

HINWEIS

Mixing of ester-based, rapidly biodegradable third-party oils with mineral oilsmay cause damage to the hydraulic system!

Liebherr recommends:

� Do not mix rapidly biodegradable third-party oils from different

manufacturers.

� Do not mix rapidly biodegradable third-party oils with mineral oils.

Third-party oils are oils from other manufacturers.

Use of a rapidly biodegradable hydraulic oil must be cleared in advance withLiebherr.

Plant-based oils must not be used because of their poor temperature stability.

Using Liebherr hydraulic oils ensures that none of the disadvantages listed

above will occur.

Mixing Liebherr hydraulic oils

Liebherr mineral oils with one another

Can be mixed in any ratio

Liebherr mineral oils withbiodegradable Liebherr oils

Can be mixed in any ratio

To ensure biodegradability, do not addmore than 2% mineral oil (as per regulations in most European countries)

Liebherr oils with third-party oils To ensure that oil properties are notaltered, do not mix to a proportionhigher than 10%.

Maintenance

CBG_HD / V001230

5.2.5 Conservative agent (anti-corrosion coating)

Recommended anti-corrosion agents

1 LPS PROCYON Id.No.: 861010214

2 LPS 3 in spray can Id.No.: 861009614

3 LPS 1 in 25 l drums Id.No.: 861010014

4 MOLECULAR NATO FLUID in 5 litre cans Id.No.: 861010114

HINWEIS

� The various preservation media can be ordered directly from Liebherr withthe corresponding identification number (Id.no.).

Store conservative agents in a cool, dry place. Must be stored at a temperaturebetween 15°C and 20°C.

Maintenace

CBG_HD / V001 231

5.2.6 Oil diagnosis system

HINWEIS

� Do not delay the first oil change of the unit in question, because increasedcontamination occurs during the running-in period.

The Liebherr oil diagnosis system is a preventive maintenance system for the

main machine components. It is based on an analysis of the oiland has the following objectives:

� To prevent machine failures.

� To reduce downtimes.

� To minimise repair costs.

� To highlight abnormal wear patterns.

� To identify potential causes of damage in good time.

Taking an oil sample


� The Liebherr analysis kit is available.

� The machine is switched off.

� The machine is secured to prevent unauthorised operation.

� The relevant unit has been warmed up for approx. 15 minutes.

� Take the oil samples either directly from the housing of the relevant unit or

from the oil that is drained out when the oil is changed.

� Drain off at least a 1/4 litre of oil before taking the sample and then fill thecontainer with well-mixed oil.

Maintenance

CBG_HD / V001232

Figure 80 Liebherr oil diagnosis kit

1 Plastic syringe container cap

2 Plastic syringe container

3 Syringe neck

4 Adapter

5 Plastic hose

6 Shipping carton

7 Sample data sheet

� Screw the plastic hose (5) with adapter (4) onto the plastic syringe container

(2).

Figure 81 Taking an oil sample

Maintenace

CBG_HD / V001 233

� Take at least 200ml of oil.

� Complete all sections of the sample data sheet (7).

� Place the oil sample and the sample data sheet into the shipping carton (6)and send to the pre-printed address.

Oil diagnosis report

The oil diagnosis report contains the detailed results of the oil sample analysis

and provides information about any measures that need to be taken. Four symbols are used for this purpose:

Symbol Meaning

Normal

High value, take a second oil sample for cross checking

Oil change needed

Repair needed

Maintenance

CBG_HD / V001234

5.3 Slewing gear

Figure 82 Slewing gear

1 Sight glass

2 Vent screw

3 Filler neck

4 Slewing pinion

5.3.1 Checking the gearbox oil level


� The engine has been switched off.


� The slewing gearbox is at normal operating temperature.

� Wear protective clothing.

� Check gearbox oil level in sight glass.

If no gearbox oil is visible in sight glass:

� Top up using the appropriate gearbox oil according to the lubrication chart.

Maintenace

CBG_HD / V001 235

5.3.2 Topping up the gearbox oil




� The slewing gearbox is at normal operating temperature.


ACHTUNG

Dirt and foreign bodies in the slewing gear!

Damage to the slewing gear.

� Make sure the filler neck is free of dirt and foreign bodies.

� Clean the area around the oil filler neck.

� Remove the venting screw from the oil filler neck.

� Top up gearbox oil to halfway on sight glass.

� Reattach and close the venting screws on the oil filler necks.

� Start machine and let it run at idle speed for 10 minutes.

� Operate the slewing gear in both directions.

� Turn off the machine, after 1 minutes check the gearbox oil level of the sle

wing gear and top up if necessary.

Entsorgung




Maintenance

CBG_HD / V001236

5.4 Electric motor

ACHTUNG

Wrong grease!

Damage to electric motor.

� Exclusively use lubricants in accordance with the lubricant informationlabel affixed to the electric motor.

VORSICHT

Hot surfaces, live and rotating parts.

Burns, electric shocks and injuries.

� Inspect the electric motor exclusively when it is at rest.


VORSICHT

Auxiliary heating switched off!

Damage to electric motor by condensation.

� Always leave auxiliary supply switched on.

VORSICHT

Overheating of electric motor!

Damage to electric motor.

� Ensure sufficient fresh air in machinery house.

� Do not position any objects in the vicinity of the electric motor.

Figure 83 Electric motor

1 Electric motor

2 Grease nipple

Maintenace

CBG_HD / V001 237

5.4.1 Lubricate ball bearings



� Grease gun with suitable grease is available.

Figure 84 Lubrication opening

1 Lubrication opening closed

2 Lubrication opening open

� Open lubrication opening.

� Lubrication channels are open.

� Start electric motor.

� Place grease gun on grease nipple.

� Inject suitable grease according to the lubrication information label on the

electric motor.

� Grease spreads throughout ball bearings.

� Allow motor to run for 1 to 2 hours.

� Surplus grease is squeezed out of the ball bearings.

� Close lubrication opening.

Entsorgung




Maintenance

CBG_HD / V001238

5.5 Distributor gearbox

VORSICHT

Hot gearbox components and gearbox oil!

Burns.

� Carry out maintenance and inspection work on distributor gearboxexclusively when diesel engine is switched off and has cooled down.


Figure 85 Distributor gearbox viewed from above

3 Oil dipstick

4 Vent valve

Figure 86 Distributor gearbox viewed from below

1 Drive for pump

2 Oil drain

3 Driven by engine

Maintenace

CBG_HD / V001 239

5.5.1 Check gearbox oil level


� Engine is turned off.

� Machine is secured to prevent unauthorised operation.


VORSICHT


Burns.



� Clean area around oil dipstick.

� Pull out oil dipstick and wipe with a clean, lint-free cloth.

� Insert oil dipstick as far as it will go.

� Pull oil dipstick out again and hold it horizontally.

If gearbox oil level is below MIN mark:


If gearbox oil level is above MAX mark:

� Drain the gearbox oil.

Entsorgung




Maintenance

CBG_HD / V001240

5.5.2 Topping up gearbox oil





VORSICHT


Burns.



ACHTUNG

Dirt and foreign bodies in winch gearbox!

Damage to winch gearbox.

� Make sure filler neck is free of dirt and foreign bodies.

� Clean the area around the oil dipstick and oil filler neck.


� Open vent valve.

� Top up gearbox oil to MAX mark.


� Close vent valve.


� Turn off machine and after 1 minute check gearbox oil and top up if ne

cessary.

Entsorgung




Maintenace

CBG_HD / V001 241

5.5.3 Draining gearbox oil





� A suitable and sufficiently large collecting container is to hand.

� An oil drain hose is to hand.

VORSICHT


Burns.




� Place collecting container in position.

� Open oil drain

� Attach oil drain hose.

� Oil drains out.

� Disconnect oil drain hose.

� Close oil drain.

Entsorgung




Maintenance

CBG_HD / V001242

5.6 Slewing connection

5.6.1 Grease the toothing





If rotary connection open gear is not lubricated by central lubrication system:

� Lubricate the open gear of the rotary connection and the pinion of the rotaryconnection with suitable grease according to the lubricant table.

� Turn the machine on and operate the slewing gear in both directions.

� The open gear and pinion are evenly lubricated.

Maintenace

CBG_HD / V001 243

5.6.2 Checking bearing lubrication





VORSICHT

Rotating slewing column!

Crushing of limbs.

� Ensure that persons stay outside danger zone during lubrication process.

� Leave the danger zone.

� Check the bearing lubrication grease collar.

� If a grease collar is visible, no further action is required.

� If no grease collar is visible, check the central lubrication system or fillwith suitable grease according to the lubricant table with a grease gun viathe grease nipple until the grease collar is visible.

Figure 87 Bearing lubrication grease collar

1 Grease collar

� After each grease nipple, turn the machine by 45° to distribute the grease.

� Grease collar is visible.

Maintenance

CBG_HD / V001244

5.6.3 Slewing bearing tilt measurement

Wear of the bearing races increases play in the bearing.

Carry out the first measurement (initial measurement) in new condition.

Measuring points

The following overview shows the possible measuring points.

Figure 88 Slewing bearing tilt measurement, ball-bearing slewing ring measu

ring points

1 Slewing column (rotating)

2 Slewing ring

3 Base column (non-rotating)

Maintenace

CBG_HD / V001 245

Figure 89 Slewing bearing tilt measurement, roller-bearing slewing ring mea

suring points

1 Slewing column (rotating)

2 Slewing ring

3 Base column (non-rotating)

Maintenance

CBG_HD / V001246

Measurement

Figure 90 Slewing bearing tilt measurement, crane positions

Measuring method 1 (recommended)

� Define and identify 0° boom position.

� Bring boom without load to min. outreach.

� Set dial gauge at position 1 and 2 to 0.

� Move crane to max. outreach and load it with the max. permissible load atthat position.

� Read measured value from the dial gauge and log it.

� After the crane has been slewed 90°, repeat the tilt measurement (set dial

gauge at position 3 and 4 to 0).

Measuring method 2 (alternative)

HINWEIS

� Only use the alternative measuring method if measuring method 1 cannotbe used.

� Move the boom to 0° position or lay it down in boom rest position.

� Attach jack-up cylinder at position 1 between base column and slewing co

lumn.

� Set dial gauge at position 1 to 0.

� Raise jack-up cylinder 1 until the measured value on dial gauge 1 remainsconstant.

� Read measured value from the dial gauge and log it.

� Repeat measurements at positions 2 - 4.

Repeated measurement (see maintenance schedule)

Carry out the measurement with the same prerequisites (hook size, boomradius, measuring instrument, load, jack-up cylinder position).

Maintenace

CBG_HD / V001 247

Permissible tilting play

Limit values table:

Initial play in

new condition

Max. wear Max. tilting

play

Ball slew bearings with outer diameter up to 2500 mm 0.5 mm 1.5 mm 2 mm

Ball slew bearings with outer diameter over 2500 mm 0.5 mm 2.5 mm 3 mm

all roller slew bearings 0.5 mm 1 mm 1.5 mm

If a measurement indicates that the bearing play limit value has been reached:

� Replace ball/roller slew bearing.

Maintenance

CBG_HD / V001248

5.7 Hoisting gear

Figure 91 Hoist winch

1 Closing winch oil drain

2 Closing winch dipstick, oil filler inlet

3 Closing winch air breather

4 Holding winch air breather

5 Holding winch dipstick, oil filler inlet

6 Holding winch oil drain

Maintenace

CBG_HD / V001 249






VORSICHT

Hot winch components and hot gearbox oil!

Burns and open wounds.

� Carry out maintenance and inspection work on winches exclusively whenmachine has been switched off and has cooled down.

� Wear protective equipment.

ACHTUNG












Entsorgung




Maintenance

CBG_HD / V001250






VORSICHT





ACHTUNG











� Move winch in both directions at low speed.

� Turn off machine and after 1 minute check gearbox oil and top up if necessary.

Entsorgung




Maintenace

CBG_HD / V001 251








VORSICHT





ACHTUNG






� Remove protective cap from oil drain.


� Oil drains out.

� Detach oil drain hose and replace protective cap.

Entsorgung




Maintenance

CBG_HD / V001252

5.8 Luffing mechanism

Figure 92 Luffing winch

1 Air breather

2 Oil dipstick, oil filler inlet

3 Oil drain

Maintenace

CBG_HD / V001 253






VORSICHT





ACHTUNG












Entsorgung




Maintenance

CBG_HD / V001254






VORSICHT





ACHTUNG











� Move winch in both directions at low speed.

� Turn off machine and after 1 minute check gearbox oil and top up if necessary.

Entsorgung




Maintenace

CBG_HD / V001 255








VORSICHT





ACHTUNG






� Remove protective cap from oil drain.


� Oil drains out.

� Detach oil drain hose and replace protective cap.

Entsorgung




Maintenance

CBG_HD / V001256

5.9 Hydraulic system

5.9.1 Check the hydraulic system for leaks

� Secure the machine to prevent unauthorised startup.

VORSICHT

Hot hydraulic oil!

Burns.

� Maintenance and inspection work on hydraulic system to be carried outexclusively when engine is switched off.


� Check hydraulic system for leaks.

If there is a leak in hydraulic system:

� Switch off machine.

� Contact Liebherr service department.

Maintenace

CBG_HD / V001 257

5.10 Hydraulic oil tank

Figure 93 Overview of hydraulic tank

1 Air extractor

2 Oil level sensor

3 Return filter

4 Inspection hatch

5 Sight glass for checking oil level

Maintenance

CBG_HD / V001258

5.10.1 Checking the hydraulic oil level


� The engine has been switched off for five minutes.


� All hydraulic cylinders are retracted.

VORSICHT

Hot hydraulic oil!

Burns.

� Maintenance and inspection work on hydraulic system to be carried outexclusively when engine is switched off.


� Check the hydraulic oil level in the sight glasses.

If no hydraulic oil is visible in the lowest sight glass:

� Top up with permitted hydraulic oil according to the lubricant table.

Maintenace

CBG_HD / V001 259

5.10.2 Carrying out a hydraulic oil analysis

For further information see Liebherr oil diagnosis system

5.10.3 Topping up with hydraulic oil

HINWEIS

� Before changing from “mineral oil-based hydraulic oil” to “synthetic-basedhydraulic oil”, please contact Liebherr service department.




� Suitable tools are available (torque wrench 69Nm).

VORSICHT

Hot engine parts and hydraulic oil!

Burns.

� Do not open the cover of the return filter unless the engine is switched offand the temperature of the hydraulic oil is 40° or less.


ACHTUNG

Hydraulic oil topped up incorrectly!


� Only top up hydraulic oil via the return filter.

Figure 94 Opening the return filter

� Undo all cylinder screws.

ACHTUNG

Dirt and foreign bodies in return filter!


� Make sure the return filter is free of dirt and foreign bodies.

� Remove the cover from the filter housing.

Maintenance

CBG_HD / V001260

ACHTUNG

Incorrect hydraulic oil.


� Top up with suitable hydraulic oil only.

� Do not add any additives or concentrates.

� Fill with hydraulic oil.

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

Figure 95 Closing the return filter

� Tighten the screws by hand.

� Tighten the screws with a torque of 69Nm.

Maintenace

CBG_HD / V001 261

5.10.4 Draining the hydraulic oil




� The gear oil is at normal operating temperature.




Entsorgung




Figure 96 Oil drain valve

1 Oil drain valve

� Place a suitable collecting container (oil-resistant, free of leaks, sufficient

capacity) under the oil drain valve.

� Remove the cover from the oil drain valve.

� Connect the oil drain hose from the Liebherr tool kit to the oil drain valve.

� Drain the hydraulic oil.

� Close the cover of the oil drain valve.

Maintenance

CBG_HD / V001262

5.10.5 Cleaning magnetic rod in return filter




� Suitable tools are available (torque wrench 69Nm).

Opening the return filter

VORSICHT

Hot engine parts and hydraulic oil!

Burns.

� Do not open the cover of the return filter unless the engine is switched offand the temperature of the hydraulic oil is 40° or less.


Figure 97 Opening the return filter

� Undo all cylinder screws.

ACHTUNG

Dirt and foreign bodies in return filter!


� Make sure the return filter is free of dirt and foreign bodies.

� Remove the cover from the filter housing.

Maintenace

CBG_HD / V001 263

Cleaning the magnetic rod

Figure 98 Hydraulic oil return filter

1 Screw with circlip

2 Filter cover

3 Sealing ring

4 Magnetic rod

5 Compression spring

6 Pressure flange

7 O-ring

8 Filter element

9 Filter housing

� Carefully remove the filter cover and the sealing ring lying underneath it.

� Remove the magnetic rod, compression spring, pressure flange, O-ring and

the used filter element from the filter housing.

� Check the magnetic rod for metal dust and clean with a clean, lint-free cloth.

� Clean all parts thoroughly.

� Check the O-ring and sealing ring for damage, replace if necessary.

� Clean the inside of the filter housing thoroughly.

� Insert a new original filter element.

� Reassemble the parts in the reverse order.

� Check to make sure the O-ring and sealing ring are clean and seated correctly.

Maintenance

CBG_HD / V001264

Entsorgung




Closing the return filter

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

Figure 99 Closing the return filter

� Tighten the screws by hand.

� Tighten the screws with a torque of 69Nm.

Maintenace

CBG_HD / V001 265

5.11 Fuelling system*

ACHTUNG

Incorrect use of fuelling system!

Environmental damage.

� Operate fuelling system exclusively if the refueling process is monitoredby 2 persons.

Figure 100 Fuelling system


2 Fuel filler neck

3 Fuel valve

4 Feed hose

5 Bayonet connection

6 Filter unit

7 Power unit

8 Suction hose

9 Supply container

Maintenance

CBG_HD / V001266

5.11.1 Fill hydraulic oil tank

� Connect feed hose to bayonet connection.

� Insert fuel valve in fuel filler neck.

� Immerse suction hose in supply container.

� Check filter unit for contamination.

� Switch on power unit.

� Hydraulic oil tank is filled.

� Monitor supply container.

� Monitor hydraulic oil tank.

Maintenace

CBG_HD / V001 267

5.12 Hydraulic oil filter

5.12.1 Replace pressure filter

Figure 101 Filter overview

1 Upper housing section

2 Pressure sensor

3 Sealing ring

4 O-ring

5 Filter element

6 Lower housing section

7 Nut (welded)

� Undo and remove (6) lower housing section (7) using nut.

� Carefully remove filter element (5) and dispose of remaining oil from lower

housing section (6).

� Clean all parts thoroughly.

� Check the O-ring (4) and sealing ring (3) for damage.

If O-ring or sealing ring is damaged:

� Replace the O-ring (4) and sealing ring (3).

� Thoroughly clean inside the filter housing.

� Insert a new filter element.

Check to make sure the O-ring and sealing ring are clean and seated correctly.

� Reassemble the parts in the reverse order.

Maintenance

CBG_HD / V001268

� Tighten nut (7) of lower housing section (6) as far as it will go.

� Start the engine and leave it to idle for at least 5 minutes.

� Switch off engine and re-tighten nut (7) of lower housing section (6) as far asit will go.

� Start the engine and leave it to idle.

� Check hydraulic system for leaks.

If there is a leak in hydraulic system:


Maintenace

CBG_HD / V001 269

5.13 Pressure accumulator

Figure 102 Pressure accumulator

1 Connection for pressure gauge

2 Pressure accumulator

3 Drain valve

WARNUNG

Incorrect handling of the pressure accumulator.

Explosion and bursting!

� Maintenance work on the accumulator must exclusively be carried out bytrained maintenance personnel.

� In case of uncertainty contact Liebherr after sales service.

VORSICHT

Hot hydraulic oil escaping under high pressure.


� Wait a few minutes until the pressure has fallen to 0 bar and thetemperature of the hydraulic oil is no more than 40°C.


ACHTUNG

Dirt and foreign bodies in hydraulic system.


� Make sure the hydraulic system is free of dirt and foreign bodies.

Maintenance

CBG_HD / V001270

5.13.1 Check pressure accumulator





� Pressure gauge is available.

� Close shut-off valve.

� Open drain valve.

� Oil drains from the pressure accumulator.

� Connect pressure gauge to pressure gauge connection point.

� Compare the actual pressure displayed by the pressure gauge with thetarget pressure indicated by the operating data of the pressure accumulator.

If actual pressure is below target pressure:

� Change the pressure accumulator.

5.13.2 Change pressure accumulator




� Original Liebherr pressure accumulators are available.

� The hydraulic oil pressure is 0 bar.

� The hydraulic oil temperature is 40°C.

� Suitable tools are available.


� Close shut-off valve.

� Open drain valve.

� Oil drains from the pressure accumulator.

� Replace pressure accumulator with new original Liebherr pressure accumulator.

� Thoroughly clean the outside of the pressure accumulator so that the markings and operating data are clearly visible.

Maintenace

CBG_HD / V001 271

5.14 Hydraulic cylinders

5.14.1 Check hydraulic cylinder for leaks

� Check that the hydraulic cylinder fits properly and does not leak.

If the hydraulic cylinder is leaking or loose:


5.14.2 Preserving hydraulic cylinders




� Anti-corrosion agent is available.

HINWEIS

Anti-corrosion agent

� Liebherr recommends CORTEC VCI 369.

ACHTUNG

Dirt and lack of corrosion protection

are liable to damage the hydraulic cylinders.

� Ensure that the hydraulic cylinders are free from dirt and have adequatecorrosion protection.

The following hydraulic cylinders require maintenance:

� Luffing cylinders

� Slewing interlock cylinder

� Clean the cylinder pistons thoroughly.

� Treat the cylinder pistons with a suitable anti-corrosion agent.

� Fully extend and retract the cylinder pistons 2-3 times.

� The pistons of the hydraulic cylinders are now treated.

Maintenance

CBG_HD / V001272

5.15 Hydraulic hoses and hose lines

Hydraulic hoses and hose lines are subject to a natural ageing process. Their

storage life and useful life are therefore limited:

Useful life will be shortened by use at the limit of permitted stress (very high/lowtemperatures, high pulse frequencies, multi-shift operation, etc.).

VORSICHT

Inadequate repair to hydraulic hoses and hose lines.

is liable to cause damage and injury.

� Hydraulic hoses and hose lines should only be renewed.

� Use only original Liebherr spare parts.


Check hydraulic hoses and hose lines for the following:

� Damage to the outer layer as far as the reinforcement (chafing, cuts andcracks, etc.).

� Degradation of the outer layer (formation of cracks in the hose material,

etc.).

� Deformation in the pressurised and depressurised state, and at bendsthat do not correspond to the original state of the hydraulic hose or hose

line (layer separation, bubble formation, etc.).

� Leaks.

� Damage or deformation of the hose fitting which reduces the strength ofthe fitting or the hose/fitting connection.

� Hose straying out of the fitting.

� Corrosion of the fitting which reduces its efficiency or strength.

� Exceeding of storage period and useful life.

� In any of the situations mentioned above, the hydraulic hoses and hose linesmust be renewed.

HINWEIS

If detaching the hydraulic connection causes oil to leak

� use the vacuum pump.

Entsorgung




Maintenace

CBG_HD / V001 273

5.16 Electrical system

5.16.1 Replace fuses and lamps




� Original Liebherr spare parts are available.

� Replace faulty fuses and lamps.

� Check that the new part is correctly seated.

5.16.2 Cleaning the slip ring unit

ACHTUNG

Use of wet or damp cleaning cloths

will damage the slip ring unit.

� Avoid using wet or damp cleaning cloths.

� Use only dry methods (compressed air or vacuum cleaner) to clean theslip ring unit.



� On-board power supply is switched off.


� Compressed air or a vacuum cleaner is available.

� Remove the cover.

VORSICHT

Swirling dust and dirt particles!

can cause eye injuries.

� Wear protective clothing (particularly safety goggles and a breathingmask).

� Clean the slip ring unit with compressed air and a vacuum cleaner.

� Check brushes for wear and correct position.

� Check tightening torque of cable lug fastening screws.

� Reattach the cover.

Maintenance

CBG_HD / V001274

5.16.3 Replacing of filter mat




� An original Liebherr filter mat is available.

Figure 103 Switch cabinet filter mat cover

1 Filter mat cover

� Remove the filter mat cover (1).

� Replace the old filter mat with a new original Liebherr filter mat.

� Reattach the filter mat cover and fasten with screws.

5.16.4 Checking screw and clamping connections




� On-board power supply is switched off.

� Check all screws and clips for tight fit and tighten if necessary.

� Check tightening torque of screws on main switch and on star-delta circuitbreaker.

Maintenace

CBG_HD / V001 275

5.17 Limit switches

5.17.1 Checking function of lifting and luffing gear limit switches

� Operate luffing gear in upper and lower limit switch.

� Check tripping of limit switches

� Slowly move hoisting gear to upper and lower limit switches.

� Check tripping of limit switches

If limit switch trips too early, or not at all:

� Switch off machine.


Maintenance

CBG_HD / V001276

5.18 Emergency stop

5.18.1 Check the emergency stop to ensure it is workingcorrectly

WARNUNG

Unauthorised triggering of the emergency stop!

� The emergency stop may only be checked when the engine is running,

the machine is not moving and no load is attached.

� Check the emergency stop to ensure it is working correctly.

If the engine does not switch off:


Maintenace

CBG_HD / V001 277

5.19 Fire extinguishers

5.19.1 Checking fire extinguishers

Figure 104 Fire extinguishers

ACHTUNG

Unsuitable or broken fire extinguishers!

� Observe the type plate on the fire extinguisher.

� Observe the national regulations.

Guidelines for checking hand extinguishers are nationally regulated.

� Check seals and inspection dates on fire extinguishers.

If fire extinguishers are missing or inspection dates have passed:

� Replace fire extinguishers or have them inspected.

Maintenance

CBG_HD / V001278

5.20 Personal protective equipment

5.20.1 Checking that personal protective equipment is inplace, intact and complete

WARNUNG

Inadequate protection

� Observe the manufacturer's guidelines on care and maintenance of the

protective equipment.


� Checking that the personal protective gear is in place, intact and complete

If the personal protective gear is not present, damaged, or incomplete:

� Complete the personal protective gear.

� Clean the personal protective gear.

� Have the personal protective gear cleaned.

Maintenace

CBG_HD / V001 279

5.21 Lowering device

5.21.1 Checking the lowering device

See section 'Operation, Emergency exit'.

1 Cover

2 Storage compartment

3 Rescue harness, rope, karabiner

� Have the rescue equipment inspected by a specialist.

� Have the result of the inspection entered in the warranty and inspection

card.

Maintenance

CBG_HD / V001280

5.22 Central lubrication system

Figure 105 Lubrication pump

1 Control unit

2 Supply container

3 "Maximum fill level" marker

4 Filling nipple

A Adjust lubrication time regulator

B Adjust break time regulator

After the engine is switched on, the yellow indication lamp lights up for 1.5 seconds, indicating readiness for operation.

5.22.1 Check that central lubrication system is working

� Press Interim lubrication button

� Interim lubrication is carried out with the programmed lubrication time.

� At the end of the programmed break time the programmed lubrication

process is continued.

If no interim lubrication takes place after pressing the Interim lubrication button:

� Contact Liebherr after sales service.

Maintenace

CBG_HD / V001 281

5.22.2 Check fill level of lubrication pump




� The grease gun from the Liebherr tool kit is present and filled with correctgrease.

ACHTUNG

Incorrect or impure grease!

Damage to machine.

� Avoid contamination: fill supply container exclusively using grease gun viathe grease nipple.

� Ensure the purity of the grease.

� Add exclusively correct grease according to lubrication chart.

ACHTUNG

Grease supply containers are empty!

Insufficient lubrication and damage to swing ring.

Costly cleaning and venting work on central lubrication pump.

� Ensure that supply containers are always topped up.

� Check fill level of lubrication pumps.

If the fill level lies well below the "Maximum fill level" marker:

� Top up with grease until the "Maximum fill level" marker is reached.

5.22.3 Check time interval on lubrication pump




To ensure optimum lubrication, the following factory-set time intervals must notbe altered:

� Lubrication time: 13 minutes

� Break time: 4 hours

� Check time intervals on each lubrication pump.

If the lubrication pump settings do not match the specifications:

� Correct the settings to match the appropriate specifications.

Maintenance

CBG_HD / V001282

5.22.4 Check lubrication points




� Check lubrication points for sufficient lubrication.

If no grease collar can be seen at a lubrication point:

� Check settings on the relevant lubrication pump.

� Check lines for damage.

� Contact Liebherr after sales service.

Maintenace

CBG_HD / V001 283

5.23 Ropes

Due to the limited service life of wire ropes, ropes must be checked at regular

intervals during use to correctly identify when the rope has reached the end ofits service life and to remove it from service before it fails completely.

The following points are important when determining the inspection intervalsand may shorten the intervals:

� National or local regulations in the country of use.

� Environmental conditions.

� Use in the first few weeks after a rope has been put on.

� Results of previous inspections.

� Time for which the rope has been used.

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:

� Check the rope and end attachments.

These rope changing criteria form part of ISO 4309. They describe the mostcommonly occurring types of rope wear.

DANGER

Incorrect maintenance of the ropes!

Load breakaway.

� All the listed criteria must be checked at the prescribed maintenanceintervals.

� Check the rope in particular around the end attachment as it is subject toincreased mechanical stresses at this point.

If any doubts on the operational safety of a rope exist:

� Lay down the rope or have the rope inspected by a qualified engineer.




Maintenance

CBG_HD / V001284

5.23.1 Checking the rope diameter

As a result of natural wear that occurs during use, ropes gradually becomethinner and must eventually be withdrawn from service. If the rope diameter hasreduced over long sections by more than 10% relative to the nominal dimension

as a result of internal friction, corrosion, etc., the rope must be changed regardless of whether or not wire breaks have occurred.




� A caliper gauge with wide jaws is available.

Figure 106 Rope diameter: (left) correct measurement, (right) incorrect mea

surement

� Measure the rope diameter on two separate points at least one metre distantfrom each other.

� Always measure the rope diameter twice at the same point.

The average corresponds to the rope diameter. The rope diameter must measure at least 90% of the nominal rope diameter.

� Calculate the average of the four measurements.

If the rope diameter is smaller than the nominal rope diameter by more than

10%:

� Remove the rope.

HINWEIS

If new ropes are to be attached:

� Checking the rope drive.

Maintenace

CBG_HD / V001 285

5.23.2 Checking ropes for deformations

Figure 107 Cage formation

The outer layer of wires is loosened or the outer wire braids are longer than theinner ones.

Figure 108 Loop formation

Single wires or groups of wires emerge from the rope structure. The loopsusually lie in a series of strands.

Figure 109 Necking

The diameter of the rope is reduced over short lengths. Rope sections imme

diately before the end attachment must be checked for necking with particularcare. Necking is often difficult to recognise at these points.

Figure 110 Knots

Deformations of the wire rope. These are formed when a loop in the rope is

pulled straight without the wire rope being able to compensate for the loop byturning on its axis.

Maintenance

CBG_HD / V001286

Figure 111 Corkscrew

The axis of the unloaded wire rope becomes helical. This prevents the ropedrive from running smoothly. The resultant damage includes increased abrasion

and wire breaks. The rope must be replaced if the deformation at the thinnestpoint of the rope exceeds ⅓ of the nominal rope diameter.

� Check the ropes for deformations.

If the rope meets one of the criteria above or exhibits specific damage:

� Switch off the machine and, if possible, determine the cause of the damage.

� Remove the rope and/or rope pair.

Maintenace

CBG_HD / V001 287

5.23.3 Check ropes for corrosion

Figure 112 Atmospheric corrosion

Corrosion occurs in corrosive and salt water atmospheres (e.g. prolonged storage of ropes in the open air, salt water atmospheres, etc.). In ropes, a distinc

tion is made between atmospheric corrosion (produces "even" rusting) and localtypes of corrosion such as pitting (forms deep holes at points where the protec

tive layer is missing or damaged). The photographs both show atmospheric corrosion.

Figure 113 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, therope must be changed regardless of whether or not wire breaks have occurred.

� Check ropes for corrosion.




Maintenance

CBG_HD / V001288

5.23.4 Check ropes for abrasion

Figure 114 Rope abrasion

Abrasion reduces both the static breaking force of the rope due to reduction ofthe metallic cross-section and its fatigue limit due to wear notches. If the rope

diameter has reduced by 10% or more relative to the nominal dimension, therope must be changed regardless of whether or not wire breaks have occurred.

� Check ropes for abrasion.




Maintenace

CBG_HD / V001 289

5.23.5 Check ropes for the effects of heat

Figure 115 Heat damage

If the temperature rises above 300 °C, the tensile fibre structure of the wire

rope caused by cold deformation recrystallises and the wire loses around 2/3 ofits original strength.

Figure 116 Heat damage in case of lightning strike

An extreme form of heat damage is caused by lightning 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 re

gardless of whether or not wire breaks have occurred.

HINWEIS

� Permitted operating temperatures for ropes and end attachments, refer toEN12385-3.

� Check ropes for significant heat damage.

If a rope displays signs of external heat damage, such as recrystallisation,melting. etc.:



Maintenance

CBG_HD / V001290

5.23.6 Checking the number of permitted wire breaks

The following tables are an extract from ISO 4309:2004.

The tables show the permitted number of wire breaks relative to a defined control section of the rope.

Single-layer spooling and lang lay ropes

Rope category

(see Annex E)

Number of bearing wires in the outer strands of the wire rope a)

n

Number of wire breaks at theend of the service lifec), d)

6 D b) 30 D b)

01 to 50 2 4

02 51 to 75 3 6

03 76 to 100 4 8

04 101 to 120 5 10

05 121 to 140 6 11

06 141 to 160 6 13

07 161 to 180 7 14

08 181 to 200 8 16

09 201 to 220 9 18

10 221 to 240 10 19

11 241 to 260 10 21

12 261 to 280 11 22

13 281 to 300 12 24

Special designs with larger outer wire diameters deviating from the norm can,if appropriate, be classified in a way that differs from table 1. Please contactthe manufacturer for more information. For Seale-design wire ropes whosenumber of outer wires in strands does not exceed 19, the rope in table 1should be classified two rows above the actual applicable row.

Note: The wire-break coefficients apply to steel grooves or plastic pulleys incombination with multiple-layer spooling (for the rope section that is subject tothe greatest strain), but not to plastic pulleys in combination with single-layerspooling.

a) Filler wires are not considered to be bearing wires. In the case of wire ropeswith several layers of strand, only the strands in the outermost layer are deemed to be outer strands. In the case of steel ropes, the steel core functions as

the inner strand.

b) Nominal rope diameter

c) A broken wire has two ends.

d) The specified number of wire breaks relates to systems classified in GroupsM1 ć M4, and the maximum permissible number of wire breaks is doubled forropes that are used on or in systems in Groups M5 ć M8.

Maintenace

CBG_HD / V001 291

Twist-free ropes

Rope category

(see Annex E)

Number of bearing wires in the outer strands of the wire rope a)

n

Number of wire breaks at theend of the service lifec), d)

6 D b) 30 D b)

21 4 Nicks in ropes

to 100

2 4

22 3 Nicks in ropes

4 Nicks in ropes

over 100

2 4

23 At least 10 outer braids 2 4

Note: The wire-break coefficients apply to steel grooves or plastic pulleys incombination with multiple-layer spooling (for the rope section that is subject tothe greatest strain), but not to plastic pulleys in combination with single-layerspooling.

a) Filler wires are not considered to be bearing wires. In the case of wire ropeswith several layers of strand, only the strands in the outermost layer are deemed to be outer strands. In the case of steel ropes, the steel core functions as

the inner strand.

b) Nominal rope diameter

c) A broken wire has two ends.

d) The specified number of wire breaks relates to systems classified in Groups

M1 ć M4, and the maximum permissible number of wire breaks is doubled forropes that are used on or in systems in Groups M5 ć M8.

DANGER

Unsuitable rope is used!

Load breakaway.

If a new rope is to be attached:

� Choose a rope that shares all the criteria of the original rope for the crane

type concerned.

� Choose a rope that meets the applicable national and internationalregulations.

Maintenance

CBG_HD / V001292

Example

if the measured diameter of D is 30 mm, this means that the number of permitted wire breaks on a control section measuring 6 x D = 180 mm may not behigher than 9. On a control section measuring 30 x D = 900 mm the number

may not be higher than 18.

� 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:



5.23.7 Storing ropes

ACHTUNG

Ropes are not labelled!

Ropes/drums could be mixed up.

If the label is missing or is no longer clearly legible,

� Label the drums immediately in accordance with the delivery

documentation.

� Check that the labeling of supplied ropes matches the material inspection

documents and the order.

� Material inspection certificates should be carefully filed away.

ACHTUNG

Incorrect storage!

Ropes may become damaged.

� Ropes should be stored correctly.

� Store wire ropes in a dry, well-ventilated area.

� Protect ropes and drums from the elements: Never store ropes or drums

directly on the ground.

� Avoid storing them outdoors for prolonged periods.

Maintenace

CBG_HD / V001 293

5.23.8 Transporting ropes

Ropes are very sensitive to external damage.

WARNUNG

Incorrect transport (loaded, unloaded)!


� Ropes should be transported correctly.

Figure 117 Lifting rope drums

Correct procedures to avoid damage to ropes during transport:

� Lift drums using textile rigging (flat lifting slings or round slings).

� Ideally, drums should be lifted with a shaft pushed through their middle..

� Lift drums using forklift forks.

Maintenance

CBG_HD / V001294

5.23.9 Winding ropes

Hoisting ropes will only work smoothly if they are laid without twisting and without external damage.

ACHTUNG

Wire ropes are not handled correctly!


� Wind ropes in accordance with the following instructions.

If the winding area of the rope is more in the upper rope layer when operatingwinches 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.

ACHTUNG

Lower rope layer loosened!

Risk of damage to the rope.

� Improve the the spooling properties and decrease wear: completelyunwind 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 thereforerecommended that an appropriate length of rope is used for lengthy operations.



ACHTUNG

Incorrect handling of the rope!


� Do not brake the rope directly.

� Do not pull the rope along the ground.

With multi-layer winding:

� 1. Pre-tension the rope layer with at least 10% of SWL (max.) whilstinstalling the rope.

Maintenace

CBG_HD / V001 295

Figure 118 Winding ropes without brake

� Unwind ropes from the rope drum A in the winding direction.

Unwinding to the side causes the rope to twist until it is destroyed by kinkformation.

� Unwind ropes from a jacked up drum B.

Figure 119 Winding ropes with brake

� Unwind ropes from a drum A that is braked.

� Check the ropes for damage, deformation, wear, etc. while it is unwound.

If the rope shows any signs of damage, deformation, wear, etc.:


Maintenance

CBG_HD / V001296

5.23.10 Luffing ropes

When luffing the rope, pay attention to the following points:

� Make sure that the rope does not become untwined or twisted.

� If an auxiliary rope is used, make sure the permitted tensile force is app

lied (at least the weight of the rope).

� If the old rope is used as the luffing rope, ensure that the new rope doesnot become twisted.

WARNUNG

Ropes fused together!

Risk of breaking as they pass over rollers. Machine and rope may be damaged

Serious injury.

� Weld on eyelets to connect the two ropes.

� A rope stocking may be used (the rope stocking manufacturer'sinstructions must be followed).

ACHTUNG

Rope deflexion angle is too large (more than 4 °)!


� Position the pulley as far away as possible and without any lateraldeflection.




� The rope is checked before luffing for damage as a result of incorrect

handling or storage.

� Wear suitable protective clothing.

WARNUNG

Sudden and violent movements as the end of the rope comes off the drum!

Serious injury.


� Unwind the rope from the rope drum carefully and as slowly as possible.

� Weld on eyelets to connect the two ropes. A rope stocking may be used (therope stocking manufacturer's instructions must be followed).

� Use an auxiliary rope or old rope to luff the rope.

� Before use, check to ensure that the newly fitted wire rope is located correctly in the grooves on drums and pulleys.

� Have the rope limit switch checked and adjusted by an authorized service

engineer.

� Hoist a light load (up to 10% of full load) several times to check that the wirerope is winding onto the winch drum correctly.

Maintenace

CBG_HD / V001 297

5.23.11 Retracting ropes

ACHTUNG

Faulty spooling properties of rope!

Damage to the rope, the winch and the pulleys.

� Do not exceed the prescribed maintenance and inspection intervals.

� Inspect spooling status of the winch and the pulleys.

� Checking the rigging material.

� Inspect the layer switches of the spooling.

� Immediately rectify faults and damage.

To ensure optimum spooling properties:

� Carry out 3 operating cycles at reduced speed and with a reduced load.

� Reduced speed: 30% of v(max)

� Reduced load: 10% of SWL(max)

� Carry out 2 operating cycles with 1/3 SWL (max.).

� Carry out 2 operating cycles with SWL (max.) and max. outreach as per the

applicable load chart.

Maintenance

CBG_HD / V001298

5.23.12 Lubricate ropes

Regular rope maintenance ensures safe operation of the crane and increasesthe service life of the rope.



� A cleaning brush is available.

� Suitable lubricant is available (see following table)

Manufacturer Make

Agip Precis

Amity UK Ltd. PCL

Amity UK Ltd. IKV Ramca 250 Spray

BP Stemkor 171

Bremer & Leguil Rivolta S.K.M 17

ELASKON UNOLIT 130

EUROL TW FLUID

Exxon-Mobil Mobiltac 375 NC

Fuchs Cedracon

Fuchs Ceplattyn KG 10

Fuchs Ceplattyn KG 10 HMF-C

Nyrosten Nyrosten N 113

Shell Enesis R Type: RB0015

Shell Enesis RX Type: RB003

Total Osyris DWX 9000

Van Meeuwen Bel-Ray Wire rope Lubricant

� Apply extra lubrication in the areas where the ropes bend around the winchdrums and the pulleys.

� Apply grease with a brush. In special cases a high-pressure lubricating device is used (Follow the manufacturer's instructions). An alternative is to use

solvent-based lubricants that can be sprayed on the rope.

� Observe maintenance intervals.

HINWEIS

Third-party ropes

� Select lubricants according to the recommendations of the rope

manufacturer concerned or contact the Liebherr service department.

VORSICHT

Broken wires and damaged spots on rope.

Risk of injury when cleaning.

� Wear protective clothing (especially protective gloves).

� Use a brush for cleaning.

Maintenace

CBG_HD / V001 299

5.24 Rope drive

5.24.1 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 theend 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.

Checking winch drum groove base for wear




� A suitable test template is available.

Figure 120 Acceptable test result

1 Test template

2 Winch drum

The diameter of the measuring device (test template) must be virtually identical

to that of the groove base so that it fits easily into the groove. The groovediameter of the winch drum (2) must be 4% to 8% larger than the diameter of

the test template (1).

� Use the test template (1) to check each individual groove on the winch drum(2).

Maintenance

CBG_HD / V001300

The diameter of the test template is not the same as the groove base of thewinch drum. There is a crescent-shaped gap between the test template and the

groove base:

Figure 121 Unacceptable test result

1 Test template

2 Winch drum


� Smooth the surface of the grooves.


Maintenace

CBG_HD / V001 301

5.25 Rope pulleys

5.25.1 Checking pulleys for ease of movement, signs ofwear and damage

Check pulleys for ease of movement.

� Check pulleys for ease of movement.

If the pulleys do not move easily:

� Lubricating the pulley bearings

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 testtemplate.

The rope grooves often exhibit an imprint corresponding to the negative imprintof the rope in question. The impressions of the individual strands in the rope

grooves are normal and not undesirable, since these produce a greater ropesupport 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 ofthe pulley smoothed.




� A test template is available.

Figure 122 Checking steel pulleys for wear

1 Test template

2 Steel pulley

A Maximum permissible wear on pulley

Maintenance

CBG_HD / V001302

The maximum permissible wear A is 4% of the nominal rope diameter.

� Use the test template to check the radius of the groove in the pulley.

If the actual wear exceeds the maximum permissible wear:

� Replace the pulley.


Checking plastic pulleys for wear

The rope grooves often exhibit an imprint corresponding to the negative imprintof the rope in question. The impressions of the individual strands in the rope

grooves are normal and not undesirable, since these produce a greater ropesupport surface, which increases the service life of the rope. When the rope ischanged, the ridges must be removed and any sharp edges on the surface of

the pulley smoothed.




� A test template is available.

Figure 123 Checking plastic pulleys for wear

1 Test template

2 Plastic pulley

A Maximum permissible wear on pulley

The maximum permissible wear A is 50% of the nominal rope diameter.

� Use the test template to check the radius of the groove in the pulley.

If the actual wear exceeds the maximum permissible wear:



Maintenace

CBG_HD / V001 303

Checking pulleys for damage

ACHTUNG

Pulleys placed in the ground without protection!

Damage to the pulleys.

� Pulleys must only be laid on the ground with protective equipment.

Figure 124 Damaged pulley

1 Crack

2 Nicks

The pulleys must be aligned with the running direction of the rope. They mustalso be in good condition, without wobbles or any other damage.

� Check pulleys for damage (nicks, wobbles, cracks, notches, etc.).

If the pulley is damaged:



Maintenance

CBG_HD / V001304

5.25.2 Lubricating pulley bearings




� The grease gun from the Liebherr tool kit is present and filled with grease.

� Boom is lowered into its parked position.

Ensure that the grease does not escape from or between the pulley bearings.

� Lubricate the pulley bearings on the slewing column and boom head via the

grease nipples using a hand lever grease pistol.

5.25.3 Cleaning plastic pulleys

ACHTUNG

Using dirty pulleys!


� Clean dirt, gum, etc. from the plastic pulleys.

ACHTUNG

Unauthorised cleaning agent!


� Exclusively clean plastic pulleys with suitable cleaning agents.

Plastic pulleys are resistant to:

� Mineral oil

� Petrol

� Kerosene

� Diesel

Plastic pulleys are not resistant or not fully resistant to:

� Concentrated mineral acids (e.g. sulphuric acid, hydrochloric acid, nitricacid)

� Concentrated organic acids (e.g. formic acid)

� Concentrated bases (e.g. sodium, caustic potash solution or corrosivepotassium salts)

� alcohol other than ethyl alcohol, methyl alcohol and propyl alcohol

� Inorganic chlorides (e.g. calcium, lithium chloride, magnesium chloride

and zinc chloride)

� Clean plastic rope pulleys using a cleaning cloth and authorised cleaningagents.

Maintenace

CBG_HD / V001 305

5.26 Cabin

5.26.1 Checking cabin windows for damage

� Check the windows of the cab for damage.

If any of the cab windows are damaged:

� Change the window.


5.26.2 Checking that cabin door and door lock workproperly

Checking the operation of the cab door

� Check the operation of the cab door.

If the cab door does not move freely or does not latch in the open position

:

� Spray the hinges with adhesive lubricant.


Checking the operation of the door lock

� Check the operation of the door lock.

If the door lock is not operating correctly:

� Spray the locks with adhesive lubricant.

� Apply frost protection to the locks in the event of low ambient temperatures.


Maintenance

CBG_HD / V001306

5.26.3 Changing the windscreen wipers


� A suitable lifting platform is available.

� Ring spanner with width across flats 13 is available.

� Open spanner with width across flats 13 is available.

� New Liebherr windscreen wiper is available.

ACHTUNG

Incorrect maintenance!

Damage to the windscreen wiper nozzles.

� Note the windscreen wiper nozzles on the windscreen wiper mount.

WARNUNG

Incorrect fall arrest system.

Risk of falling from the lifting platform.

� Maintenance personnel with suitable personal protective equipment safe.

� Maintain personal protective equipment according to manufacturer'sinstructions.

Figure 125 Windscreen wiper

� Hold the screw with the open spanner and undo the nut using the ring

spanner.

� Change the windscreen wiper.

Only tighten the screw by a certain degree so that the windscreen wiper can still

move freely.

� Place the screw through the mount and windscreen wiper.

� Tighten the nut using the ring spanner.

Maintenace

CBG_HD / V001 307

5.26.4 Filling windscreen wiper system


� Suitable windscreen wash fluid is available.

Figure 126 Windscreen wiper system containers

1 Sealing cap

2 Container

� Open cover 1.

ACHTUNG

Unsuitable windscreen washer fluid!

Damage to the system.

� Fill container 2 with suitable windscreen washer fluid only.

� Top up the windscreen washer fluid in container 2.

� Close cover 1.

� If necessary clean the windscreen wiper nozzles on the windscreen wiperswith a needle.

Maintenance

CBG_HD / V001308


5.27.1 Checking and cleaning the air conditioning system

WARNUNG

Incorrect maintenance of the air conditioning system

Risk of poisoning, frostbite.

� Work on the air conditioning system must only be carried out byauthorised Liebherr service personnel.

Figure 127 Air conditioning

� Check systems to ensure they are in good working order, free from leaks,

clean and securely seated.

� Check the functioning of ventilation flaps and outlets to ensure they areclean and in good working order.

Maintenace

CBG_HD / V001 309

5.28 Machine care

5.28.1 Cleaning the machine

Liebherr recommends that the external machine parts are cleaned regularly tomaintain an even surface quality. This is strongly advised following work with

highly corrosive materials.

ACHTUNG

Unsuitable cleaning agent is used!

Damage to the surface.

� Do not use any aggressive cleaning agents.

� Do not use any abrasive cleaning agents.

� Avoid the use of phosphate cleaners.

� Avoid the use of solvents or cleaning against containing solvents.

� Use only cleaning agents with a pH below 12.




� The machine has cooled down.


VORSICHT

Hot steam and compressed air!

Burns.


� Clean the machine using a steam cleaner.

� Maximum pressure 150 bar, minimum distance 40cm.

� If necessary use a mild cleaning agent (tenside cleaner).

� After cleaning, preserve the machine (see chapter: Maintenance, Anti-corro

sion coating)

Entsorgung




Maintenance

CBG_HD / V001310

5.28.2 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)

5.28.3 Preserving the machine




� Suitable preservation agents are available in sufficient quantities.

� The appropriate tools and accessories are available.


� Electronic components are covered up.

WARNUNG

Insufficient or incorrect preservation agents are applied to the machine!

Risk of injury to the respiratory tract, suffocation.

� Wear breathing mask.

� Spray all machined, but unpainted, parts external to the machine (e.g. pins,

bearings) with LPS PROCYON anti-corrosion coating agent.

� Spray all machined, galvanised, but unpainted, parts within the machine

(e.g. flanges, pins, screws, joints, casings, contact surfaces) withMOLECULAR NATO FLUID anti-corrosion coating agent.

� Spray the entire engine compartment with MOLECULAR NATO FLUID anti-corrosion coating agent.

� 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.

� Spray all screws on railings, boom walkways, steps, moving parts and floodlights with LPS 3 anti-corrosion coating agent.

Documents

Operating Manual